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USER`S MANUAL SMARTSTEP Junior

1. omron omron R7D ZNO1H ML2 R7D ZNO1H ML2 DRIVER DRIVER COM ALM RDY COM ALM RDY am gt l Terminating resistance Features and System Configuration Chapter 1 1 2 System Configuration 1 2 1 Basic Configuration SYSMAC Position Control Unit with MECHATROLINK I communications MECHATRO LINK II Programmable Controller Position Control Unit SYSMAC CJ1 CS1 CJ1W NCF71 CS1W NCF71 SMARTSTEP Junior Servo Driver R7D ZNL ML2 Precaution for Safe Use e Do not use a CJ1W MCH71 or CS1W MCH71 Motion Control Unit SMARTSTEP Junior Servomotor R7M Z 1 2 2 Application Restrictions Interrupt feeding OK Other functions 1 4 Features and System Configuration Chapter 1 1 3 Nomenclature and Functions 1 3 1 Servo Driver Nomenclature DRIVER 100W COM ALM RDY Rotary switch for setting command Connector for filter FIL MECHATROLINK II communications CN6 Control I O connector CN1 Encoder input connector CN2 Power supply indicator PWR Servomotor Main circuit connector CNB connector CNA FG terminals for power supply and Servomotor power With Top Cover Open Rotary switch for setting MECHATROLINK II Rotary switch for setting communications SW2 MECHATROLINK II axis number SW1 Servo status indicator RDY Alarm indicator ALM MECHATROLINK II communi cations status indicator COM
2. Peet EEPE aber yee 100 150 200 250 300 Motor torque Note 1 The motor torque indicates the percentage of the rated torque that is applied Note 2 For example if the motor torque is 300 of the rated torque an overload alarm will be gen erated after about 3 seconds 6 20 Troubleshooting Chapter 6 6 5 Periodic Maintenance Servomotors and Servo Drivers contain many components and will operate properly only when each of the individual components is operating properly Some of the electrical and mechanical compo nents require maintenance depending on application conditions Periodic inspection and part replacement are necessary to ensure proper long term operation of Servomotors and Servo Drivers The periodic maintenance cycle depends on the installation environment and application conditions of the Servomotor or Servo Driver Recommended maintenance times are listed below for Servomo tors and Servo Drivers Use these for reference in determining actual maintenance schedules NCAUTION Resume operation only after transferring all data required for operation to the new Unit Not doing so may result in an unexpected operation Do not attempt to disassemble repair or modify any Units Any attempt to do so may result in malfunction fire or electric shock 6 5 1 Servomotor Maintenance The recommended periodic maintenance schedule is listed below e Bearings 20 000 hours e Decelerator 20 000 hours
3. e When this signal turns ON while the Servomotor is moving at the origin search feed speed the Ser vomotor decelerates to the origin search approach speed e After this signal turns OFF at the first origin input signal the Servomotor decelerates to origin search creep speed and positioning is executed for the origin search final travel distance e After positioning is completed that position becomes the origin m Forward Drive Inhibit POT and Reverse Drive Inhibit NOT Pin 4 Forward drive inhibit POT Pin 3 Reverse drive inhibit NOT Functions e These two signals are the forward and reverse drive inhibit overtravel inputs e When they are input driving is enabled in the respective rotation directions e When driving is inhibited servo lock status goes into effect after deceleration to a stop e The maximum torque after deceleration to a stop is the maximum torque of the Servomotor e When driving is inhibited the Servo Driver does not go into alarm status m Emergency Stop Input STOP Pin 6 Emergency stop input STOP Function e This input is used to forcibly turn the Servo OFF from an external sequences e g in a host device e f this input turns OFF while the Servomotor is rotating the Servomotor is decelerated to a stop using the dynamic brake After stopping it will go into servo free status e When the emergency stop input STOP is turned ON while Servomotor power is ON an emer gency stop alarm A 2
4. 6 2 Alarm Table If the Servo Driver detects an error ALM alarm output will be output the power drive circuit in the Servo Driver will be turned OFF and the alarm code will be displayed e Refer to 6 3 1 Error Diagnosis Using the Alarm Indicators for details on appropriate alarm counter measures e Read the alarm code from the host controller For information on checking alarm codes when using an OMRON Controller refer to 6 1 2 Precautions When Troubleshooting e An alarm can be cleared either by a turning the power OFF and then back ON or by b inputting an error reset signal from the host controller The following alarms however can only be cleared by turning the power OFF and then back ON A 02 A 04 A 05 A 10 A 7A A b3 A bF A C2 A C5 A C9 A d6 and A EO e When an alarm occurs the Servo Driver stops the Servomotor by the following methods a DB stop Stops the Servomotor rapidly using the dynamic brake b Zero speed stop Stops the Servomotor by setting the speed reference at the Servo Driver to Zero m Alarms Alarm Error detection Detected error or cause of error Stopping Alarm code function method reset Error in internal Servo Driver parameter data DB stop A 03 Main circuit detection Error in main circuit detection values DB stop Yes error A 04 Parameter setting A user parameter value is set out of range DB stop No error A 05 Unsupported Servo Servo Driver error DB stop No Driver alarm A 1
5. Connection is faulty Wire the cable correctly for a U V or W phases at the Servo motor main circuit cable The Servo Driver is Replace the Servo Driver faulty A position command Reduce the command value input was too large The Servomotor spec Re evaluate the load and ifications do not match operating conditions the load conditions Re evaluate the Servomotor e g torque inertia capacity With a MECHA Turn the power OFF and back TROLINK II connec ON again Alternatively close tion established the communications connec communications with tion with the host controller the host controller and set up the communica were aborted and tions again then started again The MECHA TROLINK II wiring is incorrect Wire the MECHATROLINK II Communications Cable cor rectly Wire the terminating resis tance correctly A MECHATROLINK II Implement measures against data reception error noise such as modifying the occurred due to noise MECHATROLINK II Commu nications Cable and FG wir ing and installing a ferrite core in the MECHATROLINK Il Communications Cable The Servo Driver is Replace the Servo Driver faulty The Servo Driver is Replace the Servo Driver faulty Chapter 6 Troubleshooting Alarm code A E4 MECHA TROLINK II transfer cycle setting error A E5 MECHA TROLINK II syn chronization error A E6 MECHA TROLINK II Communications error
6. e Main a Connector CNA Pin Seer Ps Condition oe a circuits power sup ee 200 230 V AC a input 170 to 253 V AC 50 60 Hz E External Regeneration If regenerative energy is high connect an Exter connection terminals nal Regeneration Unit between P and N o ground This is the ground terminal Ground to a mini mum of 100 2 class D class 3 m R7A CNZ01A CNB Servomotor Connector Specifications Bb O N a a aa Servomotor con Red These are the output terminals to the nection Terminals CC Be careful to wire them correctly e Do not connect anything to this terminal 5 i me Green Yellow Connect the Servomotor FG terminal 3 4 Specifications Chapter 3 3 1 4 Control I O Specifications CN1 m Control I O Signal Connections and External Signal Processing pa 121 ALM Alarm output Maximum operating voltage 30 VDC Maximum Output Current BKIR Brake Interlock 50 mA DC OGND 24 VDC 24VIN L 9 3 3 KQ External latch signal 1 4 N o EXT1 his O amp A ee ee Origin proximity 4 S input DEC AN O O pe eee Reverse drive 4 S lt inhibit NOT Forward drive inhibit Emergency stop Shell FG Frame ground 3 5 Specifications Chapter 3 m Control I O Signals e CN1 Control Inputs Signal Function Interface name 1 EXT 1 External latch signal 1 Functions as an origin signal during origin sear
7. 24 V correct Is the operating status overtravel limit switch of the correct Is the input signal external power supply voltage 24 V fluctuating Is the operation of the overtravel limit switch unstable Input the correct voltage 24 V Make sure the overtravel limit switch is operating correctly Is the wiring to the overtravel Wire the switch correctly limit switch correct Eliminate fluctuation in the external power supply voltage 24 V Stabilize the operation of the overtravel limit switch Is the overtravel limit switch wir Correct the wiring to the ing correct Is there cable damage Are the screws tight Check whether the position of the overtravel limit switch is too overtravel limit switch close for the amount of inertia Check whether the Encoder Ca ble wires are twisted pair wires or shielded twisted pair wires of at least 0 12 mmf Check the length of the Encoder Cable Check the Encoder Cable for any damage Check whether the Encoder Ca ble is too close to high current lines Check for ground problems loss of ground or incomplete ground at equipment such as welding machines near the Servomotor Check whether noise is infiltrat ing signal lines from the encod er There are problems with me chanical vibration or Servomotor installation such as mounting surface attachment or axial off set overtravel limit switch Check the POT
8. 6 9 Troubleshooting Chapter 6 Alarm Status when error Probable cause Countermeasures code occurs A 7A A b3 A b6 6 10 The overload alarm is Re evaluate the load and being reset when the operating conditions power is turned OFF Re evaluate the Servomotor and is operating Board overheat Occurs when the ing error power is turned ON capacity repeatedly aii The built in cooling Replace the cooling fan fan in the Servo Driver has stopped Cooling fan ventila Inspect the cooling fan tion is obstructed by dirt or foreign objects have gotten inside The Servo Driver is Replace the Servo Driver faulty Occurs during Ser The torque is greater Re evaluate the load and vomotor operation than the rated torque operating conditions The overload alarm is Re evaluate the Servomotor being reset when the capacity power is turned OFF and is operating repeatedly The ambient tempera Lower the ambient tempera ture for the Servo ture for the Servo Driver to Driver is above 55 C 55 C or below There is a problem Modify the installation condi with the Servo Driver tions so that the ambient tem installation such as perature for the Servo Driver direction or Spacing is 55 C or below between Units Is there heat radiation at the mounting panel or heat from the sur roundings The built in cooling Replace the cooling fan fan in the Ser
9. OMRON USER S MANUAL SMARTSTEP Junior MECHATROLINK II MODELS R7D ZNLI ML2 Servomotors Servo Drivers Thank you for choosing this SMARTSTEP Junior product This manual provides information on installation wiring switch setting and troubleshooting for the SMARTSTEP Junior Servomotors and Servo Drivers m Intended Audiences This manual is intended for the following personnel who must also have knowledge of electrical systems an electrical engineer or the equivalent e Personnel in charge of installing FA systems e Personnel in charge of designing FA systems e Personnel in charge of managing FA systems and facilities m NOTICE This manual contains information necessary for the operation of the SMARTSTEP Junior Servomotors and Servo Drivers Please read this manual thoroughly and understand its contents before attempting to operate the product Please keep this manual handy for future reference after reading it Be sure that this manual accompanies the product to its final user OMRON 2006 All rights reserved No part of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means mechanical electronic photocopying recording or otherwise without the prior written permission of OMRON No patent liability is assumed with respect to the use of the information contained herein Moreover because OMRON is con stantly striving to improve its high quality produ
10. The model number provides information such as the Servo Driver type the applicable Servomotor capacity and the power supply voltage R7D 2ZN01H ML2 SMARTSTEP Junior Servo Driver Driver Type P Pulse string input Applicable Servomotor Capacity 01 100 W 02 200 W 04 400 W 08 750 W Power Supply Voltage H 200 VAC Communications Type Blank Pulse train input ML2 MECHATROLINKII communications e Servo Driver and Servomotor Combinations Rated output Without brake Pulse MECHATROLINK II string input communications 100 W_ R7M Z10030 S1 R7M Z10030 B S1 R7D ZP01H R7D ZNO1H ML2 200 W_ R7M Z20030 S1 R7M Z20030 B S1 R7D ZP02H R7D ZNO2H ML2 400 W R7M Z40030 S1 R7M Z40030 B S1 R7D ZP04H R7D ZNO4H ML2 750 W R7M Z75030 S1 R7M Z75030 B S1 R7D ZP08H R7D ZNO8H ML2 Table of Contents Read and Understand this Manual secar 3 General Warnings 2 ua dto ies e da ad dd dis dd dba 6 Ttems to Check When Unpacking 0 34 dy nk Mev eee tela dd lao 12 ADOU Unis Montal boca rra Sia Geechee de ak ode elle do enw ints eet tae Se 15 Chapter 1 Features and System Configuration 1 1 Tel Ir dC OR a ais salsa cathe aa Diosa 1 2 152 System Contisura Oy ess patea os ads dl sta cla lides 1 4 1 3 Nomenclature and Functions go 0 4 4 04 5 0 paca Geb te det te baw hie ke bak babe 1 5 l 4 System Block Diagrams na souk date ee ced fe r ees A eda wae aes 1 7 l5 Applicable Standards
11. e Servo Drivers should be operated in environments in which there is minimal temperature rise to maintain a high level of reliability e Temperature rise in any Unit installed in a closed space such as a control box will cause the Servo Drivers ambient temperature to rise Use a fan or air conditioner to prevent the Servo Drivers ambi ent temperature from exceeding 55 C e Servo Driver surface temperatures may rise to as much as 30 C above the ambient temperature Use heat resistant materials for wiring and keep separate any devices or wiring that are sensitive to heat 4 2 System Design Chapter 4 e The service life of a Servo Driver is largely determined by the temperature around the internal elec trolytic capacitors The service life of an electrolytic capacitor is affected by a drop in electrolytic vol ume and an increase in internal resistance which can result in overvoltage alarms malfunctioning due to noise and damage to individual elements e If a Servo Driver is always operated at the maximum ambient temperature of 40 C and at 80 of the rated torque then a service life of approximately 50 000 hours can be expected excluding axial flow fan A drop of 10 C in the ambient temperature will double the expected service life m Keeping Foreign Objects Out of Units e Place a cover over the Units or take other preventative measures to prevent foreign objects such as drill filings from getting into the Units during ins
12. Appendix Chapter 7 Other Parameters from Pn800 PRM Parameter Factory Setting range oe No name setting eS ev Pn800 Communica Not Do not 0040H tions control used change the setting O Normal 2 oma data setting warn ing A 94 Ignore com mand warn ing A 95 3 Ignore A 94 and A 95 4 Ignore com munications warning A 96 5 Ignore A 94 and A 96 Ignore A 95 and A 96 7 Ignore A 94 A 95 and A 96 Do not change the setting Pn801 Function Software 0003H selection limit application 6 Software 7 LS software limit dis abled 2 Reverse software limit dis abled 3 Forward and reverse soft ware limits disabled 1to3 Not Do not used ai the setting Pn803 Zero point Sets the origin position output range 1com O to 250 width mand unit 7 5 Appendix Chapter 7 Parameter Factory Setting range Restart E eo Pn804 Forward soft Sets the software limit in the forward 1 073 741 823 1 com 1 073 741 823 to ware limit direction mand 1 073 741 823 unit Pn806 Reverse soft Sets the software limit in the reverse 1 073 741 823 1 com 1 073 741 823 to ware limit direction mand 1 073 741 823 unit Pn80B Linear accel Sets the acceleration 100 x10 000 1 to 65 535 eration con Com stant mand units s Pn80E Linear decel Sets the deceleration 100 x10 000 1 to 65 535 eration con Com stant mand units s 100 Pn81
13. Da A Y Servomotor end 7 EEES E 80 Cana Y e Wiring Servo Driver Servomotor Signa AWG20 Red Phase U Phase U AWG20 White Phase V Phase V AWG20 Blue Phase W 6 AwG2o OT Green Yellow OU AWG20 Black OU AWG20 Brown Servo Driver Connector Connector plug O4JFAT SAYGF N JST Mfg Co Ltd Servomotor Connector Connector plug 5557 06R 210 Molex Japan Connector case 5556TL Molex Japan 3 31 Specifications Chapter 3 Power Cables without Connectors Loose Wires for Servomotors with Brakes Cable Models Length L Outer diameter of cable See note 1 R7A CAZO1B 1 m See note 2 Approx 0 1 kg Note 1 The maximum distance between the Servo Driver and Servomotor is 20 meters Note 2 Cables are sold in 1 m increments It is cut to the specified length 3 4 4 Encoder Cable Specifications The Encoder Cable connects the encoder between the Servo Driver and Servomotor Encoder Cables are available in two forms Encoder Cables with an attached CN2 Connector and plain cable only Note When connecting to moving parts use robot cable to make a custom cable Encoder Cable CN2 Connector Attached e Cable Models Length L Outer diameter of cable See note R7A CRZ003C 7 1 dia Approx 0 4 kg R7A CRZ005C Approx 0 8 kg R7A CRZ010C Approx 1 2 kg R7A CRZ015C Approx 1 6kg R7A CRZ020C Approx 2 0kg Note The maximum distance bet
14. R7D ZNO8H ML2 e Application Example gt G QOL O TI T AE The diagram above shows two fuses mounted in a Servo Driver 4 14 System Design Chapter 4 No fuse Breakers NFB When selecting a no fuse breaker consider the maximum input current and the inrush current e Maximum Input Current e The Servo Drivers maximum momentary output is approximately three times the rated output and can be output for up to three seconds Therefore select no fuse breakers with an operating time of at least five seconds at 300 of the rated maximum output General purpose and low speed no fuse breakers are generally suitable e The table under 4 2 4 Wiring the Main Circuit and Servomotor Connections above shows the rated power supply input current for each Servomotor Select a no fuse breaker with a rated current greater than the total effective load current when multiple Servomotors are used e Add the current consumption of other controllers and any other components when selecting the NFB e Inrush Current e The following table lists the Servo Drivers inrush currents e With low speed no fuse breakers an inrush current 10 times the rated current flows for 0 02 sec ond e When there is a simultaneous inrush for multiple Servo Drivers select a no fuse breaker with a 20 ms allowable current greater than the total inrush current for those Servo Drivers shown in the fol lowing table Servo Dr
15. R7D ZPO8H R7D ZNO8H ML2 R88A PX5056 2 5 Standard Models and Dimensions Chapter 2 2 2 External and Mounted Dimensions 2 2 1 Servo Drivers R7D ZN01H ML2 ZNO2H ML2 ZNO4H ML2 100 W 200 W 400 W Mounting Dimensions Two M4 screw holes T 2 ol al D F 2 Ye gt aad To y om S Exterior alo TE Ground terminals Two M4 screws R7D ZNO8H ML2 750 W ooo gt 0000 IIE Mounting Dimensions Three M4 screws 5 ale Exterior o y gt ay LO E ES S le Ground terminals Two M4 screws 58 0 5 mounting pitch 70 2 6 Standard Models and Dimensions Chapter 2 2 2 2 Servomotors m 100 W Servomotor without a Brake R7M Z10030 S1 0 1 A ee 18 S oo oS SS oO oD O 0 30 025 Key Key groove 8 dia height 6 Two 4 3 dia m 100 W Servomotor with Brake R7M Z10030 BS1 Key Key groove 8 dia height 6 30 dia height 8 Two 4 3 dia Standard Models and Dimensions Chapter 2 m 200 W 400 W 750 W Servomotors without Brakes R7M Z20030 S1 Z40030 S1 Z75030 S1 300 20 Output Section on 750 W Servomotor L LL LM LR C D1 D2 G Z S QK mm mm mm mm mm mm mm mm mm mm mm R7M Z20030 S1 125 5 95 5 70 30 70 50h8 Four 14h6 20 5 5 dia R7M Z40030 S1 148 5 118 5193 30 70 50h8 Four 14h6 20 5 5 dia a je ep e ll 7 dia Standard Models and Dimensions Chapter 2
16. er supply is OFF Note 5 When turning OFF the main circuit power supply turn off the emergency stop input STOP at the same time 4 2 4 Wiring the Main Circuit and Servomotor Connections When wiring a Terminal Block use proper wire sizes grounding systems and anti noise measures m Terminal Block Names and Functions Signal Function Conton L1 Main circuits power supply input Single phase 200 230 V AC 170 to 253 V AC 50 60 Hz ION uo External regeneration resistance If regenerative energy is high connect an External connection terminals Regeneration Unit Servomotor connection terminals Red These are the terminals for outputs to the White Servomotor Be sure to wire these termi nals correctly Blue y Green Yellow Frame ground This is the ground terminal Ground to a minimum of 100 Q class D class 3 m Terminal Block Wire Sizes Model R7D ZP01H ZP02H ZP04H ZP08H tem U ZN01H ML2 ZNO2H ML2 ZNO4H ML2 ZNO8H ML2 Power supply capacity Main circuit power Rated curren External Regenera Wire size mm2 1 25 Wiring length 0 5 m max tion Unit connection terminals Servomotor connec Rated current A rms 3 3 Pe oP Poo 1 25 Wiring length 20 m max tion terminal U V W maximum A rms 2 5 See note momentary current Screw size v4 No fuse breaker or fuse capacity C C ECOS Note Connect an OMRON Servomotor Cable to the Ser
17. 1 5 Features and System Configuration Chapter 1 1 3 2 Servo Driver Functions m Rotary Switch for Setting Command Filter FIL This switch does not need to be set if the machine is not subject to vibration The switch is factory set to 0 Filter setting Acceleration deceleration Approx time from end of Description See note 1 time for STEP command command to end of positioning See note 2 settling time See note 3 o 45ms 100to200ms Smaller filter time constant 7 50 ms o oea short positioning time 2 60 ms 13010260 me 3 m 150to300ms 170 10 340 ms 200 to 400 ms Larger filter time constant 6 8BBms____ 250to500ms longer positioning time 500 to 1 000 ms a ducal Do not set this switch to 8 to F Note 1 Increase the value of the filter setting if there is vibration when starting or stopping Note 2 Use the acceleration deceleration times as a guideline for determining the Servomotor ca pacity that can be driven when using STEP commands without commanded acceleration deceleration Note 3 The settling time depends on the commanded acceleration deceleration the rigidity of the machine motor drive the encoder resolution and other factors 1 6 Features and System Configuration Chapter 1 1 4 System Block Diagrams HI K HI e VCC gt Switching power 15V2 ma ee y supply main cir cuit control VCC2 Relay drive ae VCC Phase U GR O Control power VCC Gate drive Curr
