SYNAPTICON SOMANET Circulo User manual

Installation Guide
Documentation v 4.20.15 | Built 2022-08-17
© 2021 Synapticon GmbH

Table of Contents
1 Installation Guide
1.1 Wiring instructions
1.1.1 Power and brake
1.1.1.1 Supply and phases
1.1.1.1.1 Warning about using contactors behind the power supply
1.1.1.1.1.1 Functional Earth
1.1.1.2 Connecting a brake
1.1.2 Encoders and IO
1.1.2.1 Encoder overview
1.1.2.2 Analog Input
1.1.2.3 Encoder ports
1.1.2.3.1 Encoder port 1
1.1.2.3.2 Encoder port 2
1.1.2.4 Digital IO
1.1.2.4.1 Voltage Levels of the Digital Inputs/Outputs
1.1.2.5 EtherCAT / STO-SBC IN & OUT
1.1.2.5.1 Voltage level of the Safety Inputs
1.1.3 Analog input specification
1.1.3.1 Differential
1.1.3.2 Single-ended
1.1.4 Temperature sensor
1.1.4.1 Specification for the single-ended temperature sensor input
1.1.5 Battery for Multi-Turn
1.1.5.1 Suitable batteries
1.1.5.2 Power consumption of multi-turn
1.1.6 EtherCAT-STO Cable
1.1.6.1 Overview
1.1.6.2 Pinout of the connectors
1.1.6.2.1 Hybrid connector (JST GHR-08V-S)
1.1.6.2.2 STO/SBC Connections
1.1.6.2.3 EtherCAT Connection
1.1.6.3 Instructions for manufacturing the cables
1.1.6.3.1 General Cable and Wire Specifications
1.1.6.3.2 Drive-to-Drive Cable
1.1.6.3.2.1 Cable details
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1.1.6.3.2.2 Wire details and pinout
1.1.6.3.2.3 Connectorization
1.1.6.3.3 Y-Splitter Cable
1.1.6.3.3.1 Overview
1.1.6.3.3.2 Wire details and pinout
1.1.6.3.3.3 Connectorization
1.1.6.3.3.4 Insulation Voltage
1.1.6.3.3.5 Cable Thickness and Flexibility
1.1.7 Maximum cable lengths
1.1.8 Mating parts
1.1.8.1 Connector details and mating part numbers
1.2 Mechanical integration
1.2.1 Circulo Mounting Example
1.2.1.1 Mounting the encoder disc
1.2.1.2 Mounting a hollow-shaft secondary bearing
1.2.1.3 Routing the motor phase cables
1.2.2 Dimensions and Drawings
1.2.2.1 Dimensions
1.2.2.2 Weight and inertia of the encoder rings
1.2.2.3 Drilling patterns
1.2.2.4 Mounting a bearing
1.2.2.5 Side view with phase connectors
1.2.3 Mounting encoder rings
1.2.3.1 Axial distance tolerances
1.2.3.2 Planar displacements
1.2.3.2.1 Radial displacement (r)
1.2.3.2.2 Tangential displacement (t)
1.2.3.2.3 Mounting eccentricity or radial runout (e)
1.2.4 Thermal Mounting Considerations
1.2.4.1 Current as a function of mounting temperature
1.2.4.2 Ambient air
1.3 Encoder Calibration
1.3.1 Encoder accuracy
1.3.1.1 Narrow angle errors (encoder system-specific non-linearity)
1.3.1.1.1 Analogue signals errors
1.3.1.1.2 Magnetic ring magnetization errors
1.3.1.2 Wide angle error (installation-dependent non-linearity)
1.3.1.3 Detecting the encoder non-linearity
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1.3.2 Calibration Procedure
1.3.2.1 Prerequisite
1.3.2.2 Performing the procedure
1.3.2.2.1 Starting the Internal Encoder Calibration
1.3.2.2.2 Limited Range Calibration (Available from OBLAC Drives v21.3.0)
1.3.2.2.3 Calibration in Progress
1.3.2.3 Troubleshooting
1.3.2.3.1 The magnetic ring is too close to the encoder chip
1.3.2.3.2 The magnetic ring is too far from the encoder chip
1.3.2.3.3 The magnetic ring is damaged
1.3.2.4 Encoder system diagnostic
1.3.2.4.1 Magnetic ring distance checker
1.3.2.4.2 Check encoder system
1.3.2.4.3 Check encoder errors
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1 Installation Guide
This manual will guide you through the basic steps to get your SOMANET Circulo running.
Attention
When dealing with electronic devices, always consider these handling instructions!
Wiring instructions
Power and brake
Encoders and IO
Analog input specification
Temperature sensor
Battery for Multi-Turn
EtherCAT-STO Cable
Maximum cable lengths
Mating parts
Mechanical integration
Mounting Example
Dimensions
Mounting encoder rings
Thermal Mounting Considerations
Encoder calibration
Encoder accuracy
Calibration Procedure
After you have successfully set up your servo drive you can proceed to commission and tune your drive:
Commissioning and tuning with OBLAC Drives
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1.1 Wiring instructions
Overview of connectors
Circulo 7
Circulo 9
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Power and brake
Encoders and IO
Analog In Specification
Temperature sensor
Battery for Multi-Turn
EtherCAT-STO Cable
Maximum cable lengths
Mating parts
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1.1.1 Power and brake
1.1.1.1 Supply and phases
Circulo 7
Circulo 9
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Important
The power cables must be twisted for EMC reasons.
