HLTNC AC Servo Motor Kit Instruction Manual

1. Product Overview

This manual provides detailed instructions for the HLTNC ZE Series AC Servo Motor Kit, designed for smooth operation, high performance, and easy installation in various industrial applications such as 3D printers, CNC machines, textile machines, and cutting machines.

Figure 1.1: HLTNC ZE Series AC Servo Motor Kit

1.1 Key Features

• Motor Type: AC Servo Motor, Permanent Magnet
• Input Voltage: AC 200-240V
• Input Frequency: 50/60 Hz
• Rated Speed: 3000 RPM
• Encoder Feedback: Incremental 17bit
• Control Mode: IGBT PWM control, sine wave current drive mode
• Certifications: CCC, CE

1.2 Product Components

The kit typically includes the AC servo motor, servo driver, motor power line (orange), and encoding line (green). Brake options are available for certain motor models.

Figure 1.2: Servo Motor Views (with and without brakes)

Figure 1.3: Various Servo Motor Wattages

Figure 1.4: MZ870 Series Servo Drivers

Figure 1.5: Power and Signal Cables

2. Safety Precautions

Always observe the following safety precautions during inspection, installation, wiring, operation, maintenance, and inspection to prevent harm and damage.

2.1 General Safety

• Danger: May cause death or serious injury.
• Warning: May result in injury or property damage.

2.2 Installation and Wiring Safety

• Never connect the motor directly to a commercial power source; otherwise, it can cause fires and malfunctions.
• Do not place flammable materials around the motor or driver; otherwise, it will cause a fire accident.
• The drive must be protected by an outer box. Keep the distance between the machine and the drive as specified in the user manual to prevent electric shock, fire, and malfunction.
• Install in a place with less dust and no contact with water, oil, etc., to prevent electric shock, fire, malfunction, and damage.
• Motors and drives must be installed on non-combustible materials such as metal to prevent fire accidents.
• Wiring must be done by a professional electrician to prevent electric shock.
• The FG terminals of the motor and driver must be grounded to prevent electric shock.
• The upper circuit breaker must be disconnected in advance for proper wiring to prevent electric shock, injury, malfunction, and damage.
• Cables should be properly connected, and energized parts securely insulated to prevent electric shock, fire, and malfunction.

2.3 Operation and Running Safety

• Do not touch the inside of the drive to prevent burns and electric shock accidents.
• Do not subject the cable to damage, excessive external force, heavy pressure, or clamping to prevent electric shock, malfunction, and damage.
• Do not touch the rotating parts of a running motor to prevent injury accidents.
• Do not use in areas with water, corrosive or flammable gases, or near flammable materials to prevent fire.
• Do not use in places with intense vibration or shock to prevent electric shock, injury, fire, and accident.
• Do not use cables immersed in oil or water to prevent electric shock, injury, fire, and accident.
• Do not wire or operate with wet hands to prevent electric shock, injury, fire, and accident.
• Do not touch the keyway with bare hands when using an electric motor with a keyway at the end of the shaft to prevent injury accidents.
• The temperature of the motor, driver, and heat sink will rise. Do not touch them to prevent burns or component damage and accidents.
• Do not use external power to drive the motor to prevent fire accidents.

2.4 Maintenance and Inspection Safety

• The drive has dangerous high-voltage sections. Wiring and inspection work must be carried out after the power is cut off and left to discharge (for more than 5 minutes). It is absolutely not allowed to disassemble it.
• Do not carry out disassembly and repair work outside our company.
• Do not frequently turn the main circuit power switch on and off.
• Do not touch the heat sinks and regenerative resistors of the motor, driver, etc. while powered on or for a certain period of time after power is cut off.
• When the drive malfunctions, cut off the control power and the main circuit power.
• Be sure to cut off the main power supply when not in use for a long time to prevent injury accidents due to misoperation.

3. Technical Specifications

3.1 General Specifications

3.2 Motor and Driver Specifics

Figure 3.1: 400W Servo Motor and Driver Dimensions/Parameters

4. Setup and Installation

4.1 Environmental Conditions

For optimal performance and longevity, install the servo drive and motor in an environment that meets the following criteria:

• Not directly exposed to sunlight.
• Inside a control box.
• Not submerged by water, oil (cutting oil, oil mist), or moisture.
• Away from explosive, flammable, corrosive gases (sulfurized, chlorinated, ammonia, acids/bases, salts).
• Free from dust, iron powder, cutting powder.
• Away from high temperatures, continuous vibration, and excessive shock.
• For motors, if used in places with grinding fluid, oil mist, or iron powder, choose models with oil seals.
• Do not use the motor in a closed environment, as it can overheat and shorten its lifespan.

4.2 Servo Drive Mounting

Mount the servo drive vertically to ensure proper heat dissipation. Ensure sufficient space around the drive for airflow (≥5mm on sides, ≥50mm top/bottom). If installed in a sealed enclosure, fans or coolers may be needed to keep the temperature below 55°C.

