SBC HPD N Series User manual

HPD N
“high power”
( HPD25N, HPD35N,
HPD45N, HPD67N )
User’s Manual
rev. 8
February 2001
(software rel. 35 and later)

S.B.C. Elettronica S.p.A. - Engineering Division HPDxxN – High Power User’s Manual
2
HPD
HIGH PERFORMANCE DRIVE DIGITAL-LOCK
VARIABLE RATIO
POSITIONER
STEP MOTOR
SIMULATION
EASY
MAINTENANCE
TORQUE CONTROL
ACCELERATION
CONTROL
SPINDLE ORIENTATION
FOR TOOL CHANGING
SOFTWARE & HARDWARE
EXPANSION
RS-485 or RS-422 SERIAL LINK BUILT-IN P.L.C.
EXTENDED
VOLTAGE RANGE
M+-
X1
X2 X3
1
11
2020
10
X5
X6
X7
HPD :
everywhere
for any
application
Via Gounod, 1-Cinisello B. (MI)-Italy
tel. [phone] fax. [phone]
http://www.sbcelettronica.com
E L E T T R O N I C AE L E T T R O N I C A

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WARNING
HIGH VOLTAGE !
Certain circuits in the HPD N drive carry dangerously high voltages that could cause serious personal
injury or death.
Do not attempt to service any parts of the drive when it is connected to the power supply.
If you need to access internal parts, before working on the drive allow at least 15 minutes after
power-down to allow the DC bus capacitors to discharge. It is the User’s responsibility to make
sure that the installation is executed in accordance with established industrial health and safety
standards.
In relation to the interpretation of standards, note that the drive is considered as a component and
not as a machine.
Any tampering or unauthorised modification of the drive will invalidate the guarantee immediately.
Guarantee cover is otherwise provided for 1 (one) year.
This instruction manual is applicable to the standard version of the drive.
S.B.C. Elettronica S.p.A. declines all liability for any whatsoever form of damage caused by
inappropriate use of the drive.
Training courses can be supplied by S.B.C. Elettronica S.p.A. on request.
ISBN0102091439
Installation and maintenance of the drive and connected
equipment must be performed exclusively by qualified and
trained personnel with basic skills in electronics.
Commissioning of the drive must performed exclusively by
qualified and trained personnel with advanced skills in
electronics and drive technology.
The quoted performance of the HPD N drive is guaranteed
only when used with series MB synchronous motors
manufactured by S.B.C. Elettronica S.p.A.

S.B.C. Elettronica S.p.A. - Engineering Division HPDxxN – High Power User’s Manual
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CONTENTS:
1INTRODUCTION .............................................................................. 6
1.1 General information...................................................................................... 6
1.2 Product description....................................................................................... 6
1.3 Direct mains connection............................................................................... 7
1.4 Identification................................................................................................. 7
1.5 Main hardware characteristics...................................................................... 8
1.6 Software features.......................................................................................... 9
1.7 Compliance with EMC standards................................................................. 9
1.8 Safety............................................................................................................9
2INSTALLATION................................................................................ 10
2.1 Safety instructions........................................................................................ 10
2.2 Interference suppression hints...................................................................... 11
2.3 Installation instruction to ensure EMC......................................................... 11
2.4 Control cubicle layout example.................................................................... 13
2.5 Terminal assignments................................................................................... 14
2.6 Power connections........................................................................................ 16
2.7 Power connection layout.............................................................................. 17
2.8 Signal cable connections.............................................................................. 17
2.9 Signal cable connection layout.................................................................... 18
2.10 Frequency input connection......................................................................... 18
2.11 Encoder emulation....................................................................................... 19
2.12 Serial line connection.................................................................................. 20
2.13 Braking resistor…….................................................................................... 20
2.14 Backup......................................................................................................... 21
3PARAMETERS AND PROGRAMMING........................................ 22
3.1 Using the keypad......................................................................................... 23
3.2 Commissioning the HPD N drive.................................................................... 24
3.3 Basic parameters.......................................................................................... 27
3.4 Basic commands.......................................................................................... 31
3.5 Calibrating speed loop................................................................................. 32
3.6 Operating modes.......................................................................................... 38
3.6.1 Torque control.............................................................................................. 38
3.6.2 Acceleration control..................................................................................... 38
3.6.3 Maintenance and commissioning................................................................ 39
3.6.4 Positioner..................................................................................................... 40
3.6.5 Digital locking............................................................................................. 41
3.6.6 Stepper motor emulation............................................................................. 43
3.6.7 Spindle orientation...................................................................................... 44
3.7 Block diagrams........................................................................................... 44
3.8 Digital input and output programming....................................................... 51
3.8.1 Pico-PLC..................................................................................................... 51
3.8.2 Examples and applications ......................................................................... 56
3.9 Programming with Pcbrush ........................................................................ 73

