Faulhaber SC 1801 Series User manual





dff_080418_bedien_alle.indd 12 14.04.2008 11:55:57 Uhr

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Version:
1st issue, 15.04.2008
Copyright
by Dr. Fritz Faulhaber GmbH & Co. KG
Daimlerstr. 23 / 25 · 71101 Schönaich
All rights reserved, including those to the translation.
This description, whether in part or whole, may not be
duplicated, reproduced, stored in an information system or
processed or transferred in any other form without the ex-
plicit written consent of Dr. Fritz Faulhaber GmbH & Co. KG.
This instruction manual has been prepared with due care.
However, Dr. Fritz Faulhaber GmbH & Co. KG does not
accept any liability for possible errors in this instruction
manual and their consequences. Equally, no liability is ac-
cepted for direct losses or consequential damages resulting
from improper use of the devices.
When using the devices the relevant
regulations regarding safety technology and interference
suppression as well as the requirements specified in this
instruction manual shall be observed.
Subject to change without notice.
Imprint

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Contents
1 Important Information 5
1.1 Symbols used in this instruction manual 5
1.2 Safety instructions 6
2 Description 7
2.1 General product description 7
3 Installation 9
3.1 Assembly 9
3.2 EMC compatible installation 10
3.2.1 Description of the EMC measures 10
3.3 Connector pin assignment 13
3.4 Connection functions 14
3.5 Quick start 18
3.5.1 Connection examples for the supply end 18
3.5.2 Connection examples for the motor end 19
4 Configuration 21
4.1 Configuration for DC motors 22
4.1.1 DC motors with encoders 22
4.1.2 DC motors without encoders 23
4.2 Configuration for BL motors 25
4.2.1 BL motors with digital hall sensors 25
4.2.2 BL motors without hall sensors (sensorless operation) 26
4.2.3 BL motors with AES64 absolute encoder (with SC1801F only) 27
4.3 Special configurations 29
4.3.1 Speed setpoint input via PWM signal 29
4.3.2 Operation with fixed speed (fixed speed mode) 30
4.3.3 Operation as voltage controller (volt mode) 30
4.3.4 Digital output (FG) 30
4.4 Parameter settings 31
4.4.1 Motor constants 31
4.4.2 Current limiting values 31
4.4.3 Fixed speed value 31
4.4.4 Pulses per motor revolution 31
4.4.5 Maximum speed value 32
4.4.6 Controller parameter 32
4.4.7 Encoder resolution (DC motors only) 33
4.4.8 Starting time (for BL motors in sensorless operation only) 33
4.4.9 Minimum speed (for BL motors in sensorless operation only) 33
4.4.10 Delayed Current Error (with error output only) 33

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Contents
4.5 Technical information 34
4.5.1 I²t current limiting 34
4.5.2 Overtemperature cut-off 35
4.5.3 Adjusting the controller parameters 35
4.5.4 Effect of pulse width modulation (PWM) 35
5 Operation 37
5.1 Startup 37
6 Maintenance 38
6.1 Servicing / maintenance 38
6.2 Troubleshooting 38
7 Technical Data 39
7.1 Operating data 39
7.2 Product dimensions 41
7.3 Ambient conditions 42
8 EMC 43
8.1 EC Directive / national laws 43
8.2 Electromagnetic compatibility (EMC) 43
8.3 EC Declaration of Conformity 45
9 Manufacturer‘s declaration 46
10 Warranty 47
11 Index 48

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1 Important Information
1.1 Symbols used in this instruction manual
WARNING!
CAUTION!
REGULATION
NOTE
The handling and technical features of FAULHABER speed controllers (SC1801S, SC1801F, SC1801P,
SC2804S and SC2402P) are described in this instruction manual.
n Please read the complete instruction manual before using the controller.
n Keep this instruction manual in a safe place for subsequent use.
The information given in this instruction manual refers to the standard versions of the speed
controller. Please refer to any additional information sheet provided in the event of differences in
information due to a customer-specific modification.
Warning!
This pictogram with the wording “Warning!” indicates an imminent danger which can result in
physical injuries.
} This arrow points out the appropriate action to take to prevent the imminent danger.
Caution!
This pictogram with the wording “Caution!“ indicates an imminent danger which can result in slight
physical injuries or material damage.
} This arrow points out the appropriate precautions.
Regulations, guidelines and directives
This pictogram with the wording “Regulation“ indicates a statutory regulation, guideline or direc-
tive which must be observed in the respective context of the text.
Note
This “Note“ pictogram provides tips and recommendations for use and handling of the component.

