halstrup-walcher PSD4 Series User manual

Instruction manual
PSD4xx positioning system

Safety precautions
7100.006384_Instruction manual_PSD4xx_E_ENG 2 15.06.2020
halstrup-walcher GmbH
Stegener Straße 10
79199 Kirchzarten
Tel. [phone]
[email protected]
www.halstrup-walcher.com
©2020
The manufacturer owns the copyright to this instruction manual. It contains technical data,
instructions and drawings detailing the device’s features and how to use them. It must not
be copied either wholly or in part or made available to third parties.
The instruction manual is part of the product. Please read this manual carefully, follow our
instructions, and pay special attention to the safety information provided. This instruction
manual should be available at all times. Please contact the manufacturer if you do not
understand any part of the instructions.
The manufacturer reserves the right to continue developing this device model without
documenting such development in each individual case. The manufacturer will be happy to
determine whether this manual is up-to-date.

Safety precautions
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Table of contents

Safety precautions
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1 Safety precautions
1.1 Appropriate use
Positioning systems are especially suitable for automatically setting tools, stops or spindles
for wood-processing equipment, packing lines, printing equipment, filling units and other
types of special machines.
PSD4xx positioning systems are not stand-alone devices and may only be used if
coupled to another machine.
Always observe the operating requirements –particularly the permissible supply voltage –
indicated on the type label and in the “Technical data” section of this manual.
The device may only be handled as indicated in this manual. Modifications to the device are
prohibited. The manufacturer is not liable for damages caused by improper use or failure to
follow these instructions. Violations of this type render all warranty claims null and void.
Never apply force to the housing cover, e.g. for supporting weight.
1.2 Assembly, electrical connections and start-up
Assembly and the electrical connections should only be handled by professionals. They
should be given proper training and be authorised by the operator of the facility.
The device may only be operated by appropriately trained individuals who have been
authorised by the operator of the facility.
Specific safety precautions are given in individual sections of this manual.
The device must be installed by trained technical personnel.
1.3 Troubleshooting, maintenance, repairs
The individual responsible for the electrical connections must be notified immediately if the
device is damaged or if errors occur.
This individual must take the device out of service until the error has been corrected and
ensure that it cannot be used unintentionally.
This device requires no maintenance.
Only the manufacturer may perform repairs that require the housing to be opened.

Safety precautions
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1.4 Symbols
The device has been designed and tested to ensure its safety. However, it may still be
dangerous if used inappropriately. Precautions must be taken to prevent the device being
used incorrectly by mistake.
The following warnings are used in this instruction manual:
WARNING This warns you of a potential hazard and possible
consequences that could lead to serious bodily injury up to
and including death if the corresponding instructions are
not followed.
ATTENTION This warns you of a situation where incorrect use could
cause damage to the drive.
NOTE This provides information about individual functions or
special features
1.5 Storage and transportation
The PSD4xx positioning drive should always be stored and transported to the place of
installation in its original packaging.
Information about storage and transportation can be found in the technical data sheet:
www.halstrup-walcher.de/en/products/positioning-systems/direct-drives-psd/
1.6 Disposal
The electronic components of the device contain environmentally hazardous materials and
materials that can be reused. The device must therefore be sent to a recycling plant when
you no longer wish to use it. Compliance with the environmental codes of your country is
essential.
1.7 Purpose of this user information
Some sections of this manual refer to external device-specific documents.
Requirement: An Internet connection is required.
The following additional documents are part of this instruction manual:
- Assembly instructions (general)
- Description of electrical connections and connectors (specific)
- Description of bus connections (specific)
Click the following link to find more technical information about your product: www.halstrup-
walcher.de/technicaldocu

Description of the device and its functions
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2 Description of the device and its functions
2.1 PSD4xx positioning system with bus interface
The PSD4xx positioning system is an integrated drive for the accurate adjustment of
auxiliary and positioning axes. The drive enables the operator to perform reproducible and
simultaneous adjustments at all the required positions.
The PSD4xx positioning system converts a digital positioning signal into a rotational angle.
The integrated absolute measuring system eliminates the need for time-consuming
reference runs. A bus system connection simplifies the wiring. A hollow shaft with an
adjustable collar makes assembly quite simple.
The positioning system is especially suitable for automatically setting tools, stops or spindles
for wood-processing equipment, packing lines, printing equipment, filling units and other
types of special machines. The devices require no maintenance.
2.2 Technical data
- Stepping motor
- Power amplifier and control electronics with galvanic separation (power and bus)
- Absolute measuring system (battery-free)
- Bus interface (options):
oCANopen (incl. switchable terminating resistor)
oIO Link
oPROFINET
oEtherCAT
- Protection class:
oStandard: IP 50
oOptional: IP 65
- Solid circular shaft (flattened), 5 mm or 8 mm
- Optional: Hollow shaft, 8 mm or 14 mm (with gear reducer)
- Optional: Gearbox kit for increased torque requirements with 8 mm or 14 mm hollow
shaft
- Selectable connector orientation (horizontal or vertical with regard to the output box)
- Positioning runs:
oPositioning run with loop
oPositioning run without loop

