Faulhaber 3242 BX4 Series Instruction Manual Download Page 3 | Manualshive

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Version:
3rd edition, 10.03.2011

Copyright
by Dr. Fritz Faulhaber GmbH & Co. KG
Daimlerstr. 23 / 25 · 71101 Schönaich

All rights reserved, including those to the translation.
No part of this description may be duplicated, reproduced,
stored in an information system or processed or trans-
ferred in any other form without prior express written
permission of Dr. Fritz Faulhaber GmbH & Co. KG.

This instruction manual has been prepared with care.
Dr. Fritz Faulhaber GmbH & Co. KG cannot accept any li-
ability for any errors in this instruction manual or for the
consequences of such errors. Equally, no liability is ac-
cepted for direct losses or consequential damages resulting
from improper use of the devices.

The pertinent regulations regarding
safety engineering and interference suppression as well as
the specifications in this instruction manual must be com-
plied with when using the equipment.

Subject to change without notice.

The respective current version of this instruction manual is
available on FAULHABER's internet site:

www.faulhaber.com

Imprint

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Summary of Contents for 3242 BX4 Series

Page 1: ...EN Brushless DC Servomotors Series 3242 BX4 3268 BX4 Instruction Manual WE CREATE MOTION ...

Page 2: ......

Page 3: ...with care Dr Fritz Faulhaber GmbH Co KG cannot accept any li ability for any errors in this instruction manual or for the consequences of such errors Equally no liability is ac cepted for direct losses or consequential damages resulting from improper use of the devices The pertinent regulations regarding safety engineering and interference suppression as well as the specifications in this instruct...

Page 4: ...te encoder 19 3 3 4 Motor with SC speed controller 20 3 3 5 Motor with SCDC Speed Controller 21 3 4 Connection examples 22 3 4 1 Motor without attachment 22 3 4 2 Motor with encoder IE3 22 3 4 3 Motor with encoder IE3 L 23 3 4 4 Motor with AES absolute encoder 24 3 4 5 Motor with SC speed controller 25 3 4 6 Motor with SCDC Speed Controller 26 4 Functional Description 27 4 1 Motor without attachme...

Page 5: ...ith SCDC Speed Controller 47 4 5 1 Connection functions 47 4 5 2 Configuration 47 4 5 3 Technical information 47 5 Operation 48 5 1 Commissioning 48 6 EC Product Safety Directives 49 7 Warranty 50 Table of Contents ...

Page 6: ...ces in information due to a customer specific motor modification 1 1 Symbols used in this instruction manual WARNING Warning This pictogram with the wording Warning indicates an imminent danger which can result in physical injuries f f This arrow points out the appropriate action to take to prevent the imminent danger CAUTION Caution This pictogram with the wording Caution indicates an imminent da...

Page 7: ...The motor may not be used in environments where contact with water chemicals and or dust is possible or in potentially explosive atmospheres The forces torques and accelerations acting on the motor are limited Please ask the manufacturer for information about individual use under special ambient conditions 1 3 Documentation The following table gives an overview of the documentation of the FAULHABE...

Page 8: ... shock or vibration loads CAUTION Risk of damage The ribbon cables may be damaged if the static or dynamic load is too high The following applies to cables with contact spacing 1 27 AWG28 f f The tension exerted on the cable must not exceed 30 N in each direction If the cable is exposed to constant tensile loads the limit is 17 N f f If the radii are small the cable may not be bent several times a...

Page 9: ...measures are necessary 1 6 Troubleshooting The servomotor is designed to be fault free provided the parameters given in this instruction manu al are complied with Should a malfunction occur in spite of this please contact the manufacturer Switchboard 49 0 7031 638 0 E Mail info faulhaber de Internet www faulhaber com ...

Page 10: ...uted brushless DC motor Compared to mechanically com muted electric motors its main outstanding feature is a much longer life The motor is based on the self supporting coil technology FAULHABER system and essentially con sists of a three phase winding stator and a four pole permanent magnet rotor The commutation takes place via an additional external control The rotor position is detected by 3 Hal...

Page 11: ... request Example Motor 3242 BX4 IE3 128 L Features Motor 3242 BX4 with encoder 128 pulses revolution line driver Line driver Encoders with an L in the encoder designation have differential encoder signal outputs in accord ance with TIA 422 Therefore common mode interferences are suppressed and longer supply connec tors are enabled These three differential signals must be joined together again on t...

Page 12: ...available immediately after switching on The absolute encoder is optimally suited to commutation speed and position control It can also be used for sinus commutation The advantage in this case is that the motor is run more efficiently and torque ripple is minimised It is connected via only one ribbon cable unlike the version with incremental encoder Example Motor 3242 BX4 AES 4096 Features Motor 3...

