YASKAWA AC Servo Drive HR Series (CACR-HR) Multi functional/Positioning Control



YASKAWA AC Servo Drive HR Series (CACR-HR) Multi functional/Positioning Control

Overview

This document is a multifunctional/positioning control manual for the Yaskawa AC servo drive HR series (model CACR-HR, including rack mounted CACR-HR □□ BAB and base mounted CACR-HR □□□ BB), covering in detail the model identification, rated specifications (such as motor output power 0.07-8.2HP, drive input voltage 100-230VAC), mechanical characteristics (allowing radial/axial loads, anti vibration and anti impact performance), wiring connections (typical connections and terminal definitions for main circuit/control circuit/encoder/brake power supply, etc.) of the servo motor (M/F/G/D/S/R/P series) and servo drive I/O signal operation (2CN/5CN input/output signal timing and function), serial communication (RS422 protocol, supporting baud rates such as 9600/4800), parameter setting (100 parameters, including core parameters such as position loop gain Kp and speed loop gain Kv), display/monitoring function (LED indicator light and 7-segment digital tube status display), installation and wiring specifications, trial operation and maintenance (battery replacement, troubleshooting), while emphasizing safety precautions (such as opening the cover after 5 minutes of power outage, anti electric shock/anti scald measures), providing comprehensive guidance for the selection, installation, debugging and maintenance of servo systems.

Product Model and Configuration

1. Analysis of servo motor models (taking USAGED-13A2 as an example)

Explanation of the meaning of model segmentation

USA product prefix Yaskawa servo motor identification

G series (fully enclosed self cooling type, IP65 protection)

ED structural characteristics with encoder

13 output specification 1.3kW (corresponding to 1.7HP)

A-axis end specification with keyway

2 encoder types incremental 8192P/R

2. Analysis of servo drive models (taking CACR-HR03BAB12 as an example)

Explanation of the meaning of model segmentation

CACR-HR Product Series Yaskawa HR Series Servo Drivers

03 Output capacity 300W (0.4HP)

BAB installation and power supply B=rack mounted, A=single-phase, B=200VAC

12th Design Version 12th Design

3. Matching principle between motor and driver

Power matching: The output capacity of the driver needs to cover the rated power of the motor (such as a 300W motor matched with HR03 series driver).

Voltage matching: 100V motor (R series DS model) matches HR □□ BAB11 driver, 200V motor matches HR □□ BAB12/BB driver.

Encoder matching: The absolute encoder motor requires the driver to support battery backup (the HR series panel comes with a 3.6V battery).

Rated specifications and mechanical characteristics

1. Core specifications of servo motors (examples by series)

Motor series model example Rated output Rated speed Rated torque Peak torque Encoder type

M-series USAMED-03B2 0.3kW (0.4HP) 1000r/min 2.84N · m 8.92N · m incremental 8192P/R

S-series USASEM-15A2 1.5kW (2.1HP) 3000r/min 4.90N · m 13.7N · m incremental 2048P/R

R series (200V) USAREM-05CS 500W (0.67HP) 3000r/min 1.59N · m 4.76N · m absolute formula 8192P/R

P Series USAPEM-07CW 750W (1.0HP) 3000r/min 2.39N · m 7.06N · m Absolute 1024P/R

2. Core specifications of servo drive

Driver model input power output current (continuous/peak) control mode protection function

CACR-HR03BAB12 single-phase 200-230VAC 2.7A/7.8A full wave rectification+PWM sine wave drive OC, OV, OL, PG disconnection, etc

CACR-HR15BB three-phase 200-230VAC 11.7A/33.0A full wave rectification+PWM sine wave drive OC, OV, OL, phase loss (O-PH), etc

CACR-HR05BAB11 single-phase 100-115VAC 5.5A/16.3A full wave rectification+PWM sine wave drive OC, OV, OL, battery low voltage (BATALM), etc

3. Mechanical characteristics (motor)

Allowable load: Radial load 78.4-1764N (such as S series 02A model 78.4N, M series 60B model 1764N), axial load 39.2-588N.

Environmental tolerance:

Temperature: 0-40 ℃ for operation, 20-60 ℃ for storage;

Vibration: below 15 μ m (10-50Hz);

Protection level: IP44 (S/R series), IP65 (M/F/G/D/P series, excluding shaft ends).

Connection and wiring

1. Typical connection circuit

Main circuit connection: three-phase/single-phase power supply → circuit breaker (MCCB) → noise filter → servo driver (R/S/T) → motor (U/V/W).

Control circuit connection:

I/O signals: 2CN (servo enable SVON, start AST), 5CN (manual operation MCW/MCCW);

Encoder: 3CN (A/B/C phase signals,+5V power supply);

Serial communication: 4CN (TXD/RXD, RS422 protocol).

