ServoWire SD Drives

Installation and Operation Manual

SAC-SD 01c

Copyright © 2006-2009

ORMEC Systems Corp.

All Rights Reserved

19 Linden Park
Rochester, NY 14625
(585) 385-3520

April 3, 2009
ServoWire SD Drive Manual Table of Contents

Copyright Notice
Copyright © 2006-2008 by Ormec Systems Corp. All rights reserved. This manual and any software that it
may describe, remain the exclusive property of Ormec Systems Corp. No part of either may be reproduced
in any form without the prior written permission of ORMEC.

Trademark Notice
ServoWire™, ServoWire Pro™, ServoWire Setup™, ServoWire Upgrade™, ServoWire Monitor™, ServoWire
Tune™ and ServoWire Scope™ are trademarks of Ormec Systems Corporation.
Ormec® is a registered trademark of Ormec Systems Corporation.

Warranty
ORMEC extends no warranty with respect to the merchantability or fitness of this product for any particular
purpose. It is the customer’s responsibility to determine whether it is suitable for the specific application and
whether it meets performance, reliability and safety requirements when used in that application. ORMEC
reserves the right to make improvements to the product as well as this documentation at any time without
notice.

Terms and Conditions

All hardware and software sold or otherwise provided by ORMEC is made available subject to ORMEC's
published Standard Terms and Conditions of Sale.

UL Listed

UL Recognized Component
G-Series Servomotors are recognized under the Component Program of Underwriters Laboratories Inc., and
are distinguished by the UL trademark symbols shown below.

CE Mark
G-Series Servomotors carry the CE Mark, as shown below.

SAC-SD 01c page i

Table of Contents ServoWire SD Drive Manual

Table of Contents
1 Welcome................................................................................................................ 1
2 General Description ............................................................................................. 3
2.1 ServoWire SD Drive Capabilities and Features ............................................................................ 3
2.1.1 ServoWire SD Drive Model Number Description ........................................................................... 6
2.1.2 Differences between SAC-SW / SAC-SM / SAC-SD Drives.......................................................... 7
2.1.3 SAC-SD Drives 1394 Cable change. ............................................................................................. 8
2.1.4 SAC-SD Drives changes marked by version 1.2. .......................................................................... 8
3 Installation ............................................................................................................ 9
3.1 Receiving and Inspection ............................................................................................................... 9
3.2 ServoWire SD Drive Panel and Environment Considerations .................................................... 9
3.3 ServoWire SD Drives Outline Drawings ...................................................................................... 11
3.3.1 Mounting Information for SAC-SD_203, 205, 210, 217, 220 ....................................................... 11
3.3.2 Mounting Information for SAC-SD_225, 235, 260, 417 & 425..................................................... 12
3.3.3 Mounting Information for SAC-SD_405 & 410 ............................................................................. 13
3.3.4 Mounting Information for SAC-SD_435 & 450 ............................................................................. 14
3.4 Software Configuration Setup ...................................................................................................... 16
3.5 ServoWire SD Drives Power Considerations.............................................................................. 17
3.5.1 Supply Power for 115/230 VAC (SAC-SD_2__) Drives............................................................... 17
3.5.2 Supply Power for 460 VAC (SAC-SD_4__) Drives...................................................................... 17
3.5.3 Shielding, Power Line Filtering & Noise Suppression.................................................................. 17
3.5.4 Sizing Fuses, Line Filters, and Transformers for 115/230 VAC (SAC-SD_2__) and 460 VAC (SAC-
SD_4) Drives .............................................................................................................................................. 18
3.5.5 Power Dissipation ........................................................................................................................ 19
3.5.6 Line Filters.................................................................................................................................... 19
3.5.7 Terminal Block Wiring Guidelines ................................................................................................ 21
3.6 ServoWire SD Drive Connections ................................................................................................ 22
3.6.1 Drive Sensor Connections for All Models (TB4) .......................................................................... 26
3.6.2 Drive Input / Output Connections for All Models (TB5)................................................................ 26
3.6.3 ServoWire SD 115/230 VAC (SAC-SD_2__) Drive Power Terminal Block (TB1) ....................... 28
3.6.4 ServoWire SD Drive (SAC-SD_225 – SD_260) Control Power Terminal Block (TB2)................ 29
3.6.5 ServoWire SD 460 VAC (SAC-SD_4__) Drive Power Terminal Block (TB1) .............................. 29
3.6.6 ServoWire SD Drive (SAC-SD_417 – SD_450) Control Power Terminal Block (TB2)................ 30
3.6.7 Drive Analog I/O Connections for All Models (TB3)..................................................................... 30
3.6.8 ServoWire Connectors for All Models (J1, J2 & J3)..................................................................... 30
3.6.9 ServoWire Cable for All Models ................................................................................................... 31
3.6.10 1394 network topology requirements........................................................................................... 32
3.6.11 Motor Feedback Connector for Serial Encoder Models SAC-SDxxxx-S (J4) ............................ 33
3.6.12 Motor Feedback Connector for Resolver Models SAC-SDxxxx-R (J4) ....................................... 34
3.6.13 Pacer Feedback Connector for All Models (J5 - mounted on bottom of drive)............................ 35
3.6.14 High Speed Sensor Inputs (ASEN, BSEN) .................................................................................. 36
3.6.15 High Speed Sensor Inputs (ASEN, BSEN) (continued)............................................................... 37
3.6.16 Discrete Inputs (IN1’, IN2’, IN3’, IN4’/OUT4')............................................................................... 38
3.6.17 Discrete Outputs (OUT1’-OUT5’)................................................................................................. 39
3.6.18 External Regen Resistor Wiring (RG) .......................................................................................... 40
3.6.19 Bus Sharing Wiring (230 V SD_225 – SD_260 and 460 V SD_405-SD_450) ............................ 42
3.7 ServoWire SD Drive ID .................................................................................................................. 43
3.8 Servomotor Installation................................................................................................................. 44
3.8.1 Motor Use and Environment ........................................................................................................ 44
3.8.2 Recommended Servomotor Wiring Methods ............................................................................... 44
3.8.3 Motors with Integral Fail-Safe Brakes .......................................................................................... 45
3.8.4 G-Series Servomotor Connections .............................................................................................. 47
3.8.5 D-Series Servomotor Connections .............................................................................................. 48
3.8.6 H-Series Servomotor Connections .............................................................................................. 49