18. 2 3 Encoder Specifications lem Specification Encoder method Optical encoder incremental encoder Number of output pulses Phase A B 256 waves revolution Phase Z 1 pulse revolution Power supply voltage 5 VDC 5 Output interfacs PA ce 3 19 Specifications Chapter 3 3 3 Decelerator Specifications The following Decelerators are available for use with SMARTSTEP Junior Servomotors Select a Decelerator to match the Servomotor capacity 3 3 1 Standard Models and Specifications m Backlash 3 Arcminutes Max speed torque momentary momentary inertia radial thrust aa torque load load 100 W Tau es ee eee LR ws rra vaseeosBroo eas 220 ao so iesi_ taaaxto an 2e foss ns aro vaseeaiseroo 200 382 ao soo Jus asex10 see 20 oz es Rr vasrPaescioo 120 636 ao fio 12 asexto reza es 17 200w 1 5 _ R7e vRSFPBosB200 600 271 es 900 ee rssx1o ose fie ozz e R7evRsFPBoocaoo 388 37a os 500 ma 2wexi0 es es 17 is zo vaseeaiscaoo 200 est es soo 1e9 armo mre see 21 wow 15 a7G VASFPBOSCA0O 600 540 es 900 162 s22xto rea see h7 760 w 1 5 A7GVASFPSOSO7SO 600 108 so 90 ezo 7imio vea ose 21 Note 1 The Decelerator inertia is the Servomotor shaft conversion value Note 2 The enclosure rating for Servomotors with Decelerators is IP44 Note 3 The allowable radial load is the value at the center of the shaft m Backlash 45 Arcminutes Max
19. 5 2 UL and cUL Standards Standard Product Applicable standards File number Comments UL AC Servo Drivers UL 508C E179149 Power Conversion Equipment AC Servomotors UL 1004 E179189 Electric Motors cUL AC Servo Drivers cUL C22 2 No 14 E179149 Industrial Control Equipment AC Servomotors cUL C22 2 No 100 E179189 Motors and Generation Equipment 1 8 Chapter 2 Standard Models and Dimensions 2 1 Standard Models 2 2 External and Mounted Dimensions Standard Models and Dimensions Chapter 2 2 1 Standard Models 2 1 1 Servo Drivers Specifications Model With MECHATROLINK II 100 W R7D ZN01H ML2 communications 200 W R7D ZN02H ML2 400 W R7D ZN04H ML2 750 W R7D ZNO8H ML2 2 1 2 Servomotors Specifications TO Model Without brake With brake 2 1 3 Servo Driver Servomotor Combinations Rated output Without brake With MECHATROLINK II communications 100 W R7M Z10030 51 R7M Z10030 BS1 R7D ZN01H ML2 200 W R7M Z20030 S1 R7M Z20030 BS1 R7D ZNO2H ML2 400 W R7M Z40030 S1 R7M Z40030 BS1 R7D ZN04H ML2 750 W R7M Z75030 S1 R7M Z75030 BS1 R7D ZNO8H ML2 Note Only the Servomotor and Servo Driver combinations listed here can be used Do not use other combinations 2 2 Standard Models and Dimensions Chapter 2 2 1 4 Decelerators Straight Shaft with Key m Backlash 3 Arcminutes Max 100 W 200 W 400 W 1 9 750 W 115 R7G VRSFPB15D750 1 25 R7G VRSFPB25E750 m Backlash 45 Arcminutes Max Spec
20. 9 Encoder Connector Specifications CN2 Pin No Function interface Signal Name Power supply output for the encoder 5 V 70 mA 2 lew lenaerponersuppGND AAN 6 Phase E Encoder phase B input Phase U Pole sensor phase U impui Open coleciorinput 8 Phase Y Pole sensor phase Vinput Open coleciorinput OOO I Pole sensor phase W input Open collector input Shell Shield ground Cable shield ground Connectors for CN2 10 pin eo Soldered Connector Plug Cable and Cover Set 54599 1005 Molex Japan Co Plug Connector 51593 1011 e Crimped Solderless Connector Plug Cable and Cover Set 54559 1005 Molex Japan Co Plug Housing 51209 1001 Crimp Terminal 59351 8187 Loose wire Crimping Tool 57401 5300 3 12 Specifications Chapter 3 3 1 10 MECHATROLINK II Communications Specifications CN6 ica ios Minimum transmission distance 0 5 m between nodes 2 core shielded twisted pair cable Note This is the total length of cable connected between the devices The maximum length will vary depending on the number of connected devices For details on the total cable length refer to 3 4 1 MECHATROLINK II Communications Cable Spec ifications Communications Repeaters The table below shows when a Communications Repeater is required or not required depending on the number of MECHATROLINK II devices connected and the maximum transmission distance e Communications Repeater Model Number
21. A 05 Unsupported Occurs when the The Servo Driver is Replace the Servo Driver Servo Driver power is turned faulty alarm ON 6 6 Troubleshooting Chapter 6 Alarm code Status when error Probable cause occurs Occurs when the power is turned ON or during oper ation The connection between the U V or W phases and the ground terminal is faulty The ground wire is linked to another ter minal Short circuiting is occurring between the U V or W phases for the Servomotor main circuit cable anda ground The Regeneration Unit wiring is incor rect Short circuiting is occurring between the Servo Driver U V or W phases and a ground Short circuiting is occurring between the Servomotor U V or W phases and the ground or between the Servomotor U V and W phases The load is too large and exceeds the regeneration absorp tion capacity There is a problem with the Servo Driver installation such as direction Spacing between Units or ambient temperature The Servomotor is operating at over the rated output The Servomotor and Servo Driver combina tion is not correct Countermeasures Check and correct the wiring Repair or replace the Servo motor main circuit cable Caution Before turning ON the power again be sure to verify that there are no short circuits or interconnected lines Check and correct the wiring Replace the Servo Driver Replace the S
22. Communications Repeater FNY REP2000 e Communications Repeater Requirements Number of connected Maximum transmission distance owm 3tiosom 1 to 15 Repeater not required Repeater not required Repeater not required Repeater required 17 to 30 Repeater required Repeater required 3 13 Specifications Chapter 3 a System Configuration The following diagram shows the basic system configuration Connection Example CJ1W NCF71 and CS1W NCF71 Host device Servo Driver Servo Driver Servomotor Servomotor 3 1 11 MECHATROLINK II Communications Settings This section describes the switch settings required for MECHATROLINK II communications Communications Specifications MECHATROLINK II communications specifications are set using the DIP switch SW2 for MECHA TROLINK II communications settings The settings are shown in the following table Changes to the settings go into effect after the power is turned ON Contents Factory setting Axis No 16 min Filter setting selection OFF Enables or disables the rotary switch for setting the command filter FIL m Transmission Cycle The following table shows the transfer times that can be used by the Servo Driver and the numbers of axes that can be connected Axis No setting O Axis No 15 max SF SW factory settings Transmission cycle See note 0 5 ms 1 0 ms 1 5 ms 2 0 ms 2 5 ms 3 0 ms 3 5 ms 4 0 ms Num
23. E SS rating E is IS Models with MECHATROLINK II_ ZNO1H ML2 ZNO2H ML2 ZNO4H ML2 ZNO8H ML2 communications Note 1 These are the values when the Servomotor is combined with a Servo Driver and the arma ture winding temperature is 100 C Other values are at normal conditions 20 C 65 The momentary maximum torque shown above indicates the standard value Note 2 This is the value without an accessory such as an External Regeneration Unit Note 3 The brakes operate when the circuit is open i e they are released when voltage is applied Note 4 The operation time is the measured value reference value with a varistor installed as a surge suppressor Brake i Radial load Thrust load a 3 17 Specifications Chapter 3 m Torque and Rotation Speed Characteristics The following graphs show the characteristics with a 3 m standard cable and a 200 V AC input R7M Z10030 S1 N m Repetitive usage Continuous usage r 1000 2000 3000 4000 5000 R7M Z40030 S1 N m 4 0 43 82 3 0 Repetitive usage 2 6 2 0 1 0 Continuous usage r 1000 2000 3000 4000 5000 3 18 min min R7M Z20030 S1 N m 2 0 71 91 15 1 3 Repetitive usage 1 0 oo 0 419 Continuous usage r min 1000 2000 3000 4000 5000 R7M Z75030 S1 N m 8 0 6 0 Repetitive usage 4 0 2 0 Continuous usage 1 45 r min 1000 2000 3000 4000 5000 Specifications Chapter 3 Tem
24. Note There is some loss due to winding resistance so the actual regenerative energy will be approx imately 90 of the values derived from these equations 4 25 System Design Chapter 4 e The average regeneration power Pr is the power consumed by regeneration resistance in one cycle of operation Pr Eg1 Eg2 T W T Operation cycle s e Since there is an internal capacitor to absorb regenerative energy the value for Eg1 and Eg2 unit J must be lower than the Servo Driver s regenerative energy absorption capacity The capacity varies depending on the model For details refer to 4 3 2 Servo Driver Regenerative Energy Absorption Capacity below If an external External Regeneration Unit is connected be sure that the average regeneration power Pr does not exceed the external External Regeneration Unit s regenerative energy absorp tion capacity 12 W m Vertical Axis N1 Falling Servomotor operation Rising N2 Servomotor output torque Note In the output torque graph acceleration in the positive direction rising is shown as positive and acceleration in the negative direction falling is shown as negative e The regenerative energy values in each region can be derived from the following equations Egi EZ Ni Tort J 0 0524 N1 TD1 t1 J 2T Eg2 y N2 Tia t2 J 0 105 N2 Tp2 t3 J Eo a No Tpe ts J 0 0524 N2 Tb2 t
25. Servomotor and Servo Driver according to the installation con 4 7 Installation installation ditions Do not connect the Servomotor to the mechanical system before Conditions checking the no load operation Wiring and Connect to power supply and peripheral devices 4 2 Wiring connections Note Specified installation and wiring requirements must be satisfied particularly for models conforming to the EC Directives y Switch settings Make sure that the power supply is turned OFF and set the Servo 5 2 Switch Set Driver s front panel switches tings Preparing for After checking the necessary items turn ON the Unit s power supply 5 3 Preparing operation Check to see whether there are any internal errors in the Servo Driver for Operation Function set Set the functions with the user parameters according to the application 5 4 User tings Parameters y Trial operation First turn the power OFF and then ON again to enable the parameters 5 5 Trial Oper that have been set ation Then check Servomotor operation with no load Next turn OFF the power again and connect the Servomotor to the mechanical system Turn ON the power and check to see whether protective functions such as emergency stop and operational limits are working reliably Check operation at both low speed and high speed with either no work piece or a dummy workpiece Execute the operations using commands from the host controller Adjustme
26. cn a ae a a 1 8 Chapter 2 Standard Models and Dimensions 2 1 Zzal Standard Models dad as ed a lia ee ee ee x 2 2 2 2 External and Mounted DIMENSIONS 0 A a 2 6 Chapter 3 Specincations s 460 a 3 1 3 1 Servo Driver SpecinCallOnS ia A A A A E 3 2 552 SEEVOMOLOL gt PECTMCALONS da a E AS 3 16 325 Decelerator SpecinCallOns se taria di ee Sd 3 20 3 4 Cable and Connector pecIfiCatI0NS o oooooooooor eee ees 3 21 3 5 External Regeneration Unit and External Regeneration Resistor 3 35 De Or ACRO poo cede ates ao ata So Ree Aas 3 37 Chapter 4 System Design eeoeeeeeeeee amp ee ee we 405uweoeexee 50oeee e0e t8tRt8 8ee eeee8e0 00 00 0 4 1 4 1 Installation Conditions lt a A AS A SESS 4 2 AD W arrasa pi ele acacia ia 4 7 4 3 Regenerative Energy Absorption criada dd tiara 4 25 Chapter 5 Operation 00000 0 0 0 000 0 0000Oo00O00Oo00Oo0Oo0OoaOAOAaOAaAOAAOAOAOAAAAAAAaAAsAseA 5 1 Sal Operational Procedure Za y Bee d bie uae Renee ee ble eee eae ee 5 2 3 2 WHOSE nseries des 5 3 gt Preparin tor OPa Oi 2 5 anna Seek ned Na A Ae 5 6 34 User Parameters stilo Ae KOR NSE ee EN a 5 8 So Tia l Operon sas ee eek ee ea tee ae eh ee ee he ee 5 17 FO Operating FUNCOMS ss 2 haw 6 crea et Beas 5 19 Chapter 6 Troubleshooting ccc cece cece cece ooo 6 1 6 1 6 2 6 3 6 4 6 5 Error Processing Alarm Table Troubleshooting Overlo
27. codes for alarms that occur at the Servo Driver are stored at the Controller as 40L 11 1 hex The alarm code is displayed in the L digits For example alarm code 40B3 hex would be stored at the Controller for a current detection error A b3 e Controller Storage Area Controller Storage variable memory Stored data area name Position Control Unit Input area for individual Stored as error codes for errors CJ1W NCF71 axis operation axis error that occur at each axis CS1W NCF71 code Note For details on system variables and memory areas refer to the user s manual for the particular Position Controller 6 1 3 Replacing the Servomotor and Servo Driver Use the following procedure to replace the Servomotor or Servo Driver m Replacing the Servomotor 1 Replace the Servomotor 2 Establish the mechanical origin for position control e When the Servomotor is replaced the Servomotor s origin position Z phase may become in correct so the origin must be established e Refer to the Position Controller s manual for details on establishing the origin m Replacing the Servo Driver 1 Copy the parameters e Use the CX Process Tool at the personal computer to transfer all of the user parameters in the Servo Driver to the personal computer or host controller and save the parameters there 2 Replace the Servo Driver 3 Set the parameters e Transfer all the saved user parameters to the Servo Driver Troubleshooting Chapter 6
28. conform to EMC Directives The following conditions must be met to conform to EMC Directives e The Servo Driver must be installed in a metal case control panel The Servomotor does not how ever have to be covered with a metal plate e Noise filters and surge absorbers must be installed on all power supply lines e Shielded cables must be used for all I O signal lines and encoder lines Use tin plated soft copper wires for the shield weaving e All cables leaving the control panel must be wired in metal ducts or conduits with blades The 30 cm power cable encoder cable and connector do not have to be inserted in metal ducts or con duits e Clamp filters must be installed on cables with braided shields and the shield must be directly grounded to a ground plate m Wiring Method Control panel Device with built in motor Brake Mone m pow er fa T Radio noise filter Radio R7D Z noise filter Metal duct or conduit Metal duct or conduit AC power oe supply LP filter an gt filter Class ground to 100 Qor less Clamp filter Ground Controller plate power supply Clamp filter Controller NN NN A SS SS A ental Note 1 Make 1 5 turns for the ferrite core s cable winding Note 2 Peel the insulation off the cable at the clamp and directly connect
29. for Encoder Cables use clamp filters e The following table shows the recommended ferrite core clamp filter models Maker Productname Model number Specifications SES TOKIN Clamp type EMI Core ESD SR 250 For cable diameter up to 13 mm Clamp Filters for Cable ZCAT2032 0930 For cable diameter up to 9 mm ZCAT3035 1330 For cable diameter up to 13 mm ZCAT2035 0930A For cable diameter up to 9 mm e Do not place the Encoder Cable in the same duct as Control Cables for brakes solenoids clutches and valves m Improving Control I O Signal Noise Resistance Positioning can be affected and I O signal errors can occur if control I O is influenced by noise Fol low the methods outlined below for the power supply and wiring e Use completely separate power supplies for the control power supply especially 24 VDC and the external operation power supply In particular do not connect the two power supply ground wires e Install a noise filter on the primary side of the control power supply e f Servomotors with brakes are being used do not use the same 24 VDC power supply for both the brakes and the control I O Also do not connect the ground wires Connecting the ground wires may cause I O signal errors e l the control power supply wiring is long noise resistance can be improved by adding 1 uF lami nated ceramic capacitors between the control power supply and ground at the Servo Driver input section or the Controller outp
30. for connecting to the Con Block nector Terminal Block The figures indicated by the boxes LL 11 1 in the model number show the length of the Cable The Cable is available in two lengths 1 m or 2 m Example model number XW2Z 100J B19 1 m General purpose Control Cable R7A CPZUULIS This cable has a connector attached to connect to the Control I O Connector CN 1 The UUL digits in the model number indicate the cable length either 1 m or 2 m Example model number R7A CPZ001S 1 m m Servomotor Power Cables CNB There are two kinds of Servomotor Power Cables one for Servomotors with a brake and another for Servomotors without a brake Select the Cable to match the Servomotor being used Specification Modelnumber number Comments For a Servomotor without a R7A ee eer The ULIL digits in the model number indicate the brake cable length 3 m 5m 10 m 15 m or 20 m For a Servomotor with a brake R7A CAZL IL JJB Example model number R7A CAZ0035S 3 m cable for a Servomotor without a brake 4 8 System Design Chapter 4 Encoder Cables CN2 Modelnumber number Encoder Cable R7A eesel number Comments The L digits in the model number indicate the cable length 3 m 5m 10 m 15 m or 20 m Example model number R7A CRZ003C 3 m System Design Chapter 4 4 2 3 Peripheral Device Connection Examples m R7D ZN01H ML2 2N02H ML2 2N04H ML2 2N08H ML2 R
31. has occurred Check the status of the alarm indicators A L 1 1 and evaluate the problem based on the alarm indi cated e When an alarm has not occurred Evaluate the problem with the error information 6 1 2 Precautions When Troubleshooting When checking and verifying I O after a problem has occurred the Servo Driver may suddenly start to operate or suddenly stop so always take the following precautions In addition never attempt operations that are not specified in this manual m Precautions e Disconnect any cables before checking whether they are broken or damaged Even if you have checked the conduction of the wiring there is a risk of conduction due to the return circuit e If the encoder signal is lost the Servomotor may overrun or an error may be generated Be sure that the Servomotor is disconnected from the mechanical system before checking the encoder sig nal e When performing tests first check that there are no personnel in the vicinity of the mechanical equipment and that the equipment will not be damaged even if the Servomotor overruns Before performing the tests verify that you can immediately stop the machine using an emergency stop even if the Servomotor overruns Troubleshooting Chapter 6 Checking the Alarm Code at the Controller With CJ1W NCF71 and CS1W NCF71 Position Control Units alarm codes at the Servo Driver are stored at the Controller as follows e Alarm Codes at the Controller Alarm
32. is established by exe cuting origin search the present position is cleared to 0 m Operation Overview Zero point return feed speed Zero point return approach speed 1 Pn817 a Zero point return approach speed 2 Pn818 l l Final travel distance to return to zero point Pn819 l Phase Z input or external latch signal 1 EXT1 m Origin Search Direction Pn816 0 Setting O 1 Unit Factory Restart to range setting enable Set Values Set value O Forwardrotation e Set the speed for after the origin proximity input DEC signal turns ON during an origin search m Origin Search Approach Speed Pn817 e Set the speed for after the origin proximity input DEC signal turns ON during an origin search m Origin Search Creep Speed Pn818 e Set the speed for finding the origin after the origin proximity input DEC signal turns from ON to OFF during an origin search 5 15 Operation Chapter 5 m Origin Position Offset Pn819 Pn819 Final travel distance to return to zero point reste _ 1 073 741 823 Unit 1 command Factory Restart to range to unit setting enable 1 073 741 823 e Set the distance from the phase Z input signal or external latch signal 1 EXT1 input position until the origin during an origin search e If the origin position offset Pn819 is in the opposite direction of the origin search or if the distance is too short positioning will decelerate to a stop an
33. is infiltrating the Encoder Cable because it is too long Noise is infiltrating the signal wires because the Encoder Cable is dam aged or the sheath is cut Too much noise is reach ing the Encoder Cable The FG potential is fluc tuating due to devices such as welding ma chines near the Servo motor Errors are being caused by excessive vibration or shock at the encoder The filter setting is not suitable Inspect the machinery to see whether any foreign objects may have gotten inside and look for any damage deformation or looseness Check whether the Encoder Ca ble wires are twisted pair wires or shielded twisted pair wires of at least 0 12 mmf Check the length of the Encoder Cable Check the Encoder Cable for any damage Check whether the Encoder Ca ble is too close to high current lines Check for ground problems loss of ground or incomplete ground at equipment such as welding machines near the Servomotor There are problems with me chanical vibration or Servomotor installation such as mounting surface attachment or axial off set Check the setting on the com mand filter setting rotary switch FIL Correct any problems Use Encoder Cable that meets the specifications Use Encoder Cable no more than 20 m in length Correct the Encoder Ca ble pathway to prevent damage Install the Encoder Cable where it will not be subject to surges Ground the equipment pro
34. on the Servomotor e When installing the Servomotor avoid the Servomotor shafts key groove when installing the set bolt Rubber cap Input shaft Set bolt Servomotor installation bolt 1 Remove the rubber cap and check that the set bolt is loose 2 Insert the Servomotor shaft into the input shaft 3 Tighten the Servomotor installation bolt to the torque specified in the following table Servomotor installation bolt Tightening torque N m Ma Me 5B 4 Tighten the set bolt to the torque specified in the following table Set bolt Tightening torque N m 5 After tightening the set bolt replace the rubber cap Using a Decelerator from Another Company Reference Information If the system configuration requires another company s decelerator to be used in combination with a SMARTSTEP Junior Servomotor select the decelerator so that the load on the motor shaft i e both the radial and thrust loads is with the allowable values Refer to 3 2 2 Characteristics under for details on the allowable loads for Servomotors Also select the decelerator so that the allowable input speed and allowable input torque of the decelerator is not exceeded System Design Chapter 4 4 2 Wiring 4 2 1 Connecting Cables This section shows the types of connecting cables used in a SMARTSTEP Junior system A wide selection of cables are available for OMRON SYSMAC Position Control Units making it easy to wire a