4.3 Servo Motor Installation

• Wipe the shaft extension end clean before installation.
• Do not strike the shaft extension end during installation to avoid damaging the internal encoder.
• When installing pulleys on servo motor shafts with keyways, use screw holes at the shaft ends.
• For safety, install a protective cover or device in the rotating area.
• Ensure proper centering and alignment when connecting to the machine to prevent vibration and damage to bearings/encoders.
• Do not use the motor or cables immersed in oil or water. If water may drip, ensure the motor has an oil seal and install with the terminal facing down.
• Avoid bending or tensioning cables, especially thin signal lines.
• Ensure connectors are free of debris and pins are correctly aligned.
• Hold the main body of the servo motor when handling with cables connected to avoid damaging connectors.

4.4 Wiring Diagrams

Proper wiring is crucial for safe and correct operation. Refer to the following diagrams and instructions carefully.

Figure 4.1: System Wiring Diagram

4.4.1 Power Wiring (Single-phase 220Vac)

Connect the main circuit terminals L1 and L2. Do not connect to reserved terminals. Ensure proper wire gauge for power cables (e.g., 18AWG for S1R6/S2R8/S5R5/S7R6, 14AWG for S012/S018).

Figure 4.2: Single-phase 220Vac Main Circuit Wiring

4.4.2 Motor Power Socket Wiring

For motors with flange surface 90 or less (4-core AMP socket) and 110 and above (4-core aviation socket):

4.4.3 Absolute Encoder Socket Wiring

For 9-pin socket:

4.4.4 Control Signal Terminals (CN1)

The CN1 terminal is used for user I/O connectors. It includes terminals for pulse input, instruction symbols, and high-speed instruction pulses.

4.4.5 Battery Box Installation for Multi-turn Encoder

The multi-turn encoder battery box is essential for retaining encoder position information when the drive is powered off. It typically contains a 3.6V 2700mAh battery.

Slot Fixing: The plastic case with a battery box slot can be fixed by the card slot. For metal casing, use three countersunk screws to fix the battery box slot, then insert the battery box.

No Slot Fixing: Bind the battery box directly to the cable using a wiring harness.

Disassembly: Batteries should be replaced every two years to prevent leakage. When closing the battery box cover, avoid pinching the connector cable.

• Insert the battery correctly (+ and - directions).
• Do not disassemble the battery.
• Do not throw batteries into fire.
• Do not short-circuit the battery.
• Do not charge this battery.
• Discard replaced batteries according to local regulations.

4.5 Pre-run Check

Before operating the servo drive and motor, perform the following checks:

1. Ensure the main circuit power input terminals are properly connected.
2. Verify that the main circuit output terminals (U, V, W) and motor cables are in phase and properly connected.
3. Confirm that the main circuit power input terminals L1, L2 and output terminals U, V, W are not short-circuited.
4. Check that control signal cables, including brake and overtravel protection, are reliably connected.
5. Ensure the servo driver and motor are reliably grounded.
6. If using an external braking resistor, remove the short-circuit between driver B2 and B3.
7. Verify all cables are within the specified range and insulated.
8. Ensure no foreign objects are inside or outside the servo drive that could cause short circuits.
9. Confirm the servo drive and external braking resistor are not placed on flammable objects.
10. Verify the servo motor installation and shaft connection to machinery are reliable and in operational condition.

5. Operating Modes and Debugging

The servo drive supports Position, Speed, and Torque control modes. The following outlines basic settings and operation for each mode.

5.1 Basic Settings

The general setup process involves wiring inspection, power-on, jog operation, parameter settings, servo running, and servo stop.

5.1.1 Power Supply Connection

Connect the control circuit and main circuit power supplies. For single-phase 220V, use L1 and L2. For three-phase 220V or 380V, use L1, L2, and L3. After power-on, the panel should display "Reset" → "Nrd" → "Rdy", indicating operational status.

5.1.2 Servo Enable (S-ON)

Configure a DI terminal for S-ON (FunIN.1) and ensure its valid logic. The servo motor is powered on when S-ON is effective.

5.1.3 Point Operation (JOG)

Use point operation to confirm normal motor rotation without abnormal vibration or noise. This can be done via the panel, external DI, or debugging platform.

• Panel JOG: Use P0D-11 to enter JOG mode, adjust speed with UP/DOWN keys, and press SET to start.
• DI JOG: Configure DI terminals (FunIN.18 for JOGCMD+, FunIN.19 for JOGCMD-) and set P06-04 for jog speed.

5.2 Position Control Mode

In position control mode, motor movement is determined by pulse count, and rotational speed by pulse frequency. Set P02-00 to 1 to enable this mode.

5.2.1 Pulse Control Settings

• Parameters: P03.07=1 (Internal Enable), P05.02 (Modify pulses per cycle).
• Wiring: Pulse+(24V) to pin 35, Pulse+(5V) to pin 41, Pulse- to pin 43, SIGN+(Dir+) to pin 37, SIGN-(Dir-) to pin 39.

5.2.2 Electronic Gear Ratio

Set the electronic gear ratio (P05-07 for numerator, P05-09 for denominator) according to machinery and upper computer requirements. This defines the proportional relationship between motor position and input instruction.