S.B.C. Elettronica S.p.A. - Engineering Division HPDxxN – High Power User’s Manual
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4SERIAL INTERFACE ..................................................................... 74
4.1 Communication protocol ............................................................................ 74
4.2 Serial addresses and parameter lengths ...................................................... 79
APPENDIXES
AHPD N drive mechanical dimensions .............................................................. 81
BMB series motor connectors .......................................................................... 82
CHardware characteristics ............................................................................... 83
DDC bus voltage thresholds ............................................................................ 84
EStandard settings ........................................................................................... 84
FSoftware timers .............................................................................................84
GPico-PLC default program ............................................................................ 85
HFlash information .......................................................................................... 86
IRemote communications interface …............................................................ 87
LApplication description form ........................................................................ 88

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1 - INTRODUCTION
1.1 General information
This manual describes operations required for the installation and commissioning of the high
power family HPD N (High Performance Drive – New series with extended maximum voltage
range) drive for brushless motors. Read all chapters of the manual carefully before using the drive.
Changes.
Upgraded to “N” standard. New resolver’s cable specification.
1.2 Product description
The HPD N drive is a digital frequency converter for driving AC brushless motors. The adoption
of a Parametric Operator Interface makes drive configuration procedures faster and easier to repeat.
The large number of configuration possibilities makes the drive suitable for numerous applications.
A high power 16 bit micro-controller allows speed control with the characteristics required of a
servo controller, plus a range of auxiliary functions that can help reduce the presence of control
electronics in the application and thus permit considerable economic savings.
In addition to the positioner functions with Trapezoidal Profile, Digital Lock, Spindle
Orientation, Stepper Motor Emulation, Torque Control and Acceleration Control, the HPD
N drive also has an internal pico-PLC. The pico-PLC adopts the most diffused industrial
programming standards and offers considerable freedom for use of inputs and outputs. It also
enables users to develop a range of additional functions that are not among the basic features of the
drive.
The HPD N drive is complete with an RS-422/RS-485 Serial Interface which can be used for
configuration, monitoring, or simultaneous transmission of commands to a multiple system comprising
up to 32 HPD N drives.
In addition to the above functionality, the HPD N drive is designed as an open system with the
facility to accommodate hardware and software expansion cards. For further information on
currently available expansion cards contact S.B.C. Elettronica directly or your Local Dealer.

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1.3 Direct mains connection
The HPD N series of drives is specifically designed for direct connection to a three-phase mains
power supply from 90 to 480V~ 50/60 Hz, without interposing transformers. It is the responsibility
of the User to connect the system via protection fuses.
The HPD N require an auxiliary voltage (220V~, single phase) for the internal control circuits.
All protections required for safety, such as overvoltage detection, short circuit fault protection and
inverter and motor overtemperature detection are integral with the drive.
To simplify the design of electrical cubicle, the HPD N has inside a filter (mains and motor) to
meet the EMC standards. In order to qualify your machine for CE marking, adhere scrupulously to
specification on next chapters.
The presence of internal filter MAY generate undesired interventions of differential-switches: in
these cases change the set-point of differential-switch or even eliminate it!
Chapter 2 provides a detailed view of problems related to EMC.
N.B. leave at least 60 sec. after switching the drive off before
switching it on again.
1.4 Identification
HPD N High Power Drives are available in four models: HPD25N, HPD35N, HPD45N and
HPD67N. The number that follows HPD is the value of drive rated current in amperes.
HPD N drives carry an identification plate on the right hand side
showing all essential information for correct identification of the
unit.
Make a note of the information on this plate before
consulting S.B.C. on technical matters.
model identification plate