35. screwdriver end width 2 5 to 3 0 mm into the opening for Servo Driver in stallation and press down firmly to open the slot as in Fig B 4 Insert the wire into the slot With the slot held open insert the end of the wire Then let the slot close by releasing the pres sure from the lever or the screwdriver 5 Mount the Terminal Block to the Servo Driver After all of the terminals have been wired return the Terminal Block to its original position on the Servo Driver 4 13 System Design Chapter 4 4 2 5 Selecting Connection Components This section explains the criteria for selecting the connection components required to improve noise resistance Review each component s characteristics such as its capacity performance and appli cable conditions when selecting the components For more details contact the manufacturers directly m Fuses e Always install fuses at each Servo Driver to prevent fire or burn damage e Two fuses are required per Servo Driver e We recommend the following fuses based on the rated current current at the maximum momen tary torque and inrush current when the power is turned ON Servo Driver Fuse Littelfuse Inc Fuse block Littelfuse Inc Capacity Momentary ES Specifications W rating A rms R7D ZP01H a po KLKO15 a Max AC voltage 600 V R7D ZNO1H ML2 Max rated current 30 A R7D ZP02H Screw Q C Terminals R7D ZNO2H ML2 R7D ZP04H pice R7D ZP08H 750 P 30
36. setting if there is vibration when starting or stopping Note 2 The settling time depends on the commanded acceleration deceleration the rigidity of the machine motor drive the encoder resolution and other factors Note 3 Use the acceleration deceleration times as a guideline for determining the Servomotor ca pacity that can be driven when using STEP commands without command acceleration de celeration 5 5 Operation Chapter 5 5 3 Preparing for Operation This section explains the procedure following installation wiring and switch setting of the Servomo tor and Servo Driver to prepare the mechanical system for trial operation It explains what you need to check both before and after turning ON the power 5 3 1 Items to Check Before Turning ON the Power e Checking Power Supply Voltage e Check to be sure that the power supply voltage is within the ranges shown below R7D ZNULIH ML2 Single phase 200 V AC input Main circuit power supply Single phase 200 230 V AC 170 to 253 V 50 60 Hz e Checking Terminal Block Wiring e The main circuit power supply inputs L1 L2 must be properly connected to the terminal block e The Servomotor s red U white V and blue W power lines and the yellow green ground wire must be properly connected to the terminal block e Checking the Servomotor e There should be no load on the Servomotor Do not connect to the mechanical system e The Servomotor s power lines and Servo
37. signal selection Change the setting of Pn50A 3 user parameter Pn50A 3 Check the NOT signal selection Change the setting of Pn50B 0 user parameter Pn50B 0 Correct the position of the Use Encoder Cable that meets the specifications Use Encoder Cable no more than 20 m in length Correct the Encoder Ca ble pathway to prevent damage Install the Encoder Cable where it will not be subject to surges Ground the equipment properly and prevent cur rents from flowing to the encoder FG Implement noise counter measures in the encoder wiring Reduce the mechanical vibration or correct the Servomotor installation Troubleshooting Chapter 6 Problem Probable cause Probable cause Countermeasures The encoder is faulty SSIES e whether the encoder is Replace the Servomotor faulty The Servo Driver is Check whether the Servo Driver Replace the Servo Driver faulty PCB is faulty Position devia There is a problem with Check whether there is slippage Correct the coupling tion The posi the coupling between the in the coupling section between tion is not machine and the Servo the machine and the Servomo correct but no motor tor AANS OPUN The encoder is faulty Check whether the encoder is Replace the Servomotor Pulses are not chang faulty ing 6 19 Troubleshooting Chapter 6 6 4 Overload Characteristics Electronic Thermal Function An overloa
38. was bers correctly setting warning II command is set sent A value outside of the Set the value in the setting setting range was set in the user parame ters A 96 MECHA Occurs at the start The MECHA Wire the MECHATROLINK II TROLINK II of or during TROLINK II wiring is Communications Cable cor communications MECHATROLINK incorrect rectly error warning Il communications Wire the terminating resis tance correctly A MECHATROLINK Implement measures against Il data reception error noise such as modifying the occurred due to MECHATROLINK II Commu noise nications Cable and FG wir ing and installing a ferrite core in the MECHAT ROLINK Il Communications Cable Troubleshooting Chapter 6 6 3 3 Error Diagnosis Using the Operating Status The power supply cable Check whether the power sup Input the correct power is wired incorrectly ply input is within the allowed supply voltage voltage range Check whether the power sup Wire correctly ply input is wired correctly The External Regenera Check whether the connection Wire correctly tion Unit is wired incor to the External Regeneration rectly Unit is wired correctly The Servomotor The I O CN1 wiring is Check the CN1 connector and Wire the CN1 connector does not start incorrect the wiring correctly Servomotor or encoder Check the wiring Connect the wiring wiring is disconnected There is an overlo
39. 0 Overcurrent Overcurrent flowed to the IGBT or the Servo DB stop No Driver heat sink overheated A 28 Emergency stop An emergency stop was input during Servomo DB stop Yes tor operation Overvoltage The main circuit DC voltage is abnormally high DB stop A 41 Undervoltage The Servo Driver power was turned back ON __ Zero Y before it was completely turned OFF speed stop The Servomotor speed is abnormally high DB stop A 71 Overload Momen Operated for several seconds at a torque Zero Y tary maximum load greatly exceeding the rated load speed stop Overload Continu Continuously operated at a torque exceeding DB stop Yes Y es es es 72 ous maximum load the rated load 73 Dynamic brake over The Servomotor did not stop even when three DB stop es load or more seconds elapsed after the Servo turned OFF TA Board overheating The Servo Driver internally overheated or the Zero No error built in cooling fan stopped speed stop A b3 Current detection The Servomotor s current detector failed or the DB stop No error Servomotor power line became disconnected A A A 6 4 Troubleshooting Chapter 6 Alarm Error detection Detected error or cause of error Stopping Alarm code function method reset A b6 MECHATROLINK II Error in MECHATROLINK II communications DB stop No communications LSI LSI error System alarm The Servo Driver is faulty DB stop A C1 Runaway prevention Servomotor has run out of control
40. 070 16 07 250 V 0 4 mA phase Note The last two digits of the noise filter model number indicate the type of terminal connection The 07 models have lead wires the 06 models have fast on connections that can be sol dered and the 08 models have screw terminals Select the appropriate version for your appli cation Contact the manufacturer www schaffner com for details Dimensions The following diagram shows the dimensions of a noise filter with lead wires Contact the manufac turer for dimensions of the noise filters with other connections e Single phase Input Models FN2070 6 07 and FN2070 10 07 45 4 56 5 9 oe 4 16 System Design Chapter 4 e Single phase Input Model FN2070 16 07 57 6 140 98 5 140 9 SS ER A 0 A AS A m P O 109 119 Noise Filter for the Brake Power Supply e Use the following noise filter for the brake power supply Rated Rated Leakage current current voltage SUP P5H EPR 250 V 0 6 mA at 250 Vrms 60 Hz Okaya Electric Industries Co Ltd Dimensions e Noise Filter for the Brake Power Supply SUP P5H EPR i 100 2 E _ 84 1 l 5 74 7 1 l 38 1 63 541 50 8 1 4 17 System Design Chapter 4 Surge Suppressors e Install surg
41. 14 52A0 008 Sumitomo 3M 3 24 Specifications Chapter 3 Connector Terminal Block Conversion Unit XW2B 20GL The Servo Driver s control I O connector CN1 can be converted to a terminal block by using it in combination with Connector Terminal Block Cable KW2Z _ J B19 o XW2B 20G4 M3 screw Terminal Block A lt I Ial Note 1 Use power lines of 0 3 to 1 25 mm AWG22 to 16 Note 2 The power line insertion opening is 1 8 mm height x 2 5 mm width Note 3 As shown in the diagram below peel back the power line insulation for 6 mm from the end ee P 45 3 3 25 Specifications Chapter 3 eo XW2B 20G5 M3 5 screw Terminal Block e Dimensions aes TL ee XG4A A Note 1 When using crimp terminals use the dimensions shown below Note 2 Mount power lines and crimp terminals to the terminal block at a torque of 0 59 N m Round Crimp Terminal Forked Crimp Terminal 3 7 dia mm t 6 8 mm max HC 3 mm 6 8 mm max Applicable crimp terminals Applicable power lines power Applicable power lines Round terminals 1 25 3 AWG22 16 0 3 to 1 25 mm AWG16 14 1 25 to 2 0 mm Y terminals 1 25Y 3 AWG22 16 0 3 to 1 25 mm 2 3 5 AWG16 14 1 25 to 2 0 mm 3 26 Specifications Chapter 3 e XW2D 20G6 M3 screw Terminal Block ot Two 4 5 dia ute A ee Note 1 When using crimp terminals use t
42. 16384 4096 Electronic gear ratio x G2 500 1 500 125 e Check to make sure that the following condition is satisfied 0 01 lt Electronic gear ratio G1 G2 lt 100 If the electronic gear ratio is outside of this range the Servo Driver will not operate correctly In that case change either the machine configuration or the command unit 5 11 Operation Chapter 5 6 Set the values in the user parameters e The electronic gear ratio G1 G2 is reduced as shown above and so that both G1 and G2 are integers smaller than 1 073 741 824 and then the values are set in the user parameters Set G1 in Pn20E and G2 in Pn210 e The results in this example are 4 096 for G1 and 125 for G2 and they are set respectively in user parameters Pn20E and Pn210 This completes the setting of the electronic gear 5 4 4 Setting the Positioning Completion Width The positioning completion width provides a width for the output signal for the target position i e for the positioning completed signal As the positioning completion width is increased the positioning completed signal is output farther before the target position but the Servomotor will continue to oper ate until the target position is reached There is thus no problem with controlling stopping Positioning completion range A Included in positioning Machine coordinate system ye _ completion range we i lt _ _ Positioning completion widt
43. 20 ma ms mo 12 fie 4 fa 25 200 v s A7G RGsFosB200 725 32 52 eo 7o feo so as io as fio 12 20 ms ms ma 12 to 4 4 2s 9 a7e rasroscaoo 895 so 7e so zo joo 70 e2 17 s e to so ms mo meo 20 22 o 6 as is R7a RGSF15C400 100 so 7s so zo oo 7o e2 iw fa le to so ms m6 m4 20 2 e fe ss 4oow 15 RA7G ResFosc4o0 895 so ze jeo 70 so 7o e2 17 s 8 19 so ms ms ma 20 22 e 6 ss 19 R7G RGSFo9c400 895 50_ 78 so 70 so 70 e2 fi fa fe 19 30 ms me m 20 22 fo 6 ss is R7a ResF15c4o0 100 so 7e so 7o 9 7o e2 iw a je i9 so ms me m 20 2 e e as Note AT is the size of the set bolt Outline Drawings p ES pa Four Z2 Effective depth I Four Z1 A D2 dia D4 dia D3h7 dia Set bolt AT Key dimensions QK t1 2 11 Standard Models and Dimensions Chapter 2 2 2 4 External Regeneration Unit and Resistor Dimensions m External Regeneration Unit Mounting Dimensions SS Two M4 screws m External Regeneration Resistor Thermal switch output 1 5 dia 0 3 mm 3 dia 0 75 mm gt 28 8 AAA EA E gt 6 Y Else 500 J 200 20 A 220 Ll p 230 e 2 12 Standard Models and Dimensions Chapter 2 2 2 5 AC Reactor Dimensions Nameplate Dimension
44. 211 Bank of China Tower 200 Yin Cheng Zhong Road PuDong New Area Shanghai 200120 China Tel 86 21 5037 2222 Fax 86 21 5037 2200 OMRON Authorized Distributor Cat No 1554 E1 01 Note Specifications subject to change without notice Printed in Japan This manual is printed on 100 recycled paper
45. 3 9 reverse rotation mode 5 8 rotary switch for command filter setting 5 5 rotary switch for setting command filter 1 6 I 1 rotary switch for setting the axis number 3 15 5 4 S sequence inputs 3 8 Servomotor Connector CNB 2 5 Servomotor Connector for Encoder Cable 2 5 Servomotor Connector for Servomotor Power Cable 2 5 Servomotor Power Cable 4 8 STOP 3 9 surge absorber 4 15 surge suppressor 4 18 SW1 3 15 5 4 SW2 3 14 5 3 y Terminating Resistor 2 4 4 8 Index Revision History A manual revision code appears as a suffix to the catalog number on the front cover of the manual Cat No 1554 E1 01 Revision code The following table outlines the changes made to the manual during each revision Page numbers refer to the previous version Revision code Date Revised contort November 2006 Original production OMRON Corporation Control Devices Division H Q Shiokoji Horikawa Shimogyo ku Kyoto 600 8530 Japan Tel 81 75 344 7109 Fax 81 75 344 7149 Regional Headquarters OMRON EUROPE B V Wegalaan 67 69 NL 2132 JD Hoofddorp The Netherlands Tel 31 2356 81 300 Fax 31 2356 81 388 OMRON ELECTRONICS LLC 1 East Commerce Drive Schaumburg IL 60173 U S A Tel 1 847 843 7900 Fax 1 847 843 8568 OMRON ASIA PACIFIC PTE LTD 83 Clemenceau Avenue 11 01 UE Square Singapore 239920 Tel 65 6835 301 1 Fax 65 6835 271 1 OMRON CHINA CO LTD Room 2
46. 4 Final travel Sets the distance from the interrupt 1 073 741 823 to distance for signal EXT1 input position during 1 073 741 823 external interrupt feeding See note positioning Note In the negative direction or when the distance is short the rotation is reversed after decelerat ing to a stop Parameter Description Factory Setting range Restart name setting to enable Pn816 Zero point Zero point HO Forward direction OOOOH return mode return A settings direction 1to Not used Do not change 3 the setting 50 Pn817 Zero point Sets the speed for after the origin prox x100 O to 65 535 imity input signal turns ON during an Command origin search units s Pn818 Zero point Sets the speed for finding the origin x100 O to 65 535 return after the origin proximity input signal Command approach turns ON and OFF during an origin units s speed 2 search Pn819 Final travel Sets the distance from the phase Z sig 1 command 1 073 741 823 to distance to nal or external latch signal 1 EXT1 unit 1 073 741 823 return to zero input position to the origin during an ori point gin search See note Note In the origin search or reverse direction or when the distance is short the rotation is reversed after decelerating to a stop 7 6 Appendix Chapter 7 7 3 Position Data Range The position data length handled by MECHATROLINK II is four bytes Limitless operation beyond this length is as shown in th
47. 8 is generated PAN ININaININ Ce When turning OFF the main circuit power supply turn OFF the emergency stop input S TOP signal at the same time Even when the main circuit power supply is turned OFF by an external emergency stop the Servo motor continues to rotate due to residual voltage This can cause injury or damage to equipment Specifications Chapter 3 3 1 7 Control Output Circuits Sequence and Alarm Outputs Servo Driver Maximum operating voltage 30 VDC Maximum output current 50 mA External power supply 24 VDC 1 V Di Diode for preventing surge voltage Use high speed diodes 3 1 8 Control Output Details The CN1 connector output pins are described in detail below m Control Output Sequence ON L1 and L2 OFF Approx 2S 30 s max M gt Nf fd Alarm output ALM OFF ON Brake Interlock output BKIR OFF O to 35 ms o 2 ms gt ON Servo ON OFF 3 10 Specifications Chapter 3 m Alarm Output ALM Pin No 12 Alarm Output ALM Function e The alarm output is turned OFF when the Servo Driver detects an error e This output is OFF at startup and turns ON when the initial processing has been completed Approx 2 s is required for initial processing m Brake Interlock Output BKIR Pin No 13 Brake Interlock output BKIR Function e The external brake timing signal is output 3 11 Specifications Chapter 3 3 1
48. D ZNO1H ML2 R7D ZP02H R88A PX5053 2 0 20 0 Approx 0 6 R7D ZNO2H ML2 R7D ZP04H R88A PX5054 3 0 5 0 Approx 0 4 R7D ZNO4H ML2 R7D ZP08H R88A PX5056 4 0 2 0 Approx 0 4 R7D ZNO8H ML2 3 37 Specifications Chapter 3 3 38 Chapter 4 System Design 4 1 Installation Conditions 4 2 Wiring 4 3 Regenerative Energy Absorption System Design Chapter 4 4 1 Installation Conditions 4 1 1 Servo Drivers m Space around Drivers e Install Servo Drivers according to the dimensions shown in the following illustration to ensure proper heat dis persion and convection inside the panel Also install a fan for circulation if the Servo Drivers are installed side by side to prevent uneven temperatures from developing inside the panel i i D D D 2 _ Q Q Q o o o gt gt gt be Q o o Y Y Y wl w W 10 mm min Mounting Direction e Mount the Servo Drivers in a direction perpendicular such that the lettering for the model number and so on can be seen m Operating Environment e The environment in which Servo Drivers are operated must meet the following conditions Servo Drivers may malfunction if operated under any other conditions e Ambient operating temperature O to 55 C Take into account temperature rises in the individ ual Servo Drivers themselves e Ambient operating humidity 20 to 90 with no condensation e Atmosphere No corrosive gases Ambient Temperature
49. DB stop Yes detection A C2 Phase detection A Servomotor magnetic pole signal was incor DB stop No error rectly detected A C5 Magnetic pole detec A Servomotor magnetic pole signal was incor DB stop No tion error rectly detected Encoder signal error Error in encoder output signal amplitude DB stop Excessive following There is excessive residual following error DB error A MECHATROLINK II Error in synchronization between MECHA internal synchroniza TROLINK II communications and Servo Driver speed aon tion error 1 A EA MECHATROLINK II Error in synchronization between MECHA Zero internal synchroniza TROLINK II communications and Servo Driver speed Jeni tion error 2 A ED MECHATROLINK II Servo Driver internal command error Zero Yes internal command speed stop error A E4 MECHATROLINK II Error in transfer cycle setting for MECHA Zero Yes transfer cycle setting TROLINK I communications speed stop error A E5 MECHATROLINK II Synchronization error in MECHATROLINK II Zero Yes synchronization error communications speed stop A E6 MECHATROLINK II A communications error occurred during Zero Yes communications MECHAT ROLINK II communications or the speed stop error transfer cycle fluctuated m Warnings Warning Error detection Description code function A 91 Overload warning This warning is displayed before an overload alarm A 71 or A 72 occurs If operation continues in the same way an alarm ma
50. Error Diagnosis Using the Warning Indicators Warning Status when Probably cause Countermeasures code warning occurs A 91 Overload warn Occurs when the Servomotor wiring Wire the Servomotor main ing displayed servo is turned error Faulty wiring or circuit cable correctly before an over ON connections load alarm 4 71 Encoder wiring error Wire the Encoder Cable cor or A 72 occurs Faulty wiring or con rectly nections The Servo Driveris Replace the Servo Driver faulty Occurs during a Servomotor wiring Wire the Servomotor main command input error Faulty wiring or circuit cable correctly without the Servo connections motor rotating Encoder wiring error Wire the Encoder Cable cor Faulty wiring or con rectly nections The starting torque Re evaluate the load and exceeds the maxi Operating conditions mum torque Re evaluate the Servomotor capacity The Servo Driveris Replace the Servo Driver faulty Occurs during Ser The effective torque Re evaluate the load and vomotor operation exceeds the rated operating conditions torque Re evaluate the Servomotor capacity The ambient temper Keep the ambient tempera ature for the Servo ture for the Servo Driver at Driver is above 55 C 55 C or below The Servo Driveris Replace the Servo Driver faulty A 94 MECHA Occurs when a An unusable parame Set the user parameter num TROLINK II data MECHATROLINK ter data number
51. FF y See note 3 l A is gt 100 ms max See note 4 OFF Speed See note 2 Pulse command Speed Energized Servomotor power Not energized Note 1 Refer to the stop sequence on the following page Servo OFF and Error Timing when Ser vomotor is Rotating Note 2 The timechart above shows the time it takes from Servo ON until the brake is released Take this delay into account when sending the RUN command so that the RUN command is sent after the brake has been released There is also a delay between a change in the BKIR brake interlock signal and the brake power switching so check the relay response time Note 3 The time from turning ON the brake power supply to the brake being released depends on the Servomotor being used The following table shows the delay for each model R7M Z10030 B 60 ms max R7M Z20030 B R7M 240030 B R7M Z75030 B 5 19 Operation Chapter 5 Note 4 The maximum time from turning OFF the brake power supply to the brake engaging is 100 ms The brake s operation time depends on the type of surge suppressor installed on the brake Servo OFF and Error Timing When Servomotor Is Rotating RUN ON Run command OFF ALM ON alarm output OFF gt See note 1 BKIR ON brake interlock OFF s Energized ervomotor power Not energized See note 2 Ep Servomotor speed O0Or MIN nt A 3 Note 1 The BKIR
52. LINK II MLK Communications Cable CN6A B FNY W6003 6 po MC Connect an External Regeneration Terminating Unit as required Resistor FNY W6022 Servomotor R7M Z Power Cable R7A CAZLIS Red ae R7A CAZLIB O O O O 24 WDC 1 Be careful to wire the signals correctly Incorrect wiring can cause damage to the Unit and the Servo Driver 2 Do not wire unused signal lines but leave them open 3 For the surge absorbing diode the ERA22 06 by Fuji Electric or equivalent is recommend ed 4 Do not use the brake power supply 24 VDC for the control 24 VDC power supply 5 When turning the main circuit power supply OFF turn OFF the emergency stop input STOP signal at the same time Refer to 4 2 3 Peripheral Device Connection Examples for information on wiring Appendix Chapter 7 7 2 Parameter Tables Function Selection Parameters from Pn000 Parameter Factory Setting Reset to name ae ee ene Explanation setting range enable Pn000 Function Reverse CCW rotation 0010 selection rotation with positive basic command switches 1 CW rotation with positive command Not Do not ae used le setting 2 ia Not ES not cl E mm o setting PnOOA Command a when there is a problem such as over 0000H OOOOH to filter setting shooting OOOFH See note Note The setting method is the same as with the command filter setting rotary s
