Omron SMARTSTEP R7D-AP Series User manual

Servomotors/Servo Drivers
Cat. No. I533-E1-04
SMARTSTEP A SERIES
R7M-A@(Servomotors)
R7D-AP@(Servo Drivers)
USER’S MANUAL

Thank you for choosing this SMARTSTEP A-series product. Proper use and handling
of the product will ensure proper product performance, will lengthen product life, and
may prevent possible accidents.
Please read this manual thoroughly and handle and operate the product with care.
Please keep this manual handy for reference after reading it.
1.To ensure safe and proper use of the OMRON Inverters, please read this USER'S MANUAL (Cat. No.
I533-E1) to gain sufficient knowledge of the devices, safety information, and precautions before actual
use.
2.The products are illustrated without covers and shieldings for closer look in this USER'S MANUAL. For
actual use of the products, make sure to use the covers and shieldings as specified.
3.This USER'S MANUAL and other related user's manuals are to be delivered to the actual end users of the
products.
4.Please keep this manual close at hand for future reference.
5.If the product has been left unused for a long time, please inquire at our sales representative.
Items to Check Before Unpacking
1.Check the following items before removing the product from the package:
• Has the correct product been delivered (i.e., the correct model number and specifications)?
• Has the product been damaged in shipping?
2.Check that the following accessories have been delivered.
• Safety Precautions
No connectors or mounting screws are provided. Obtain these separately.
NOTICE
1.This manual describes information about installation, wiring, switch setting, and troubleshooting of the
SMARTSTEP A-series Servomotors and Servo Drivers. For information about actual operating proce-
dures using a Parameter Unit, refer to the SMARTSTEP A Series Operation Manual (I534).
2.Be sure that this manual accompanies the product to its final user.
3.Although care has been given in documenting the product, please contact your OMRON representative
if you have any suggestions on improving this manual.
4.Assume that anything not specifically described in this manual is not possible.
5.Do not allow the Servomotor or Servo Driver to be wired, set, or operated (from a Parameter Unit) by
anyone that is not a profession electrical engineer or the equivalent.
6.We recommend that you add the following precautions to any instruction manuals you prepare for the
system into which the product is being installed.
• Precautions on the dangers of high-voltage equipment.
• Precautions on touching the terminals of the product even after power has been turned OFF. (These
terminals are live even with the power turned OFF.)
7.Specifications and functions may be changed without notice in order to improve product performance.
8.Positive and negative rotation of AC Servomotors described in this manual are defined as looking at the
end of the output shaft of the motor as follows: Counterclockwise rotation is positive and clockwise rota-
tion is negative.
9.Do not perform withstand-voltage or other megameter tests on the product. Doing so may damage inter-
nal components.
10.Servomotors and Servo Drivers have a finite service life. Be sure to keep replacement products on hand
and to consider the operating environment and other conditions affecting the service life.
11.Do not set values for any parameters not described in this manual. Operating errors may result. Consult
your OMRON representative if you have questions.
12.Before using the product under conditions which are not described in the manual or applying the product
to nuclear control systems, railroad systems, aviation systems, vehicles, combustion systems, medical
equipment, amusement machines, safety equipment, and other systems, machines, and equipment that
may have a serious influence on lives and property if used improperly, consult your OMRON represen-
tative.

USER’S MANUAL
SMARTSTEP ASERIES
MODELS R7M-A@(Servomotors)
R7D-AP@(Servo Drivers)
Servomotors/Servo Drivers

Notice:
OMRON products are manufactured for use according to proper procedures by a qualified operator
and only for the purposes described in this manual.
The following conventions are used to indicate and classify precautions in this manual. Always heed
the information provided with them. Failure to heed precautions can result in injury to people or dam-
age to property.
!DANGER Indicates an imminently hazardous situation which, if not avoided, will result in
death or serious injury. Additionally, there may be severe property damage.
!WARNING Indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury. Additionally, there may be severe property damage.
!Caution Indicates a potentially hazardous situation which, if not avoided, may result in
minor or moderate injury, or property damage.
OMRON Product References
All OMRON products are capitalized in this manual. The word “Unit” is also capitalized when it refers to
an OMRON product, regardless of whether or not it appears in the proper name of the product.
The abbreviation “Ch,” which appears in some displays and on some OMRON products, often means
“word” and is abbreviated “Wd” in documentation in this sense.
The abbreviation “PC” means Programmable Controller and is not used as an abbreviation for anything
else.
Visual Aids
The following headings appear in the left column of the manual to help you locate different types of
information.
Note Indicates information of particular interest for efficient and convenient operation of the product.
OMRON, 2001
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form, o
r
by any means, mechanical, electronic, photocopying, recording, or otherwise, without the prior written permission o
f
OMRON.
No patent liability is assumed with respect to the use of the information contained herein. Moreover, because OMRON is con-
stantly striving to improve its high-quality products, the information contained in this manual is subject to change without
notice. Every precaution has been taken in the preparation of this manual. Nevertheless, OMRON assumes no responsibility
for errors or omissions. Neither is any liability assumed for damages resulting from the use of the information contained in
this publication.