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ServoWire SD Drive Manual Table of Contents

3.8.7 DC Servomotor Connections ....................................................................................................... 50

3.8.8 Coupling the Servomotor to the Load .......................................................................................... 50
4 Operation ............................................................................................................ 51
4.1 Power On and Off Sequencing ..................................................................................................... 51
4.2 Discrete Inputs (IN1’, IN2', IN3', IN4’/OUT4')................................................................................ 52
4.2.1 Hardware Travel Limits (IN1', IN2') .............................................................................................. 52
4.2.2 E-Stop Input (IN3’) ....................................................................................................................... 52
4.2.3 Quick Stop Input (IN3’)................................................................................................................. 53
4.3 Discrete Outputs (OUT1’ – OUT5’) ............................................................................................... 53
4.3.1 Brake Control Output (OUT3’)...................................................................................................... 54
4.3.2 Drive Ready Output (OUT4’)........................................................................................................ 54
4.3.3 Encoder Feedback Zero Reference Output (OUT5’) ................................................................... 54
4.4 Status Indications.......................................................................................................................... 55
4.4.1 ServoWire Communications (Middle Dot of ID/Status Display) ................................................... 56
4.4.2 Torque Enabled (Right lower dot of ID/Status Display) ............................................................... 56
4.4.3 Bus Power (Yellow LED above TB1) ........................................................................................... 56
4.4.4 Sensor Status LED (to the side of TB4)....................................................................................... 56
4.4.5 Digital Input LEDs (to the side of TB5 INx positions)................................................................... 56
4.4.6 Digital Output LEDs (to the side of TB5 OUTx positions) ............................................................ 56
4.4.7 Axis ID and Fault ID ..................................................................................................................... 56
4.5 Commutation Modes ..................................................................................................................... 61
4.6 Commutation Feedback Signals – Quadrature Feedback sources .......................................... 61
4.7 ServoWire Drive Commutation Feedback ( Hall Signals ) ......................................................... 62
4.8 Quadrature Feedback Signals ...................................................................................................... 63
4.9 Commutation Feedback Signals – Resolver Feedback drive ................................................... 63
4.10 Regenerative Loads ................................................................................................................... 64
4.10.1 Shunt Regulator ........................................................................................................................... 65
4.10.2 Sizing a Regen Resistor: Application-specific Formulas ............................................................ 65
4.10.3 Sizing a Regen Resistor: Use Average Regenerative Power..................................................... 68
4.10.4 Sizing a Regen Resistor: Regen Transistor and Resistor Limitations ......................................... 68
4.10.5 Bus Sharing.................................................................................................................................. 71
4.10.6 Bus Sharing Limitations ............................................................................................................... 71
4.10.7 Shunt Regulator Overload............................................................................................................ 72
4.10.8 Servomotor Temperature Protection............................................................................................ 73
4.11 Tuning - Loop Diagram.............................................................................................................. 74
4.12 Filter … Low-Pass Current Cutoff ............................................................................................ 77
4.13 Filter … Digital Notch................................................................................................................. 77
5 Getting Started ................................................................................................... 78
5.1 Test Run.......................................................................................................................................... 78
5.1.1 Servomotor Check ....................................................................................................................... 78
5.1.2 ServoWire SD 115/230 VAC Drive Check (SAC-SD_2__) .......................................................... 78
5.1.3 ServoWire SD 460 VAC Drive Check (SAC-SD_4__) ................................................................. 78
5.1.4 Preparation for Test Run.............................................................................................................. 79
6 Specifications ..................................................................................................... 81
6.1 ServoWire SD Drive Specifications ............................................................................................. 81
6.1.1 Environmental Specifications ....................................................................................................... 81
6.1.2 Mechanical Specifications............................................................................................................ 81
6.1.3 General Electrical Specifications for 115/230 VAC Drives (SAC-SD_2__) ................................. 83
6.1.4 General Electrical Specifications for 460 VAC Drives (SAC-SD_4__) ........................................ 83
6.1.5 ServoWire SD Drives Performance Specifications ...................................................................... 84
6.1.6 Output Specifications for 115/230 VAC Drives (SAC-SD_2__) ................................................... 85
6.1.7 I/O Specification (TB4 & TB5) ...................................................................................................... 86
6.1.8 SAC-SDx-S drive version Motor Encoder Interface Specifications (J4) ...................................... 88
6.1.9 SAC-SDx-R drive version Motor Resolver Interface Specifications (J4) ..................................... 89
6.1.10 Analog I/O Specificatoins (TB3) .................................................................................................. 90

