Cooper Power Tools ARS-310/5 User manual

Metronix Meßgeräte und Elektronik GmbH Telefon: [phone]
Kocherstraße 3 Telefax: [phone]
D-38120 Braunschweig E-mail: [email protected]
Germany http://www.metronix.de
Product Manual
Servo Positioning Controller
ARS-310/5(UL)
ARS-310/10

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Product Manual “Servo Positioning Controller ARS-310/5(UL) ARS-310/10“ Version 2.3
Copyrights
©2003 Metronix Meßgeräte und Elektronik GmbH. All rights reserved.
The information and data in this document have been composed to the best of our knowledge.
However, deviations between the document and the product cannot be excluded entirely. For the
devices and the corresponding software in the version handed out to the customer, Metronix
guarantees the contractual use in accordance with the user documentation. In the case of serious
deviations from the user documentation, Metronix has the right and the obligation to repair, unless it
would involve an unreasonable effort. A possible liability does not include deficiencies caused by
deviations from the operating conditions intended for the device and described in the user
documentation.
Metronix does not guarantee that the products meet the buyer’s demands and purposes or that they
work together with other products selected by the buyer. Metronix does not assume any liability for
damages resulting from the combined use of its products with other products or resulting from
improper handling of machines or systems.
Metronix Meßgeräte und Elektronik GmbH reserves the right to modify, amend, or improve the
document or the product without prior notification.
This document may, neither entirely nor in part, be reproduced, translated into any other natural or
machine-readable language nor transferred to electronic, mechanical, optical or any other kind of data
media, without expressive authorisation by the author.
Trademarks
Any product names in this document may be registered trademarks. The sole purpose of any
trademarks in this document is the identification of the corresponding products.
Microsoft and Windows are either registered trademarks or trademarks of Microsoft Corporation in the
United States and/or other countries.

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Product Manual “Servo Positioning Controller ARS-310/5(UL) ARS-310/10“ Version 2.3
Revision log
Author: Metronix Meßgeräte und Elektronik GmbH
Manual name: Product Manual „Servo Positioning Controller ARS-310/5(UL)
ARS-310/10“
File name: ProductManual_ARS_310_5_10_V2p3.doc
File location:
Series
no. Description Revision index Date of change
001 Release for distribution 2.0 09.12.2003
002 Numbers of AWG and
marks about the (European standard) 2.1 15.01.2004
003 final corrections 2.2 03.02.2004
004 Correction of Windows®Trademark and CPT 2.3 10.01.2005

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Product Manual “Servo Positioning Controller ARS-310/5(UL) ARS-310/10“ Version 2.3
Table of Contents:
1 GENERAL.........................................................................................................12
1.1 Documentation .......................................................................................12
1.2 Scope of supply......................................................................................13
2 SAFETY NOTES FOR ELECTRICAL DRIVES AND CONTROLLERS ...........14
2.1 Used symbols.........................................................................................14
2.2 General notes.........................................................................................14
2.3 Danger resulting from misuse.................................................................16
2.4 Safety notes............................................................................................16
2.4.1 General safety notes..................................................................16
2.4.2 Safety notes for assembly and maintenance.............................18
2.4.3 Protection against contact with electrical parts ..........................19
2.4.4 Protection against electrical shock by means of protective extra-
low voltage (PELV) ....................................................................20
2.4.5 Protection against dangerous movements.................................21
2.4.6 Protection against contact with hot parts ...................................21
2.4.7 Protection during handling and assembly ..................................22
2.5 Overload behaviour ................................................................................22
3 PRODUCT DESCRIPTION...............................................................................23
3.1 General...................................................................................................23
3.2 Power supply..........................................................................................25
3.2.1 AC supply ..................................................................................25
3.2.2 Power supply .............................................................................25
3.2.3 Mains fuse .................................................................................25
3.3 Brake chopper........................................................................................25
3.4 Communication interfaces......................................................................26
3.4.1 RS232 interface.........................................................................26
3.4.2 CAN-Bus....................................................................................26
3.4.3 Profibus......................................................................................26
3.4.4 I/O functions and device controller.............................................27
4 TECHNICAL DATA ..........................................................................................28
4.1 Operating and display elements.............................................................29
4.2 Supply [X9].............................................................................................30
4.3 Motor connection [X6].............................................................................31
4.4 Motor feedback connection [X2].............................................................31