Description of the device and its functions
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oManual run
2.3 Examples of applications
Wood-processing machines
Packaging machines
Food processing and beverages industry
etc.
Format changeover in packaging
machines:
Format changeover in bottle filling:

Description of the device and its functions
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2.4 Models
The PSD4xx positioning system can be adapted to specific requirements. The possible
models can be configured using the order key:

Description of the device and its functions
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2.5 Construction of devices with hollow shafts/gear reducers
1
M12 male connector for power supply (A-coded)
(for devices with IO-Link also for communication)
2
M12 connector for bus (not for devices with IO Link)
CA: M12 female connector (B-coded)
EC/PN: M12 female connector (D-coded)
3
M12 connector for bus (not for devices with IO Link)
CA: M12 male connector (B-coded)
EC/PN: M12 female connector (D-coded)
4
Sealing plug (device controls (not for devices with IO Link) and status elements)
5
Connection diagram (on the opposite side of the connectors) (not for devices
with IO Link)
6
Housing section with power and control electronics
7
Type label
8
Ground screw

Description of the device and its functions
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9
Gearbox with hollow shaft PSD403 / -413 / -426 / -436 / -428 / -438:
Attachment housing with hollow shaft PSD401 / -411 / -422 / -432:
10
Hollow shaft, 8 mm or 14 mm, with Allen screw (M4 x 16 DIN 912) for spindle
mounting
11
Sealing plate (1.5 mm): to offset lash in the spindle
12
Torque support: Mechanical fixation to prevent the drive from twisting

Description of the device and its functions
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2.6 Construction of devices with solid circular shafts
1
M12 male connector (A-coded) (for device with IO Link for bus and power supply)
2
M12 connector for bus (not for devices with IO Link)
CA: M12 female connector (B-coded)
EC/PN: M12 female connector (D-coded)
3
M12 connector for bus (not for devices with IO Link)
CA: M12 male connector (B-coded)
EC/PN: M12 female connector (D-coded)
4
Sealing plug (for device controls (not for devices with IO Link) and status
elements)
5
Connection diagram (on the opposite side of the connectors)
6
Housing section with power and control electronics
7
Type label
8
Ground screw
9
Flange holes M3 (PSD40x/41x) or ∅4.5 (PSD42x/43x)
10
Solid circular shaft (flattened), 5 mm or 8 mm

Description of the device and its functions
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2.7 Type label
1
Manufacturer and website
2
Country of manufacture
3
Technical data
4
Article number (specific)
5
MAC-adress (only for devices with IE buses)
6
Order key
7
Serial number
8
CE conformity certification

Description of the device and its functions
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2.8 Device controls and status elements
There is a rectangular sealing plug on the side where the connector is located –the precise
location depends on the selected orientation of the connectors. The device controls and
status elements are located under the sealing plug.
2.8.1 Device controls and status elements CANopen / IO-Link
1
DIP-switches (left to right switches 1..4) (not present with IO Link)
2
Status LEDs (red and green LED = bus status; yellow LED = motor status)
3
Address switches 10x (not present with IO Link)
4
Address switches 1x (not present with IO Link)
2.8.2 Device controls and status elements IE (Industrial Ethernet)
1
Status LEDs (bus status and motor status)
2
Address switches 10x
3
Address switches 1x
Click the following link to find more technical information about the control and status
elements in the bus description: www.halstrup-walcher.de/technicaldocu

Installing the device
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3 Installing the device
WARNING Risk of injury if used inappropriately.
The device must be installed by trained technical
personnel.
WARNING Risk of burns due to hot drive.
The drive can become very hot during operation.
Allow the drive to cool before touching it.
WARNING Risk of crushing due to rotary movement.
Do not reach into the working area of the drive when it is
still turning.
The user/operator must ensure appropriate protective
measures are taken.
WARNING Incorrect assembly can lead to the destruction of the drive.
WARNING Check that the supply lines are not pinched or crushed.
Lay the supply lines according to the general and specific
local assembly regulations.
If the supply lines have not been delivered together with
the device, please select suitable cables for the application.
Do not operate the positioning unit if the supply lines are
noticeably damaged.
WARNING Risk of injury. High contact voltages can occur in the case
of malfunctions.
This can be prevented by grounding.
ATTENTION The drive must be protected against excessive heating.
The user/operator must ensure appropriate protective measures
are taken.
ATTENTION Never apply force to the housing of the drive, e.g. for supporting
weight.
ATTENTION Submerged operation of the PSDs is not permitted.