53. MANCE DATA Performance data given in this manual 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 users must correlate it to actual application requirements Actual performance is subject to the OMRON Warranty and Limitations of Liability ERRORS AND OMISSIONS The information in this manual has been carefully checked and is believed to be accurate however no responsibility is assumed for clerical typographical or proofreading errors or omissions General Warnings To ensure safe and proper use of SMARTSTEP Junior Servomotors and Servo Drivers read the general warnings provided below along with the rest of this manual to gain sufficient knowledge of the devices safety information and precautions before actual use This OPERATION MANUAL is to be delivered to the actual end users of the products Please keep this manual close at hand for future reference The following conventions are used to indicate and classify precautions in this manual Always heed the information provided with them Failure to heed precautions can result in injury to people or damage to property Indicates a potentially hazardous situation which if not avoided could result in N WARNING ee A death or serious injury Additionally there may be severe property damage Caution Indicates a potentially hazardous situation which if not avoide
54. Occurs at the start of MECHA TROLINK II com munications Occurs at the start of or during MECHATROLINK Il communications Occurs at the start of or during MECHATROLINK Il communications Status when error Probable cause occurs The MECHA TROLINK II transfer cycle setting is out of the specified range The MECHA Countermeasures Set an appropriate value for the MECHATROLINK II trans fer cycle setting at the host controller Make sure that the host con TROLINK II communi troller WDT data is properly cations data WDT that updated is updated by the host controller is not being normally updated With a MECHA TROLINK II connec tion established communications with the host controller were aborted and then started again The MECHA TROLINK II wiring is incorrect A MECHATROLINK II data reception error occurred due to noise Turn the power OFF and back ON again Alternatively close the communications connec tion with the host controller and set up the communica tions again Wire the MECHATROLINK II Communications Cable cor rectly Wire the terminating resis tance correctly Implement measures against noise such as modifying the MECHATROLINK II Commu nications Cable and FG wir ing and installing a ferrite core in the MECHATROLINK Il Communications Cable The Servo Driver is Replace the Servo Driver faulty 6 13 Troubleshooting Chapter 6 6 3 2
55. Rated Rated Maximum Maximum Decelerator Allowable Allowable speed torque momentary momentary inertia radial thrust speed torque load load O A mn Nm km N N kg rie nro mosresstoo as lez feo loo enact ann fee joss ins mramosriseroo 200 ase Jeo Joo ms asexio see aoe or 200w ws mre masrosezoo 600 ari Jes ooo asa wsaxio fas 1 lorz a aranesos ess ors Jee soo ne leeris oo aes 17 gt fins mramosriscsoo 200 eat Jee Jooo ieo ijarixio nre see er xow 15 nre masroscaoo eoo 540 Jes Joo 62 saxo vee ae r Note 1 The Decelerator inertia is the Servomotor shaft conversion value Note 2 The enclosure rating for Servomotors with Decelerators is IP44 Note 3 The allowable radial load is the value at the center of the shaft 3 20 Specifications Chapter 3 3 4 Cable and Connector Specifications 3 4 1 MECHATROLINK II Communications Cable Specifications MECHATROLINK II Communications Cable is special cable for connecting a SMARTSTEP Junior Servo Driver and a Position Controller with MECHATROLINK II Communications m MECHATROLINK II Communications Cable with USB Connectors at Both Ends With Core Model Length L Outer diameter of cable Weight 51da Dimensions L all E m Terminating Resistor for MECHATROLINK II Mode TFNYW6022 Dimensions 3 21 Specifications Chapter 3 MECHATROLINK II Communications Connection Example The following example
56. Single phase 200 to 230 VAC 50 60 Hz R7D ZN O O Ground to 100 Q or less O mo O Main circuit power supply Main circuit contactor OFF ON See note 1 o reactor d 2 10 O Oo Gas mc Fuse See note 1 Surge a 7 See note E i Servo error display SMARTSTEP Junior SMARTSTEP Junior Servo Driver Servomotor Servomotor faded cable External Regeneration Unit 7 See note 3 24 VDC iMG Ses Y a T Sl de ss 24 VDC re X O O User control device AA MECHATROLINK II cable Note 1 Recommended products are listed in 4 2 6 Conforming to EMC Directives Note 2 Recommended Relay OMRON MY series Relay 24 V model Note 3 An R88A RR22047S External Regeneration Resistor can be connected to the External Re generation Unit Connect the R88A RR22047S if the regenerative energy exceeds the re generative absorption capacity of the External Regeneration Unit Refer to the External Regeneration Unit specifications in 3 5 External Regeneration Unit and External Regener ation Resistor Connect the External Regeneration Resistor so that the power supply is cut off when the thermal switch output opens Refer to 4 3 4 Absorbing Regenerative Energy with an External Regeneration Resistor 4 10 System Design Chapter 4 Note 4 The dynamic brake will operate while the main circuit power supply or the control circuit pow
57. These values presume an ambient Servomotor operating temperature of 40 C shaft loads within the allowable range rated operation rated torque and rated r min and proper installation as described in the Operation Manual e The radial loads during operation rotation on timing pulleys and other components contacting belts is twice the still load Consult with the belt and pulley manufacturers and adjust designs and system settings so that the allowable shaft load is not exceeded even during operation If a Servomotor is used under a shaft load exceeding the allowable limit the Servomotor shaft can break the bearings can burn out and other problems can occur e When requesting repairs or investigations separate the Servomotors and Decelerators and make separate requests for each product 6 5 2 Servo Driver Maintenance The recommended periodic maintenance schedule is listed in the following table Please consult with your OMRON representative to determine whether or not components need to be replaced Aluminum electro 50 000 hours at an ambient Servo Driver operating tempera lytic capacitors ture of 40 C 80 of the rated operation output rated torque installed as described in operation manual 30 000 hours at an ambient Servo Driver operating tempera ture of 40 C and an ambient humidity of 65 6 21 Troubleshooting Chapter 6 e When using the Servo Driver in continuous operation use fans or air conditioners to mainta
58. V AC for 1 min Degree of protection Built into panel IP10 Interna EC Directives EMC EN 55011 Class A Group 1 tional Directive EN 61000 6 2 SANGAS ow Voltage EN 50178 Directive UL standards UL 508C cUL standards cUL C22 2 No 14 Note 1 The above items reflect individual evaluation testing The results may differ under compound conditions Note 2 Depending on the operating conditions some Servo Driver parts will require maintenance Refer to 6 5 Periodic Maintenance for details Note 3 The service life of the Servo Driver is 50 000 hours at an average ambient temperature of 40 C at 80 of the rated torque excluding axial flow fan ANNAN INTE Never perform withstand voltage or other megameter tests on the Servo Driver Specifications Chapter 3 3 1 2 Characteristics Control Specifications Servo Driver model R7D ZNO1H ML2 ZNO2H ML2 ZNO4H ML2 ZNO8H ML2 Input power supply voltage Single phase 200 to 230 VAC 170 to 253 V 50 60 Hz For main circuit and control circuit Input power supply current rms 1 8A 3 5 A 5 5 A 10A For main circuit and control circuit Heat generated Control circu Continuous output current rms 0 84 A rent rms 3 3 Specifications Chapter 3 3 1 3 Main Circuit and Servomotor Connector Specifications CNA and CNB m R7A CNZ01P CNA Main Circuit Connector Specifications CNA Connector
59. a Servomotor it will reduce the service life of the motor bearings and may damage the motor shaft e When connecting to a load use couplings that can sufficiently absorb mechanical eccentricity and variation e For spur gears an extremely large radial load may be applied depending on the gear precision Use spur gears with a high degree of accuracy for example JIS class 2 normal line pitch error of 6 um max for a pitch circle diameter of 50 mm e f the gear precision is not adequate allow back lash to ensure that no radial load is placed on the motor shaft 7 K Ball screw center line amet hehopepeN ND Ni Do not offset center lines Servomotor shaft center line A Adjust backlash by adjusting the distance between shafts Backlash System Design Chapter 4 e Bevel gears will cause a load to be applied in the thrust direction depending on the structural preci sion the gear precision and temperature changes Provide appropriate backlash or take other mea sures to ensure that no thrust load is applied which exceeds specifications e Do not put rubber packing on the flange surface e When connecting to a V belt or timing belt consult the maker for belt selection and tension e A radial load twice the belt tension will be placed on the motor shaft Do not allow a radial load exceeding specifications to be placed on the motor shaft due to belt tension If an excessive radial
60. ad Try operating the Servomotor Either reduce the load or with no load use a Servomotor with a greater capacity The Servo ON command Check the host controller com Send a Servo ON com is not being sent mands mand The emergency stop in Check the STOP POT and NOT Turn ON the STOP POT put STOP forward signals and NOT signals drive prohibit POT and reverse drive prohibit NOT signals are re Probable cause The power indi cator PWR does not light when the power is turned ON maining OFF The power is not ON Check the PWR indicator to see Turn ON the power if the power is ON Check the voltage between the Wire the power ON circuit power supply terminals correctly The Servo Driver is The Servo Driver PCB is faulty Replace the Servo Driver faulty The Servomotor The Servomotor is wired Check the Servomotor wiring Wire the Servomotor cor operates mo incorrectly rectly mentarily but The encoder is wired in Check the encoder wiring Wire the encoder correct then it does not correctly ly operate Servomotor ro The wiring to the Servo tation speed is motor is faulty unstable Check the wiring of the Servo Tighten any looseness in motor Power Cable U V and W the terminals and connec phases and check whether the tors encoder connector is stable The coupling between Check the mechanical system s Review and adjust th
61. ad Characteristics Electronic Thermal Function Periodic Maintenance 6 2 6 4 6 6 6 20 6 21 Table of Contents Chapter 7 Appendix cuand 7 1 Tal Conector Example yr bai ii dedo titi andres 7 2 72 Parameter Tabletas o Sn o be 7 3 JS POSTUOM Data ande sr o dad daa dae 7 7 WNGOX a5 Bae E EEEE LET T T EEEE EE T 1 1 About this Manual The contents of this manual is outlined in the following table Use this table as a guide to read required information Chapter Chapter 1 Features and System Con Describes SMARTSTEP Junior features and components as well as EC Direc figuration tive and UL Standard compliance Chapter 2 Standard Models and Describes the models external dimensions and installation dimensions of the Dimensions Servo Drivers Servomotors Decelerators and accessories Chapter 3 Specifications Provides general specifications characteristics connector specifications and I O circuit specifications for Servo Drivers general specifications characteristics and Encoder specifications for Servomotors and specifications for accessories Chapter 4 System Design Describes installation conditions for Servo Drivers Servomotors and Decelera tors wiring methods including EMC compliant wiring calculation methods for regenerative energy and the performance of External Regeneration Units and External Regeneration Resistors Chapter 5 Operation Describes operating procedu
62. ber of connectable axes 3 8_ t4 20 25 so jso 30 Note For details on settings refer to the user s manual for the Position Controller with MECHA TROLINK II Communications 3 14 Specifications Chapter 3 m Axis Number Setting The axis number is set as shown below using the rotary switch for setting the MECHATROLINK II axis number SW1 and the DIP switch for setting MECHATROLINK II communications SW2 pin 3 SW 1 factory setting SW2 factory settings Se pins SWI Ae No SW pind Swi Axis No OFF 5 Notvala OR m Filter Setting Selection There are two methods for setting the command filter as shown below The selection is made using Sw2 Ea 4 Set using the rotary switch for setting the command filter Set using PNOOA Disables the rotary switch for setting the command filter of FIL Factory setting 3 15 Specifications Chapter 3 3 2 Servomotor Specifications Select a Servomotor based on the mechanical system s load conditions and the installation environ ment There are various options available on the Servomotors such as brakes 3 2 1 General Specifications o 20 to 80 with no condensation Ambient storage humidity 20 to 80 with no condensation Storage and operating atmosphere No corrosive gases Vibration resistance 10 to 2 500 Hz with a 0 2 mm double amplitude or accelera tion of 24 5 m s whichever is smaller in the X Y a
63. brake interlock signal will be turned OFF if the Servomotor rotation speed falls below 100 r min after 130 ms has elapsed since the Servo turned OFF or if 500 ms has elapsed since the Servo turned OFF Note 2 The Servomotor will continue to rotate due to momentum for about 6 ms after the Servomo tor de energizes until the dynamic brake operates Note 3 Be careful because the dynamic brake will not operate if the Servo turns OFF with the Ser vomotor rotation speed at 100 r min or less 5 6 2 Interrupt Feeding Control Interrupt feeding control is used for positioning by a fixed amount in the direction of travel or in the reverse direction separately from the position command value when external latch signal 1 EXT1 is input for an axis during a positioning operation Positioning for the fixed amount of movement is executed at the speed in effect when external latch signal 1 is input If external latch signal 1 is not input positioning is executed to the specified target position using the position command value Operation Overview Specified Amount of Movement in Direction of Travel Target speed External latch signal 1 Acceler ation Position control specified amount of movement Deceleration Position Speed 5 20 Operation Chapter 5 Specified Amount of Movement in the Reverse Direction Target speed External latch signal 1 Accelera Speed tion Ps Deceleration Position Deceleration Accel
64. ch and as an input interrupt signal during interrupt feeding 2 DEC Origin proximity input Deceleration input during origin search Em Reverse drive inhibit Reverse rotation overtravel input input Forward drive inhibit Forward rotation overtravel input input 5 24VIN 24 V power supply 24 VDC power supply input terminal for sequence inputs pin 6 input for control DC 6e STOP Emergency stop input ON Servo OFF Stops power to Servomotor e CN1 Control Outputs Signal Function Interface name Alarm output When the Servo Driver generates an alarm the output turns OFF Note OFF for approx 2 s after the power is turned ON 13 BKIR Brake interlock output Outputs the holding brake timing signals Release the holding brake when this signal is ON OGND Output ground common Ground common for sequence outputs pins 12 and 13 Note An open collector output interface is used for sequence outputs maximum operating voltage 30 V DC maximum output current 50 mA m CN1 Pin Arrangement Signal Signal name name EXT1 External latch signal 1 input 2 pec origin proximity input Jo Reverse drive inhibit input Forward drive inhibit input 24VIN 24 V power supply 12 ALM Alarm output input for control DC 7 STOP BKIR Brake interlock output z oGND Output ground common 4 fe 3 6 Specifications Chapter 3 CN1 Connectors 14P Soldered Connectors Cable plug 10114 3000VE Sumitomo 3M Cab
65. cts the information contained in this manual is subject to change without notice Every precaution has been taken in the preparation of this manual Nevertheless OMRON assumes no responsibility for errors or omissions Neither is any liability assumed for damages resulting from the use of the information contained in this publication Read and Understand this Manual Please read and understand this manual before using the product Please consult your OMRON representative if you have any questions or comments Warranty and Limitations of Liability WARRANTY OMRON s exclusive warranty is that the products are free from defects in materials and workmanship for a period of one year or other period if specified from date of sale by OMRON OMRON MAKES NO WARRANTY OR REPRESENTATION EXPRESS OR IMPLIED REGARDING NON INFRINGEMENT MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE OF THE PRODUCTS ANY BUYER OR USER ACKNOWLEDGES THAT THE BUYER OR USER ALONE HAS DETERMINED THAT THE PRODUCTS WILL SUITABLY MEET THE REQUIREMENTS OF THEIR INTENDED USE OMRON DISCLAIMS ALL OTHER WARRANTIES EXPRESS OR IMPLIED LIMITATIONS OF LIABILITY OMRON SHALL NOT BE RESPONSIBLE FOR SPECIAL INDIRECT OR CONSEQUENTIAL DAMAGES LOSS OF PROFITS OR COMMERCIAL LOSS IN ANY WAY CONNECTED WITH THE PRODUCTS WHETHER SUCH CLAIM IS BASED ON CONTRACT WARRANTY NEGLIGENCE OR STRICT LIABILITY In no event shall the responsibility of OMRON for any act exceed the individual p
66. d may result in minor or moderate injury or property damage e This manual may include illustrations of the product with protective covers or shields removed in order to describe the components of the product in detail Make sure that these protective covers and shields are on the product before use e Consult your OMRON representative when using the product after a long period of storage N WARNING N WARNING N WARNING N WARNING N WARNING N WARNING N WARNING N WARNING N WARNING N WARNING N WARNING N WARNING PAN ININININ Ce Always connect the frame ground terminals of the Servo Driver and the Servomotor to a class 3 ground to 100 Q or less Not connecting to a class 3 ground may result in electric shock Do not touch the inside of the Servo Driver Doing so may result in electric shock Turn OFF the emergency stop input STOP whenever turning OFF the main circuit power supply Even if the main circuit power supply is turned OFF e g using an external emergency stop signal the motor may continue to turn due to residual voltage possibly resulting in injury or equipment damage Turn OFF the emergency stop input STOP whenever a Servo alarm occurs or a system emergency stop is executed Otherwise the motor may continue to turn due to residual voltage possibly resulting in injury or equipment damage Do not remove the front cover terminal covers cables or optional items while the power
67. d protection electronic thermal function is built into the Servo Driver to protect against Servo Driver and Servomotor from overloading If an overload does occur first eliminate the cause of the error and then wait at least one minute for the Servomotor temperature to drop before turning on the power again If the power is turned ON again repeatedly at short intervals the Servomotor wind ings may burn out The overload characteristics are for a Servomotor with an aluminum heat sink 250 x 250 x 6 mm mounted and an ambient temperature of 40 C so use the Servomotor under these conditions 6 4 1 Overload Characteristics Graphs The following graphs show the characteristics of the load rate and electronic thermal function s oper ation time R7M Z10030 S1 Servo Motor 100 W Electronic thermal function s operation time s fLitiiditiidiiny 100 150 200 250 300 Motor torque Note 1 The motor torque indicates the percentage of the rated torque that is applied Note 2 For example if the motor torque is 300 of the rated torque an overload alarm will be gen erated after about 2 seconds when an R7M Z10030 S1 is being used m R7M Z20030 S1 240030 S1 275030 S1 Servo Motors 200 W to 750 W 1000 Ll 22 1d EL EL 23223 EC EOI 1212 Ran Sy m E OA ATA EL J E b lt E 4 4 4 EE EoE f o JE i Li I t 1 1 Li I I t t 1 1 I t Electronic 100 a thermal function s operation ert Melee ee time s 10 CoN Ea
68. d then rotate in the opposite direction 5 16 Operation Chapter 5 5 5 Trial Operation Once mounting wiring switch setting and connecting a power supply have been finished and nor mal status has been confirmed perform trial operation The main purpose of trial operation is to con firm that the servo system is operating correctly electrically First no load operation and then loaded operation is checked Note If an error occurs during the trial operation refer to Chapter 6 Troubleshooting to eliminate the cause Then check for safety reset the alarm and then retry the trial operation 5 5 1 Preparing for Trial Operation m Switch Settings After turning OFF the power supply set the following switches e Set the DIP switch SW2 for MECHATROLINK II communications and the rotary switch SW1 for the MECHATROLINK II axis number to the same settings as the host controller e Set the command filter rotary switch FIL to O m Turning OFF the Servomotor Set up the system so that the power and the RUN command can be turned OFF so that the Servo motor can be immediately turned OFF if an abnormality occurs in the system 5 5 2 Trial Operation 1 No load Operation e Turn ON the power supply to the control circuits main circuits and peripheral devices e Turn ON close the circuits for the emergency stop input STOP the forward drive prohibit input POT and the reverse drive prohibit input NOT e Check that Servomot