General Warnings
Observe the following warnings when using the SMARTSTEP Servomotor and Servo Driver and all
connected or peripheral devices.
This manual may include illustrations of the product with protective covers removed in order to
describe the components of the product in detail. Make sure that these protective covers are on the
product before use.
Consult your OMRON representative when using the product after a long period of storage.
!WARNING Always connect the frame ground terminals of the Servo Driver and the Servomo-
tor to a class-3 ground (to 100 Ωor less). Not connecting to a class-3 ground may
result in electric shock.
!WARNING Do not touch the inside of the Servo Driver. Doing so may result in electric shock.
!WARNING Do not remove the front cover, terminal covers, cables, or optional items while the
power is being supplied. Doing so may result in electric shock.
!WARNING Installation, operation, maintenance, or inspection must be performed by autho-
rized personnel. Not doing so may result in electric shock or injury.
!WARNING Wiring or inspection must not be performed for at least five minutes after turning
OFF the power supply. Doing so may result in electric shock.
!WARNING Do not damage, press, or put excessive stress or heavy objects on the cables.
Doing so may result in electric shock.
!WARNING Do not touch the rotating parts of the Servomotor in operation. Doing so may
result in injury.
!WARNING Do not modify the product. Doing so may result in injury or damage to the product.
!WARNING Provide a stopping mechanism on the machine to ensure safety. The holding
brake is not designed as a stopping mechanism for safety purposes.
!WARNING Provide an external emergency stopping mechanism that can stop operation and
shutting off the power supply immediately. Not doing so may result in injury.
!WARNING Do not come close to the machine immediately after resetting momentary power
interruption to avoid an unexpected restart. (Take appropriate measures to secure
safety against an unexpected restart.) Doing so may result in injury.
!Caution Use the Servomotors and Servo Drivers in a specified combination. Using them
incorrectly may result in fire or damage to the products.

!Caution Do not store or install the product in the following places. Doing so may result in
fire, electric shock, or damage to the product.
• Locations subject to direct sunlight.
• Locations subject to temperatures or humidity outside the range specified in the
specifications.
• Locations subject to condensation as the result of severe changes in tempera-
ture.
• Locations subject to corrosive or flammable gases.
• Locations subject to dust (especially iron dust) or salts.
• Locations subject to shock or vibration.
• Locations subject to exposure to water, oil, or chemicals.
!Caution Do not touch the Servo Driver radiator, Servo Driver regeneration resistor, or Ser-
vomotor while the power is being supplied or soon after the power is turned OFF.
Doing so may result in a skin burn due to the hot surface.
Storage and Transportation Precautions
!Caution Do not hold the product by the cables or motor shaft while transporting it. Doing so
may result in injury or malfunction.
!Caution Do not place any load exceeding the figure indicated on the product. Doing so
may result in injury or malfunction.
Installation and Wiring Precautions
!Caution Do not step on or place a heavy object on the product. Doing so may result in
injury.
!Caution Do not cover the inlet or outlet ports and prevent any foreign objects from entering
the product. Doing so may result in fire.
!Caution Be sure to install the product in the correct direction. Not doing so may result in
malfunction.
!Caution Provide the specified clearances between the Servo Driver and the control panel
or with other devices. Not doing so may result in fire or malfunction.
!Caution Do not apply any strong impact. Doing so may result in malfunction.
!Caution Be sure to wire correctly and securely. Not doing so may result in motor runaway,
injury, or malfunction.

!Caution Be sure that all the mounting screws, terminal screws, and cable connector
screws are tightened to the torque specified in the relevant manuals. Incorrect
tightening torque may result in malfunction.
!Caution Use crimp terminals for wiring. Do not connect bare stranded wires directly to ter-
minals. Connection of bare stranded wires may result in burning.
!Caution Always use the power supply voltage specified in the User’s Manual. An incorrect
voltage may result in malfunction or burning.
!Caution Take appropriate measures to ensure that the specified power with the rated volt-
age and frequency is supplied. Be particularly careful in places where the power
supply is unstable. An incorrect power supply may result in malfunction.
!Caution Install external breakers and take other safety measures against short-circuiting in
external wiring. Insufficient safety measures against short-circuiting may result in
burning.
!Caution Take appropriate and sufficient countermeasures when installing systems in the
following locations. Failure to do so may result in damage to the product.
• Locations subject to static electricity or other forms of noise.
• Locations subject to strong electromagnetic fields and magnetic fields.
• Locations subject to possible exposure to radioactivity.
• Locations close to power supplies.
Operation and Adjustment Precautions
!Caution Confirm that no adverse effects will occur in the system before performing the test
operation. Not doing so may result in equipment damage.
!Caution Check the newly set parameters and switches for proper execution before actually
running them. Not doing so may result in equipment damage.
!Caution Do not make any extreme adjustments or setting changes. Doing so may result in
unstable operation and injury.
!Caution Separate the Servomotor from the machine, check for proper operation, and then
connect to the machine. Not doing so may cause injury.
!Caution When an alarm occurs, remove the cause, reset the alarm after confirming safety,
and then resume operation. Not doing so may result in injury.
!Caution Do not use the built-in brake of the Servomotor for ordinary braking. Doing so may
result in malfunction.

