Hiwin D1-N Series Training manual

Assembly and
Commissioning Instructions
D1-N Servo Drive Amplifier
with EtherCAT® and
Safe Torque Off (STO) Safety Function
Version: 1.05
As of: 05.10.2015

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Assembly and Commissioning Instructions Servo amplifier D1-N
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15.10.2015
HIWIN GmbH Tel.: +49 (0)781 / 9 32 78-0
Brücklesbünd 2 Fax: +49 (0)781 / 9 32 78-90
77654 Offenburg E-Mail: [e-mail]
Technical customer service Tel.: +49 (0)781 / 9 32 78-77
These assembly and commissioning instructions are protected by copyright. The
written consent of HIWIN GmbH is required for reproduction, publication in part or
in whole, modification or abridgement of these instructions.
Subject to technical changes.

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Contents
1 Content ...................................................................................................... 7
1.1 Version of this documentation..............................................................................7
1.2 Information about the document..........................................................................7
1.3 Requirements ........................................................................................................7
1.4 Availability..............................................................................................................8
1.5 Scope of validity for these assembly and commissioning instructions..............8
1.6 Depiction of safety notices ....................................................................................8
1.7 Symbols used.........................................................................................................9
1.8 Warranty and liability ............................................................................................9
1.9 Manufacturer's details........................................................................................10
1.10 Copyright............................................................................................................10
1.11 Product monitoring ...........................................................................................10
2 Safety ....................................................................................................... 11
2.1 Intended use ........................................................................................................11
2.2 Disclaimer in the event of modification or improper use .................................12
2.3 Qualified trained staff..........................................................................................12
2.4 General safety notices........................................................................................13
2.5 Safety notices regarding storing the drive amplifiers.......................................13
2.6 Safety notices regarding transporting the drive amplifiers..............................13
2.7 Safety notices regarding working with energised and live products ..............14
2.8 Safety notices regarding working with hot surfaces!........................................14
2.9 Technical support................................................................................................14
3 Product description .................................................................................. 15
3.1 Order code ...........................................................................................................16
3.2 Type plates...........................................................................................................17
3.3 Guidelines and standards ...................................................................................18
3.4 Scope of supply....................................................................................................18
3.5 Technical specification........................................................................................19
4 Assembly.................................................................................................. 21
4.1 Assembling the drive amplifier ..........................................................................21
4.2 Dimensions ..........................................................................................................22
4.3 Switch cabinet assembly.....................................................................................25
5 Electrical connection................................................................................ 26
5.1 Overview of electrical connections.....................................................................27
5.2 X1 – mains connection ........................................................................................29
5.2.1 1-phase mains connection with mains filter ..................................................29
5.2.2 3-phase mains connection with mains filter ..................................................30
5.3 X2 – brake resistor connection...........................................................................31
5.3.1 Brake resistor calculation ...............................................................................33
5.3.2 DCbus capacity of D1-N servo drives ..............................................................33
5.4 X3 – motor connection.........................................................................................34
5.5 X4 – control voltage and motor brake connection.............................................35
5.6 X5 – parameterisation interface .........................................................................36
5.7 X6 – Input and output connection .......................................................................37
5.7.1 Wiring variants for step/direction input on X6................................................38
5.7.2 Switching characteristics of digital inputs on the X6 .....................................39

