HA-800 series AC servo drive

HA-800 series AC servo drive

Document and product positioning

This manual is aimed at professional electrical/operation and maintenance personnel. The driver focuses on high-precision positioning, fast response, and multiple control modes. Relying on the characteristics of harmonic reducers, it shortens the positioning stability time, supports IO switching control modes, and has rich built-in debugging and diagnostic functions, suitable for multiple scenarios of industrial automation.

Product model, specifications, and hardware structure

1. Model naming and classification

Drivers are divided according to output current, communication type, compatible encoder, and input voltage:

Current specifications: 1.5A (HA-800A-1), 3A (HA-800A-3), 6A (HA-800A-24), 24A (HA-800A-24), corresponding to maximum currents of 4A, 9.5A, 19A, 55A respectively;

Communication versions: A (Universal IO), B (MECHATROLINK), C (CC Link);

Encoder adaptation: A (13 bit absolute), B (14 bit incremental), C (4-line provincial incremental), D/E (17 bit absolute);

Input voltage: 100V/200V in two levels.

2. Electrical and mechanical parameters

power supply

200V model: Main circuit AC200~230V (single-phase/three-phase), control circuit AC200~230V;

100V model: both main and circuit are AC100~115V (single-phase);

Frequency: 50/60Hz, control circuit power consumption 30VA.

control performance

Three control modes: position, speed, torque, supporting IO signal switching;

Pulse input: Two phase/single pulse up to 1MHz, two-phase pulse 200kHz;

Simulation command: The speed/torque commands are both DC ± 10V, with an input impedance of 68k Ω and a speed ratio of 1:1000.

Environment and Machinery

Working temperature: 0-50 ℃, storage: -20~65 ℃; Anti vibration and impact comply with industrial standards;

Heat dissipation: 1/3 type naturally air-cooled, 6/24 type equipped with cooling fan;

Weight: 1/3 type about 1kg, 6 type about 1.2kg, 24 type about 5.5kg.

Protection function: Integrated multiple alarms and warnings for overspeed, overload, overcurrent, regeneration overheating, encoder failure, undervoltage, communication, overheating, etc.

3. Hardware interface and panel

Main terminals/connectors: main circuit terminal (R/S/T), control power supply (r/s), motor terminal (U/V/W), regenerative resistor terminal (R1/R2/R3), encoder interface (CN1), IO interface (CN2), communication port (CN3), waveform monitoring port (CN9), grounding terminal.

Operation panel: 5-digit digital display+4 operation buttons, supporting mode switching, parameter modification, and status viewing; Equipped with charging indicator light, dip switch (device address, terminal resistance).

4. Supporting accessories

Optional accessories: extension cable, dedicated communication line, connector, PSF-800 upper computer software, absolute encoder backup battery, regenerative resistor, magnetic ring/filter/surge protector and other EMC accessories.

Installation and wiring specifications

1. Installation requirements

The drive is vertically mounted on the wall, with reserved heat dissipation gaps around (≥ 30mm from the wall/equipment, ≥ 50mm above and below);

There are requirements for the thickness of the installation board: 1/3/6 type ≥ 2mm, 24 type ≥ 5mm;

Plan cabinet heat dissipation according to the power consumption of different models to avoid excessive temperature accumulation.

2. Cable specifications

The minimum wire diameter for distinguishing the main circuit, control circuit, motor line, encoder line, and signal line must be shielded twisted pair for encoder and IO signals, and the longest encoder cable must be ≤ 10m.

3. Power wiring and protection

The main circuit and control circuit are independently wired, and serial power supply is prohibited;

The front-end comes standard with circuit breakers, surge protectors, noise filters, and magnetic rings to meet EMC and safety requirements;

Distinguish between 100V/200V, single-phase/three-phase wiring methods, and strictly match the voltage of the model.

4. Regenerative resistor wiring

Built in resistor model: R1 and R3 are short circuited (factory default);

External resistor: Disconnect the short-circuit wire and connect an external resistor between R1-R2. The 24A model supports high-power regenerative resistors.

5. EMC electromagnetic compatibility measures

Single point grounding, with all shielding layers grounded at both ends;

Power lines and signal lines should be laid separately, and it is prohibited to use the same pipe or bundle them together;

Match filters, magnetic rings, surge devices according to recommended models to meet electromagnetic standards such as EN, FCC, CE, etc;

High voltage/interference equipment is equipped with separate filtering devices.

6. Encoder and IO wiring

Encoder: Connect the pins according to the encoder type (17 bit/13 bit/incremental), and it is strictly prohibited to connect empty pins;

IO interface CN2: includes digital inputs, outputs, pulse commands, analog speed/torque commands, encoder signals, monitoring outputs, with clear pin definitions, wiring circuits, and voltage specifications (input DC24V).

Power on and complete machine startup process

1. Check before powering on

Check the model, actuator compatibility, wiring tightness, insulation, grounding, and clean up cabinet debris.

2. Power on timing (divided into control power supply and main circuit power supply)

First connect the control power supply, then connect the main circuit; The power-off sequence is reversed;

After powering on, wait for the system to initialize (up to 10 seconds). The absolute encoder model is prone to zero/multi turn data faults when powered on for the first time and needs to perform a reset operation.