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1.5 Main hardware specifications
Parameter u.m. Value
Mains voltage V ~90..480
Auxiliary single-phase voltage V ~220 +20 % -10 %
EMC motor filter included
EMC main filter included
Models HPD
25N HPD 35N HPD 45N HPD 67N
Rated current A25 35 45 67
Peak current (30 Secs.) * A50 53 67 100
Output Power (400 V~) KW 12,5 17 22 33
Control electronics dissipation W30
Dissipation from power
components W250 297 370 470
Ambient temperature oC45
Braking Resistors internal / external
Rated power of braking resistors W400
Feedback resolver
Power stage switching frequency kHz 8
Maximum output frequency Hz 450
Protection category IP 20
Digital inputs 24V= No8
Digital outputs 24V= 100mA NPN No6
Voltage-free digital outputs No1
Encoder emulation RS-422 steps/rev 128..16384
Frequency / Sign OR encoder input kHz 800 / 200
Analogue reference V±10 diff 15 bit
Auxiliary analogue input V±10 diff 10 bit
Auxiliary analogue output V±10 - 8 bit
Tacho generator emulation output V±10 V
Serial line RS-422 / RS-485
Backup for encoder emulation V= 24V/2A
* The Overload Time for HPD25N is 4 Seconds.

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1.6 Software features
The following capabilities are implemented in the basic software supplied with the HPD N drive:
•Speed control
•Advanced torque limit manager
•Speed windows management
•Positioning with trapezoidal speed profile
•Digital locking functions with variable transmission ratio and phase shifting
•Spindle orientation
•Stepper motor emulation
•Torque control with overlaid speed control
•Acceleration ramp control with overlaid speed control
•Simplified maintenance and start-up mode
•Internal PLC for advanced input/output programming functions
1.7 Compliance with EMC standards
Immunity:
EN50082-2 Basic immunity specifications
IEC1000-4-2 (ex IEC 801-2) level 3 Electrostatic discharge immunity
IEC1000-4-3 (ex IEC 801-3) level 3 Electromagnetic field immunity
IEC1000-4-4 (ex IEC 801-4) level 4 Fast transient burst conducted immunity
Compatibility:
EN50081-2 Basic radio interference specifications
EN55011 group 1, class A Measurement limits for radio interference
1.8 Safety
Safety standard EN60065
Low voltage Directive 73/23/CEE amended by 93/68/CEE
Applied standard EN60204-1

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2 - INSTALLATION
•The HPD N drive must be installed in a vertical position (power terminal block X4 at the top).
•Leave at least 190 mm clearance above and below the drive.
2.1 Safety instructions
•Make sure the drive is correctly sized for the motor you intend to connect. Compare rated
voltage and current.
•Wire up electrical panel/drive/motor in accordance with the instructions in this section of the
manual, taking into consideration EMC requirements and established safety legislation.
•The User is responsible for installing fuses on the drive A.C. power supply.
•Power conductors and control circuits must be kept apart (at least 20 cm) and, when they must
cross, intersections must be at a right angle. Motor lines and mains power lines must never be
parallel.
•All power conductors must be sufficiently sized (refer to table in heading 2.7; in all cases
compliance with IEC227-2 must be guaranteed).
•Conductors connected to the system by means of the terminal strip must not be soldered
(EN60065, art.15.3.5).
•Make sure drive and motor and properly earthed.
•Make sure that the maximum voltage on terminals L1, L2, L3 does not exceed rated voltage by
more than 10% in the worst possible case (see EN60204-1, section 4.3.1). Excessively high
mains feeding voltage can damage the drive.
•Do not detach electrical connections when the drive is connected to the power supply.
•Follow all installation instructions in this manual step by step. If you are in doubt, contact S.B.C.
customer service.
•Dangerous voltages may remain for 60 seconds after mains disconnection and system power-
down; do not touch power cables during this interval.
•Do not open the drive casing. This action is potentially dangerous and will automatically invalidate
the guarantee.
Installation and wiring must be carried out with the entire electrical panel
disconnected from the power supply. Make sure that the drive enable
command is disconnected from the emergency circuit. Qualified
technical personnel must preside when the power panel is powered up for
the first time.