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5.7.3 Wiring of encoder output on X6 .......................................................................41
5.7.4 Wiring of analogue input on X6........................................................................41
5.8 X7 and X8 – STO safety function connection ......................................................42
5.9 X9 – motor temperature sensor .........................................................................43
5.10 X10, X11, X12 – encoder connection .................................................................44
5.11 X13 - EtherCAT ..................................................................................................45
6 STO safety function .................................................................................. 46
6.1 Definition STO ......................................................................................................46
6.2 Functional principle of the STO function on the D1-N ......................................47
6.3 Connections of STO function on D1-N................................................................47
6.4 Activation of the STO function.............................................................................50
6.4.1 Timing diagram for activating the STO function.............................................52
6.4.2 Timing diagram for releasing the STO function .............................................53
6.5 Preconditions for using the safety function.......................................................53
6.5.1 Category 0 stop 0..............................................................................................54
6.5.2 Category 1 stop.................................................................................................54
6.5.3 Parking brake behaviour..................................................................................54
6.5.4 Vertical axes and/or external application of force .........................................54
6.5.5 Unintended restart ...........................................................................................54
6.5.6 Degree of contamination when using the safety function..............................54
6.5.7 Protected cable routing ...................................................................................55
6.5.8 Data for maintenance plans and safety calculations .....................................55
6.5.9 Risk analysis .....................................................................................................56
6.6 Examples of circuits for the STO function..........................................................56
6.7 Safety function certified by TÜV..........................................................................58
7 EtherCAT.................................................................................................. 59
7.1 D1-N EtherCAT with CoE protocol......................................................................59
7.1.1 Integration of a D1-N in a TwinCAT project ....................................................59
7.1.2 Installing the ESI file ........................................................................................59
7.1.3 Adding devices by scan ....................................................................................60
7.1.4 Setting the axis resolution ...............................................................................61
7.1.5 Setting the maximum speed............................................................................62
8 “Lightening” commissioning software...................................................... 63
8.1 Installation of the software.................................................................................63
8.2 Initial launch of the "Lightening" software ........................................................65
8.2.1 Establishing connection with device ...............................................................65
8.3 Operating interface..............................................................................................67
8.3.1 The “Conf./Tune” menu....................................................................................69
8.3.2 The “Tools” menu.............................................................................................70
8.3.3 The shortcut bar ...............................................................................................71
8.3.4 Reset .................................................................................................................71
8.3.5 Status ................................................................................................................72
8.3.6 Errors and warnings ........................................................................................72
8.3.7 Variable rapid access .......................................................................................72

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8.4 “Configuration center” without/with EtherCAT .................................................73
8.4.1 AC servo motor parameterisation ...................................................................74
8.4.2 Linear motor parameterisation .......................................................................82
8.4.3 TM motor parameterisation.............................................................................91
8.4.4 Motor parameterisation with EnDat 2.2 encoder .........................................100
8.5 “Application center” ..........................................................................................101
8.5.1 Homing............................................................................................................101
8.5.2 Backlash .........................................................................................................109
8.5.3 Error map........................................................................................................110
8.5.4 “Resolver”.......................................................................................................112
8.6 “Protection center” (limitations) ......................................................................113
8.6.1 Protection........................................................................................................ 113
8.6.2 HW limit protection ........................................................................................114
8.6.3 “Brake”............................................................................................................114
8.7 Digital inputs and outputs / “I/O center”..........................................................116
8.7.1 Inputs ..............................................................................................................116
8.7.2 Outputs............................................................................................................117
9 Commissioning........................................................................................119
9.1 Commissioning ..................................................................................................119
9.2 “Auto phase center” ..........................................................................................120
9.2.1 Servo motors ..................................................................................................122
9.2.2 Linear and torque motors..............................................................................124
9.2.3 “Frequency analysis” – automatically adapting control parameters..........128
9.2.4 “Phase initialisation” – first commutation....................................................133
9.2.5 “SMCL tool” ...................................................................................................133
9.2.6 LM and TM with EnDat 2.2 .............................................................................135
9.3 "Performance center", controller parameter optimisation............................137
9.4 First travel subject to control ...........................................................................139
9.4.1 “Debounce time” and “Target radius” in the “Performance center” ..........140
9.5 Using the “scope” functions..............................................................................141
9.6 Controller tuning ...............................................................................................148
9.7 “Advanced gains” – filter...................................................................................150
9.7.1 Setting filters ..................................................................................................151
9.7.2 “Advanced gains” – “Acc feedforward” .........................................................152
9.7.3 “Advanced gains” – “Schedule Gains + vpg”.................................................154
9.7.4 “Advanced gains” – “Analog input” ...............................................................155
9.7.5 “Advanced gains” – “current loop”................................................................156
9.7.6 “Advanced gains” – “VSF” (velocity suppression function)..........................157
9.7.7 “Advanced gains” – “Friction Compens.”......................................................158
9.8 Error history ......................................................................................................160
10 mega-ulink protocol ..............................................................................161
10.1 Features of the MPI library .............................................................................161
10.2 PDL (Process Description Language) programming ....................................162
10.3 Features of PDL programming.......................................................................162

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10.4 Programming examples (no liability accepted).............................................163
10.5 Writing PDL program to D1-N and saving .....................................................166
10.6 Stopping PDL program, allowing it to run on and deleting it .......................169
11 Troubleshooting ....................................................................................172
11.1 Error codes and troubleshooting ...................................................................172
11.2 Warnings and troubleshooting .......................................................................175
11.3 Other errors and troubleshooting ..................................................................178
12 Repair and replacement ........................................................................178
13 Parts numbers and accessories ............................................................179
13.1 Item number for drive amplifier set...............................................................179
13.2 Item number for connector kit .......................................................................180
13.3 Motor cables ....................................................................................................181
13.4 Cables for encoder systems ...........................................................................182
14 Declaration of Conformity......................................................................183