Maintenance and Inspection Precautions
!WARNING Do not attempt to disassemble, repair, or modify any Units. Any attempt to do so
may result in malfunction, fire, or electric shock.
!Caution Resume operation only after transferring to the new Unit the contents of the data
required for operation. Not doing so may result in an unexpected operation.

Warning Labels
Warning labels are pasted on the product as shown in the following illustration. Be sure to follow the
instructions given there.
Warning label
Example from R7D-AP01L
Example from R7D-AP01L

Read and Understand this Manual
Please read and understand this manual before using the product. Please consult your OMRON
representative if you have any questions or comments.
Warranty and Limitations of Liability
WARRANTY
OMRON's exclusive warranty is that the products are free from defects in materials and workmanship for a
period of one year (or other period if specified) from date of sale by OMRON.
OMRON MAKES NO WARRANTY OR REPRESENTATION, EXPRESS OR IMPLIED, REGARDING NON-
INFRINGEMENT, MERCHANTABILITY, OR FITNESS FOR PARTICULAR PURPOSE OF THE
PRODUCTS. ANY BUYER OR USER ACKNOWLEDGES THAT THE BUYER OR USER ALONE HAS
DETERMINED THAT THE PRODUCTS WILL SUITABLY MEET THE REQUIREMENTS OF THEIR
INTENDED USE. OMRON DISCLAIMS ALL OTHER WARRANTIES, EXPRESS OR IMPLIED.
LIMITATIONS OF LIABILITY
OMRON SHALL NOT BE RESPONSIBLE FOR SPECIAL, INDIRECT, OR CONSEQUENTIAL DAMAGES,
LOSS OF PROFITS OR COMMERCIAL LOSS IN ANY WAY CONNECTED WITH THE PRODUCTS,
WHETHER SUCH CLAIM IS BASED ON CONTRACT, WARRANTY, NEGLIGENCE, OR STRICT
LIABILITY.
In no event shall the responsibility of OMRON for any act exceed the individual price of the product on which
liability is asserted.
IN NO EVENT SHALL OMRON BE RESPONSIBLE FOR WARRANTY, REPAIR, OR OTHER CLAIMS
REGARDING THE PRODUCTS UNLESS OMRON'S ANALYSIS CONFIRMS THAT THE PRODUCTS
WERE PROPERLY HANDLED, STORED, INSTALLED, AND MAINTAINED AND NOT SUBJECT TO
CONTAMINATION, ABUSE, MISUSE, OR INAPPROPRIATE MODIFICATION OR REPAIR.

Application Considerations
SUITABILITY FOR USE
OMRON shall not be responsible for conformity with any standards, codes, or regulations that apply to the
combination of products in the customer's application or use of the products.
At the customer's request, OMRON will provide applicable third party certification documents identifying
ratings and limitations of use that apply to the products. This information by itself is not sufficient for a
complete determination of the suitability of the products in combination with the end product, machine,
system, or other application or use.
The following are some examples of applications for which particular attention must be given. This is not
intended to be an exhaustive list of all possible uses of the products, nor is it intended to imply that the uses
listed may be suitable for the products:
• Outdoor use, uses involving potential chemical contamination or electrical interference, or conditions or
uses not described in this manual.
• Nuclear energy control systems, combustion systems, railroad systems, aviation systems, medical
equipment, amusement machines, vehicles, safety equipment, and installations subject to separate
industry or government regulations.
• Systems, machines, and equipment that could present a risk to life or property.
Please know and observe all prohibitions of use applicable to the products.
NEVER USE THE PRODUCTS FOR AN APPLICATION INVOLVING SERIOUS RISK TO LIFE OR
PROPERTY WITHOUT ENSURING THAT THE SYSTEM AS A WHOLE HAS BEEN DESIGNED TO
ADDRESS THE RISKS, AND THAT THE OMRON PRODUCTS ARE PROPERLY RATED AND
INSTALLED FOR THE INTENDED USE WITHIN THE OVERALL EQUIPMENT OR SYSTEM.
PROGRAMMABLE PRODUCTS
OMRON shall not be responsible for the user's programming of a programmable product, or any
consequence thereof.