Page 13: ...oltage Switchover of direction of rotation via switch input Reading out the speed signal via the frequency output CAUTION Risk of damage Switching over the motor s direction of rotation reversing duty too quickly can cause damage f f Do not use the speed controller for reversing duty 1 2 3 4 5 6 8 7 11 9 10 12 13 14 15 1 Cover 2 Heat transfer pad 3 Built on housing 4 Ribbon cable 5 Controller boar...

Page 14: ...by reversing the connection cables Integrated current limiting Optionally on request Speed limiting fixed speed control CAUTION Risk of damage Switching over the motor s direction of rotation reversing duty too quickly can cause damage f f Do not use the speed controller for reversing duty 2 1 3 4 5 6 7 8 9 12 10 11 13 14 15 16 1 Small cover plates 2 Cover 3 Heat transfer pad 4 Built on housing 5 ...

Page 15: ...nd observed Mounting flange When fixing the servomotor to the front flange the screws must be locked as they can loosen at high temperatures The maximum length of the fixing screws must be noted and observed as otherwise the motor will be destroyed The depth of engagement in the motor may not be exceeded Right The motor is fixed by the screws on the mounting flange Wrong The motor is securely clam...

Page 16: ... to immunity The units are intended for industrial use only If the devices are used in the home in business or in commerce or in a small business appropriate measures must be taken to ensure that the emitted interference is below the permitted limits 3 2 1 Description of the EMC measures The EMC suppressor circuit motor with Speed Controller SC only Circuit diagram 1 FG DIR Unsoll GND C2 C1 Umot U...

Page 17: ...without attach ment CAUTION Electronic damage ESD protection Electrostatic discharges at the connection pin assignment of the ribbon cable can result in irreparable damage to the motor f f It may only be processed in ESD protected workplaces Incorrect connection of the cores can cause damage to or destruction of the electronics f f Connect the ribbon cable in accordance with the connector pin assi...

Page 18: ...may only be processed in ESD protected workplaces Incorrect connection of the cores can cause damage to or destruction of the electronics f f Connect the ribbon cable in accordance with the connector pin assignment see table Connection pin assignment of the ribbon cable for encoders without line driver IE3 1 2 3 4 5 6 Core 1 motor cable Core Function 1 red n c 2 Channel I index 3 GND Enc 4 UDD Enc...

Page 19: ...damage ESD protection Electrostatic discharges at the connection pin assignment of the ribbon cable can result in irreparable damage to the motor f f It may only be processed in ESD protected workplaces Incorrect connection of the cores can cause damage to or destruction of the electronics f f Connect the ribbon cable in accordance with the connector pin assignment see table Connection pin assignm...

Page 20: ...e damage to the motor f f It may only be processed in ESD protected workplaces Incorrect connection of the cores can cause damage to or destruction of the electronics f f Connect the ribbon cable in accordance with the connector pin assignment see table Connection pin assignment of the ribbon cable for motor with commutation electronics Core Function Value 1 red UP 5 30 V DC 2 Umot 5 30 V DC 3 GND...

Page 21: ...protection Electrostatic discharges at the connection pin assignment of the ribbon cable can result in irreparable damage to the motor f f It may only be processed in ESD protected workplaces f f Connect the ribbon cable in accordance with the connector pin assignment see table Connector pin assignment of the ribbon cable for motor with commutation electronics DC version Core Function Value 1 red ...

Page 22: ...CC SGND Mot A Mot B Mot C Sens A Sens B Sens C In the example the servomotor is operated with the FAULHABER control SC 2804 S 3 4 2 Motor with encoder IE3 UDD GND Phase A Phase B Phase C motor controller Hall sensor A Hall sensor B Hall sensor C VCC SGND Mot A Mot B Mot C Sens A Sens B Sens C GND Enc Channel I Channel A Channel B UDD Enc Channel I Channel A Channel B ...

Page 23: ...Hall sensor C VCC SGND Mot A Mot B Mot C Sens A Sens B Sens C GND Enc Channel B Channel A Channel A UDD Enc Channel I Channel B Channel A Channel I Channel I Channel B ST26C32A GND VCC BIN1 AIN2 AIN1 CIN2 CIN1 BIN2 COUT BOUT AOUT The differential encoder signals are joined with a TIA 422 compatible receiver module on the connection side here ST26C32A ...

Page 24: ... 4 Motor with AES absolute encoder UDD Enc GND Enc Phase A Phase B Phase C FAULHABER SC 2804 S 3980 DATA Res CS CLK VCC SGND Mot A Mot B Mot C Sens A Sens B Sens C In the example the servomotor is operated with the FAULHABER control SC 2804 S 3980 ...