Attention
No reverse polarity protection! Always ensure that the power cables are connected correctly,
otherwise the Drive may be damaged beyond repair!
Note
SOMANET servo drives are densely packed with high-performance components. Even at idle/torque
off, several components such as power supplies, cause the servo drive to get warm, especially when
it’s not connected to any heat conducting structure. The servo drives’ power stages and control
algorithms were optimized for efficiency at high power output and actually make them one of the
most efficient servo drives available. The heat generation is not linear, which makes it actually more
noticable at idle or low power. Please ensure by design of your mounting situation that the heat
interface is connected to sufficient structure to appropriately dissipate generated heat.
Note
Use a protected extra-low voltage (PELV) power supply.
1.1.1.1.1 Warning about using contactors behind the power supply
Attention
Our servo drives are designed for voltages between 24 V and 48 V (55 V ; Max,cont 60 V
Max,peak), they should be run with an appropriate extra-low voltage supply. Please do not use
contactors behind the power supply since the transient-voltage-suppression diodes could get
damaged due to the power-up voltage increase (Surge). This is likely to happen when the power up
occurs fast and can lead to complete failure of your servo drive.
If contactors behind the power supply are used, it’s necessary to include an uni-directional TVS
diode type 1.5KE62A-E3/54* between Main Power Supply and Ground of the terminal.
* this model has been successfully tested by Synapticon. Other products with the same specifications
may also be appropriate but can’t be recommended.
DC DC DC DC
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In case you are running several servo drives behind a contactor, please use an uni-directional TVS diode on
each drive because of the inductances of the wiring.
1.1.1.1.1.1 Functional Earth
Functional Earth (FE) and the Ground (GND) of the electronic boards are electrically isolated.
The blank bottom side of the heatsink has a flat conductive surface and can be used as a connection for
Functional Earth (FE).
For a better EMI shielding around the electronic boards, it is necessary to electrically connect the
conductive surfaces (marked blue in the following picture) to the chassis of the motor or the robot.
Important
Please ensure that the chassis is properly grounded.
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Note
Protective Earthing is not required for Extra-Low Voltage Drives.
1.1.1.2 Connecting a brake
If your system has an attached brake, please connect the brake cables to the brake connector. These two
threads should be twisted together or at least be paired to have a minimum area between them.
Note
This brake integrates Safe Brake Control functionality (SBC).
Attention
The brake output is not short circuit protected. The brake power output may get irreversibly damaged
in case of a short circuit.
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Circulo 7
Circulo 9
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1.1.2 Encoders and IO
1.1.2.1 Encoder overview
Important
One encoder has to be mounted on the motor side for commutation purpose. An encoder on a gear
out side can not be used for commutation!
Circulo 7
Circulo 9
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1.1.2.2 Analog Input
Note
Details about measuring Analog signals can be found in our system integration guideline: Connecting
and configuring analog inputs
Circulo 7
Circulo 9
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Pin # Signal Function Object Mapping
1 +5 V * Supply for external use **
2 Analog In 2 - Differential - Analog input 2 (0x2402)
3 Analog In 2 + Differential + Analog input 2 (0x2402)
4 GND Ground
5 Analog In 1 Single-ended 0-5 V Analog input 1 (0x2401)
6 not connected
* The supply is protected against short to ground and keeps the current below 400 mA in a continuous
short.
** The current capacity of 5 V output is shared between all connectors and the total consumption is limited
to 250 mA.
The Analog Inputs have a 12 bit resolution
1.1.2.3 Encoder ports
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Note
When the integrated encoder 1 is used, no external encoder can be used on port 1.
If integrated encoder 2 is used, only Hall can be configured as external encoder 2 on port 2.
Please refer to the following image for details:
1.1.2.3.1 Encoder port 1
Circulo 7
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Circulo 9
Note
This connector also carries the pins for the battery that is required if the optional integrated encoder 1
is used with Multi-Turn. For selecting a suitable battery, please check these notes.
Protocol/Function Multi turn
battery supply
BiSS (Diff.) SSI (Diff.)
Encoder Type Integrated
Encoder 1
External Encoder
on port 1
External Encoder
on port 1
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Pin # Config. # 1 Config. # 2 Config. # 3
1 5 V *
2 MA- Clock-
3 MA+ Clock+
4 Ground
5 SLO- Data-
6 SLO+ Data+
7 V_BAT
* The current capacity of 5 V output is shared between all connectors and the total consumption is limited to
250 mA.
1.1.2.3.2 Encoder port 2
Circulo 7
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Circulo 9
Pin
#
ABI / Fast ABI *
(Diff.)
ABI (Single-
Ended)
BiSS-C
(Diff.)
SSI
(Diff.)
Half-Duplex/A-
Format (Diff.)
HALL (Single-
Ended)
1 5 V **
2 MA- Clock- SD- / A
3 MA+ Clock+ SD+ / B
4 Ground
5 A- A SLO- Data- H3 / C
6 A+ SLO+ Data+
7 B- B H2 / B
8 B+
9 I- I H1 / A
10 I+
* Fast ABI is supported from firmware 5.0 on
** The current capacity of 5 V output is shared between all connectors and the total consumption is limited
to 250 mA.
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1.1.2.4 Digital IO
Circulo 7
Circulo 9
Pin
#
GPIO REM 16MT BiSS(LVTTL) SSI (LVTTL) SPI
1 +3.3 V OUT *
2 Digital I/O 1 (Fast Push-Pull) SCK SLO Data SCK
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