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Table of Contents ServoWire SD Drive Manual

6.1.11 Connector Part Numbers ............................................................................................................. 91

7 Maintenance and Troubleshooting ................................................................... 93
7.1 ORMEC Product Support .............................................................................................................. 93
7.2 ServoWire SD Drive Troubleshooting Guide .............................................................................. 94
7.3 Servomotor Troubleshooting Guide.......................................................................................... 107

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ServoWire SD Drive Manual Table of Contents

Appendix A: System Wiring Diagram

115 / 230 / 460 VAC System Wiring Diagram.....................................................................................A-1
Appendix B: Drive I/O Schematics
Resolver Option Board........................................................................................................................ B-1
SD Drive Logic Board - Sensor Interface............................................................................................ B-2
SD Drive Logic Board - External Connection Pinout........................................................................... B-3
SD Drive Logic Board - Encoder Interface.......................................................................................... B-4
SD Drive Logic Board - Optical Inputs & Outputs ...............................................................................B-5
Appendix C: Drive Component Outline Drawings
ServoWire SD Drive 115 / 230 VAC Mounting Information ................................................................C-1
ServoWire SD Drive 460 VAC Mounting Information..........................................................................C-2
Regen Resistors..................................................................................................................................C-4
Line Filters SAC-LF30C, 55C, 100C ...................................................................................................C-6
Line Filters SAC-LF215U, 230U......................................................................................................... C-7
Appendix D: G-Series Cable Drawings
CBL-GMSW (1-50 ft) ...........................................................................................................................D-1
CBL-GMSW (51-150 ft).......................................................................................................................D-2
CBL-QE25SW .....................................................................................................................................D-3
CBL-GMSW1, CBL-GMSWB1 ............................................................................................................D-4
CBL-GMSW2.......................................................................................................................................D-5
CBL-GMSW3.......................................................................................................................................D-6
CBL-GMSW2T ....................................................................................................................................D-7
CBL-GMSWT3, CBL-GMSWT5, CBL-GMSWT6, CBL-GMSWT9......................................................D-8
CBL-GMSWB (1-50 ft) ........................................................................................................................D-9
CBL-GMSWB (51-150 ft) ..................................................................................................................D-10
CBL-GMSWBT2 ................................................................................................................................D-11
CBL-GMSWB2 ..................................................................................................................................D-12
Appendix E: DE-Series Cable Drawings
CBL-DEMSW1, CBL-DEMSWB1........................................................................................................E-1
Appendix F: D-Series Cable Drawings
CBL-DMSW (1-50 ft) ........................................................................................................................... F-1
CBL-DMSW (51-150 ft) ....................................................................................................................... F-2
CBL-DMSW1, CBL-DMSMS2, CBL-DMSW4 ..................................................................................... F-3
CBL-DMSWT1, CBL-DMSWT2, CBL-DMSWT3, CBL-DMSWT4, CBL-DMSWT5,
CBL-DMSWT6..................................................................................................................................... F-4
CBL-DMSWB1, CBL-DMSWB2, CBL-DMSWB4 ................................................................................ F-5
CBL-DMSWBT1, CBL-DMSWBT2, CBL-DMSWBT3, CBL-DMSWBT4 ............................................. F-6
CBL-DMACB ....................................................................................................................................... F-7
Appendix G: H-Series Cable Drawings
CBL-HMSW (1-50 ft) .......................................................................................................................... G-1
CBL-HEMSW (51-150 ft).................................................................................................................... G-2
CBL-HEMSW (1-50 ft)........................................................................................................................ G-3