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2.2 Interference suppression hints
Because of the high speed voltage wavefronts in PWM, high levels of stray current may
sometimes flow through capacitive couplings and earth systems. Stray currents of this type can affect
other functional units. It is therefore prudent to calculate the presence of an amount of spurious
energy that depends on the size of the system (drives, motor lines, motor). Spurious energy generates
EM radiation that can interfere with the operation of nearby systems. Existing standards do not set
down limits for this type of radiation.
Preventive measures
Basic methods for preventing interference are: decoupling of drive from its surroundings, high
quality and properly sized conductors to neutralise voltages (earthing), and adequate shielding.
Shields, filters and drives must have a large contact area to achieve the maximum possible decoupling
and hence optimal noise suppression. Attention must be paid, however, to the entire installation, as
this is one of the most important precautions in assuring efficient noise suppression.
High frequency interference takes the form of radiation, especially from the motor lines. This
effect can be reduced with the use of shielding.
Another essential counter-measure for noise suppression is the use of filters.
The use of filters is aimed at reducing conducted interference on wiring and the return of
conducted interference to source (drive) through routes offering the lowest impedance. This method
provides effective protection for other systems connected to the same electrical line, also protecting
the drive from interference originating from other systems. When installing filters consider the mains
input and motor feeding output; the motor feeding output can be protected with output filters that
minimise interference levels (generally torroidal ferrite core coils bearing several windings of all three
motor wires).
2.3 Installation instructions to ensure EMC
To guarantee electromagnetic compatibility in compliance with the relevant standards the
maximum priority must be awarded to EMC requirements when designing the control cubicle. To
obtain the best results from internal filters follow the instructions in this section carefully, because
Avoid:
- routing noise emitting cables parallel to “clean” cables
- parallel cables, especially in the vicinity of the filter (ensure physical separation)
- cable loops (keep cables as short as possible and close to the common potential).
even a complex and expensive filter is ineffective unless it is
installed taking EMC aspects into consideration !

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Additional measures
- With the exception of mains cables to the filter, all power and control wiring must be shielded
and, wherever possible, kept segregated (minimum distance 20 cm). If control and power cables
must cross, the intersection must be at a right angle.
- Shielded cables must be installed on a copper bar by means of a high conductivity wire clamp.
The area of contact must be as large as possible and the shield must be unbroken. In general the
shield should be connected at each extremity. In certain circumstances, however, control cable
shields may be connected only at one end to eliminate mains hum that could interfere with the control
signal. Decide case by case as numerous factors must be considered. Adopt the following general
approach: if the shield is solely for shielding, connect at both ends. If current flowing in the shield
interferes with the shielded signals, connect at one end only.
- The incoming cable must be connected to an earth terminal by means of a screw to ensure
proper contact between shield and earth.
- RF interference suppression filters must be installed as close as possible to the drive and must
have a large area of contact with the power panel or the baseplate. Remove all paint. The filter earth
terminal must be connected to the earth bar along the shortest possible route.
- As far as possible keep the power side (drive) and control side (PLC or NC) physically
separated by separating the metal mounting plates. Do not route any cables through the mounting
plates.
Protective measures for drives with > 3.5mA dispersion current per phase
Interference currents dispersed through the earth system may be considerable in certain
conditions. Therefore, make sure all suppression filters are properly earthed before they are
connected. Cable sizes must be in line with the requirements of safety standards.
If a suppression filter is permanently connected and current dispersion during normal operation is
greater than 3.5mA (which would be expected with most drives) adopt one of the following
measures additionally:
a) Increase shield size to at least 10 mm².
b) Install a detection system to monitor the shield and automatically disconnect the drive in the
presence of faults.
c) Install a second conductor in parallel (electrically) with the shield using separate terminals.