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1 Important Information
Observance of the following safety instructions is prerequisite for trouble-free and safe operation of
the speed controllers. Therefore, please carefully read through all the notes and follow them when
using the controllers.
Intended use
FAULHABER speed controllers are designed for the driving and speed control of DC and BL motors in
the low (SC1801) and higher power range (SC2804 and SC2402).
The speed controllers‘ control parameters can be individually adjusted to the respective application
via a PC. This requires a programming adapter, which can be ordered separately, as well as a version
of the FAULHABER Motion Manager PC software suitable for the speed controllers. The software is
available on request or from the FAULHABER homepage http://www.faulhaber-group.com.
n Subject to compliance with the conditions described in Chapter 8 "EMC", the speed controllers
fulfil the relevant EMC Directives. Any effects as well as the specific relevant national regulations
must be taken into account when using the speed controllers.
n The speed controllers contain electronic components and are to be treated according to the ESD
regulations.
n The speed controllers may not be used in environments where contact with water, chemicals and /
or dust is possible or in potentially explosive atmospheres.
n The inertia of the motors operated at the speed controllers may not be noticeably increased by
the motor load.
n The speed controllers are not suitable for reversing operation.
n The housings of the SC1801S and SC1801F speed controllers are not solvent resistant and must not
come into contact with certain solvents (see Chapter 7 “Technical Data“) or substances containing
solvents.
n Please ask the manufacturer for information about individual use under special ambient condi-
tions.
The following motor types can be operated with the speed controllers:
n DC motors with incremental encoders.
n DC motors without encoders.
n BL motors with digital hall sensors.
n BL motors without hall sensors (sensorless operation).
n SC1801F only: BL motors with absolute encoders (e.g. AES64).
1.2 Safety instructions

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2 Description
FAULHABER speed controllers SC1801, SC2804 and SC2402 are based on an integrated microcontrol-
ler and are used to control the speed of the motor types listed in Chapter 1.2 “Safety Instructions“.
The speed controller product family consists of the following products:
Speed controller for motors in the low power range
n SC1801S
Speed controller with housing and screw-type terminal strips on the supply and motor end.
n SC1801F
Speed controller with housing, screw-type terminal strip on the supply end and flexboard connec-
tion on the motor end.
Speed controller for motors in the high power range
n SC2804S
Speed controller with metal housing and screw-type terminal strips on the supply and motor end.
1 Fixing sockets
2 Screw-type terminal strip, motor end
3 Screw-type terminal strip, supply end
1 Fixing sockets
2 LIF connector for FFC and FPC, 3-pole
3 LIF connector for FFC and FPC, 8-pole
4 Screw-type terminal strip, supply end
2.1 General product description






1 Mounting threads
2 Screw-type terminal strip, motor end
3 Screw-type terminal strip, supply end




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2 Description
Functions
The speed controllers have the following functions for controlling the motors:
n Speed control through setpoint input via an analog voltage.
n Speed control through setpoint input via a PWM signal.
n Operation with fixed speed.
n Operation as voltage controller.
n Current limiting.
n Direction of rotation change via switch input.
n Digital output, configurable as error or frequency output.
n Configuration and parameter assignment through firmware download.
Areas of use
Due to their compact design the speed controllers can be used in diverse applications with little wir-
ing effort. The flexible interfacing possibilities open up a wide range of uses in all areas, for example
in decentralised automation technology systems, in handling and tool machines as well as in pump
drives.
2.1 General product description