CBL-HEMSW1 (1-50 ft)...................................................................................................................... G-4
CBL-HMSW (51-150 ft) ...................................................................................................................... G-5
CBL-HMSW1, CBL-HMSW2, CBL-HMSW3, CBL-HMSW4, CBL-HMSW5, CBL-HMSW6, .............. G-6
Appendix H: Coupling Tech Note
Coupling High Performance Servos to Mechanical Loads................................................................. H-1

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Table of Contents ServoWire SD Drive Manual

List of Tables
Table 1, Differences between SAC-SW_, SAC-SM_ and SAC-SD_ Drives.................................................8
Table 2, Power Dissipation..........................................................................................................................19
Table 3, Line Filter Recommendations .......................................................................................................20
Table 4, Terminal Block Wiring Gauge and Screw Torque.........................................................................21
Table 5, Drive Sensor (TB4) Connections ..................................................................................................26
Table 6, Drive Input / Output (TB5) Connections ........................................................................................27
Table 7, ServoWire SD 115/230 VAC Drive (SAC-SD_2__) Power Connections (TB1)............................28
Table 8, ServoWire SD Drive (SAC-SD_225 – SD_260) Control Power Connections (TB2).....................29
Table 9, ServoWire SD 460 VAC Drive (SAC-SD_4__) Power Connections (TB1) ...................................29
Table 10, ServoWire SD Drive (SAC-SD_225 – SD_260) Control Power Connections (TB2)...................30
Table 11, Drive Analog I/O (TB4) Connections...........................................................................................30
Table 12, Encoder Motor Feedback Connector (J4) Descriptions (also see cable drawings in Appendix E)
..... 33
Table 13, Resolver Motor Feedback Connector (J4) Descriptions (also see cable drawings in Appendix E)
..... 35
Table 14, Pacer Feedback Connector Descriptions (also see cable drawings in Appendix E) .................35
Table 15, Additional Components for use with Fail-Safe Brakes G-Series Servomotor Connections........46
Table 16, Cable Drawings for G-Series Motors Without Brakes................................................................47
Table 17, Cable Drawings for G-Series Motors With Brakes .....................................................................47
Table 18, Cable Drawings for D-Series Motors Without Brakes................................................................48
Table 19, Cable Drawings for D-Series Motors With Brakes .....................................................................48
Table 20, Cable Drawings for H-Series Motors Without Brakes................................................................49
Table 21, Quick Stop Operation..................................................................................................................53
Table 22, ServoWire SD Drive Fault Codes (continued from previous page) ...........................................60
Table 23, Valid Hall Signal Sequences .......................................................................................................62
Table 24, Regen Resistor Selection Requirements ....................................................................................69
Table 25, Standard Regen Resistor Specifications ....................................................................................70
Table 26, Standard Regen Resistor Drive Compatibility.............................................................................70
Table 27, Regen Transistor Turn-On and other Bus Voltage Levels ..........................................................71
Table 28, Motor Over-Temperature Input ...................................................................................................73
Table 29, Environmental Specifications ......................................................................................................81
Table 30, Mechanical Specifications...........................................................................................................82
Table 31, General Electrical Specifications for 115/230 VAC Drives (SAC-SD_2__) ................................83
Table 32, General Electrical Specifications for 460 VAC Drives (SAC-SD_4__) .......................................84
Table 33, PWM Frequencies and Torque Loop Update Rates ...................................................................84
Table 34, SMLC/MotionObjects Command and Loop Update Rates .........................................................84
Table 35, Output (TB1 pins U, V, W) Specifications with Single Phase Input Power .................................85
Table 36, Output (TB1 pins, U, V, W) Specifications with Three Phase Input Power.................................85
Table 37, Output (TB1 pins, U, V, W) Specifications with Three Phase Input Power.................................85
Table 38, I/O Specifications (TB4 and TB5)................................................................................................87
Table 39, SAC-SDxx-S version Motor Encoder Specifications (J4)............................................................89
Table 40, SAC-SDx-R drive version Motor Encoder Specifications (J4) ....................................................90
Table 41, Analog I/O Specifications (TB3) ..................................................................................................90
Table 42, Connector Part Numbers ............................................................................................................91