69. diagram shows connections by MECHATROLINK II Communications Cable between a Position Controller with MECHAT ROLINK II Communications and Servo Drivers Position Control Unit omron R7D ZNO1H ML2 DRIVER COM ALM RDY OMRON omron R7D ZNO1H ML2 R7D ZNO1H ML2 DRIVER DRIVER COM ALM RDY COM ALM RDY O EN SMARTSTEP 7 PAN DRE O AO Cy A lt E 3 10 z Terminating resistance Y FE EN SMARTSTEP 2 6 ieee gt y 6h F E ie TN Int JALU f Te F l Note 1 Use a minimum Cable length L1 L2 Ln of 0 5 m between the Servo Drivers Note 2 The total Cable length must be no more than 50 m L1 L2 Ln lt 50 m 3 22 Specifications Chapter 3 3 4 2 Control Cable Specifications General purpose Control Cables A General purpose Control Cable connects to the Servo Driver s Control I O Connector CN1 There is no connector on the controller end Wire a connector to match the controller if you are connecting to a Position Control Unit and a compatible cable is not available or connecting to a controller manu factured by another company e Cable Models Length L Outer diameter of cable R7A CPZ001S 5 6 dia Approx 0 1 kg R7A CPZ002S Approx 0 2kg e Connection Configuration and Dimensions L 39 Controller end 5 Driver end t 12 7 e Wiring No Wire coloriMark color Si
70. e current shown above is for Servomotor power cables less than 5 meters long The leakage current depends on the power cable length and the insulation Note 2 The leakage current shown above is for normal temperature and humidity The leakage cur rent depends on the temperature and humidity e The following table shows the recommended leakage breakers Conform to UL CSA and CE stan dards Maker Model number Rated current Fuji Electric Corp EG33CM 30 30MA CE EG33CM 30 100MA CE 100 mA Leakage Breaker Connection Example AC power No fuse Leakage supply side breaker Surge absorber breaker Noise filter Servo Driver side m Radio Noise Filters e Use a radio noise filter to reduce the Servo Driver s PWM noise e The following table shows some available radio noise filters Model number FDK Corporation RN603620M Hitachi Metal 4 19 System Design Chapter 4 m Improving Encoder Cable Noise Resistance Take the following steps during wiring and installation to improve the encoder s noise resistance e Always use the specified Encoder Cables e f cables are joined midway be sure to connect them with connectors and do not remove more than 50 mm of the cable insulation In addition always use shielded cable e Do not coil cables If cables are long and are coiled mutual induction and inductance will increase and will cause malfunctions Always use cables fully extended e When installing noise filters
71. e following diagram MECHATROLINK II position data command unit 7FFFFFFFH FF00000000 NS FF80000000 Physical position command unit Noto0000000 80000000H Appendix Chapter 7 7 8 A AC Reactors 2 5 3 37 alarm output 3 11 ALM 3 11 5 7 ALM indicator 5 7 BKIR 3 11 brake interlock output 3 11 C Cables for Connector Terminal Blocks 2 4 command filter setting 3 15 5 4 Communications Repeaters 3 13 contactor 4 18 Control Input Connector CN1 2 5 D DEC 3 8 DIP switch for communications settings 3 14 5 3 E emergency stop input 3 9 Encoder Cable 4 9 4 20 Encoder Cables 2 5 Encoder Input Connector CN2 2 5 EXT1 3 8 external latch signal input 3 8 External Regeneration Resistor 2 5 3 36 4 29 External Regeneration Unit 3 35 4 28 F FIL 1 6 5 5 forward drive inhibit 3 9 fuses 4 14 Index G General purpose Control Cable 2 4 4 8 L leakage breaker 4 19 M Main Circuit Connector CNA with Ejector Levers 2 5 MECHATROLINK II Cable 2 4 4 8 N NFB 4 15 no fuse breaker 4 15 noise filter for the brake power supply 4 17 noise filter for the power supply input 4 16 4 20 noise filters for Servomotor output 4 21 NOT 3 9 O origin proximity input 3 8 P Pn000 5 8 Pn00a 3 15 5 4 POT 3 9 PWR indicator 5 8 R radio noise filter 4 19 RDY 5 7 Regeneration Resistance Unit 2 5 reverse drive inhibit
72. e ma the Servomotor shaft and coupling section the mechanical system Try operating the Servomotor has eccentricities or with no load looseness The load inertia exceeds Try operating the Servomotor Either reduce the load or the allowable value for with no load use a Servomotor with a the Servo Driver greater capacity The Servomotor The Servo Driver is The Servo Driver PCB is faulty Replace the Servo Driver rotates withouta faulty 6 15 Troubleshooting Chapter 6 Probable cause Hemstocheck Countermeasures The Servomotor is overheating The Servomotor holding brake does not oper ate The servo is turned OFF while the Servo motor is rotat ing but the Servomotor does not stop or is hard to stop The emergency stop STOP does not oper ate 6 16 The ambient tempera Check to see whether the ambi Lower the ambient tem ture is too high ent temperature is below 40 C perature to 40 C or below Use a cooler or fan The ventilation is ob Check to see whether anything Improve the ventilation structed is blocking the ventilation The Servomotor has an Try operating the Servomotor Either reduce the load or overload with no load use a Servomotor with a greater capacity Power is being supplied Check to see whether power is Configure a circuit that to the holding brake being supplied to the holding cuts power to the holding brake brake when the motor stops and the
73. e suppressors for loads that have induction coils such as relays solenoids brakes clutches etc e The following table shows types of surge killers and recommended products Type Features Recommendedproducts Diodes are used for relatively small Use a fast recovery diode with a short loads when the reset time is not an reverse recovery time issue such as relays The reset time is increased because the surge voltage is the lowest when power is cut off Used for 24 48 V DC systems Thyristor Thyristors and varistors are used for Select the varistor voltage as follows or varistor loads when induction coils are large as 24 VDC system 39 V in electromagnetic brakes solenoids etc and cee reset time is an issue 109 MDG system 200 V The surge voltage when power is cut off 100 VAC system 270 V is approximately 1 5 times the varistor 200 VAC system 470 V voltage Capacitor The capacitor resistor combination is Okaya Electric Industries Co Ltd resistor used to absorb vibration in the surge XEB120020 2 uF 120 Q when power is cut off The reset time XEB120030 3 uF 120 Q Example Fuji Electric Co ERA22 06 can be shortened by selecting the appropriate capacitance and resistance Note Thyristors and varistors are made by the following companies Refer to manufacturers docu mentation for details on these components Thyristors Ishizuka Electronics Co Varistors Ishizuka Electron
74. ectronic gear function sets the amount of movement per pulse for command pulses from the host controller A single command pulse from the host controller is called a command unit When the electronic gear is used the host controller position and speed can be set without paying attention to the deceleration rate of the machine or the number of encoder pulses Electronic Gear Not Used Electronic Gear Used Workpiece Workpiece E eae Command unit 1 um A A Encoder pulses 8 192 Ball screw pitch 6 mm Encoder pulses 8 192 Ball screw pitch 6 mm Using command units to move Moving the workpiece 10 mm the workpiece 10 mm One rotation moves the workpiece When one command unit equals 1 um and 6 mm so 10 6 1 6666 rotations 8 192 pulses make one rotation the workpiece is moved 10 mm 10 000 um at 1 um per pulse 10 000 1 10 000 pulses so 1 666 x 8 192 13 653 pulses Therefore 13 653 pulses must be input from the Host Controller Therefore moving the workpiece 10 mm requires that 10 000 pulses be input 5 9 Operation Chapter 5 m Setting the Electronic Gear Ratio Pn20E Electronic gear ratio G1 numerator Setting 1 to 1073747824 Unit Factory set Restart to range ting enable Pn210 Electronic gear ratio G2 denominator Setting 1 to 1073747824 Unit Factory set Restart to range ting enable e Set in the following range 0 01 lt Electronic gear ratio G1 G2 lt 100 e When G1 G2 1 inputting 8 192 p
75. eneration that each Servo Driver can absorb If these values are exceeded take the following measures e Connect an External Regeneration Unit to increase the regeneration processing capacity e Reduce the operating rotation speed The amount of regeneration is proportional to the square of the rotation speed e Lengthen the deceleration time to decrease the regenerative energy produced per time unit e Lengthen the operation cycle i e the cycle time to decrease the average regenerative power Servo Driver Regenerative energy that can be Allowance when decelerating to stop from absorbed by the internal capacitor 3 000 min R7D ZP01H R7D ZN01H ML2 6 0 x 107 PA R7D ZP02H 30x 10 9 1 R7D ZNO2H ML2 N R7D ZP04H 5 0 x 10 R7D ZNO4H ML2 R7D ZP08H 1 0 x 1078 R7D ZNO8H ML2 4 27 System Design Chapter 4 4 3 3 Absorbing Regenerative Energy with an External Regeneration Unit Connect an External Regeneration Unit if the amount of regeneration exceeds the capacity of the Servo Driver alone Connect the P and N terminals of the External Regeneration Unit to the and terminals respectively of the main circuit connector CNA at the Servo Driver Refer to 4 2 3 Periph eral Device Connection Examples Double check the terminal names when connecting the External Regeneration Unit The Unit can be damaged if the terminals are connected incorrectly The External Regeneration Unit does not con form to EC Direc
76. ent detection detection Overcurrent protection Overcurrent protection En G ADC Phase W Main circuit voltage detection MPU amp ASIC e oG Fan alarm Position speed and torque processor Set value read circuit Alarm output Brake output Origin proxim ity input Reverse drive Emergency External latch signal input Forward drive inhibit inhibit stop input MECHATROLINK II Command MECHATROLINK II com setting filter setting Control I O connector munications connector M S Same O 9 oO oO el O o 2 Q oO E cp p oO jo O QO Lu GR 1 7 Features and System Configuration Chapter 1 1 5 Applicable Standards 1 5 1 EC Directives EC Directive Product Applicable standards Comments Low Voltage AC Servo Drivers EN 50178 Safety requirements for electronic equip Directive ment for measurement control or labo ratory use AC Servomotors IEC 60034 1 5 8 and 9 Rotating electric machines EN 60034 1 and 9 EMC Directive AC Servo Drivers and EN 55011 Class A Group1 Limits and methods of measurement of AC Servomotors radio disturbance of industrial scientific and medical radio frequency equipment EN 61000 6 2 Electromagnetic compatibility EMC Immunity standard for industrial environ ments Note To conform to EMC Directives the Units must be installed under the conditions described in 4 2 6 Conforming to EMC Directives 1
77. eration Position control specified amount of movement m Final Travel Distance for Interrupt Feeding Pn814 Pn814 Final travel distance for interrupt feeding pois 1 073 741 823 Unit 1 command Factory Restart to range to unit setting enable 1 073 741 823 5 21 Operation 5 22 Chapter 5 pm Mn Ml Chapter 6 Troubleshooting 6 1 6 2 6 3 6 4 6 5 Error Processing Alarm Table Troubleshooting Overload Characteristics Electronic Thermal Function Periodic Maintenance Troubleshooting Chapter 6 6 1 Error Processing 6 1 1 Preliminary Checks when a Problem Occurs This section explains the preliminary checks and analytical tools required to determine the cause of a problem if one occurs Checking the Power Supply Voltage e Check the voltage at the power supply input terminals Main circuit Power Supply Input Terminals L1 L2 Single phase 200 230 V AC 170 to 253 V 50 60 Hz If the voltage is outside of this range there is a risk of incorrect operation so be sure that the power supply is correct e Check the voltage of the sequence input power supply and verify that the 24 VIN Terminal pin CN1 5 is within the allowed range of 23 to 25 VDC If the voltage is outside of this range there is a risk of malfunction so be sure that the power supply is correct m Checking Whether an Alarm Has Occurred Refer to 6 3 Troubleshooting in the following situations e When an alarm
78. eration resistance is disconnected or the regeneration transistor failed ALARM OV Lit when there is an overvoltage 3 35 Specifications Chapter 3 e Error Detection Function e If an error is detected an alarm is output from the External Regeneration Unit Set up a sequence so that the power to the Servo Driver L1 and L2 is turned OFF when an alarm occurs e When an error is detected and the Servo Driver s power is turned OFF the External Regeneration Unit will not reset normally unless the Servo Driver s power is OFF for 2 to 3 seconds The External Regeneration Unit will reset to its normal status after the Servo Drivers internal capacitors dis charge completely and the voltage drops across terminals P and N 3 5 2 External Regeneration Resistor R88A RR22047S Specifications m Specifications Resistance Nominal Regenerative Heat radiation Thermal switch Capacity absorption output with specifications temperature rise of 120 C R88A RR22047S 47 9 5 220 W 70 W t1 0 x 350 x 350 Operating temper SPCC ature 170 C 5 NC contact Rated output 3 A 3 36 Specifications Chapter 3 3 6 AC Reactors An AC Reactor can be connected to the Servo Driver to suppress harmonic currents Select a model to match the Servo Driver being used m Specifications Servo Driver AC Reactor model Model Rated current A Inductance mH Weight kg R7D ZP01H R88A PX5052 1 0 45 0 Approx 0 4 R7
79. ervomotor Re evaluate the load and the operating conditions Lower the ambient tempera ture for the Servo Driver to 55 C or below Lighten the load Combine the Servomotor and Servo Driver correctly The Servo Driver is Replace the Servo Driver faulty Servomotor failure Replace the Servomotor 6 7 Troubleshooting Chapter 6 Alarm Status when error Probable cause Countermeasures code occurs A 28 Emergency stop Occurs when a The emergency stop Wire the emergency stop sig servo lock com signal is not wired mand is executed from the host con troller Occurs during Ser The emergency stop Correct the emergency stop vomotor operation signal was input signal operation sequence The emergency stop Check and correct the wiring signal operated incor rectly A 40 Overvoltage Occurs when the The AC power supply Keep the AC power supply power is turned voltage is over 290 V voltage within the normal ON range The Servo Driver is Replace the Servo Driver faulty Occurs during Ser A large voltage Keep the AC power supply vomotor operation chance occurred in voltage within the normal the AC power supply range Servomotor speed is Check Regeneration Unit and high and there is large External Regeneration Resis load inertia Regen tor use eration capacity Is Re evaluate the load and insufficient operating conditions The Servo Driver is Replace the Servo D
80. function fire or electric shock m Warning Labels Warning labels are pasted on the product as shown in the following illustra tion Be sure to follow the instructions given there Warning label Example from R7D ZN0O1H ML2 m Warning Label Contents Read manual before installing RAIS UATE ARR ETO RCL T REA e AsO CC Disconnect all power and wait 5 min WARN I NG before servicing May cause electric shock BS ea A POMBE T A ARBHAR E BR BERSLUSRATE SPMRTRCHSE BZOBNDY Do not touch heatsink when power is ON and CAUTION power is OFF 15 min after May cause burn A y gp APURINRAEN 1590A OME AZNAR E BERBLUERA TA 1 OSME KYYICMSE KEORN HY Use proper grounding techniques PH FIN UST ARETES Items to Check When Unpacking Check the following items after removing the product from the package Has the correct product Check the model number on the nameplate on the side been delivered of the product Has the product been Inspect the outside of the product and carefully check damaged in shipping that there has been no damage during shipping Accessories 1 Special screw driver for setting the rotary switch 2 Safety Precautions document x 1 No connectors or mounting screws are provided Obtain these separately If something is missing the Servo Driver is damaged or some other fault exists please contact the point of purchase or your OMRON representa tive Interpreting the Model Number
81. g accuracy into account when determining the command unit e For this calculation example it is assumed that the command unit is 0 01 mm When table movement is specified in increments of 0 01 mm Command unit 0 01 mm A 4 Find the amount of load travel per load axis rotation in command units Amount of travel when the load axis is rotated once Load travel per load axis rotation Command unit e In this calculation example it is assumed that the ball screw pitch is 5 mm and the command unit is 0 01 mm Therefore the calculation becomes 5 500 0 01 e In this calculation example the amount of travel per load axis rotation was calculated using a ball screw as an example For other mechanical systems refer to the following descriptions when doing the calculation Ball screw Turntable Belt drive Load axis gt P Load axis nD yD y P Pitch ADO Load axis D Pulley diameter Amount of travel per _ P Amount of travel per _ 360 l Amount of travel per _ TD load axis rotation Command unit load axis rotation Command unit load axis rotation Command unit 5 Find the electronic gear ratio G1 G2 e f the Servomotor axis and load axis deceleration rate is n m if the load axis rotates n times when the Servomotor axis rotates m times Electronic gear ratio E AA AA i G2 Travel per load axis rotation n In this example the pulley deceleration rate is assumed to be 1 2 Therefore an G1 8192 2
82. g down screws Case A i Door i B Door Oil resistant gasket Conductive gasket Control panel Cross sectional view of A B Oil resistant gasket Conductive gasket Door interior view 4 24 System Design Chapter 4 4 3 Regenerative Energy Absorption The Servo Drivers have internal regenerative energy absorption circuitry which absorbs the regener ative energy produced during Servomotor deceleration and prevents the DC voltage from increasing An overvoltage error is generated however if the amount of regenerative energy from the Servomo tor is too large If this occurs measures must be taken to reduce the regenerative energy produced by changing operating patterns or to increase the regenerative energy absorption capacity by con necting external regeneration resistance 4 3 1 Calculating the Regenerative Energy m Horizontal Axis N1 Servomotor operation N2 Servomotor output torque Note In the output torque graph acceleration in the positive direction is shown as positive and acceleration in the negative direction is shown as negative e The regenerative energy values for each region can be derived from the following equations Ey L ar Ni TD1 ti J 0 0524 Na Tos ti J E 1 27 2 5 Eo N2 Tp2 t2 J 0 0524 N2 To2 t2 J Ny No Rotation speed at beginning of deceleration r min Toi Tpo Deceleration torque N m ty to Deceleration time s
83. gnal 4 Gray Black e elon Blad STOP CAMEL TO gt o 9 Pse gt o o 10 omneo S m oane e 14 Wewa O SooS S Connector plug 10114 3000VE Sumitomo 3M Connector case 10314 52A0 008 Sumitomo 3M Cable AWG24 x 7P UL20276 Wires with the same wire color and the same number of marks are a twisted pair 3 23 Specifications Chapter 3 e Connector Pin Arrangement m Connector Terminal Block Cable XW2Z 11 J B19 This is the Cable for the Connector Terminal Block for the Servo Driver s control I O connector CN1 e Cable Models Wedel Length 1 Outer diameter of cable Weight XW2Z 100J B19 8 dia Approx 0 1 kg XW2Z 200J B19 Approx 0 2kg e Connection Configuration and Dimensions 6 L 39 Connector Terminal Block end Servo Driver end XW2B 20G4 XW2B 20G5 ar R7D ZO XW2D 20G6 e Wiring Terminal Block Connector Servo Driver end Wire code Mark color Blue Red 7 OO OO A O o CO 24VIN AAA A O EXT1 NA 1 Pink Red EXT1 EE pee Fe a T Greenined C NS a CT S aT orangeyRed ce ona a po ep HL A ___ ES to GreyRed o y a gt gt e so s a 6 Blue Red f STOP OGND BKR 17 7 o f mee ee ALM_ 19 m o Shield Shell Connector at Connector Terminal Block Connector Socket XG4M 2030 Strain Relief XG4T 5004 Cable AWG28 10P UL20276 Connector at Servo Driver Connector Plug 10114 3000PE Sumitomo 3M Connector Case 103
84. h Pn522 Pn524 Target position a m Positioning Completion Width 1 Pn522 Positioning completion width 1 Setting O to 1073741824 Unit Command unit Factory 10 Restart to range setting enable e Set the deviation counter value for outputting positioning completion width 1 e The output turns ON when the deviation counter residual pulses fall below the set value m Positioning Completion Width 2 Pn524 O to 1073741824 Unit Command unit Factory 100 Restart to setting enable e Set the deviation counter value for outputting positioning completion width 2 e The output turns ON when the deviation counter residual pulses fall below the set value e For example this parameter can be used for purposes such as shortening processing time by using positioning completion output 2 as a near coincidence signal to prepare for the next sequence before positioning completion output 1 turns ON In this case set a greater value for Pn524 than for Pn522 5 12 Operation Chapter 5 5 4 5 Setting Software Limits When the machine s movable parts enter a software limit area positioning is forcibly stopped in the same way as for drive prohibit overtravel Servomotor operation is stopped by setting the speed ref erence at the Servo Driver to zero m Software Limit Function Pn801 0 Pn801 0 Function selection application 6 software limit switch Software limit function Setting 0to3 Unit Factory Restart to
85. he dimensions shown below Note 2 Mount power lines and crimp terminals to the terminal block at a torque of 0 7 N m Round Crimp Terminal Forked Crimp Terminal 3 2 dia mm 15 5 8 mm max HC 3 2 mm 5 8 mm max Applicable crimp terminals Applicable power lines Round terminals 1 25 3 AWG22 16 0 3 to 1 25 mm Y terminals 1 25Y 3 AWG22 16 0 3 to 1 25 mm 3 27 Specifications Chapter 3 e Terminal Block Wiring Example XW2B 20G4 XW2B 20G5 and XW2D 20G6 Note 1 Use a maximum of 300 mA total for the 24 VDC inputs Note 2 Do not use inputs other than sensor inputs e Terminal Block Signal Names 3 28 24 VDC Terminal Block ee 2 lA a A MESA DES 8 Nor 9 lO pa lo pa la pas IO a i ares E 20 Specifications Chapter 3 3 4 3 Servomotor Power Cable Specifications The Servomotor Cable supplies power between the Servo Driver and Servomotor Servomotor Power Cables are available in two forms Servomotor Power Cables with an attached CNB Connec tor and Servomotor Power Cables without a connector Cable Only Select the Cable to match the Servomotor being used Note When connecting to moving parts use robot cable and make a custom cable Power Cables with CNB Connector for Servomotors without Brakes Length L Outer diameter of cable Weight See note R7A CAZ003S 7 4 dia Approx 0 4 kg R7A CAZ005S Approx 0 8 kg Cable Models R7A CAZ010S Appr