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Product Manual “Servo Positioning Controller ARS-310/5(UL) ARS-310/10“ Version 2.3
4.4.1 Resolver connection [X2]...........................................................32
4.4.2 Encoder connection [X2], [X10], additional 15-pole connector
[X21] ..........................................................................................32
4.5 Communication interfaces......................................................................36
4.5.1 RS232 [X5] ................................................................................36
4.5.2 CAN bus technology plug-in module..........................................36
4.5.3 Profibus technology plug-in module...........................................37
4.5.4 I/O interface [X1]........................................................................38
4.5.5 Incremental encoder input [X10]................................................39
4.5.6 Incremental encoder output [X11]..............................................39
5 FUNCTION OVERVIEW ...................................................................................40
5.1 Motors ....................................................................................................40
5.1.1 Synchronous servo motors........................................................40
5.2 Functions of the servo positioning controller ARS-310/xx.......................40
5.2.1 Pulse width modulation (PWM)..................................................41
5.2.2 Setpoint management................................................................41
5.2.3 Torque-controlled mode.............................................................41
5.2.4 Speed-controlled mode..............................................................42
5.2.5 Torque-limited speed control......................................................42
5.2.6 Positioning and position control .................................................42
5.2.7 Synchronization, electrical transmissions ..................................43
5.2.8 Brake management....................................................................43
5.3 Positioning control ..................................................................................43
5.3.1 Overview....................................................................................43
5.3.2 Relative positioning....................................................................44
5.3.3 Absolute positioning...................................................................44
5.3.4 Driving profile generator.............................................................44
5.3.5 Homing ......................................................................................45
6 MECHANICAL INSTALLATION.......................................................................46
6.1 Important notes.......................................................................................46
6.2 View of the device ..................................................................................48
6.3 Mounting.................................................................................................51
7 ELECTRICAL INSTALLATION........................................................................53
7.1 Connector configuration..........................................................................53
7.2 ARS-310/xx complete system.................................................................54
7.3 Connection: Power supply [X9]...............................................................56

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Product Manual “Servo Positioning Controller ARS-310/5(UL) ARS-310/10“ Version 2.3
7.3.1 Device side [X9].........................................................................56
7.3.2 Counterplug [X9]........................................................................56
7.3.3 Pin configuration [X9].................................................................56
7.3.4 Cable type and design [X9]........................................................57
7.3.5 Connection notes [X9]................................................................57
7.4 Connection: external break resistor [X12]...............................................58
7.5 Connection: Motor [X6]...........................................................................58
7.5.1 Device side [X6].........................................................................58
7.5.2 Counterplug [X6]........................................................................58
7.5.3 Pin configuration [X6].................................................................59
7.5.4 Cable type and design [X6]........................................................59
7.5.5 Connection notes [X6]................................................................60
7.6 Connection: I/O communication [X1]......................................................61
7.6.1 Device side [X1].........................................................................63
7.6.2 Counterplug [X1]........................................................................63
7.6.3 Pin configuration [X1].................................................................64
7.6.4 Cable type and design [X1]........................................................65
7.6.5 Connection notes [X1]................................................................65
7.7 Connection: Resolver [X2]......................................................................66
7.7.1 Device side [X2].........................................................................66
7.7.2 Counterplug [X2]........................................................................66
7.7.3 Pin configuration [X2].................................................................66
7.7.4 Cable type and design [X2]........................................................67
7.7.5 Connection notes [X2]................................................................67
7.8 Connection: Encoder [X2].......................................................................68
7.8.1 Device side [X2].........................................................................68
7.8.2 Counterplug [X2]........................................................................68
7.8.3 Pin configuration [X2].................................................................68
7.8.4 Cable type and design [X2]........................................................69
7.8.5 Connection notes [X2]................................................................70
7.9 Connection: Encoder [X21] (additional 15-pole connector).....................71
7.9.1 Device side [X21] (additional 15-pole connector).......................71
7.9.2 Counterplug [X21] (additioanl 15-pole connector)......................71
7.9.3 Pin configuration [X21] (additional 15-pole connector)...............71
7.9.4 Cable type and design [X21] additional 15-pole connector........73
7.10 Connection: Incremental encoder input [X10].........................................75
7.10.1 Device side [X10].......................................................................75
7.10.2 Counterplug [X10]......................................................................75