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1
Content
1.1
Version of this documentation
Version
Date
Remark
1.05 05/10/2015 Endat 2.2, homing procedures, errors and warnings, new
article numbers
1.04 21/01/2014 EtherCAT integration, motor shield, mega_ulink, PDL,
STO
1.03 16/01/2014 Type plate, EMC standards, Technical data adapted
1.02 07/11/2013 Format adjustments, Technical data adapted
1.01a 01/10/2013 General corrections
1.01 02/08/2013 General corrections, addition of chapters STO safety
function and EtherCAT
1.00 01/07/2013 First edition
Table 1.1: Versions of this document
1.2
Information about the document
These assembly and commissioning instructions are intended for planners, devel-
opers and operators of machines and equipment in which Hiwin D1-N servo drive
amplifiers are already integrated or are to be used. They are also intended for peo-
ple who perform the following work on or with the D1-N:
•transport
•assembly
•electrical connection, including linking to a superordinate controller
•integration in a safety system
•conversion or upgrading
•set-up
•commissioning
•operation
•maintenance
•troubleshooting
•taking out of operation, dismantling and disposal
1.3
Requirements
It is assumed that operating staff are trained in safe operating practices and have
read and understood these assembly and commissioning instructions in full.

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1.4
Availability
These assembly and commissioning instructions must be available at all times to
everyone working with or on the D1-N servo drive amplifier.
1.5
Scope of validity for these assembly and commissioning instructions
These assembly and commissioning instructions apply to servo drive amplifiers
from HIWIN with the following product designations:
•D1-N-09-xx-x-x-xx
•D1-N-18-xx-x-x-xx
•D1-N-36-xx-x-x-xx
•D1-N-90-xx-x-x-xx
They also apply if two or more of the drive amplifiers listed above are combined.
1.6
Depiction of safety notices
Safety notices are always indicated using a signal word and sometimes also a sym-
bol for the specific risk (see section 1.7).
The following signal words and risk levels are used in these instructions:
DANGER!
Direct danger!
Non-compliance with the safety notices will result in serious injury or death!
WARNING!
Potentially dangerous situation!
Non-compliance with the safety notices runs the risk of serious injury or death!
CAUTION!
Potentially dangerous situation!
Non-compliance with the safety notices runs the risk of moderate to slight injury!
ATTENTION!
Potentially dangerous situation!
Non-compliance with the safety notices runs the risk of damage to property or
environmental pollution!

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1.7
Symbols used
The following signal symbols are used in these instructions:
Warning signs
Warning of dangerous, electrical voltage!
Warning of magnetic fields!
Warning of hot surfaces!
Substance hazardous to the environment!
Table 1.2: Warning signs
Signs giving orders
Wear protective gloves!
Isolate before work!
Table 1.3: Signs giving orders
Information

Note
Describes general information and recommendations.
Table 1.4: Information
1.8
Warranty and liability
The “General conditions of sale and delivery” of HIWIN GmbH apply.

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1.9
Manufacturer's details
Address
HIWIN GmbH
Brücklesbünd 2
77654 Offenburg
Tel. +49 (0) 781 / 9 32 78 - 0
Technical customer service
+49 (0) 781 / 9 32 78 - 77
Fax +49 (0) 781 / 9 32 78 - 90
Technical customer service fax
+49 (0) 781 / 9 32 78 - 97
E-mail [e-mail]
Internet www.hiwin.de
Table 1.5: Manufacturer's details
1.10
Copyright
These instructions are protected by copyright. The written consent of HIWIN GmbH
is required for reproduction, publication in part or in whole, modification or
abridgement of these instructions.
•Windows is a registered trademark of the Microsoft Corp.
•EnDat is a registered trademark of Dr. Johannes Heidenhain GmbH
•Beckhoff®, TwinCAT® and EtherCAT® are registered and licenced trade-
marks of Beckhoff Automation GmbH.
1.11
Product monitoring
As the manufacturer of the D1-N servo drive amplifier, please inform HIWIN about:
•accidents
•potential sources of risk
•misunderstandings in these assembly instructions