Page 25: ...target velocity of 3000 rpm The actual speed at FG is 300 Hz 6 pulses per revolution 60 s 3000 rpm Rotational direction com mand anti clockwise made by 0 V at DIR External speed control FG DIR Unsoll GND Umot Up 12 V DC e g 8 3 V DC 10 V DC approx 190 Hz Motor example 5500 rpm at 24 V at Umot The motor rotates e g with 1900 rpm in a clockwise direction the speed is controlled by the motor voltage ...

Page 26: ...ent motor The rotational direction of the motor is determined by the polarity of the connection cores Clockwise if plus at Mot and minus at Mot Anti clockwise if plus at Mot and minus at Mot Clockwise rotating motor Mot Mot Anti clockwise rotating motor Mot Mot NOTE The minimum and maximum supply voltage must be noted and observed See Chapter 3 3 5 Motor with SCDC Speed Controller ...

Page 27: ...tation or PWM harmonic components can arise as a result of which the emission behaviour of the motor can worsen f f Ensured operation of the motor within the EMC requires a harmonic free rotating field or the suggested FAULHABER control See Chapter 3 4 Connection examples GND core 4 Joint ground of the Hall sensors UDD core 5 Supply voltage for Hall sensors Voltage range 2 2 18 V DC Input current ...

Page 28: ...tputs of the Hall sensors are designed as open collectors Therefore pull up resistors are re quired for operation with a control not made by FAULHABER No pull up resistors are required if using a FAULHABER control Phase B Phase A GND UDD Hall sensor C 2 2 18 V DC Phase C Hall sensor B Hall sensor A R pull R pull R pull Rpull 820 ...

Page 29: ...erated with block commutation or PWM harmonic components can arise as a result of which the emission behaviour of the motor can worsen f f Ensured operation of the motor within the EMC requires a harmonic free rotating field or the suggested FAULHABER control See Chapter 3 4 Connection examples GND core 4 Joint ground of the Hall sensors UDD core 5 Supply voltage for Hall sensors Voltage range 4 5...

Page 30: ...UHall B t 120 UHall A 1 revolution 360 t T T T NOTE The internal resistance of the decoder circuit should not exceed 5 k Filtering of the analog signals is recommended Wiring example Phase B Phase A GND UDD Hall sensor C 4 5 5 5 V DC D A Phase C Hall sensor B Hall sensor A ...

Page 31: ...L compatible Output current max 4 mA Encoder without line driver Channel I core 2 Output signal index signal Pulse rate 1 pulse revolution GND Enc core 3 Ground connection for the encoder UDD Enc core 4 Supply voltage for the encoder Voltage range 4 5 5 5 V DC IE3 32 64 128 256 Encoder and Hall sensors supply isolated UDD UDD Enc IE3 512 1024 Encoder and Hall sensors supply connected UDD UDD Enc C...

Page 32: ...nal Description 4 2 Motor with encoder IE3 or IE3 L Channel I t 90 e Channel B t 90 e Channel A 360 e t t The display of the signals and phase displacement relates to a clockwise rotating motor intended for output ...

Page 33: ...r isolated from the motor Channel A core 5 Inverted output signal A of the pulse generator TIA 422 compatible Pulse rate depending on the encoder setup 32 64 128 256 512 or 1024 pulses revolution Channel A core 6 Output signal A of the pulse generator TIA 422 compatible Pulse rate depending on the encoder setup 32 64 128 256 512 or 1024 pulses revolution Channel B core 7 Inverted output signal B o...

Page 34: ... Motor with encoder IE3 or IE3 L Channel I t 90 e Channel I t 90 e Channel B t Channel B t 90 e Channel A t Channel A 360 e t The display of the signals and phase displacement relates to a clockwise rotating motor intended for output ...

Page 35: ...observe limit speed according to product data sheet Umax 50 V AC below the Low Voltage Directive GND Enc core 4 Ground connection for the absolute encoder UDD Enc core 5 Supply voltage for the absolute encoder Voltage range 4 5 5 5 V DC CLK core 6 Input for the clock signal of the serial interface SSI Res CS core 7 Input reserved for chip select DATA core 8 Output for the data of the serial interf...

Page 36: ...ledge Ack start and control bit CDS in the fixed cyclic start sequence the binary 12 bit sensor data is sent Two reserved and six CRC bits then follow If no other clock signals are sent to the CLK cable the encoder runs in a timeout 16 µs which ends the communication This is also optionally already possible after the 12 bit sensor data Angle position values rising in clockwise direction Clockwise ...

Page 37: ...e 4 Control voltage for the target velocity Voltage range 0 10 V DC max UP The defined control range for Unsoll lies between 0 10 V DC If the motor s nominal voltage is ap plied the maximum speed can be reached before the control limit of 10 V In this case the actual speed is limited by the motor s properties Full control results If the motor voltage is increased at Unsoll 10 V to achieve a higher...