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2.4 Control cubicle layout example
All conductors down-line of the mains filter
must be shielded and mounted to a copper
bar with large contact area.
Also the copper bar must present an ample
area of contact with the cubicle mounting plate.
Large surface area partition shield with
generous contact area around perimeter.
Remove paint from contact points in the cubicle.
POWER CONTROL
HPD
Cubicle interior or mounting plate
control
cable
mains
cable
max.
30 cm
cable
motor
keep separate as far as possible

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2.5 Terminal assignments
Resolver
Serial Interface
Encoder in
Encoder out
Analogue Signals and
Aux Voltages and Digital Inputs
power connections
R1 C1 R2 C2
AB BB-DCBUS
220Vac
L1 L2 L3 UVW
PE
X4
Digital Outputs

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Terminal board X1 Terminal board X4
1motor PTC + ( 24 V ) L1 live 1
2motor PTC - L2 live 2
3resolver Excit. high L3 live 3
4resolver Excit. low Umotor, phase
5resolver Sin high Vmotor, phase
6resolver Sin low Wmotor, phase
7resolver Cos high AB
8resolver Cos low BB
90 V -DC BUS
10 0 V R1
C1
R2
C2
220V~ AUX aauxiliary voltage
220V~ AUX bauxiliary voltage
Terminal board X2 Terminal board X3
1reference high 1+ 10V= / 10 mA max
2reference low 20 V
30 V 3- 10 V / 10 mA max
4Aux reference high 40 V
5Aux reference low 5+ 24 V (Input)
60 V 60 V
7Aux. analogue output 70 V
80 V 8+ V backup
9tacho output 9- V backup
10 0 V 10 0 V
11 digital out 0 11 drive enable
12 digital out 1 12 digital input 1
13 digital out 2 13 digital input 2
14 digital out 3 14 digital input 3
15 digital out 4 15 digital input 4
16 digital out 5 16 digital input 5
17 digital out 6 A 17 digital input 6
18 digital out 6 B 18 digital input 7
19 + 24 V - OUT 200 mA 19 + 24 V - OUT 200 mA
20 0 V 20 0 V
X5 (DB9 female) X6 (DB9 female) X7 (DB9 male)
1TX 1A1PHA
2RX 2 /A 2 /PHA
3/TX 3B3PHB
4/RX 4/B 4/PHB
5- 5-BRA 5PHC
6+BR 6+BRB 6/PHC
7-BR 70 V 70 V
80 V 8-BRB 8
90 V 9+BRA 9

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2.6 Power connections
For the motor cable consider
Choice between cable for fixed or floating installation.
Cable must be shielded and suitably sized in terms of insulation and wire sections.
Reticulated polypropylene is the preferred insulation material.
Length (max 100 m); note that conductor-conductor capacitance must not exceed 8 nF.
If cable length exceeds 50 m install a triple 1 mH inductance between drive and motor with rated
current identical to HPD N rated current.
Minimum conductor size is 6 mm2for l’HPD25N, 8 mm2for HPD35N, 12 mm2for HPD45N
and 16 mm2for HPD67N.
For the mains power cable
Power cables must not be shielded.
Minimum conductor size is 6 mm2for l’HPD25N, 8 mm2for HPD35N, 12 mm2for HPD45N
and 16 mm2for HPD67N.
Input fuses must be rated as follows:
MODEL Slow blow fuses (A)
HPD25N 50
HPD35N 50
HPD45N 75
HPD67N 100
Resolver cable
The cable must comprise 4 twisted pairs with individual insulated shields and one common shield.
Capacitance for the length of cable must not exceed 10 nF; wire size must be no less than
0.35mm2.
Maximum length is 100 m.
Earth connections
To reduce the length of individual conductors that must be connected to earth we recommend
using an earth busbar located as near as possible to the drive.
The busbar must be made of copper to
ensure low inductance. It must also be
mounted on insulated fixings. The adjacent
table shows minimum dimensions according to
length.
Length (m) width (mm) thickness
(mm)
0.5 20 8
1 40 8
1.5 50 8