86. hines vehicles safety equipment and installations subject to separate industry or government regulations e Systems machines and equipment that could present a risk to life or property Please know and observe all prohibitions of use applicable to the products NEVER USE THE PRODUCTS FOR AN APPLICATION INVOLVING SERIOUS RISK TO LIFE OR PROPERTY WITHOUT ENSURING THAT THE SYSTEM AS A WHOLE HAS BEEN DESIGNED TO ADDRESS THE RISKS AND THAT THE OMRON PRODUCTS ARE PROPERLY RATED AND INSTALLED FOR THE INTENDED USE WITHIN THE OVERALL EQUIPMENT OR SYSTEM PROGRAMMABLE PRODUCTS OMRON shall not be responsible for the user s programming of a programmable product or any consequence thereof Disclaimers CHANGE IN SPECIFICATIONS Product specifications and accessories may be changed at any time based on improvements and other reasons It is our practice to change model numbers when published ratings or features are changed or when significant construction changes are made However some specifications of the products may be changed without any notice When in doubt special model numbers may be assigned to fix or establish key specifications for your application on your request Please consult with your OMRON representative at any time to confirm actual specifications of purchased products DIMENSIONS AND WEIGHTS Dimensions and weights are nominal and are not to be used for manufacturing purposes even when tolerances are shown PERFOR
87. ics Co Matsushita Electric Industrial Co m Contactors e Select contactors based on the circuit s inrush current and the maximum momentary current e The Servo Driver inrush current is covered in the preceding explanation of no fuse breaker selec tion and the maximum momentary current is approximately twice the rated current e The following table shows the recommended contactors Model number Rated current Coil voltage J7L 09 22200 200 VAC J7L 12 22200 200 VAC J7L 18 22200 200 VAC J7L 32 22200 200 VAC 4 18 System Design Chapter 4 m Leakage Breakers e Use leakage breakers designed for motors e Since switching takes place inside the Servo Drivers harmonic current leaks from the armature of the motor With leakage breakers designed for motors harmonic current is not detected preventing the breaker from operating due to leakage current e When selecting leakage breakers remember to add the leakage current in devices besides the Servomotor that use the switching power supply such as noise filters and inverters e For details on leakage breakers refer to the manufacturer s catalog e The following table shows the Servomotor leakage current for each Servo Driver model Servo Driver model Driver Leakage current resistor capacitor measurement in the commercial power supply frequency range R7D ZP01 H ZP02H ZP04H 3 mA max ZNO1H ML2 ZNO2H ML2 ZNO4H ML2 R7D ZPO8H ZNO8H ML2 5 MA max Note 1 The leakag
88. ifications Motor capacity 100 W R7G RGSF05B100 R7G RGSF09B100 1 15 R7G RGSF15B100 iS __ RTG RGSF0sC400 e ma 1 5 1 9 R7G RGSFO9C400 R7G RGSF15C400 2 3 Standard Models and Dimensions Chapter 2 2 1 5 Accessories and Cables MECHATROLINK II Cables and Terminating Resistance for CN6 eo MECHATROLINK II Cables Specifications MECHATROLINK II Cable FNY W6003 A5 FNY W6003 01 FNY W6003 03 e Terminating Resistance Specifications Model MECHATROLINK II Terminating Resistor FNY W6022 m Control Cables for CN1 Model Cables for Connector Terminal Blocks O ei General purpose Control Cables m Servomotor Power Cables for CNB Specifications Power Cables for Servomotors without R7A CAZ003S Brakes connector attached R7A CAZ005S R7A CAZO10S R7A CAZ015S R7A CAZ020S A Cables for Servomotors with Brakes connector attached 5m E Standard Models and Dimensions Chapter 2 Encoder Cables for CN2 Specifications Model Encoder Cables connector attached Connectors eins O Model m Regeneration Resistance Unit Z Specifications Regeneration current 8 A R88A ae Internal resistance 50 Q 12 W m External Regeneration Resistor Specifications Model Regeneration capacity 70 W 47 Q R88A RR22047S AC Reactors Specifications Wee R7D ZP01H R7D ZN01H ML2 R88A PX5052 R7D ZP02H R7D ZNO2H ML2 R88A PX5053 R7D ZP04H R7D ZNO4H ML2 R88A PX5054
89. in an ambient operating temperature below 40 C e We recommend that ambient operating temperature and the power ON time be reduced as much as possible to lengthen the maintenance intervals for Servo Drivers e The life of aluminum electrolytic capacitors is greatly affected by the ambient operating tempera ture Generally speaking an increase of 10 C in the ambient operating temperature will reduce capacitor life by 50 e The aluminum electrolytic capacitors deteriorate even when the Servo Driver is stored with no power supplied If the Servo Driver is not used for a long time we recommend a periodic inspection and part replacement schedule of five years e f the Servomotor or Servo Driver is not to be used for a long time or if they are to be used under conditions worse than those described above a periodic inspection schedule of five years is recom mended 6 5 3 Replacing the Cooling Fan Please contact your OMRON representative regarding cooling fan replacement 6 22 Chapter 7 Appendix 7 1 Connection Example 7 2 Parameter Tables 7 3 Position Data Range Appendix Chapter 7 7 1 Connection Example m Connecting to SYSMAC CJ1W NCF71 or CS1W NCF71 Note Note Note Note Note 7 2 Main circuit power supply NFB OFF ON Main circuit contact 3 Surge absorber Single phase 200 to 230 VAC 5 60 Hz p Servo error display 2 TO CJ1W NCF71 CS1W NCF71 Ground to 100 Q MECHATRO
90. is being supplied Doing so may result in electric shock Installation operation maintenance or inspection must be performed by authorized personnel Not doing so may result in electric shock or injury Wiring or inspection must not be performed for at least five minutes after turning OFF the power supply Doing so may result in electric shock Do not damage press or put excessive stress or heavy objects on the cables Doing so may result in electric shock Do not touch the rotating parts of the Servomotor in operation Doing so may result in injury Do not modify the product Doing so may result in injury or damage to the product Provide a stopping mechanism on the machine to ensure safety The holding brake is not designed as a stopping mechanism for safety purposes Do not come close to the machine immediately after resetting momentary power interruption to avoid an unexpected restart Take appropriate measures to secure safety against an unexpected restart Doing so may result in injury Caution Caution NCAUTION Use the Servomotors and Servo Drivers in a specified combination Using them incorrectly may result in fire or damage to the products Do not store or install the product in the following places Doing so may result in fire electric shock or damage to the product e Locations subject to direct sunlight e Locations subject to temperatures or humidity outside the range specified in the specificatio
91. it COM ALM RDY Approx 2 s after power COM ALM RDY 5 LI Et is turned ON E ET Lt Lit OFF Bl Flashing M e If the indicators do not light as described above or if the alarm indicator ALM remains lit refer to Chapter 6 Troubleshooting and correct the error Operation Chapter 5 5 4 User Parameters This section describes the user parameters that must be set and checked before using the Servomo tor or Servo Driver If these parameters are not set correctly it may cause faulty Servomotor opera tion Set the parameters to match the system m User Parameter Precautions e Some parameters require that the power be turned OFF and then back ON before changes to the settings will go into effect This is shown individually for each parameter below After changing the settings for those parameters turn OFF the power checking to be sure that the PWR indicator has turned OFF and then turn it back ON again e Parameters for which digits must be set individually have their particular digits indicated by adding a decimal point and an extra digit after the parameter number For example digit No O of Pn000 is indicated by Pn000 0 Example PnOOO Digit3 2 1 0 00000 ____ PRO00 0 Pn000 1 Pn000 2 Pn000 3 e Do not set parameters or digits which are indicated as not used 5 4 1 Changing the Servomotor Direction of Rotation The SMARTSTEP Junior Servo Driver is provided with a reverse rotation mode for reversi
92. ith other devices Not doing so may result in fire or malfunction Do not apply any strong impact Doing so may result in malfunction Be sure to wire correctly and securely Not doing so may result in motor runaway injury or malfunction Be sure that all the mounting screws terminal screws and cable connector screws are tightened to the torque specified in the relevant manuals Incorrect tightening torque may result in malfunction Use crimp terminals for wiring Do not connect bare stranded wires directly to terminals Connection of bare stranded wires may result in burning Always use the power supply voltage specified in the User s Manual An incorrect voltage may result in malfunction or burning Take appropriate measures to ensure that the specified power with the rated voltage and frequency is supplied Be particularly careful in places where the power supply is unstable An incorrect power supply may result in malfunction Install external breakers and take other safety measures against short circuiting in external wiring Insufficient safety measures against short circuiting may result in burning Take appropriate and sufficient countermeasures when installing systems in the following locations Failure to do so may result in damage to the product e Locations subject to static electricity or other forms of noise e Locations subject to strong electromagnetic fields and magnetic fields e Locations subject to possible expos
93. itions torque or the starting Re evaluate the Servomotor torque exceeds the capacity maximum torque The Servo Driver is Replace the Servo Driver faulty Servomotor wiring Wire the Servomotor main cir error Faulty wiring or cuit cable correctly connections Encoder wiring error Wire the encoder correctly Faulty wiring or con nections The Servo Driver is Replace the Servo Driver faulty Servomotor wiring Wire the Servomotor main cir error Faulty wiring or cuit cable correctly connections Encoder wiring error Wire the encoder correctly Faulty wiring or con nections The starting torque Re evaluate the load and exceeds the maxi operating conditions mum torque Re evaluate the Servomotor Capacity The Servo Driver is Replace the Servo Driver faulty The effective torque Re evaluate the load and exceeds the rated operating conditions torque or the starting Re evaluate the Servomotor torque exceeds the capacity Occurs when the servo is turned ON Occurs when a command is input without the Servo motor rotating Occurs during Ser vomotor operation maximum torque The Servo Driver is Replace the Servo Driver faulty The Servomotor is Re evaluate the load and being rotated by exter operating conditions nal force motor operation The Servo Driveris Replace the Servo Driver faulty Occurs when the servo is turned OFF during Servo
94. iver model Inrush current Ap Main circuit power supply R7D ZP01H ZP02H ZP04H 30 ZN01H ML2 2N02H ML2 2N04H ML2 A7D ZPOBH ZNO8H ML2 CON Surge Absorbers e Use surge absorbers to absorb surges from power supply input lines due to lightning abnormal voltages etc e When selecting surge absorbers take into account the varistor voltage the amount of surge immu nity and the amount of energy resistance e For 200 V AC systems use surge absorbers with a varistor voltage of 470 V e The surge absorbers shown in the following table are recommended Max limit Surge Type Remarks voltage immunity Okaya R A V 781BYZ 2 783 V 2 500 A Between power supply lines Between power supply line grounds Electric R_A V 781BWZ 4 783 V 2 500 A Industries Co Ltd Note 1 Refer to the manufacturers documentation for operating details Note 2 The surge immunity is for a standard impulse current of 8 20 us If pulses are wide either decrease the current or change to a larger capacity surge absorber 4 15 System Design Chapter 4 m Noise Filters for the Power Supply Input Use the following noise filters for the Servo Driver s power supply Servo Driver model Noise filter Model Rated Rated Leakage current See note current voltage 50 Hz R7D ZP01H ZP02H FN2070 6 07 6A 250 V 0 4 mA phase Schaffner ZNO1H ML2 ZNO2H ML2 R7D ZP04H ZN04H ML2 FN2070 10 07 250 V 0 4 mA phase R7D ZP08H ZN08H ML2 FN2
95. le case shell kit 10314 52A0 008 Specifications Chapter 3 3 1 5 Control Input Circuits Sequence Inputs External power supply 24 V 1 VDC Power supply capacity 50 mA min per Unit Photocoupler input 24VDC 7 mA Minimum ON time 40 ms To another input circuit To another input circuit GND common Signal Levels On level Minimum 24 VIN 11 V OFF level Maximum 24 VIN 1 V 3 1 6 Control Input Details The CN1 connector input pins are described in detail below External Latch Signal 1 Input EXT1 Pin 1 External latch signal 1 input EXT 1 Functions 1 Function During Origin Search e Functions as an origin input signal during origin search e Normally the encoder s Z phase is used for origin inputs during an origin search but this signal can be used when it is desirable to use an external sensor signal without using the Z phase 2 Function During Interrupt Feeding Control e Functions as interrupt signal during interrupt feeding control e When this signal turns ON during a positioning operation positioning is executed from the sig nal input position for the specified final travel distance for external positioning e When this signal does not turn ON during a positioning operation the positioning specified first is executed m Origin Proximity Input DEC Pin 2 Origin proximity input DEC Function e This is the deceleration signal during origin search Specifications Chapter 3
96. load is applied the motor shaft and bearings may be damaged e Set up a movable pulley between the motor axis and the load axis so that the belt tension can be adjusted Pulley Pulley for tension adjustment Make adjustable Tension Water and Drip Resistance The enclosure ratings for the Servomotors are as follows IP55 except for through shaft parts and cable exit holes m Other Precautions Take measures to prevent the shaft from rusting The shafts are coated with anti rust oil when shipped but anti rust oil or grease should also be applied when connecting the shaft to a load AN IINSN INTE Do not apply commercial power directly to the Servomotor Applying commercial power directly will burn out the motor coils Do not attempt to disassemble repair or modify any Units Any attempts to do so may result in electric shock or other injury 4 5 System Design Chapter 4 4 1 3 Decelerators m Installing Decelerators e Use only the specified combinations of Servomotors and Decelerators Refer to 3 3 Decelerator Specifications The service life of the motor bearings may be shortened by using a combination that is not specified or a decelerator or servomotor from another company e The dimensions of the Servomotor mounting flange on the Decelerators differ for each Servomotor Do not install Decelerators on a Servomotor other than the one specified e Use the following procedure when installing a Decelerator
97. load will be held by the holding brake The load inertia is too Check the following Re evaluate the load and large Is the load too large operating conditions Is the Servomotor speed too Re evaluate the Servomo high tor capacity The stop circuit is faulty Replace the Servo Driver The external emergency Check the switch and the wiring Replace the switch or wire stop input switch is faulty it correctly or wired incorrectly The parameter for the Check the setting for user pa Change the setting for emergency stop input rameter Pn515 2 user parameter Pn515 2 signal STOP is set to disable the emergency stop The Servo Driver is The Servo Driver PCB is faulty Replace the Servo Driver faulty Troubleshooting Chapter 6 Problem Probable cause ltemstocheck Countermeasures The Servomotor There is a problem with is making un the installation of the ma usual noises or chinery the machinery is vibrating Check whether Servomotor Tighten the mounting mounting screws are loose screws Check for misalignment in the Align the couplings couplings Check whether the couplings Balance the couplings are unbalanced There is a problem with Check for noise or vibration Contact an OMRON rep the bearings around the bearings resentative There is a vibration source in another ma chine Noise is infiltrating the Encoder Cable because it does not meet specifi cations Noise
98. m 200 W 400 W 750 W Servomotors with Brakes R7M Z20030 BS1 Z40030 BS1 Z75030 BS1 300 2 Output Section on 750 W Servomotor L LL LM LR C D1 D2 G Z S QK mm mm mm mm mm mm mm mm mm mm mm R7M Z20030 BS1 165 5 135 5 70 30 70 50h8 Four 14h6 20 5 5 dia R7M Z40030 BS1 188 5 158 5 93 30 70 50h8 Four 14h6 20 5 5 dia A 7 dia 2 9 Standard Models and Dimensions Chapter 2 2 2 3 Decelerator Dimensions m Backlash 3 Arcminutes Max See note __ k b hn 100w 15 R7G vAsFPBosBi00 675 32 s2 ao 46 oo so as 1o a fe 12 20 m ms me 12 fie fa 4 25 19 R7GVRSFPBo9B100 67 5 s2 52 40 se 60 so as 10 3 fe 12 20 ma ms ms i2 16 a 4 2s 115 R7G VRSFPB15B100 78 32 52 40 46 60 so 45 to a fe 12 20 me mo mo 12 ie a la 25 125 R7G vRSFPB25C100 92 so 78 40 46 so 70 62 z s o 19 so ma me me 20 22 fe s os 200W 1 5 R7G VRSFPBo5B200 725 32 52 60 70 feo so 45 to s io 12 20 ms ms ma 12 16 a a 25 19 R7GVRSFPBo9c400 ses 50 78 so 70 eo 70 e2 17 s a 19 so ms me m 20 22 fe fs os 115 R7G VRSFPB15C400 100 50 78 eo 70 oo 70 62 17 a fs i9 so ms me ma 20 22 fe 6 as 125 R7 vRSFPB25c200 100 so 78 eo 70 so 70 62 17 3 s 19 so ms me m 20 22 fe e ss 400W 15 A7G VRSFPBO5C400 895 so 78 eo 70 90 70 62 17 s 8 19 30 ms
99. me ma 20 22 fe 6 ss 5o ze eo 7o so 70 62 1z s fa io 30 ms me m4 20 22 e 6 ss 115 R7G VRSFPB15C400 100 so 78 60 70 oo 70 e2 17 3 fs 19 so ms me ma 20 22 fe 6 as 125 R7G VRSFPB25D400 104 61 os 60 70 115 oo 75 18 5 s 24 40 ms me m 20 30 8 7 a 750W 1 5 R7G vRSFPBosc750 935 50 78 so joo oo 70 62 17 s to 19 so mo mo ma 20 22 fe je ss 19 R7G VRSFPBo9D750 975 61 os so oo 115 oo 75 18 5 10 24 40 mo me ma 20 30 8 7 a 115 A7G VASFPBISD7S0_ 110 61 98 80 oo 115 00 75 is s to 24 40 mo me ma 20 30 fe 7 4 125 R7 vRSFPB25E750_ 135 75 125 so 90 135 10 os 17 s io s2 ss ms mio ma 20 fas io je s Note AT is the size of the set bolt Outline Drawings Pa Four Z2 Effective depth I Four Z1 gt D2 dia D4 dia D3h7 dia ad LM LR Set bolt AT Key dimensions 2 10 Standard Models and Dimensions Chapter 2 m Backlash 45 Arcminutes Max Model Dimensions mm PEPEPEPE E EES e ee mote ok b om tt toow 15 m7e ResFoseroo 675 32 52 40 as 60 so jio fs e 12 20 ma mo mo 12 ie a 4 25 19 m7a ResrosBioo 675 32 52 40 46 eo fso as fio fa fe 12 20 ma ms ms 12 jie fa f4 2s vis R7G RGSF15B100 78 32 s2 40 46 feo 50 45 10 3 o 12
100. motor Power Cable must be connected securely e The Encoder Cable must be securely connected to the Encoder Connector CN2 at the Servo Driver e The Encoder Cable must be securely connected to the Encoder Connector at the Servomotor e Checking the Control Connectors e The Control Cable must be securely connected to the I O Control Connector CN1 e The reverse drive prohibit NOT forward drive prohibit POT and emergency stop STOP inputs must be input properly e Checking the MECHATROLINK II Connections e The MECHATROLINK II cable most be securely connected to the MECHAT ROLINK II connector at the host controller e The MECHATROLINK II Cable most be securely connected to the MECHATROLINK II Connector CN6 at the Servo Driver e The terminating resistance must be securely connected at the end Servo Drivers Operation Chapter 5 5 3 2 Turning ON Power e First carry out the preliminary checks and then turn ON the main circuit power supply e The ALM output will take approximately 2 seconds to turn ON after the power has been turned ON Do not attempt to detect an alarm using the host controller during this time when power is being supplied with the host controller connected 5 3 3 Checking Displays e When the power is turned ON check that the alarm indicator ALM and the Servo indicator RDY light After approximately two seconds check that the ALM indicator turns OFF and that only the REF indicator remains l
101. nd Z directions Impact resistance 98 m s max twice in vertical direction Insulation resistance 10 M min at 500 VDC between the power terminals and FG terminal Dielectric strength 1 500 VAC 50 or 60 Hz for 1 minute between the power ter minals and FG terminal Any direction Operating position Insulation class Type B Construction Totally enclosed self cooling Degree of protection IP55 excluding the through shaft portion Vibration class 15 Mounting method Flange mounting International EC Directives EMC Directive EN 55011 Class A Group1 standards EN 61000 6 2 Low Voltage IEC 60034 1 5 8 and 9 Directive EN 60034 1 and 9 UL standards cUL standards cUL C22 2 No 100 E m as O O Motor Rotation Directions In this manual the Servomotors rotation directions are defined as forward and reverse Viewed from the end of the motor s output shaft counterclockwise CCW rotation is forward and clockwise CW rotation is reverse Reverse Forward 3 16 Specifications Chapter 3 3 2 2 Characteristics Saar p A fee tr paie Z10030 S1 S1 r S1 S1 eee CN EC E Max momentary ourent See note 1 Jamo 25 ps 0 m weight wmm Je bs o h he a CTN C EI ICRA E Radiation shield dimensions material x 250 x 250 Al Da Excitation Excitation voltage See note 3 Excitation voltage See note 3 note 3 24 VDC 10 e e We Curentcarsumpien 120 C A 0502 T ose Bews E
102. ng the direction of Servomotor rotation without having to change the Servomotor wiring The forward direction is the counterclockwise CCW direction as seen from the Servomotor load side Refer to 3 2 Servomotor Specifications m Reverse Rotation Pn000 0 P000 0 Setting range O 1 Unit Factory Restart to Yes setting enable e This parameter reverses the Servomotor direction of rotation e The polarity of Servomotor data such as feedback positions and feedback speeds is not changed e When 0 is set a forward command rotates the Servomotor in the forward CCW direction and when 1 is set a forward command rotates the Servomotor in the reverse CW direction Operation Chapter 5 5 4 2 Setting the Command Filter The command filter does not need to be set if the machine is not subject to vibration but set it as trou bleshooting for problems such as overshooting There are two methods for setting the command filter and the method using PnOOA is covered here The other method is to use the rotary switch for command filter setting FIL on the front of the Servo Driver For information on that method refer to 5 2 2 Switch Functions Command Filter Setting Pn00A Setting 0000H to OOOOFH Unit Factory 0000H Restart to range setting enable e The setting method is the same as for the rotary switch for command filter setting FIL e Do not set 8 0008H to F OOOFH 5 4 3 Setting the Electronic Gear The el