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Product Manual “Servo Positioning Controller ARS-310/5(UL) ARS-310/10“ Version 2.3
7.10.3 Pin configuration [X10]...............................................................76
7.10.4 Cable type and design [X10]......................................................76
7.10.5 Connection notes [X10]..............................................................76
7.11 Connection: Incremental encoder output [X11].......................................77
7.11.1 Device side [X11].......................................................................77
7.11.2 Counterplug [X11]......................................................................77
7.11.3 Pin configuration [X11]...............................................................78
7.11.4 Cable type and design [X11]......................................................78
7.11.5 Connection notes [X11]..............................................................78
7.12 Connection: CAN-Bus Technology Modul ..............................................79
7.12.1 Device side as presented by the CAN-Bus Module ...................79
7.12.2 Counterplug ...............................................................................79
7.12.3 Cable type and design...............................................................80
7.12.4 Connection notes.......................................................................80
7.13 Connection: RS232/COM [X5]................................................................81
7.13.1 Device side [X5].........................................................................81
7.13.2 Counterplug [X5]........................................................................81
7.13.3 Pin configuration [X5].................................................................82
7.13.4 Cable type and design [X5]........................................................82
7.13.5 Connection notes [X5]................................................................82
8 NOTES ON SAFE AND EMC-COMPLIANT INSTALLATION..........................83
8.1 Definition and terms................................................................................83
8.2 General information on EMC..................................................................83
8.3 EMC areas: first and second environment..............................................84
8.4 EMC-compliant cabling...........................................................................84
8.5 Additional EMC equipment for operation with long motor cable .............85
8.5.1 Content of the EMC kit...............................................................86
8.5.2 External Cabling and Assembly.................................................87
8.5.3 Assembly Instructions for the EMC Kit:......................................88
8.5.3.1 Alternative in case of restricted room....................................................89
8.5.4 EMC Kit applications..................................................................89
8.6 ESD protection .......................................................................................90
9 INITIAL OPERATION .......................................................................................91
9.1 General notes on connection..................................................................91
9.2 Tools / material.......................................................................................91
9.3 Connecting the motor .............................................................................91

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Product Manual “Servo Positioning Controller ARS-310/5(UL) ARS-310/10“ Version 2.3
9.4 Connecting the servo positioning controller ARS-310/xx to the power
supply.....................................................................................................92
9.5 Connecting the PC .................................................................................92
9.6 Checking operability ...............................................................................92
10 SERVICE FUNCTIONS AND ERROR MESSAGES.........................................93
10.1 Protection and service functions.............................................................93
10.1.1 Overview....................................................................................93
10.1.2 Overcurrent and short-circuit monitoring....................................93
10.1.3 Overvoltage monitoring for the DC bus......................................93
10.1.4 Temperature monitoring of the heat sink ...................................94
10.1.5 Monitoring of the motor..............................................................94
10.1.6 I²t monitoring..............................................................................94
10.1.7 Power monitoring for the brake chopper....................................94
10.1.8 Initial operation status................................................................94
10.2 Display of operating mode and error messages.....................................95
10.2.1 Display of operating mode and errors........................................95
10.2.2 Error messages..........................................................................95
11 INFORMATION CONCERNING UL..................................................................99
11.1 Circuit protection.....................................................................................99
11.2 Wiring and environment regards.............................................................99
11.2.1 Motor and mains supply and sensor wiring according to AWG..99
11.3 Overload behaviour ................................................................................99