2. Definition of Key Terminals (Taking 2CN as an Example)

Terminal number, signal name, type, and function

8 SVON input servo enable, main circuit transistor unlocked when ON, motor powered on

Automatic operation/zeroing start with 16 AST inputs, valid rising edge, must be maintained for ≥ 5ms

15 STOP input temporarily stops, when ON, the motor decelerates and stops according to the parameter settings

11 ALM output fault alarm, transistor cutoff during fault (normally ON)

12 BK output brake release, when servo ON, ON, release motor brake

3. Wiring specifications

Cable selection:

Main circuit: 1.25-8mm ² copper core wire (e.g. 8mm ² for HR60BB);

Signal circuit: 0.2mm ² shielded twisted pair (DP8409123 and other dedicated wires are used for encoder lines).

Grounding requirements:

Driver FG terminal → grounding electrode (Class 3 grounding, resistance ≤ 100 Ω);

Motor frame ground → driver FG terminal to avoid common ground interference.

Noise control:

Install a noise filter on the power side (such as HR03BAB with LF-205A);

The distance between power lines and signal lines should be ≥ 30cm, and wiring in the same conduit is prohibited.

Functional operations (I/O, communication, parameters)

1. I/O signal operation

Input signal timing: SVON, AST and other signals need to maintain a stable level of ≥ 5ms to avoid false triggering;

Output signal status:

POS1 (positioning completed): ON when the deviation between the current position and the target position is ≤ P6 (positioning completed width, 1-250 units);

NEAR (positioning proximity): ON when the deviation is ≤ P45 (positioning proximity width, 0-3000 units).

2. Serial communication (RS422)

Communication specifications:

Baud rate: 9600/4800/2400/1200Baud (default 9600);

Data format: 1 start bit+7 data bits+1 even check bit+1 stop bit.

Core command:

SVON: Servo Enable;

MOV ± nnnnnn: Absolute positioning (± 8-bit position data);

ZRN: Start back to zero;

PRMpp=± nnnnnnnn: Set parameters (pp=parameter number).

Multi axis control: Supports 16 axes and specifies the control object through axis addresses (1-16).

3. Parameter Setting (Example of Core Parameters)

Parameter Number, Parameter Name, Unit Range, Function Description

P1 position loop gain Kp s ⁻¹ 0-200 adjusts position control response speed, the larger the value, the faster the response (prone to oscillation)

P2 speed loop gain Kv × 2.5Hz 1-200 adjustment speed control response speed, matching system rigidity

P4 1st feed rate x 1000 units/minute 1-240000 reference speed in automatic/manual mode

When the deviation of the width unit 1-250 after P6 positioning is ≤ this value, the POS1 signal is ON

P7 motor selection -0-79 matching motor model (e.g. 32=USAREM-A5CS)

P8 encoder pulse P/R (× 4) 4096-32768 encoder pulse per revolution (absolute 8192P/R set to 32768)

Display/Monitoring and Maintenance

1. Display function

LED indicator light:

MAIN (red): residual voltage in the main circuit (slowly extinguishes after power failure);

RUN (green): Control power supply is normal (+5V normal);

ALM (red): Fault alarm (check the 7-segment digital tube code when it lights up).

7-segment digital tube:

Normal state: Display current position (PUN) and speed (NFB);

Fault status: Display code (such as OC=overcurrent, OL=overload, BAT=low battery).

2. Trial operation process

Preparation stage:

Check the wiring (main circuit/control circuit is not loose) and parameters (P7/P8/P9 matching motor and encoder);

Absolute encoder reset: Short circuit the specific pin of the encoder and release it after powering on for ≥ 2 minutes.

Test operation:

Servo Enable: Send SVON command, confirm that RUN light is on and ALM light is off;

Jogging test: Send JOG+1000 command (1000 units/minute) to confirm that the motor rotates smoothly;

Positioning test: Send MOV+10000 command and confirm that POS1 signal is ON after positioning is completed.

3. Maintenance and troubleshooting

Battery replacement: Replace the absolute encoder battery (3.6V) when the voltage is ≤ 3.3V, and replace it after power failure (to avoid data loss).

Common troubleshooting:

|Alarm code | Fault cause | Handling measures|

|OC (overcurrent) | Main circuit overcurrent (≥ 1.2 times peak current) | Check if the motor wiring and load are stuck|

|OL (overload) | Motor overload (exceeding allowable load inertia) | Reduce load inertia and acceleration rate|

|PG (Encoder Disconnected) | Encoder Cable Loose/Disconnected | Check 3CN Wiring and Encoder for Damage|

|BAT (low battery) | Absolute encoder battery voltage low | Replace 3.6V lithium battery (such as CR2450)|

Installation and environmental requirements

Motor installation:

Installation method: Both horizontal and vertical can be used, with axis centering deviation ≤ 0.03mm;

Axial load: The radial/axial load shall not exceed the specifications in Table 3.9 (such as M series 03B model radial 490N).

Driver installation:

Rack mounted (BAB): vertically installed, with a spacing of ≥ 10cm (for heat dissipation);

Base type (BB): vertically installed, avoiding direct sunlight/condensation environment.

Environmental restrictions:

Temperature: driver 0-55 ℃, motor 0-40 ℃;

Humidity: 20% -80% RH (without condensation);

Dust: Do not use in dusty or corrosive gas environments.