halstrup-walcher PSD4 Series User manual

Instruction manual
PSD/PSC 4xx positioning system

Safety precautions
7100.006834 Instruction manual PSD/PSC 4xx B EN 2 15.03.2022
halstrup-walcher GmbH
Stegener Straße 10
79199 Kirchzarten
Germany
Tel. [phone]
[e-mail]
www.halstrup-walcher.com
© 2022, Kö
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
7100.006834 Instruction manual PSD/PSC 4xx B EN 3 15.03.2022
Table of contents

Safety precautions
7100.006834 Instruction manual PSD/PSC 4xx B EN 4 15.03.2022
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.
PSD/PSC 4xx 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 data sheet.
The drive 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.
Provide sufficient ventilation in the mounting location to avoid excessive self-heating.
The drives are designed as appropriate use under normal conditions (according to EN / IEC /
UL 61010- 1) except the extended ambient temperature range:
- Indoor use
- Altitudes up to 2,000 m
- Ambient temperature, deviating from standard: 0°C to 40 °C;
- Maximum relative humidity of 80 % at temperatures up to 31 °C,
decreasing linearly to 50 % relative humidity at 40 °C;
- Mains supply voltage fluctuations up to ± 10 % of the nominal voltage;
- The IP protection ratings are manufacturer's specification
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
7100.006834 Instruction manual PSD/PSC 4xx B EN 5 15.03.2022
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 PSD/PSC 4xx positioning system 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/technicaldocu
Please search for “PSD” or “PSC”, select your type, click on “Data sheets” and download the file.
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 (such as data sheets, bus descriptions
and manuals, function blocks or STP-files): www.halstrup-walcher.de/technicaldocu

Description of the drive and its functions
7100.006834 Instruction manual PSD/PSC 4xx B EN 6 15.03.2022
2 Description of the drive and its functions
2.1 PSD/PSC 4xx positioning system with bus interface
The PSD/PSC 4xx 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 PSD/PSC 4xx 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 drive 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 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 drive and its functions
7100.006834 Instruction manual PSD/PSC 4xx B EN 7 15.03.2022
2.3 Overview of features
- Stepper motor
- Power amplifier and control electronics with galvanic separation (power and bus)
- Absolute measuring system (battery-free)
- Several bus interface options (see order key, chapter 2.4)
- 2 Protection class options (see order key chapter 2.4)
- 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 axis)
- Positioning runs:
oPositioning run with loop
oPositioning run without loop
oManual run
2.4 Models and order key
The PSD/PSC 4xx positioning systems can be adapted to specific requirements. The possible
models can be configured using the order key:

Description of the drive and its functions
7100.006834 Instruction manual PSD/PSC 4xx B EN 8 15.03.2022

Description of the drive and its functions
7100.006834 Instruction manual PSD/PSC 4xx B EN 9 15.03.2022
2.5 Construction of devices with hollow shafts/gear reducers
Illustration exemplary, here: PSD403-14H
1
M12 male connector for power supply (A-coded)
(for devices with IO-Link also for communication)
2
M12 connector for bus
CA: M12 female connector (B-coded)
IE buses: M12 female connector (D-coded)
IO: not used (1 cable for power supply and communication signal)
3
M12 connector for bus
CA: M12 male connector (B-coded)
IE buses: M12 female connector (D-coded)
IO: not used (1 cable for power supply and communication signal)
4
Sealing plug with
- device controls (not for devices with IO Link)
- status elements (see chapter 2.8)
5
Connection diagram on the adjoining side of the connectors
(not for devices with IO Link)
6
Housing section with power and control electronics
7
Type label (see chapter 2.7)
8
Grounding screw

Description of the drive and its functions
7100.006834 Instruction manual PSD/PSC 4xx B EN 10 15.03.2022
9
Gearbox with hollow shaft:
Illustration exemplary, Models: see order code
Attachment housing with hollow shaft:
Illustration exemplary, Models: see order code
10
Hollow shaft, 8 mm or 14 mm,
with allen screw (M4 x 16 DIN 912) for spindle mounting
11
Damping plate (1.5 mm): to offset lash in the spindle
12
Torque support: Mechanical fixation to prevent the drive from twisting

Description of the drive and its functions
7100.006834 Instruction manual PSD/PSC 4xx B EN 11 15.03.2022
2.6 Construction of devices with solid circular shafts
Illustration exemplary, here: PSD422-8V
1
M12 male connector (A-coded) (for device with IO Link for bus and power supply)
2
M12 connector for bus
CA: M12 female connector (B-coded)
Ethernet based buses: M12 female connector (D-coded)
IO: not used (1 cable for power supply and communication signal)
3
M12 connector for bus
CA: M12 male connector (B-coded)
Ethernet based buses: M12 female connector (D-coded)
IO: not used (1 cable for power supply and communication signal)
4
Sealing plug with
- device controls (not for devices with IO Link)
- status elements (see chapter 2.8)
5
Connection diagram (on the adjoining side of the connectors)
6
Housing section with power and control electronics
7
Type label (see chapter 2.7)
8
Grounding screw
9
Flange holes M3 (PSD/PSC 40x/41x) or ∅4.5 (PSD/PSC 42x/43x)
10
Solid circular shaft (flattened), 5 mm or 8 mm

Description of the drive and its functions
7100.006834 Instruction manual PSD/PSC 4xx B EN 12 15.03.2022
2.7 Type label
1
Manufacturer and website
2
Country of manufacture
3
Technical data
4
Article number (specific)
5
MAC-address (only for devices with IE buses)
6
Order key
7
CE and UKCA conformity symbols
8
Serial number
9
Warning symbols:
observe installation and operating instructions
let the positioning system cool down sufficiently before touching

Description of the drive and its functions
7100.006834 Instruction manual PSD/PSC 4xx B EN 13 15.03.2022
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
Please search for “PSD” or “PSC”, select your type, click on “Instruction manuals” and download
the files appropriate to your bus communication interface.