Disclaimers
CHANGE IN SPECIFICATIONS
Product specifications and accessories may be changed at any time based on improvements and other
reasons.
It is our practice to change model numbers when published ratings or features are changed, or when
significant construction changes are made. However, some specifications of the products may be changed
without any notice. When in doubt, special model numbers may be assigned to fix or establish key
specifications for your application on your request. Please consult with your OMRON representative at any
time to confirm actual specifications of purchased products.
DIMENSIONS AND WEIGHTS
Dimensions and weights are nominal and are not to be used for manufacturing purposes, even when
tolerances are shown.
PERFORMANCE DATA
Performance data given in this manual is provided as a guide for the user in determining suitability and does
not constitute a warranty. It may represent the result of OMRON's test conditions, and the users must
correlate it to actual application requirements. Actual performance is subject to the OMRON Warranty and
Limitations of Liability.
ERRORS AND OMISSIONS
The information in this manual has been carefully checked and is believed to be accurate; however, no
responsibility is assumed for clerical, typographical, or proofreading errors, or omissions.

Table of Contents
Chapter 1. Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-1 Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-2 System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1-3 Servo Driver Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
1-4 Applicable Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1-5 System Block Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
Chapter 2. Standard Models and Specifications. . . . . . . . . . . . . . . . 2-1
2-1 Standard Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2-2 External and Mounted Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2-3 Servo Driver Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
2-4 Servomotor Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
2-5 Reduction Gear Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
2-6 Cable and Connector Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
2-7 Servo Relay Units and Cable Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58
2-8 Parameter Unit Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-111
2-9 External Regeneration Resistor Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-113
2-10 DC Reactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-114
Chapter 3. System Design and Installation . . . . . . . . . . . . . . . . . . . . 3-1
3-1 Installation Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3-2 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3-3 Regenerative Energy Absorption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
Chapter 4. Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4-1 Operational Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4-2 Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4-3 Preparing for Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4-4 Trial Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4-5 Gain Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4-6 User Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
4-7 Operating Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Chapter 5. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5-1 Measures when Trouble Occurs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5-2 Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5-3 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5-4 Overload Characteristics (Electron Thermal Characteristics) . . . . . . . . . . . . . . . . . . . . . . . . 5-15
5-5 Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Chapter 6. Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6-1 Connection Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R-1

Chapter 1
Introduction
1-1 Features
1-2 System Configuration
1-3 Servo Driver Nomenclature
1-4 Applicable Standards
1-5 System Block Diagrams

Chapter 1
1-2
Introduction
1-1 Features
The SMARTSTEP A-series Servomotors and Servo Drivers have been developed as pulse string
input-type Position Controllers to replace stepping motors in simple positioning systems. The
SMARTSTEP A-series Servomotors and Servo Drivers combine the stepping motor’s ease of use
with faster positioning resulting from high speed and high torque, higher reliability with no loss of
positioning accuracy even during sudden load changes, and other advanced features.
■Faster Response and Rotation Speed
SMARTSTEP A-series Servomotors and Servo Drivers incorporate the same high-speed and high-
torque features, unachievable with stepping motors, as the OMNUC W Series. The SMARTSTEP A-
series Servomotors provide faster rotation speeds of up to 4,500 r/min, with constant operation pos-
sible at this speed. Faster output torque of up to 1 s can output up to approximately 300% of the
rated torque, providing even faster middle- and long-stroke positioning.
■Constant Accuracy
The A-series product line’s higher encoder resolution of 2,000 pulses/rotation provides feedback
control enabling continuous operation without loss of positioning accuracy, even with sudden load
changes or sudden acceleration or deceleration.
■Minimal Setting with Servo Driver Front Panel Switches
The SMARTSTEP A Series can be operated immediately without time-consuming parameter setting.
The A-series Servo Drivers’ front panel switches enable easier alteration of function or positioning
resolution settings.
●Resolution Settings
SMARTSTEP A-series Servomotor resolution can be selected from the following four levels:
500 pulses/rotation (0.72°/step); 1,000 pulses/rotation (0.36°/step) (default setting); 5,000 pulses/
rotation (0.072°/step); or 10,000 pulses/rotation (0.036°/step)
●Command Pulse Input Setting
SMARTSTEP A-series command pulse input setting can be switched between CW/CCW (2-pulse)
and SIGN/PULS (single-pulse) methods to easily adapt to Position Controller output specifica-
tions.
●Dynamic Brake Setting
SMARTSTEP A-series Servomotors can be forcibly decelerated to a stop at RUN OFF or when
an alarm occurs.
●Gain Setting
A special rotary switch on SMARSTEP A-series Servo Drivers enables easy gain setting. Online
autotuning can also be activated with the flick of a switch, and responsiveness can be easily
matched to the machinery to be used.