103. ns e Locations subject to condensation as the result of severe changes in temperature e Locations subject to corrosive or flammable gases e Locations subject to dust especially iron dust or salts e Locations subject to shock or vibration Locations subject to exposure to water oil or chemicals Do not touch the Servo Driver radiator Servo Driver regeneration resistor or Servomotor while the power is being supplied or soon after the power is turned OFF Doing so may result in a skin burn due to the hot surface Storage and Transportation Precautions NCAUTION N Caution N Caution Do not hold the product by the cables or motor shaft while transporting it Doing so may result in injury or malfunction Do not place any load exceeding the figure indicated on the product Doing so may result in injury or malfunction Installation and Wiring Precautions N Caution N Caution Caution N Caution N Caution N Caution N Caution N Caution N Caution N Caution N Caution N Caution ANOTA VELO Do not step on or place a heavy object on the product Doing so may result in injury Do not cover the inlet or outlet ports and prevent any foreign objects from entering the product Doing so may result in fire Be sure to install the product in the correct direction Not doing so may result in malfunction Provide the specified clearances between the Servo Driver and the control panel or w
104. nts Adjust the command filter setting as required 5 2 Switch Set tings and 5 4 User Parame ters y Operation Operation can now begin If any trouble should occur refer to Chapter 6 Chapter 6 Troubleshooting Troubleshoot ing Operation Chapter 5 5 2 Switch Settings With SMARTSTEP Junior Servo Drivers the settings required for MECHATROLINK II communica tions can be made simply by setting the front panel switches under the cover Command filter set tings can also be made using the rotary switch on the front panel Set the switches according to the system configuration 5 2 1 Switch Names With Top Cover Open DIP switch SW2 for Rotary switch SW1 for e MECHATROLINK II MECHATROLINK II axis number el ES iS SMARTSTEP Tas Rotary switch for command filter setting FIL 5 2 2 Switch Functions Communications Specifications MECHATROLINK II communications specifications are set using the DIP switch SW2 The settings are shown in the following table Changes to the settings are enabled by turning the power OFF and then ON again Contents Factory setting Reserved for system ON gt TON Reserved for system ON ON m 3 Axis No setting OFF Axis No 15 max a 1 2 a Axis No 16 min SW2 factory settings a 4 Filter selection Enables or disables the rotary al switch for setting the command filter 5 3 Operation Chapter 5 m Setting the Axis Numbe
105. o 1553 1 1 2 SMARTSTEP Junior Features The SMARTSTEP Junior has the following features No Setup Parameters No parameter settings are required for setup so you can start using the Servo Driver immediately simply by removing it from the box and wiring it If it is necessary to set the positioning resolution or reference pulse method these settings can be set or changed easily with the rotary switches on the front of the Servo Driver m No Servo Adjustments Required With the newest auto tuning function it isn t necessary to adjust the Servo Driver to achieve excellent responsiveness Auto tuning achieves excellent responsiveness while providing compatibility with a range of stepping motors A Servomotor with moderate inertia is used to improve control system sta bility Reduced Wiring through Using MECHATROLINK II CommunicationsAiModels with MECHATROLINK II Communications In combination with a MECHATROLINK II compatible Position Control Unit CS1W NCF71 or CJ1W NCF71 the Servo Driver and the Controller can be connected with a single MECHATROLINK II Cable Moreover when wiring multiple Servo Drivers connecting one Servo Driver to another by a single MECHATROLINK Cable makes it possible to greatly reduce the time involved in wiring without hav ing to worry about wiring mistakes Features and System Configuration Chapter 1 CJ1W NCF71 EERERER
106. ons R88A RR22047S 47 Q 5 220 W 70 W t1 0 x 350 x 350 Operating temperature SPCC 170 C 5 NC contact A Rated output 3A e Wiring Method When installing an External Regeneration Resistor remove the shorting bar between the RG JP ter minals and connect the resistor between the P RG terminals Shorting bar Note Connect the thermal switch output just like the External Regeneration Unit s ALM output so that the power supply will be shut off when the contact opens If a sequence is not added to cut off the power with this output the Resistor may overheat e Combining External Regeneration Resistors Resistor Regeneration absorption capacity configurations ow w See note RHR HE Note Select a combination that has an absorption capacity greater than the average regeneration power Pr 4 29 System Design Chapter 4 4 30 mm MU im Chapter 5 Operation 5 1 5 2 5 3 5 4 5 5 5 6 Operational Procedure Switch Settings Preparing for Operation User Parameters Trial Operation Operating Functions Operation Chapter 5 5 1 Operational Procedure After mounting and wiring connect a power supply and check the operation of the Servomotor and Servo Driver lf the parameter settings are incorrect the Servomotor may operate in dangerous and unexpected ways Be careful to make the settings correctly according to the procedures described in this manual Mounting and Install the
107. or is ON e Send a command from the host controller to rotate the Servomotor and confirm that Servomo tor rotation direction is correct and that the rotation speed and rotation amount match the com mand that was sent 2 Power OFF Mechanical Device Connection Power ON e Turn OFF the power supply e Connect the mechanical device to the Servomotor shaft e Turn ON the power supply 3 Loaded Low speed Operation e Send a low speed command from the host controller to rotate the Servomotor The definition of low speed varies depending on the mechanical system but a rough estimate is 1 10 to 1 5 of the normal operating speed 5 17 Operation Chapter 5 e Check the following items a Are the emergency stop STOP the forward drive prohibit POT and the reverse drive prohibit NOT operating correctly b Is the operating direction of the machinery correct c Are the operating sequences correct d Are there any abnormal sounds or vibration If the machine vibrates when starting or stopping refer to 5 2 2 Switch Functions and adjust the com mand filter rotary switch FIL e Is any error or alarm generated If anything abnormal occurs refer to Chapter 6 Troubleshooting and apply the appropriate counter measures 4 Operation under Actual Conditions e Operate the Servomotor in a regular pattern and check the following items a Is the operating speed correct b Is the load torque roughly equivalent to the meas
108. ox 1 2 kg R7A CAZ015S Approx 1 6 kg R7A CAZ020S Approx 2 0 kg Note The maximum distance between the Servo Driver and Servomotor is 20 meters e Connection Configuration and Dimensions 19 6 Servo Driver end Servomotor end 34 24 Taan 8707 A ESO ERES A Ce A Y 3 29 Specifications Chapter 3 e Wiring Servo Driver AWG20 Red al Green Yellow M4 crimp terminal Servo Driver Connector Connector plug 04JFAT SAYGF N JST Mfg Co Ltd AWG20 White AWG20 Blue Servomotor a pomo je lo gt Servomotor Connector Connector plug 5557 06R 210 Molex Japan Connector case 5556TL Molex Japan m Power Cables without Connector Loose Wires for Servomotors without Brakes e Cable Models Length L Outer diameter of cable See note 1 R7A CAZO01 T m See note 2 Approx 0 1 kg Note 1 The maximum distance between the Servo Driver and Servomotor is 20 meters Note 2 Cables are sold in 1 m increments It is cut to the specified length 3 30 Specifications Chapter 3 Power Cables with CNB Connector for Servomotors with Brakes e Cable Models IE ae See note 74da R7A CAZ010B R7A CAZ015B Approx 1 6 kg R7A CAZ020B Approx 2 0 kg Note The maximum distance between the Servo Driver and Servomotor is 20 meters e Connection Configuration and Dimensions Servo Driver end lt 34 24 i
109. perature Characteristics of the Servomotor and Mechanical System e SMARTSTEP Junior Servomotors use rare earth magnets neodymium iron magnets The tem perature coefficient for these magnets is approximately 0 13 C As the temperature drops the Servomotor s maximum momentary torque increases and as the temperature rises the Servomo tor s maximum momentary torque decreases The maximum momentary torque is about 4 higher at 10 C compared to the normal temperature of 20 C Conversely the maximum momentary torque decreases about 8 when the Servomotor warms up to 80 C from the normal temperature of 20 C e Generally when the temperature drops in a mechanical system the friction torque and the load torque increase For that reason overloading may occur at low temperatures In particular in sys tems that use a Decelerator the load torque at low temperatures may be nearly twice the load torque at normal temperatures Check with a current monitor to see whether there is overloading at low temperatures Also check operation at high temperatures to see whether there is abnormal Ser vomotor overheating or alarms e An increase in load friction torque visibly increases load inertia Therefore even if the Servo Driver parameters are properly adjusted at a normal temperature the Servomotor may not operate opti mally at low temperatures Check operation at low temperatures to see whether operation is optimal in those conditions too 3
110. perly and prevent cur rents from flowing to the encoder FG Reduce the mechanical vibration or correct the Servomotor installation Increase the value set on the command filter setting rotary switch FIL 6 17 Troubleshooting Chapter 6 Problem Probable cause Itemstocheck Countermeasures Overtravel Travel outside of the zone specified by the host controller 6 18 The forward or reverse drive prohibit input sig nals POT NOT is not changing POT CN1 4 or NOT CN1 3 is high The forward or reverse drive prohibit input sig nals POT NOT is not operating correctly The POT or NOT signal sometimes changes The forward or reverse drive prohibit input sig nals POT NOT param eters are set to always enable driving The position of the over travel limit switch is un suitable Noise is infiltrating the Encoder Cable because it does not meet specifi cations Noise is infiltrating the Encoder Cable because it is too long Noise is infiltrating the signal wires because the Encoder Cable is dam aged or the sheath is cut Too much noise is reach ing the Encoder Cable The FG potential is fluc tuating due to devices such as welding ma chines near the Servo motor Servo Driver feedback pulses are being mis counted due to noise Errors are being caused by excessive vibration or shock at the encoder Is the input signal external power supply voltage
111. r Set the axis number as shown in the following table using the rotary switch for setting the MECHA TROLINK II axis number SW1 and the DIP switch for setting MECHATROLINK II communications SW2 pin 3 SW1 factory settings ON i E OFF SW2 factory settings o praa ON m Selecting the Filter Setting mb q 2 8 EC 4 po slat 6 2 eg Ja ES 0 AJOJN Si There are two methods for setting the command filter as shown below The selection is made using SW2 pin 4 SW2 pin4 Specifications Set using the rotary switch for setting the command filter FIL Factory setting Set using PNOOA Disable the rotary switch for setting the command filter Operation Chapter 5 m Rotary Switch for Command Filter Setting FIL This switch does not need to be set if the machine is not subject to vibration The switch is factory set to 0 Filter Acceleration deceleration time Approx time from end of Description setting for STEP command command to end of positioning See See note 3 settling time See note 2 note 1 100 to 200 ms Smaller filter time constant 110 to 220 ms short positioning time a fom roto 280m a 68 ms 98070 800m 170 840 ms 200 to 400 ms Larger filter time constant 250 to 500 ms longer positioning time 70s E 1000 ms wa ite vibration Do not set this switch to 8 to F Note 1 Increase the value of the filter
112. range setting enable Set Values Set value O Software imis enabled e Specify whether software limits are to be enabled or disabled The software limit function settings are made in the following parameters e The origin be established in order for software limits to be enabled The CJ1W NCF71 or CS1W NCF71 No origin Flag must be OFF If the origin is not established the software limits will not go into effect even when positioning is out of the software limit range e When using the CJ1W NCF71 or CS1W NCF71 set OOOL H for Pn801 Enter a number from 0 to 3 for Ll Forward Software Limit Pn804 Forward software limit Setting 1073741823to Unit Command unit Factory 1073741823 Restart to range 1073741823 setting enable e Set the software limit in the positive direction e The area is set according to the direction so be sure to set the reverse software limit to a value lower than the forward software limit m Reverse Software Limit Pn806 Pn806 Reverse software limit 1073741823 to Unit Command unit Factory 1073741823 Restart to 1073741823 setting enable e Set the software limit in the negative direction e The area is set according to the direction so be sure to set the reverse software limit to a value lower than the forward software limit 5 13 Operation Chapter 5 5 4 6 Setting the Zero Point Width Like the positioning completion width this function can be
113. res setting methods for user parameters the brake interlock function and the interrupt feeding function Chapter 6 Troubleshooting Describes items to check when troubles occur troubleshooting with alarm codes troubleshooting based on operating status and periodic maintenance Appendix Provides connection examples to OMRON Position Controllers and parameter lists Registered Trademark e MECHATROLINK is a registered trademark of the MECHATROLINK Members Association Chapter 1 Features and System Configuration 1 1 1 2 1 3 1 4 1 5 Introduction System Configuration Nomenclature and Functions System Block Diagrams Applicable Standards Features and System Configuration Chapter 1 1 1 Introduction 1 1 1 Introduction The SMARTSTEP Junior is available either with pulse string input for position control or with built in MECHATROLINK II communications for reduced wiring multi axis control It is easy to set up and start because it does not require the complex parameter settings and Servo adjustments that were required for previous Servos The SMARTSTEP Junior Servomotor and Servo Driver are easy to use yet provide the responsive ness high speed high torque and precision of traditional Servo systems This manual describes the SMARTSTEP Junior Servo Driver for MECHATROLINK II communica tions Servo Driver models with pulse string input for position control are described in the SMART STEP Junior User s Manual Cat N
114. rice of the product on which liability is asserted INNO EVENT SHALL OMRON BE RESPONSIBLE FOR WARRANTY REPAIR OR OTHER CLAIMS REGARDING THE PRODUCTS UNLESS OMRON S ANALYSIS CONFIRMS THAT THE PRODUCTS WERE PROPERLY HANDLED STORED INSTALLED AND MAINTAINED AND NOT SUBJECT TO CONTAMINATION ABUSE MISUSE OR INAPPROPRIATE MODIFICATION OR REPAIR Application Considerations SUITABILITY FOR USE OMRON shall not be responsible for conformity with any standards codes or regulations that apply to the combination of products in the customer s application or use of the products At the customer s request OMRON will provide applicable third party certification documents identifying ratings and limitations of use that apply to the products This information by itself is not sufficient for a complete determination of the suitability of the products in combination with the end product machine system or other application or use The following are some examples of applications for which particular attention must be given This is not intended to be an exhaustive list of all possible uses of the products nor is it intended to imply that the uses listed may be suitable for the products e Outdoor use uses involving potential chemical contamination or electrical interference or conditions or uses not described in this manual e Nuclear energy control systems combustion systems railroad systems aviation systems medical equipment amusement mac
115. river faulty The Servo Driver Wait until the RDY indicator power was turned has turned OFF before turn back ON before it was ing the power back ON again completely turned OFF Power is momentarily Use the alarm reset to restart interrupted operation A 41 Undervoltage Occurs when the power is turned ON The Servo Driver is Replace the Servo Driver faulty A 51 Overspeed Occurs when the The Servo Driver is Replace the Servo Driver power is turned faulty ON Occurs when Ser The U V and W Check and correct the Servo vomotor operation phases at the Servo motor wiring started or during motor are wired incor high speed opera rectly tion Encoder wiring is Check and correct the incorrect encoder wiring Noise infiltrated the Take measures against noise Encoder Cable and in the encoder wiring Caused improper operation The position com Reduce the command value mand input is too large The Servo Driver is Replace the Servo Driver faulty 6 8 Troubleshooting Chapter 6 Alarm Status when error Probable cause Countermeasures code occurs A 71 Overload Momentary maximum load A 72 Overload Con tinuous maxi mum load A 73 Dynamic brake overload Occurs when the The Servo Driver is Replace the Servo Driver power is turned faulty ON Occurs during Ser The effective torque Re evaluate the load and vomotor operation exceeds the rated operating cond
116. rror ation Encoder signal error Noise is entering the Use an Encoder Cable with Encoder Cable twisted pair wires or shielded because it does not twisted pair wires of at least meet specifications 0912 mm Noise is entering the Use an Encoder Cable no Encoder Cable more than 20 m in length because it is too long The Encoder Cable is Replace the Encoder Cable faulty The encoder is faulty Replace the encoder The Servo Driver is Replace the Servo Driver faulty 6 11 Troubleshooting Chapter 6 Alarm Status when error Probable cause code occurs The Servo Driver is Replace the Milii Driver faulty Wire the cable correctly A dO Occurs when the power is turned Excessive follow ing error Occurs during high speed opera tion Occurs regardless of position com mands and with outthe Servomotor rotating Occurs when oper ation is normal but the command is long A EO A EA MECHA TROLINK II internal synchro nization error Occurs at the start of or during MECHATROLINK Il communications A ED MECHA TROLINK II internal com Occurs at the start of or during MECHATROLINK Il communications mand error 6 12 Eo Connection is faulty fora U V or W phases at the Servo motor main circuit cable Encoder wiring error Faulty wiring or con Wire the encoder correctly nections The Servo Driver is Replace the Servo Driver faulty
117. s mm AT B C D E F G Dit Dial Resa Pxsos2 35 82 80 95 30 40 4 as Rasa Px5053 as 52 90 105 35 as 50 4 43 Rasa Px5054 as 52 80 9s 30 40 45 4 45 Resa Pxsos6 as 52 80 95 30 40 45 ja 43 2 13 Standard Models and Dimensions 2 14 Chapter 2 mi l Ml Chapter 3 Specifications 3 1 3 2 3 3 3 4 3 5 3 6 Servo Driver Specifications Servomotor Specifications Decelerator Specifications Cable and Connector Specifications External Regeneration Unit and External Regener ation Resistor AC Reactors Specifications Chapter 3 3 1 Servo Driver Specifications Select the Servo Driver in combination with the Servomotor being used For details refer to 2 1 3 Servo Driver Servomotor Combinations 3 1 1 General Specifications pote Specifications O O O 90 max with no condensation Storage and operating atmosphere No corrosive gasses no dust no iron dust no exposure to mois ture or cutting oil Vibration resistance 10 to 55 Hz in X Y and Z directions with 0 1 mm double amplitude acceleration 4 9 m s max Impact resistance Acceleration 19 6 m s max in X Y and Z directions three times Insulation resistance Between power supply power line terminals and frame ground 0 5 MQ min at 500 V DC Dielectric strength Between power supply power line terminals and frame ground 1 500 V AC for 1 min at 50 60 Hz Between each control signal and frame ground 500
118. s N Ny No Rotation speed at beginning of deceleration r min Toi Tpo Deceleration torque N m TLo Torque when falling N m ty tg Deceleration time s to Constant velocity travel time when falling s 4 26 System Design Chapter 4 Note There is some loss due to winding resistance so the actual regenerative energy will be approx imately 90 of the values derived from these equations e The average regeneration power Pr is the power consumed by regeneration resistance in one cycle of operation Pr Eg1 Eg2 Eg2 T W T Operation cycle s e Since there is an internal capacitor to absorb regenerative energy the value for Eg1 and Ego Egg unit J must be lower than the Servo Driver s regenerative energy absorption capacity The capacity varies depending on the model For details refer to 4 3 2 Servo Driver Regenerative Energy Absorption Capacity below If an External Regeneration Unit is connected be sure that the average regeneration power Pr does not exceed the External Regeneration Unit s regenerative energy absorption capacity 12 W 4 3 2 Servo Driver Regenerative Energy Absorption Capacity The SMARTSTEP Junior Servo Drivers absorb regenerative energy internally with built in capacitors If the regenerative energy is too large to be processed internally an overvoltage error is generated and operation cannot continue The following table shows the regenerative energy and amount of reg