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3 Installation
Risk of damage
Incorrect assembly or assembly with the wrong fixing materials can cause damage to the speed
controllers.
 Observe the following assembly instructions.
Off load
The speed controller must be disconnected from the power supply for all types of assembly and con-
nection work.
ESD protection
The regulations for handling modules at risk from ESD must be observed.
Surface
The speed controllers may be screwed onto flat, hard surfaces only. The surface must be suitable for
supporting the assembly sleeves against the screwing forces. Screwing onto a soft or uneven surface
can cause the assembly sleeves to be pressed out.
Screw-type terminal strips
The maximum tightening torque of the screw-type terminal strips must be noted and observed. See
Chapter 7 “Technical Data”.
Flexboard connector
The motors‘ flexboards must be inserted into the connector flat. The connector pin assignment and
connection symbols must be noted.
Never press the flexboard into the connector with force as this could damage it. If necessary, use a
suitable tool (for example, tweezers or a flat-nose pliers). Ensure the flexboard is not squeezed or
crushed.
Right
The speed controller is mounted on a flat,
hard surface.
Wrong
The speed controller is screwed on over an edge.
Risk of pushing out the assembly sleeves!
3.1 Assembly
CAUTION!

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3 Installation
3.2 EMC compatible installation
Length of the connection leads
The maximum length of the connection leads is limited.
} All connection leads may not exceed a length of 3 m.
Compliance with the performance defined by the CE mark with respect to emission and immunity
requires additional EMC measures:
n Ensuring allowable emissions or necessary immunity in industrial use may require the use of an
EMC filter and / or an EMC suppressor circuit.
Speed Controller Use environment Interference type Action
SC1801 Industrial use Immunity EMC suppressor circuit
SC2804 Industrial use Emission EMC filter
Immunity EMC suppressor circuit
This table shows which additional EMC measures have to be taken to ensure the equipment fulfils
the performance regarding emission and immunity defined by the Directive in the environment in
the intended environment.
The units are intended for industrial use only. If the units are used for residential, retail, commer-
cial purposes or in a small company, suitable measures must be taken to ensure that the emission is
below the allowable limit value.
CAUTION!
3.2.1 Description of the EMC measures
The EMC filter (SC2804 only)
The electronics and motor supply cables must be laid directly on the unit, each with two turns th-
rough a suitable ferrite sleeve (e.g. Würth Elektronik No.: 74270090).
For DC motors with encoders the signal cables must be laid directly on the unit on both connection
sides with one turn through one Star-TEC each (e.g. Würth Elektronik No.: 74271132).

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3 Installation
3.2 EMC compatible installation
The EMC suppressor circuit
Circuit diagram 1
C1 Ceramic capacitor 220 nF
C2 Ceramic capacitor 220 nF
Capacitor C1:
If the ceramic capacitor C1 is used, malfunctions can occur in PWMnsetpoint operating mode.
} Use signal source with low internal resistance in PWMnsetpoint operating mode.
NOTE
Capacitor C2:
If using the ceramic capacitor C2, a firmware update with the Motion Manager PC firmware may no
longer be possible.
} Remove the C2 capacitor when updating the firmware.
NOTE




 



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Circuit diagram 2 (SC1801)
Exceptions:
It may not be necessary to implement the additional EMC measures named. If the controller is fed
e.g. from a CE-conforming power supply unit which firstly is connected with the controller by the
shortest possible connection lead and secondly no other devices are supplied, then the EMC filter
or EMC suppressor circuit (circuit diagram 3) can be dispensable. In this case the power supply unit
takes on the function of the EMC filter or the EMC suppressor circuit according to circuit diagram 3.
The same applies accordingly to the EMC suppressor circuit according to circuit diagram 2:
The EMC suppressor circuit can be dispensable if other design measures prevent emissions from
interfering with the control voltage for the desired speed and the switch input for the direction of
rotation.
NOTE








    







    
Circuit diagram 3 (SC2804)
3 Installation
3.2 EMC compatible installation
Separate suppressor diodes (D1, D2) for UP and Umot if they
have separate supply voltages.
If only one supply voltage is used, (bridge between UP and
Umot), one suppressor diode (D1) is sufficient.
D1 and D2 e.g. P6KE18 from ST Microelectronics.
The suppressor diode D2 at Umot is integrated in the control-
ler. If a joint supply voltage is used (bridge between UP and
Umot), this is sufficient. If separate supply voltages are used,
an additional external suppressor diode (D1) P6KE33A is
recommended at UP.