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ServoWire SD Drive Manual Table of Contents

List of Figures
Figure 1, ServoWire SD Drives 203 - 220 Outline Drawings......................................................................11
Figure 2, ServoWire SD Drives 203 - 220 with 1394 locking connectors, Outline Drawings .....................11
Figure 3, ServoWire SD Drives 225-260 & 417-425 w/o locking connectors, Outline Drawings ...............12
Figure 4, ServoWire SD Drives 225-260 & 417-425 with 1394 locking connectors, Outline Drawings......12
Figure 5, ServoWire SD Drives 405 & 410 w/o locking connectors, Outline Drawings ..............................13
Figure 6, ServoWire SD Drives 405 & 410 w/ 1394 locking connectors, Outline Drawings.......................13
Figure 7, ServoWire SD Drives 435 & 460 w/o locking connectors Outline Drawings ...............................14
Figure 8, ServoWire SD Drives 435 & 460 w/ 1394 locking connectors, Outline Drawings.......................14
Figure 9, ServoWire SD Drive Connections Overview (SD_203 – SD_220).............................................22
Figure 10, ServoWire SD Drive Connections Overview(SD_225 – SD_260).............................................23
Figure 11, ServoWire SD Drive Connections Overview (SD_405 – SD_410)...........................................24
Figure 12, ServoWire SD Drive Connections Overview(SD_417 – SD_450).............................................25
Figure 13, CBL-SW-A-x Figure 14, CBL-SW-BA-x .......................................................32
Figure 15, CBL-SW-B-x Figure 16, CBL-SW-BL-x ........................................................................32
Figure 17, Schematic of ASEN and BSEN wiring for NPN and PNP sensors............................................36
Figure 18, Schematic of IN1’, IN2’, IN3’ and IN4’/OUT4' Inputs .................................................................38
Figure 19, Schematic of Discrete Outputs OUT1'-OUT5', -S version, prior to version 1.2.........................39
Figure 20, Schematic of Discrete Outputs OUT1'-OUT5', -R version and –S version 1.2 or later .............40
Figure 21, Regen Resistor Connection.......................................................................................................41
Figure 22, Bus Sharing Connections ..........................................................................................................42
Figure 23, Drive ID Setup Flowchart...........................................................................................................43
Figure 24, Top View of ServoWire SD Drive showing Drive ID Pushbutton...............................................43
Figure 25, G-Series Torque Derating for High Ambient Temperature........................................................44
Figure 26, Fail-Safe Brake Interlock Circuit – SAC-SDx-S versions, versions before 1.2 .........................46
Figure 27, Fail-Safe Brake Interlock Circuit – SAC-SDx-R versions and –S versions 1.2 and later ..........46
Figure 28, Brake Output Sequence of Operation .......................................................................................54
Figure 29, ID/Status Indications..................................................................................................................55
Figure 30, Hall signals and Motor Back EMF waveforms...........................................................................61
Figure 31, Valid Hall States (6 Pole Motor Example diagram) ...................................................................62
Figure 32, Quadrature Encoder Channel Description ................................................................................63
Figure 33, Simplified Schematic of Shunt Regulator ..................................................................................65
Figure 34, Regeneration during deceleration. ............................................................................................65
Figure 35, Shared Bus Capacitors..............................................................................................................72