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Product Manual “Servo Positioning Controller ARS-310/5(UL) ARS-310/10“ Version 2.3
Table of Figures:
Figure 1: Type key .......................................................................................................................23
Figure 2: Control scheme of the ARS-310/xx..............................................................................40
Figure 3: Driving profiles of servo positioning controller ARS-310/xx..........................................45
Figure 4: Servo positioning controller ARS-310/xx: Installation space........................................47
Figure 5: Servo positioning controller ARS-310/5 (UL): Front view.............................................48
Figure 6: Servo positioning controller ARS-310/5 (UL): Top view...............................................49
Figure 7: Servo positioning controller ARS-310/5 (UL): Bottom view..........................................50
Figure 8: Servo positioning controller ARS-310/10: Bottom view................................................51
Figure 9: Servo positioning controller ARS-310/xx: Mounting plate...........................................52
Figure 10: Connection to power supply and motor........................................................................53
Figure 11: Complete setup of the ARS-310/xx with motor and PC ...............................................55
Figure 12: Supply [X9] for the servo positioning controller ARS-310/5 (UL).................................57
Figure 13: Supply [X9] for the servo positioning controller ARS-310/10 .......................................57
Figure 14: Motor connection [X6]...................................................................................................60
Figure 15: Connecting a holding brake with high current draw (> 0.5A) to the device..................61
Figure 16: Basic circuit diagram connector [X1]............................................................................62
Figure 17: Pin configuration: Resolver connection [X2].................................................................67
Figure 18: Pin configuration [X2]: In case of the Stegmann (HIPERFACE) encoder evaluation
module..........................................................................................................................70
Figure 19: Pin configuration [X2]: In case of the Yaskawa (SGM, Sigma 1) Incremental encoder
evaluation module.........................................................................................................70
Figure 20: Pin configuration X21: Analog incremental encoder –additional 15-pole connector....74
Figure 21: Pin configuration X21: Incremental encoder with serial data port (EnDat) –additional
15-pole connector.........................................................................................................74
Figure 22: Pin configuration [X21]: Digital incremental encoder –additional 15-pole connector...75
Figure 23: Pin configuration: Input of the incremental encoder [X10]............................................77
Figure 24: Pin configuration: Incremental encoder output [X11] ...................................................78
Figure 25: Pin configuration: CAN-Bus module.............................................................................79
Figure 26: Cabling example for CAN-Bus......................................................................................80
Figure 27: Pin configuration [X5]: RS232 null modem cable.........................................................82
Figure 28: Mechanical installation: EMC kit with three toroidal cores ...........................................87
Figure 29: EMC kit: wiring length of the motor cable.....................................................................87
Figure 30: Mechanical dimension of the EMC holding plate .........................................................88

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Product Manual “Servo Positioning Controller ARS-310/5(UL) ARS-310/10“ Version 2.3
Table of Tables:
Table 1: Scope of supply ............................................................................................................13
Table 2: Connector set: Connector Set 1 and 2.........................................................................13
Table 3: Technical data: Ambient conditions and qualification...................................................28
Table 4: Technical specifications: Dimensions and weight........................................................28
Table 5: Technical specifications: Motor temperature monitoring..............................................28
Table 6: Technical specifications: Cable specifications .............................................................29
Table 7: Display elements and RESET button...........................................................................29
Table 8: Technical specifications: Performance data [X9] .........................................................30
Table 9: Technical specifications: Internal brake resistor [X12].................................................30
Table 10: Technical specifications: External brake resistor [X12]................................................30
Table 11: Technical specifications: Motor connection specifications [X6]....................................31
Table 12: Technical specifications: Resolverinterface RDC16N [X2] ..........................................32
Table 13: Technical specifications: Standard incremental encoder with commutation signals
([x2], additional 15-pole connector [X21]).....................................................................33
Table 14: Technical specifications: high resolution encoder evaluation [X2], additional 15-pole
connector [X21].............................................................................................................35
Table 15: Technical specifications: RS232 [X5]...........................................................................36
Table 16: Technical specifications: CAN bus...............................................................................36
Table 17: Technical specifications: Profibus ................................................................................37
Table 18: Technical specifications: Digital inputs and outputs [X1]..............................................38
Table 19: Technical specifications: analog inputs and outputs [X1].............................................38
Table 20: Technical specifications: Incremental encoder input [X10]..........................................39
Table 21: Technical specifications: Incremental encoder output [X11]........................................39
Table 22: Pin configuration [X9]....................................................................................................56
Table 23: ARS-310/5 (UL) Connector [X12]: External brake resistor...........................................58
Table 24: Pin configuration [X6]....................................................................................................59
Table 25: Connector configuration: I/O communication [X1].......................................................64
Table 26: Pin configuration [X2]....................................................................................................66
Table 27: Pin configuration: Stegmann “HIPERFACE” Encoder evaluation................................68
Table 28: Pin configuration: YASKAWA Incremental encoder [X2]..............................................69
Table 29: Pin configuration [X21]: analog incremental encoder – additional 15-pole connector.71
Table 30: Pin configuration [X21]: Incremental encoder with serial data port (EnDat) – additional
15-pole connector.........................................................................................................72