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Depending on their type, the speed controllers are equipped with either screw-type terminal strips,
flexboard connectors or pin headers as connection options.
Electronic damage / ESD protection
Electrostatic discharges at the speed controller‘s connections can cause damage to or destruction of
the electronics.
 Note and follow the ESD protective measures.
Incorrect connection of the strands can cause damage to or destruction of the electronics.
 Connect the connections in accordance with the connector pin assignment, see table.
Please also note and follow the supplementary installation instructions in Chapter 8 “EMC“.
Connector pin assignment, supply end
3 Installation
Connection Function BL motors DC motors
9 Mot C Motor Phase C Reserved
10 Mot B Motor Phase B Motor -
11 Mot A Motor Phase A Motor +
12 SGND Signal GND Signal GND
13 VCC + 5 V DC sensor supply + 5 V DC encoder supply
14 Sens C Hall sensor C Encoder Channel B
15 Sens B Hall sensor B Encoder Channel A
16 Sens A Hall sensor A
Connector pin assignment, motor end
Connection Function SC1801 value SC2804 value SC2402 value
1 Up4 V DC – 18 V DC 5 V DC – 28 V DC 5 V DC – 24 V DC
2 Umot 1.8 V DC – 18 V DC 0 V DC – 28 V DC 0 V DC – 24 V DC
3 GND
4 Unsoll 0 – 10 V
5 DIR Switch input for the motor‘s direction of rotation
6 FG Digital output
7 IO2 reserved - SC2804 and SC2402 only
8 IO1 reserved - SC2804 and SC2402 only
Malfunction
If a motor connection cable longer than 30 cm is used malfunctions can occur during operation.
 Use motor connection cables with a maximum length of 30 cm only for the SC1801 speed control-
ler.
For the SC2804 and SC2402 speed controllers it is necessary to check whether a longer connection
cable can be used in an individual case.
CAUTION!
3.3 Connector pin assignment































CAUTION!

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3 Installation
Depending on their type, the speed controllers are equipped with either screw-type terminal strips,
an LIF interface or pin headers as connection options.
Up (Connection 1)
Supply voltage for the electronics.
Voltage: See Chapter 7 “Technical Data“.
Umot (Connection 2)
Supply voltage for the motor.
Voltage: See Chapter 7 “Technical Data“.
GND (Connection 3)
Joint ground for Up and Umot.
Power supply unit
The Up and Umot connections can be supplied from the same power supply unit. In this case it is nec-
essary to ensure that the power supply unit‘s output is adequate for supplying power to the speed
controller and to the connected motor.
Unsoll (Connection 4)
Input, speed setpoint.
The Unsoll input can be configured in different ways (see Chapter 4 “Configuration“):
Speed setpoint input via analog voltage (standard as delivered condition)
Voltage range: 0 – 10 V.
n Motor stops at Unsoll < 0.15 V.
n Motor runs at Unsoll > 0.3 V (0.5 V for BL motors in sensorless operation).
n The setpoint speed is proportional to the voltage Unsoll. The maximum setpoint speed at 10 V
can be configured. See Chapter 4.4.5 “Maximum speed value“.
Speed setpoint input via PWM signal
PWM frequency range: 500 Hz – 18 kHz.
n Motor stops at pulse duty factor < 2.0 %.
n Motor runs at pulse duty factor > 3.0 %.
n The setpoint speed is proportional to the pulse duty factor. The maximum setpoint speed at
100 % can be configured. See Chapter 4.4.5 “Maximum speed value“.
n The TTL and PLC levels can be configured as switching levels:
Mode high level low level
TTL > 3.0 V DC < 0.5 V DC
PLC > 7.5 V DC < 2.0 V DC
3.4 Connection functions
NOTE