Page 38: ...evel if current limiting is deactivated Frequency output condition on delivery Frequency output for reading out the actual motor speed Signal setup 6 pulses per motor revolution 1 revolution NOTE Pull up resistance An additional external pull up resistance can be connected to increase the edge steepness The maximum loadability of the digital output must be noted and observed See circuit diagram UP...

Page 39: ...ULHABER Motion Manager PC software suitable for the speed controller The software is available on request or on FAULHABER s internet site http www faulhaber com MotionManager CAUTION Risk of damage Before starting up check the parameters configured in the control and if necessary adjust to the con nected motor Incorrectly set values can cause fatal damage to the motor and or the speed controller I...

Page 40: ...hout active braking option If problems occur during operation with the braking function in the default setting it can be deactivated Filtering averaging of the Hall sensor signals If problems occur with the default setting the time of a complete electrical half motor revolu tion is evaluated to obtain a continuous speed signal This can cause instable motor running at low speeds as the control dyna...

Page 41: ...ional to the pulse duty factor The maximum target velocity at 100 can be configured See Chapter 4 4 4 Parameter settings Example block diagram BL motor with Hall sensors DIR Rotationaldirectioninput Evaluation rotational direction Unsoll nsoll Setpointinput Digitaloutput FG 22 kΩ Electronicssupply Up Motorsupply Umot GND MOSFET Power output stage Protectionfunction Overtemperature Microcontroller ...

Page 42: ...tor stops at Unsoll 2 4 V No function The motor always runs Operation as voltage controller volt mode The integrated speed controller can be configured for function as a voltage controller The motor voltage is then output proportionally to the voltage at the nominal speed value input Unsoll The cur rent limitation remains active With this configuration it is possible to use a master controller The...

Page 43: ...r the motor Fixed speed value For operation with a fixed speed the nominal speed value is input via an adjustable parameter See Chapter 4 4 3 Special configurations Parameter Meaning max value Units Fixed speed value NsetFix Nominal speed value which is input in operation with fixed speed 65 535 rpm Pulses per motor revolution It is possible to configure the digital output FG as a frequency output...

Page 44: ...iation the allowed overswing and the required stability reserves The control circuit must also satisfy these requirements to that the controller parameters must also be adjusted with respect to these The PI speed controller used here enables two parameters to be set proportional and integral action component Parameter Meaning max value Units V Proportional component 32 767 Digit VI Proportional co...

Page 45: ... then comes into operation and limits the current to this set point A thermal current model operating in parallel calculates a model temperature from the actually flowing current If this model temperature exceeds a critical value continuous current is switched to and the motor current is regulated to this Only when the load becomes so small that the tempera ture falls below the critical model temp...

Page 46: ...f the integrated speed controller operates with so called pulse width modulation PWM At a fixed frequency the PWM frequency the pulse duty factor is set between the on time and the off time depending on the controller output value The advantage of this procedure is that the losses in the drive electronics are very low In contrast the losses in a linear output stage can be very large and it becomes...

Page 47: ...determines the motor s direction of rotation NOTE The minimum supply voltage must be noted and observed See Chapter 3 3 5 Motor with SCDC Speed Controller Mot core 1 Positive supply voltage connection Mot core 2 Negative supply voltage connection 4 5 2 Configuration SCDC Speed Controllers are pre configured in the factory On request the following parameters can be changed as for the SC Speed Contr...

Page 48: ...the connection leads can affect the function and properties with respect to EMC All connection leads may not exceed a length of 3 m The connected mechanism is installed free of blockages The loads and stresses on the shaft axial radial and torques are within the specified values CAUTION Risk of injuries A risk of injuries can result from protruding rotating or moving parts of the driven mechanism ...

Page 49: ...ovide a standard Declaration of Incorporation Low Voltage Directive 2006 95 EC It applies to all electrical equipment with a nominal voltage from 75 to 1 500 V DC or from 50 to 1 000 V AC The products described in this instruction manual do not fall within the scope of this Directive as they are designed for smaller voltages EMC Directive 2004 108 EC The Electromagnetic Compatibility EMC Directive...

Page 50: ...ying or consequential loss for whatever legal reason are excluded This does not apply if a we are maliciously silent with regard to a legal or material defect or have issued a guarantee for the nature of the goods b the loss is due to deliberate intent or gross negligence by us our legal representatives or vi carious agents or are based on negligent breach of fundamental contract obligations by th...

Page 51: ...51 Notes ...

Page 52: ...011 DR FRITZ FAULHABER GMBH CO KG Subject to change without notice DR FRITZ FAULHABER GMBH CO KG Antriebssysteme Daimlerstraße 23 25 71101 Schönaich Germany Tel 49 0 7031 638 0 Fax 49 0 7031 638 100 info faulhaber de www faulhaber com ...

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