Installing the drive
7100.006834 Instruction manual PSD/PSC 4xx B EN 14 15.03.2022
3 Installing the drive
WARNING Risk of injury if used inappropriately.
The drive 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. They must
not touch the housing of the drive or should be designed for the
corresponding heat.
Lay the supply lines according to the general and specific local
assembly regulations.
If the supply lines have not been delivered together with the drive,
please select suitable cables for the application.
Do not operate the positioning system 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.
Ensure sufficient ventilation in the mounting location.
ATTENTION Never apply force to the housing of the drive, e. g. for supporting weight.
ATTENTION Submerged operation of the PSD/PSC is not permitted.
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.

Installing the drive
7100.006834 Instruction manual PSD/PSC 4xx B EN 15 15.03.2022
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
Damping 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
PSD/PSC 4xx.
When installing the PSD/PSC 4xx, the device should only be pushed on until the damping plate
on the base of the device is resting evenly on the machine, or being pressed together to approx.
the half thickness. Under no circumstances must the PSD/PSC 4xx be bolted on “hard” without an
air gap between it and the machine.

Installing the drive
7100.006834 Instruction manual PSD/PSC 4xx B EN 16 15.03.2022
Note: When installing the device, ensure that the damping 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.

Installing the drive
7100.006834 Instruction manual PSD/PSC 4xx B EN 17 15.03.2022
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 of the coupling
5 H9 (PSD/PSC 4xx-5V) or
8 H9 (PSD/PSC 4xx-8V)
Stepper motor flange screws (not included,
please select appropriate length)
Thread M3 (PSD/PSC 40x/41x/48x/49x),
Borehole Ø4,5 mm (PSD/PSC 42x/43x),
please use M4 screws and nuts, if applicable
Note: Install the drive according to the coupling manufacturer’s specifications.
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
Please search for “PSD” or “PSC”, select your type, click on “Instruction manuals” and download
the files appropriate to your bus communication interface, file name: Connector and pin
assignments.

Installing the drive
7100.006834 Instruction manual PSD/PSC 4xx B EN 18 15.03.2022
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 screw for mounting the grounding cable.
Note: The drive 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
PSD/PSC 4xx 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 drive
7100.006834 Instruction manual PSD/PSC 4xx B EN 19 15.03.2022
3.6 Powering the device
For the motor supply connection (SELV/PELV), it is required to provide adequate power limitation
in compliance to e.g. IEC 61010-1, Limited Energy Circuit (LEC) or IEC 60950-1, Limited Power
Supply (LPS). To ensure this, the following fuse protection is recommended:
ATTENTION: For motor power use a single fuse with max. 4.0 A for each drive.
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.
The supply lines to the PSD/PSC 4xx must be routed separately from other lines with
dangerous voltage.
3.7 Duty cycle and mode of operation
The drives are designed for intermittent operation S3. When operating the drives under nominal
power, the following duty cycle (DC) must be observed:
Device type
PSD/PSC 40x / 41x
PSD/PSC 42x / 43x
PSD 48x / 49x
Duty cycle
[%]
up to 50 % DC S3
up to 30 % DC S3
up to 50 % DC S3
The mentioned duty cycles are guiding values. A higher duty cycle can be achieved by adjusting
the parameters (speed, current).
Depending on the application, continuous operation S1 is possible with some variants. Please
contact us if you have any questions.

Installing the drive
7100.006834 Instruction manual PSD/PSC 4xx B EN 20 15.03.2022
3.8 Run drive in reverse
Depending on the model, the drive may be run in reverse up to a certain speed.
ATTENTION: Running a PSD/PSC 4xx in reverse for more than 1-2 seconds at more
than the permissible speed will damage the internal protection diode and the
PSD/PSC 4xx will be defective.
Please refer to the following table to find the maximum permissible speed:
PSD direct drives:
Device type
PSD 401/411 -5V/-8H/-14H
PSD 403/413 -8H/-14H
PSD 422/432 -8V/-8H/-14H
PSD 424/434 -14H
PSD 426/436 -14H
PSD 428/438 -14H
PSD 480/490 -5V/-8H/-14H
PSD 481/491 -8H/-14H
Maximum
permissible
speed [rpm]
200
48
200
95
60
45
200
48
PSC direct drives:
Device type
PSC 401/411 -5V/-8H/-14H
PSC 402/412 -8H/-14H
PSC 422/432 -8V/-8H/-14H
PSC 423/433 -14H
PSC 425/435 -14H
PSC 427/437 -14H
Maximum
permissible
speed [rpm]
450
110
300
145
95
75