5.2.3 Position Command Filtering

Filter position instructions (encoder units) to smooth movement. Use first-order low-pass filtering (P05-04) and average filtering (P05-06) as needed, especially if instructions are not accelerated/decelerated, pulse frequency is low, or gear ratio is high.

5.2.4 Position Deviation Clearing

The drive can clear position deviation to zero under certain conditions (P05-16). This is useful for maintaining accuracy.

5.3 Speed Control Mode

Controls rotational speed via analog input, digital, or communication settings. Set P02-00 to 0 to enable this mode.

5.3.1 Speed Command Source

Speed commands can come from digital settings (P06-03), analog voltage (Al1/Al2), or multi-segment speed commands.

5.3.2 Slope Function Settings

Use acceleration (P06-05) and deceleration (P06-06) times to smooth speed changes, preventing motor jump or vibration.

5.3.3 Speed Command Limit

Limit speed commands (P06-07, P06-08, P06-09) to protect machinery. The maximum motor speed (P00-15) is the default limit.

5.4 Torque Control Mode

Controls motor output torque. Set P02-00 to 2 to enable this mode.

5.4.1 Torque Command Source

Torque commands can be digital (P07-03), analog voltage (Al1/Al2), or communication-given.

5.4.2 Torque Command Limit

Limit torque commands (P07-09, P07-10, P07-11, P07-12) to protect mechanical devices. The maximum torque is ±300.0% of rated torque.

5.5 Hybrid Control Mode

Allows switching between control modes (Torque ↔ Speed, Speed → Position, etc.) when the servo is running. Set P02-00 to 3-6 to enable hybrid control.

5.6 Auxiliary Functions

Includes software reset (P0D-00) and DI port filter time settings (P02-18) for proper servo system operation.

5.7 Gain Adjustment

Adjust servo gain for quick and accurate motor response. This involves inertia identification, automatic gain adjustment, manual gain adjustment, notch filters, and low-frequency resonance suppression.

5.7.1 Inertia Identification

Determine the load inertia ratio (P08-15) either offline (P0D-02) or online (P09-03) for accurate gain adjustment.

5.7.2 Automatic Gain Adjustment

The drive automatically generates matching gain parameters based on rigidity level (P09-01) for speed and stability.

5.7.3 Manual Gain Adjustment

Fine-tune position loop gain (P08-02), speed loop gain (P08-00, P08-01), and torque command filter time (P07-05) if automatic adjustment is unsatisfactory.

5.7.4 Notch Filters

Suppress mechanical resonance by reducing gain at specific frequencies. The drive has four sets of notch filters, configurable manually or adaptively (P09-02).

5.7.5 Low-frequency Resonance Suppression

Reduce end vibration during emergency stops, especially for long and heavy mechanical loads, using low-frequency resonance suppression (P09-04).

6. Troubleshooting

This section provides guidance for identifying and resolving common faults and warnings.

6.1 Fault and Warning Handling at Startup

If the panel shows "FU.xxx" or "Nrd" at startup, check the following:

• Control/Main Power Supply Voltage Failure: Check wiring, voltage levels, and ensure no short circuits.
• Servo Enable Signal Invalid: Verify S-ON (FunIN.1) setting and terminal logic.
• Incorrect Control Mode: Ensure P02-00 is set correctly (e.g., 1 for Position mode, 0 for Speed mode).

6.2 Fault and Warning Handling at Runtime

Faults and warnings are classified by severity (Class 1, 2, 3). Resettable faults can be cleared by a reset signal (P0D-01=1 or FunIN.2).

6.2.1 Common Faults and Solutions

7. User Tips

• Parameter Setting: For pulse control, set P03.07=1 (Internal Enable) and P05.02 to modify the number of pulses per cycle. For analog control (-10V to +10V), set P02.00=0, P06.00=1, and P03.07=1.
• Factory Reset: If you encounter issues, a factory data reset can be performed by setting P02.31=1, then shutting down and restarting the device.
• HMI Compatibility: Ensure your Human Machine Interface (HMI) supports RS485 for communication.
• RS485 to USB Conversion: The CN3 and CN4 ports on the drive are 485 interfaces (Ethernet cables). An RS485 to USB converter may be needed for PC communication.
• Technical Drawings: Servo motor drawings, including torque and speed diagrams, and 3D drawings are available from the seller upon request.

8. Warranty and Support

8.1 Warranty Content

Under normal usage conditions as described in this manual, any malfunction will be repaired free of charge within the warranty period. Repairs for faults occurring due to incorrect usage, improper repair/modification, physical damage, use beyond specifications, natural disasters, or foreign object invasion will be charged.

8.2 Contact Information

For technical support, warranty claims, or any inquiries, please contact Chnchi Electric Nanjing Co., LTD:

• Address: 95 Xinggangwan Road, Longchi Sub-district, Luhe District, Nanjing City, Jiangsu Province, Mainland China
• Service Hotline: 025-58822988
• Website: www.chnchi.com

Any changes to this manual will not be notified separately. The company is not responsible for any printing errors. The final interpretation right belongs to the company.

8.3 Additional Resources

A detailed user manual in PDF format is available for download. This document contains comprehensive information on all parameters and advanced settings.

Reference: User manual (PDF)