119. servo system m System Configuration Controller Position Control Unit CJ1W NCF71 CS1W NCF71 i CN6 MECHATROLINK II Connector MECHATROLINK II Cable R7D ZNO ML2 DRIVER CN1 Control I O Connector CN2 Encoder Input Connector Connector Cable for Connector Terminal Block Terminal Block gt SN 1 MIO A E SS x i gt SS A S R7A CNZO1P Main Circuit Connector sold separately Servomotor Encoder Power Cable Cable 4 7 System Design Chapter 4 4 2 2 Selecting Connecting Cables MECHATROLINK II Cable CN6 e Special Cable Name Model number Comments MECHATROLINK II Cable FNY W6008 L IL Use special MECHATROLINK II Cable to connect MECHATROLINK II devices The figures indicated by the boxes LIL in the model number show the length of the Cable The Cable is available in seven lengths in meters 0 5 1 3 5 10 20 and 30 e Terminating Resistance Model number MECHATROLINK II Terminating FNY W6022 Terminating resistance is required at the ends of Resistor MECHATROLINK II communications General purpose Control Cables lf you are connecting to a controller that does not have a standard cable available use General pur pose Control Cable to assemble a cable to connect to the Servo Drivers Control I O Connector CN1 ame Model number Cable for Connector Terminal XW2Z LJL 11 1J B19 This is special cable
120. signal cables when wiring Control Panel Construction Openings in the control panel such as holes for cables operating panel mounting holes and gaps around the door may allow electromagnetic waves into the panel To prevent this from occurring observe the recommendations described below when designing or selecting a control panel e Case Structure e Use a metal control panel with welded joints at the top bottom and sides so that the surfaces will be electrically conductive e During assembly strip the paint off of joint areas or mask them during painting to make them electrically conductive e If gaps appear in the control box case when screws are tightened make adjustments to prevent this from occurring 4 23 System Design Chapter 4 e Do not leave any conductive part unconnected e Ground all Units within the case to the case itself e Door Structure e Use a door that is made of metal e Use a water draining structure where the door and case fit together and leave no gaps Refer to the diagrams below e Use a conductive gasket between the door and the case as shown in the diagrams below Refer to the diagrams below Strip the paint off of the sections of the door and case that will be in contact with the conductive gasket or mask them during painting so that they will be electrically conduc tive e Gaps may open between case panels when screws are tightened Be sure that no gaps appear when tightenin
121. t in capacitors on the Servomotor output lines e Select a noise filter with a rated current at least two times the Servo Driver s continuous output cur rent e The following table shows the noise filters that are recommended for Servomotor output Maker Model number Rated current Applicable standards Remarks NEC TOKIN LF 310KA For inverter output Faa ROA Soshin Electric CC3005C AZ 5A Forinverteroutput Company OOOO AZ 0A cos01sc az ISA Note 1 Servomotor output lines cannot use the same noise filters used for power supplies Note 2 Typical noise filters are used with power supply frequencies of 50 60 Hz If these noise filters are connected to outputs of 11 7 kHz the Servo Drivers PWM frequency a very large about 100 times larger leakage current will flow through the noise filters condenser and the Servo Driver could be damaged 4 21 System Design Chapter 4 4 2 6 Conforming to EMC Directives Conformance to EMC Directives EN55011 class A group 1 EMI and EN61000 6 2 EMS can be ensured by wiring under the conditions described below These conditions are for conformance of SMARTSTEP Junior products to EMC Directives EMC related performance of these products however will vary depending on the configuration wir ing and other conditions of the equipment in which the products are installed The customer must therefore perform final checks to confirm that devices and the overall installation
122. tallation Be sure to remove the cover after installa tion is complete If the cover is left on during operation heat buildup may damage the Units e Take measures during installation and operation to prevent foreign objects such as metal particles oil machining oil dust or water from getting inside of Servo Drivers 4 3 System Design Chapter 4 4 1 2 Servomotors m Operating Environment e The environment in which the Servomotor is operated must meet the following conditions Operat ing the Servomotor outside of the following ranges may result in malfunction of the Servomotor e Ambient operating temperature O to 40 C e Ambient operating humidity 20 to 80 with no condensation e Atmosphere No corrosive gases Impact and Load e The Servomotor is resistant to impacts of up to 98 m s Do not subject it to heavy impacts or loads during transport installation or removal e When transporting it hold onto the Servomotor itself and do not hold onto the encoder cable or connector areas Holding onto weaker areas such as these can damage the Servomotor e Always use a pulley remover to remove pulleys couplings or other objects from the shaft e Secure cables so that there is no impact or load placed on the cable connector areas Connecting to Mechanical Systems e The axial loads for Servomotors are specified in 3 2 2 Characteristics lf an axial load greater than that specified is applied to
123. the shield to the metal plate 4 22 System Design Chapter 4 e Ground the motor s frame to the machine ground when the motor is on a movable shaft e Use a grounding plate for the frame ground for each Unit as shown in the above diagrams and ground to a single point e Use ground lines with a minimum thickness of 3 5 mmf and arrange the wiring so that the ground lines are as short as possible e No fuse breakers surge absorbers and noise filters NF should be positioned near the input termi nal block ground plate and I O lines should be isolated and wired using the shortest distance pos sible e If no fuse breakers are installed at the top and the power supply line is wired from the lower duct use metal tubes for wiring and make sure that there is adequate distance between the input lines and the internal wiring If input and output lines are wired together noise resistance will decrease e Wire the noise filter as shown at the left in the following illustration The noise filter should be installed at the entrance to the control box whenever possible Correct Separate input and output Wrong Noise not filtered effectively AC input AC output AC input Ground Ground AC output e Use twisted pair cables for the power supply cables whenever possible or bind the cables Correct Properly twisted Correct Cables are bound Driver Driver O L1 J COSO D L2 a e Separate power supply cables and
124. tives m External Regeneration Unit External Regeneration Resistor Models Regeneration Regeneration Internal average Externally voltage current regenerative power connected regenerative resistance R88A RGO8UA 380 Voc 8 Apc 12 W 47 Q 5 Internal resistance 50 Q 60 W For detailed specifications refer to 3 5 1 External Regeneration Unit R88A RGO8UA Specifica tions 4 3 4 Absorbing Regenerative Energy with an External Regeneration Resistor If the regenerative energy exceeds the absorption capacity of the R88A RGO8UA External Regener ation Unit connect an External Regeneration Resistor To connect an External Regeneration Resistor remove the shorting bar between the RG JP termi nals and connect the resistor between the P RG terminals Double check the terminal names when connecting the Resistor The External Regeneration Unit can be damaged if the Resistor is connected to the wrong terminals The External Regeneration Unit does not conform to EC Directives The External Regeneration Resistor can reach a temperature of approximately 120 C so install it at a distance from heat sensitive devices and wiring In addition install a heat radiating heat sink to cool the resistor if necessary 4 28 System Design Chapter 4 m External Regeneration Resistor e External Regeneration Resistor Models lis Nominal Regeneration Heat radiation Thermal switch output capacity absorption at 120 C specificati
125. ulses generates one Servomotor rotation e The electronic gear function is useful in the following situations When fine tuning positions and speeds for two synchronized lines When setting for example 0 001 mm for the amount of machine travel per pulse When it is necessary to minimize the effect of pi z m Setting Method Use the following procedure to calculate the electronic gear ratio G1 G2 and to set it in the user parameters Pn20E and Pn210 1 Check the machine specifications The following items are related to the electronic gear ratio e Deceleration rate e Ball screw pitch e Pulley diameter etc Ball screw pitch H Deceleration rate e For this calculation example it is assumed that the pulley deceleration rate is 1 2 and that the pulley pitch is 5 mm 2 Check the encoder resolution for the Servomotor Servomotor model Encoder resolution R7M ZL 8 192 pulses rotation 3 Determine the command unit e The command unit is positioning data that specifies the load travel per command pulse The pulse rate is calculated according to the mechanical system and the encoder resolution The pulse rate is determined first and then the electronic gear ratio is set to achieve the desired command unit e Units such as the following can be used for the command unit Examples 0 01 mm 0 0001 mm 0 1 0 1 inch etc 5 10 Operation Chapter 5 e Take factors such as the machine specifications and positionin
126. ure to radioactivity e Locations close to power supplies Operation and Adjustment Precautions N Caution N Caution Caution N Caution N Caution N Caution Caution PANT ACON Confirm that no adverse effects will occur in the system before performing the test operation Not doing so may result in equipment damage Check the newly set parameters and switches for proper execution before actually running them Not doing so may result in equipment damage Do not make any extreme adjustments or setting changes Doing so may result in unstable operation and injury Separate the Servomotor from the machine check for proper operation and then connect to the machine Not doing so may cause injury When an alarm occurs remove the cause reset the alarm after confirming safety and then resume operation Not doing so may result in injury Do not use the built in brake of the Servomotor for ordinary braking Doing so may result in malfunction Do not operate the Servomotor connected to a load that exceeds the applicable load moment of inertia Doing so may result in malfunction Maintenance and Inspection Precautions N Caution N WARNING TANO ACON Resume operation only after transferring to the new Unit the contents of the data required for operation Not doing so may result in an unexpected operation Do not attempt to disassemble repair or modify any Units Any attempt to do so may result in mal
127. ured value Cc d e Are the positioning points correct When an operation is repeated is there any discrepancy in positioning Are there any abnormal sounds or vibration If the machine vibrates when starting or stopping refer to 5 2 2 Switch Functions and adjust the com mand filter rotary switch FIL f Is either the Servomotor or the Servo Driver abnormally overheating SEY e uo g Is any error or alarm generated If anything abnormal occurs refer to Chapter 6 Troubleshooting and apply the appropriate counter measures 5 Completing the Trial Operation Performing the above procedures completes the trial operation 5 18 Operation Chapter 5 56 OperatingFunctions _ _ _ _ 5 6 1 Brake Interlock m Precautions When Using the Electromagnetic Brake The electromagnetic brake of a Servomotor with a brake is a non excitation brake especially for hold ing First stop the Servomotor and then turn OFF the brake power supply If the brake is applied while the Servomotor is operating the brake disk may become damaged or malfunction due to friction causing damage to the Servomotor m Function Output the BKIR brake interlock signal which turns the electromagnetic brake ON and OFF Operation Servo ON Timing When Servomotor Is Stopped RUN ON Run command OFF About 40 See note 1 BKIR ON AS brake interlock oo A OFF Relay operation time See note 2 ON r ial O
128. used to set the width for output signals for the origin It can be set separately from the positioning completion signal Origin range a i Included in origin range l 7 I le Machine coordinate system gt I o 2 Origin Zero point width Pn803 Zero Point Width Pn803 Setting O to 250 Unit Command unit Factory 10 Restart to range setting enable e Set the zero point ZPOINT width e Zero point ZPOINT is enabled when the origin is established when the No origin Flag is OFF It cannot be used when the origin is not established 5 4 7 Setting Acceleration and Deceleration Set the acceleration and deceleration for PTP positioning control Stop the axes before changing the settings The settings can be changed when the host controller s Busy Flag is OFF m Linear Acceleration Constant Pn80B Pn80B Linear acceleration constant Setting 1 to 65535 Unit x10 000 com Factory 100 Restart to range mand unit s2__ setting enable Linear Deceleration Constant Pn80E Linear deceleration constant Setting 1 to 65535 Unit x10 000 com Factory 100 Restart to range mand unit s2__ setting enable Speed reference Target speed Time 5 14 Operation Chapter 5 5 4 8 Setting Origin Search The origin search function operates the Servomotor to establish the origin based on the limit input signal origin proximity input signal and the origin input signal When the origin
129. ut section m Selecting Other Parts for Noise Resistance This section explains the criteria for selecting other connection components required to improve noise resistance Review each component s characteristics such as its capacity performance and applicable conditions when selecting the components For more details contact the manufacturers directly o Noise Filters for the Power Supply Input e Use a noise filter to attenuate external noise and reduce noise emitted from the Servo Driver e Select a noise filter with a rated current that is at least two times greater than the effective load cur rent the rated current of the main circuit power supply input shown in the table under 4 2 4 Wiring the Main Circuit and Servomotor Connections above 4 20 System Design Chapter 4 NEC TOKIN GT 2050 5A UL CSA VDE andTUV Soshin Electric UL and TUV Company Heroa uP 0a HF2015A UP BA ECN E T TDK 6A UL CSA and NEMKO Note 1 To attenuate noise at low frequencies below 200 kHz use an isolation transformer and a noise filter Note 2 To attenuate noise at high frequencies over 30 MHz use a ferrite core and a high frequency noise filter with a through type capacitor Note 3 If multiple Servo Drivers are being connected to a single noise filter select a noise filter with a rated current at least two times the total rated current of all the Servo Drivers o Noise Filters for Servomotor Output e Use noise filters without buil
130. vo Driver has stopped Cooling fan ventila Inspect the cooling fan tion is blocked by dirt or foreign objects have gotten inside The Servo Driver is Replace the Servo Driver faulty Current detec Occurs when the The Servomotor s Fix the Servomotor s main cir tion error servo is turned main circuit cable is cuit cable ON disconnected The Servo Driver is Replace the Servo Driver faulty MECHA Occurs when the Error in MECHA Replace the Servo Driver TROLINK II power is turned TROLINK II communi communications ON cations LSI LSI error Troubleshooting Chapter 6 Alarm ME ae when error Probable cause Countermeasures code occurs Replace the Servo Driver A bF ll alarm Occurs when the The Servo Driver is power is turned faulty ON or during oper ation Runaway pre Occurs when the The Servo Driver is Replace the Servo Driver vention detection power is turned faulty ON Occurs when the The U V and W servo is turned ON phases at the Servo or during com motor are wired incor mand input Check and correct the Servo motor wiring rectly The encoder is faulty Replace the Servomotor The Servo Driver is Replace the Servo Driver faulty A C2 Phase detection Occurs when the Encoder wiring error Wire the encoder correctly A C5 error power is turned Faulty wiring or con A C9 Magnetic pole _ ON or during oper nections detection e
131. vo Drivers Servomotor Connector CNB Dimensions Servomotor Connector 04JFAT SAYGF N JST Mfg Co Ltd 3 34 Specifications Chapter 3 3 5 External Regeneration Unit and External Regeneration Resistor When using an External Regeneration Unit R88A RGO8UA or an External Regeneration Resistor R88A RR22047S refer to 4 3 Regenerative Energy Absorption to use them correctly 3 5 1 External Regeneration Unit R88A RGO8UA Specifications General Specifications em Specifications O O OO 35 to 85 with no condensation 35 to 85 with no condensation Note The External Regeneration Unit does not conform to EC Directives m Characteristics ooo n O o o Externally connected regeneration resistance Externally connected regeneration resistance regeneration resistance 47 Q a Error detection functions AO resistance disconnection Regeneration transistor failure and overvoltage Alarm output Single pole NC contact open when protection function is operating can handle 200 VAC Dimensions 85x 160x130 mm Wx Hx LED Indicator Specifications tem Specifications POWER Lit when power is being supplied to the P and N terminals REGEN Lit during regeneration operation Lit during regeneration operation regeneration operation ALARM E Lit when the regen
132. vomotor connection terminals 4 11 System Design Chapter 4 m Wire Size and Allowable Current Reference The following table shows the allowable current when there are three power supply wires Use a cur rent below these specified values e 600 V Heat resistant Vinyl Wire HIV Reference Values Cross sectional area Configuration Conductive Allowable current A for ambient wires mm resistance temperature okm o os 0 5 710 6 7108 24 125 fooie 4 12 System Design Chapter 4 m Terminal Block Wiring Procedure Spring type connectors are used for SMARTSTEP Junior Servo Drivers The procedure for wiring these is described below CNA Connector CNA Eje a 1 Remove the Terminal Block from the Servo Driver The Terminal Block must be removed from the Servo Driver before being wired The Servo Driver will be damaged if the wiring is done with the Terminal Block in place 2 Strip the covering off the ends of the wires Prepare wires of the right sizes according to the table under 4 2 4 Wiring the Main Circuit and Servomotor Connections above and strip off 9 to 10 mm of the covering from the end of each wire 9 to 10 mm 3 Open the wire insertion slots in the Terminal Block There are two ways to open the wire insertion slots as follows e Pry the slot open using the lever that comes with the Servo Driver as in Fig A e Insert a flat blade
133. ween the Servo Driver and Servomotor is 20 meters e Connection Configuration and Dimensions Servomotor end Servo Driver end R7D Z Qe E 22 7 26 4 R7M Z 3 32 Specifications Chapter 3 e Wiring Servo Driver Servomotor ee Signal FAWG26 Yellow White S B refs az z 8 Phassu EJ Phase V a KEETE arnes ra Servo Driver Connector Servomotor Connector Plug Connector plug 54593 1019 L 5557 12R 210 L Connector case Connector case 54599 1005 JST Mfg Co Ltd 5556T2L JST Mfg Co Ltd m Encoder Cable Loose Wires Only e Cable Models Length L Outer diameter of cable See note 1 R7A CRZ001 T m See note 2 Approx 0 1 kg Note 1 The maximum distance between the Servo Driver and Servomotor is 20 meters Note 2 Cable are sold in 1 m increments It is cut to the specified length 3 33 Chapter 3 Specifications 3 4 5 Connector Specifications m Main Circuit Connector R7A CNZ01P The Main Circuit Connector connects to the Servo Driver s Main Circuit Connector CNA Dimensions Main Circuit Connector 04JFAT SBXGF N JST Mfg Co Ltd Wiring Lever J FAT OT JST Mfg Co Ltd f 20 3 m Servomotor Connector R7A CNZ01A The Servomotor Connector connects to the Ser
134. witch FIL m Position Control Parameters from Pn200 Parameter Description Factory Setting Restart name emg range to QA Pn20E Electronic Sets the pulse rate for the command 1t gear ratio pulses and Servomotor travel distance 1 073 141 824 G1 Numer 0 01 lt Pn20E Pn210 lt 100 ator Electronic gear ratio 1 073 741 824 G2 Denom inator Speed Control Parameters Appendix Chapter 7 Sequence Parameters from Pn500 Parameter Description Factory Setting range Restart name setting to em a Se ote Not used 1 Do not o 2881H the setting Not used Do not se z setting POT signal Forward drive is allocation enabled by turn ing ON low the CN1 to 4 input sig nals om Always disabled NOT signal Reverse drive is 8883H allocation enabled by turn ing ON low the CN1 to 3 input sig nals Ea Always disabled 1to3 Not used Do not o gt setting Not used Do not o 8488H X setting Input signal selection 1 Input signal selection 2 Input signal selection 7 STOP signal 4 Emergency stop is allocation enabled by turn ing OFF the CN1 to 6 input signals 8 Always disabled Always Always disabled 3 Not used Do not A the setting oo Positioning Sets the positioning completion output 1 width completion 1 073 741 824 width 1 E Positioning Sets the positioning completion output 2 width completion width 2 1 073 741 824 7 4
135. y occur A 94 MECHATROLINK II The user parameter data was out of range or incorrect data was data setting warning detected A 96 MECHATROLINK II A communications error occurred during MECHATROLINK II com communications munications error warning 6 5 Troubleshooting Chapter 6 6 3 Troubleshooting If an error occurs in the machinery determine the error conditions from the alarm indicators and operating status identify the cause of the error and take appropriate countermeasures 6 3 1 Error Diagnosis Using the Alarm Indicators Alarm Status when error Probable cause Countermeasures code occurs A 02 Parameter error Occurs when the The power was inter Contact an OMRON repre power is turned rupted while the user _ sentative ON parameters were being set The number of user Replace the Servo Driver parameter write oper ations is over the upper limit The Servo Driver is faulty A 03 Main circuit Occurs when the The Servo Driver is Replace the Servo Driver detection error power is turned faulty ON or during oper ation A 04 Parameter set Occurs when the A user parameter Set the value within the set ting error power is turned value is set out of ting range ON range The electronic gear Set the electronic gear ratio ratio is set out of within the following range range 0 01 lt Electronic gear ratio Pn20E Pn210 lt 100 The Servo Driver is Replace the Servo Driver faulty

USER`S MANUAL SMARTSTEP Junior

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