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Quick stop input (low level)
Input is only used to stop the motor.
n Motor stops at Unsoll < 0.15 V.
n Motor stops if connection is open.
n Motor runs at Unsoll > 0.3 V (0.5 V for BL motors in sensorless operation).
Quick stop input inverted (high level)
Input is only used to stop the motor.
n Motor runs at Unsoll < 2.0 V.
n Motor runs if connection is open.
n Motor stops at Unsoll > 2.4 V.
No function
In this setting the input is deactivated.
Input resistance
The input resistance of the Unsoll connection differs depending on the configuration. The lowest
value is approx. 5 k.
3 Installation
DIR (Connection 5)
Switch input for the motor‘s direction of rotation.
Risk of damage
Switching over the motor‘s direction of rotation (reversing duty) too quickly can cause damage.
} Do not use the speed controller for reversing duty.
n Direction of rotation clockwise if connection > 3 V DC (is detected as high level).
n Direction of rotation clockwise if connection open (is internally set to high level). Note and ob-
serve Chapter 3.2 “EMC-compatible installation” if input open.
n Direction of rotation anti-clockwise if connection < 0.5 V DC.
n Direction of rotation anti-clockwise if connected to ground.
3.4 Connection functions
NOTE
CAUTION!

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FG (Connection 6)
Digital output.
The digital output is a switch which switches to GND (open collector with integrated pull-up resist-
ance of 22 k).
Output voltage: max. Up.
Output current: max. 15 mA.
The digital output can be configured for different tasks:
Error output
Only possible configuration for DC motors.
n Output switches to high level if current limiting is activated. The delay between activation of cur-
rent limiting and activation of the output can be adjusted. See Chapter 4.4.10 “Delayed Current
Error“.
n Output switches to low level if current limiting is deactivated.
Frequency output
Frequency output for reading out the actual motor speed. Only possible configuration for BL motors
in sensorless operation. As delivered condition for BL version.
Signal setup: 3 pulses per motor revolution.
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:
3 Installation
3.4 Connection functions
NOTE






�
 �
Due to the coupling of the internal pull-up resistance
between FG and the supply voltage UP, conducted elec-
tromagnetic RF interference, which affect the supply
voltage, can drastically worsen the FG signal.
If operated properly and as intended, the speed and
direct of rotation of the motor are not impaired by this
interference.

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Mot C – Mot A (Connections 7 – 9)
Supply connections for motor winding
BL motors
During the operation of brushless motors the motor phases are directly controlled via the Mot A,
Mot B and Mot C connections.
DC motors
During the operation of DC motors the motor winding is supplied via the Mot B (-) and Mot A (+)
connections.
SGND (Connection 10)
Joint ground of the hall sensors.
VCC (Connection 11)
Joint power supply of the hall sensors.
Voltage: 5 V DC.
Maximum output current (ICC): See Chapter 7 “Technical Data“.
Sens C – Sens A (Connections 12 – 14)
Inputs of the hall sensor signals.
3 Installation
3.4 Connection functions

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3 Installation
3.5 Quick start
Closed loop control (speed setpoint input through Unsoll)
The connected motor rotates with controlled speed in an anti-clockwise direction. The speed is set
by Unsoll and depends on the maximum speed set in the speed controller for Unsoll = 10 V. If the dig-
ital output is configured as a frequency output the speed signal can be measured there.
The speed controllers are configured to default standard values when delivered which in most cases
result in correct function. The speed controllers can be adjusted to special requirements with the
help of a PC and the FAULHABER Motion Manager PC software. See Chapter 4 “Configuration“.
Risk of damage
Operating a motor with a speed controller not suitable for the motor can cause damage to the mo-
tor.
} Before starting up the motor, ensure that the configuration of the speed controller used (BL / DC
motor, hall sensors,...) is suitable for the connected motor.
To start up a motor at a speed controller the motor must be connected according to the connection
cable and speed controller assignment.
3.5.1 Connection examples for the supply end
CAUTION!




 


   






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3 Installation
Full drive (motor speed is determined by Umot)
The connected motor rotates with load-dependent speed in a clockwise direction. The speed can be
adjusted by changing Umot. If the digital output is configured as a frequency output the speed signal
can be measured there.
3.5.2 Connection examples for the motor end
3.5 Quick start
DC motor without encoderDC motor with encoder




 

    







 
 

  
 
 

 
 
 


 
 
 

 
 
 
 
 


 
 
 

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3 Installation
3.5 Quick start
BL motor with digital hall sensors. BL motor without hall sensors
BL motor with AES64 absolute encoder

 
 

  
  
  
 
 
 


 
 
   
  

 
 
 
 
 


 
 
   

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