It is strictly prohibited to frequently turn on and off the main circuit when it is live.

3. Step by step debugging process

Jog test without load: test the operation of the actuator separately, troubleshoot wiring and phase sequence faults;

Single mode debugging: Test the position, speed, and torque modes separately, and verify the consistency between instructions and actions;

Whole machine joint debugging: connect to actual equipment, perform self-tuning and manual gain optimization;

Origin setting (absolute encoder only): Complete mechanical origin matching.

4. Common faults and troubleshooting during power on

Provide corresponding inspection items and solutions for problems such as no display on the digital tube, power on alarm, motor not turning, and reverse steering.

Detailed explanation of encoder system

Drivers are compatible with three major types of encoders, with independent differentiation in configuration, wiring, and fault handling:

17 bit absolute encoder (SHA, FHA Cmini)

Features: 17 bit single turn+16 bit multi turn, battery power-off storage location, no need to repeatedly reset to zero;

Power supply: backup battery+built-in capacitor for dual data storage;

Operation: Multiple rounds of zeroing are required for the first power on, and encoder conversion mode switching is supported;

Output: It can divide and output A/B/Z phase signals, and supports serial output at the current position.

13 bit absolute encoder (FHA-C series)

13 bit single loop+13 bit multi loop, the principle is the same as 17 bit, the parameters and alarm codes are different, and power-off relies on battery protection.

Incremental encoder (4-wire energy-saving/14 wire, FHA CMini, RSF/RKF)

Lost position due to power outage, must return to zero every time power is turned on; No backup battery, simpler wiring.

Universal encoder malfunction

Covering alarm codes such as wire breakage, communication errors, multi loop overflow, data anomalies, battery undervoltage, etc., explain the cause of the fault and repair solutions one by one.

IO signal system

1. Signal classification

Input signals (8-channel configurable+fixed servo enable): emergency stop, reset, deviation reset, forward and reverse prohibition, mode switching, electronic gear selection, etc., supporting normally open/normally closed logic configuration;

Output signal (7 channels configurable): ready to run, alarm, positioning completed, zero speed, overload, fan fault and other status outputs;

Command signals: pulse command (position mode), analog speed/torque command;

Monitoring output: encoder phase, analog waveform (speed/current), digital status monitoring.

2. IO configuration cases for three control modes

Provide standard wiring, signal logic, and command rules for position, speed, and torque modes, including pulse type and voltage command correspondence.

Panel operation and parameter system

The driver panel is divided into five operation modes, and all parameters can be set on the panel or the upper computer (PSF-800):

Status display mode (d code): View real-time data such as speed, torque, deviation, pulse, voltage, overload rate, and operating time for daily monitoring and fault diagnosis.

Alarm mode: displays current alarms and 8 historical alarm records, supports clearing alarm records.

Tuning mode (AJ parameters): servo core gain setting, including position loop, speed loop, integration, feedforward, acceleration and deceleration, torque limitation, etc., divided into automatic tuning+manual fine-tuning.

Step by step tuning method for position/speed/torque loop;

Feedforward control multi-level mode selection, suitable for different working conditions.

System parameter mode (SP parameter): IO allocation, control mode switching, electronic gear, pulse format, encoder function, filtering, limit and other extended functions. After modification, it needs to be restarted to take effect.

Test mode (T code): IO monitoring, JOG jog, parameter initialization, encoder reset, automatic tuning, bias calibration and other debugging functions.

Upper computer software (PSF-800)

Equipped with dedicated PC software, covering the following functions:

Drive connection, parameter reading and writing, saving/comparing/batch writing;

Real time status monitoring, waveform acquisition (speed, current);

Automatic tuning, IO simulation, alarm query;

Remote debugging and batch device management.

Fault diagnosis and alarm handling

1. Alarm (AL category)

Serious faults: emergency stop, overspeed, overload, overcurrent, regeneration overheating, encoder failure, communication error, hardware failure, etc. After triggering, the servo cuts off the output, and the hardware/wiring/load needs to be checked.

2. Warning (UA category)

Minor alarms: battery undervoltage, main circuit undervoltage, overload warning, fan shutdown, etc. The equipment can continue to operate, but timely maintenance is required.

The document annotates the cause of each alarm/warning and corresponding solutions, which is the core reference for on-site operation and maintenance.

Maintenance, spare parts, and lifespan

Daily inspection: Annual inspection of terminal fastening, shell cleanliness, and appearance damage; Do not shake the meter/withstand voltage test.

Regular replacement parts (reference lifespan)

Cooling fan, main circuit capacitor: 5 years;

Absolute encoder backup battery: 1 year (model HAB-ER17/3.6V);

Relay: on-off ≤ 100000 times.

Battery replacement method: Distinguish the battery reset rules for different encoder models.

Optional components, standards, and compliance

Recommended EMC accessories: filter, magnetic ring, surge protector, isolation transformer model and parameters;

Compliance certification: Passed UL, cUL, TUV, CE, compliant with EU LVD and EMC directives, compatible with international standards such as IEC, EN, CSA, FCC, etc;

High and low voltage models, compatible drivers for different actuators, and rules for reducing capacity.