Installing the device
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Note: When the drive is running at certain speeds, depending on the application,
resonances may occur which reduce its service life and increase noise.
This can be avoided by changing the target rpm.
3.1 Installing drive with a hollow shaft
How to mount the drive with hollow shaft on a shaft
Requirements
Recommended shaft diameter:
8 h9 or 14 h9
Depth of the hollow shaft bore
20 mm
Tightening torque of the adjustable collar
screw with a 3 mm Allen screw:
4 Nm
Minimum depth of pin insertion into the
hollow shaft bore
> 16 mm
Hole/long hole for torque support
6.05…6.10 mm
Sealing plate
Must be resting evenly or be pressed
together at up to half thickness
ATTENTION Depending on the operating situation, the use of significantly
shorter pins (< 16 mm) may result in damage to the drive.
The depth of the hollow shaft bore is 20 mm. For optimum operation, the length of the pin of
the shaft to be driven should correspond to this depth of the bore. Depending on the
operating situation, the use of significantly shorter pins (< 16 mm) may result in damage to
the PSD4xx. When installing the PSD4xx, the device should only be pushed on until the
foam rubber panel on the base of the device is resting evenly on the machine, or being

Installing the device
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pressed together to approx. the half thickness. Under no circumstances must the PSD4xx
be bolted on “hard” without an air gap between it and the machine.
Note: When installing the device, ensure that the sealing plate is parallel to the
base of the device, see diagram:
INCORRECT CORRECT 
Note: The backlash that occurs when the direction of rotation changes has a direct
influence on the positioning accuracy of the device. If the backlash is very high
(several mm), the impact load may damage the drive.
Note: When it has been mounted, there must be space around the drive on all
sides. This is important because the drive can move axially and/or radially during
positioning if the hollow shaft and solid shaft are not 100% aligned. This “wobble”
does not indicate a defect in the drive, nor does it impair the drive’s function as
long as it can move freely.
3.2 Installing drive with a solid circular shaft
The drive with a solid circular shaft is installed on the axle to be driven using a coupling and
an intermediate flange.
Install the drive according to the coupling manufacturer’s specifications.
Requirements
Recommended internal diameter of hollow
shaft
5 H9 or 8 H9
Stepper motor flange screws
M3
Note: Install the drive according to the coupling manufacturer’s specifications.

Installing the device
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Example:
3.3 Electrical connections and pin assignment
Technical data for the electrical connections and pin assignment can be found in the pin
assignment description on the website: www.halstrup-walcher.de/technicaldocu

Installing the device
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3.4 Earth the housing
WARNING Risk of burns due to hot drive.
The drive can become very hot during operation.
Allow the drive to cool before touching it.
WARNING Risk of injury. High contact voltages can occur in the case
of malfunctions.
This can be prevented by grounding.
Next to the connectors, there is an M4 stud bolt for mounting the grounding cable.
Note: The positioning system should be connected to the machine base using the
shortest possible cable. The minimum wire cross-section of the grounding cable is
1.5 mm².
3.5 Dismantling
WARNING Risk of burns due to hot drive.
The drive can become very hot during operation.
Allow the drive to cool before touching it.
To dismantle, undo the clamp (the adjustable collar in models with a hollow shaft) and pull
the PSD4xx off the shaft.
Note: Ensure the drive is pulled off the shaft in the axial direction. Excessive
bending can damage the output shaft.
Note: When removing models with a solid circular shaft from a coupling, please
follow the coupling manufacturer’s instructions.
Grounding screw

Installing the device
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3.6 Powering the device
ATTENTION For motor power use a single fuse with max. 2.0 A for each
PSD40x/41x and with max. 4.0 A for each PSD42x/43x.
For control power you can use a fuse with max. 2.0 A, so it is
possible to power up to 10 units parallel with one fuse.
It is strongly recommended to separate power cables to the
PSD4xx from other power cables that might have dangerous
voltage.
3.7 Run drive in reverse
Depending on the model, the drive may be run in reverse up to a certain speed.
ATTENTION Running a PSD4xx in reverse for more than 1-2 seconds at
more than the permissible speed will damage the internal
protection diode and the PSD4xx will be defective.
Please refer to the following table to find the maximum permissible speed:
Device type
PSD401
/
PSD411
-5V
PSD401
/
PSD411
-8H/14H
PSD403
/
PSD413
-8H/14H
PSD422
/
PSD432
-8V
PSD422
/
PSD432
-8H/14H
PSD426
/
PSD436
-14H
PSD428
/
PSD438
-14H
Maximum
permissible
speed [rpm]
200
200
48
200
200
60
45

Communication interface
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4 Communication interface
Technical data for the communication interface can be found in the bus description on the
website: www.halstrup-walcher.de/technicaldocu
5 Technical data
Technical data and drawings can be found in the current data sheet on the website:
www.halstrup-walcher.de/en/products/positioning-systems/direct-drives-psd
Please contact us if you require any further information.
6 Included in shipment
The shipment includes the following:
- Assembly instruction
- PSD4xx positioning system