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2.7 Power connection layout
A
BC
D
X4
MAINS
MOTOR
EARTH
STUD
A
B
C
DEF
RESOLVER
1
10
X1
E
JK
GH
PE
220 V~
L1
L2
L3
U
V
W
AB
BB
-DCBUS
R1
C1
R2
C2
SERVOMOTOR HPD DRIVE
2
3
4
5
6
7
8
9
2.8 Signal cable connections
A twisted and shielded pair must be employed for the analogue reference.
The cable for emulated encoder signals must comprise three twisted pairs with a common shield.
Normal cables could be used for digital inputs/outputs.
Minimum size of all signal wires is 0.35mm2

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2.9 Signal cable connection layout
CONTROLLER HPD
REF+
REF-
A
/A
B
/B
C
/C
2
3X2 -
Reference in
1
1
2
3
4
5
6
7
X7 -
Encoder out
24Vdc
19
11
13 X3 -Inputs
11 X2 -Outputs
TO EARTH BAR
20
MOTION
Encoder in
Output
Enable
Input
Reference out
2.10 Frequency input connection
The RS-422 type frequency input can be software-configured in two modes: the first (default) to
accept quadrature signals from encoders, the second is frequency/direction mode (see chapter Basic
parameters bit b42.5).
In the former case follow this connection diagram:
7
1
0V
2
3
4
X6
8
6
5
9
HPD
A
A
B
B
In the case of parallel connections to more than one HPD N, connections to pins 9, 5, 6, and 8,
must be made only on the last drive in the group.

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If the frequency/direction mode configuration is adopted, channel A is dedicated to frequency
while channel B handles direction. Frequently, a 24V interface is preferred to an RS-422 serial port.
The conversion can be implemented on the external connector by following this wiring diagram:
1
2
3
4
5
6
7
8
9
+24V=
X6
DIR
PULSES
3K93K9
470 470
2K2
2K2
HPD N connection with digital locking
1
2
3
4
7
X6 (HPD)
X6 (HPD)
master
A
A
B
B
GND
1
2
3
4
7
X7 (HPD)
see text for burden resistors
The example in the figure shows the connection between two HPD N drives in digital lock with a
master, but this configuration can be extended to several drives connected in series. On the final
drive in the series connect the burden resistors by jumpering pin 1 with pin 9, pin 2 with pin 5, pin 3
with pin 6 and pin 4 with pin 8 on connector X6. The master can be an externally fed encoder, or the
simulated encoder output on another drive.
The signal from the master encoder must be differential type 5V RS-422; it is therefore possible
to connect a maximum of 10 slave HPDNs.
If the master is an HPD N drive, then up to 32 units can be connected in digital lock mode using
the same simulated encoder signal (RS-422 standard).
For the relative programming of the HPD N, consult the Digital locking chapter in this manual.
2.11 Encoder emulation
On connector X7 there are signals of encoder emulation phase A, phase B and phase C
(reference zero). The signals are RS-422 type. For the relative programming of pulses per revolution
consult the Basic parameters chapter in this manual, bit b42.0, b42.1 and b42.2 (default = 1024
pulses/revolution).

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2.12 Serial line connection
The HPD N drive serial line can be configured as RS-422 or RS-485 depending on the
connection. In both cases termination resistors must be used (150 Ω). Where more than one HPD
N drive is connected to the bus the final node must be terminated as shown below. The two cases
are illustrated in the following diagrams.
TX
RX
/TX
/RX
+BR
-BR
0 V
0 V
MASTER
RS-485
X5 X5 X5
NODE 1 NODE n LAST NODE
TX
RX
/TX
/RX
+BR
-BR
0 V
0 V
RS-422
MASTER X5 X5 X5
NODE 1 NODE n LAST NODE
2.13 Braking resistor
HPD N drives are equipped with an integrated braking resistor. The effective use of the braking
resistor can be checked by monitoring the value of parameter Pr37, which is expressed as a
percentage. If you intend to dissipate more power, use two external braking resistors. To connect up
the system (which must be carried out in conditions of complete safety) disconnect the jumper
between terminals R1 C1 and R2 C2 of terminal board X4; connect one resistor between AB and
C1 and the other between BB and C2 on X4. The external resistor value must be 40 ohm and a
thermal magnetic circuit breaker must be installed between resistor and drive. The minimum wire size
for the connection is 4 mm2; the connection cables should be as short as possible and, in any event,
no longer than 3 metres.