SAC-SD 01c page vii

ServoWire SD Drive Manual Welcome

Chapter 1
Welcome
1 Welcome

This manual provides information about ORMEC's ServoWire SD servodrives,

H-Series, G-Series and D-Series Servomotors--- providing both technical
descriptions and information required for their installation, operation and
maintenance.
The manual is divided into the following chapters:
Chapter 1 Welcome introduces you to this manual.
Chapter 2 General Description gives an overview of the ServoWire SD
Drive product family.
Chapter 3 Installation provides instructions on how to install your
ServoWire SD Drive(s), including a complete hardware
description.
Chapter 4 Operation documents the power up and initial configuration
approach for the ServoWire SD Drive.
Chapter 5 Getting Started provides detailed instructions on how to run
your ServoWire SD Drive system for the first time.
Chapter 6 Specifications provides a detailed list of performance
specifications for ServoWire SD Drives.
Chapter 7 Maintenance and Troubleshooting documents the various
status and fault indicators.
Appendix Appendixes contain a detailed drawing set.

SAC-SD 01c page 1

ServoWire SD Drive Manual Welcome

page 2 SAC-SD 01c

ServoWire SM Drive Manual Installation

Chapter 2
General Description
2 General Description

This manual covers ServoWire SD Drives, which operate with SMLC or Orion
Motion Controller or a Host PC that has Open HCI IEEE-1394 interfaces and
control a wide variety of AC Servomotors, including ORMEC H-Series, G-Series
and D-Series Servomotors.

2.1 ServoWire SD Drive Capabilities and Features

• ServoWire Interface: The IEEE 1394 ServoWire interface to the SMLC or
Orion Motion Controller or Host PC simplifies panel wiring and reduces
cabling cost.
• Simple Setup: The drive’s axis ID is programmed via a pushbutton on the
top of the drive; all other drive configuration settings are set by the user’s
application software using the ServoWire interface, eliminating drive
jumpers, address switches, and potentiometers.
• All Digital: High-speed DSP-controlled current loops for precise torque,
velocity and position mode operation.
• Standard Line Voltage Input: ServoWire SD 115/230 VAC Drives (SAC-
SD_2__) are available for operation directly on commercial power lines
supplying either 115 (+15%, -20%) or 230 (+15%, -20%) VAC for the main
power as well as the control power. ServoWire SD 460 VAC Drives (SAC-
SD_4__) are available for operation directly on commercial power lines
supplying either 230 (+15%, -20%) or 460 (+15%, -20%) VAC for the main
power and either 115 (+15%, -20%) or 230 (+15%, -20%) VAC for the control
power. Note on the 35A and 50A drives control power is limited to 230 VAC.

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Installation ServoWire SD Drive Manual

• Fault Detection and Protection: Detection and protection against:

Motor short Encoder open wire detection
Peak & RMS drive current limit Hall sensor phasing error
Peak & RMS motor current limit Motor over temperature
Missing phase detection ServoWire network
(SD_225, SD_235, SD_260 SD_504, communications errors
SD_410, SD_417, SD_425, SD_435 &
SD_450 only)
• Diagnostics: A 2-digit 7-segment display that shows the servodrive
identification (ID) number, enabled status and fault status, 11 LEDs
indicating I/O status and I/O power.
• Software Configurable General Purpose I/O: ServoWire SD Drives have
general purpose I/O which can also be configured in software to provide an
emergency stop or quick stop input and drive ready and fail-safe brake
control outputs.
• Variety of Commutation Options: ServoWire SD Drives can be software
configured for sinusoidal or trapezoidal commutation for AC brushless
motors, as well as for DC operation to control DC motors, voice coils and
other single phase actuators.
• Soft Start: Circuitry is provided on all 115/230 VAC ServoWire SD Drives
(SAC-SD_2__) and all 460 VAC ServoWire SD Drives (SAC-SD_4__) to
reduce servodrive in-rush current.
• Torque Mode Operation: When combined with velocity and position loops
in high performance Host PC’s or Orion Motion Controller, torque mode
operation allows extremely high load inertia to motor inertia ratios.
• Velocity Mode Operation: Velocity mode operation allows for fast and
precise velocity control. The computing burden on the PC is reduced
compared to torque mode operation by closing the velocity loop on the
ServoWire SD Drive.
• Position Mode Operation: Position mode operation allows for precise
motion control with the minimum computing burden on the PC by closing
the velocity and position loops in the ServoWire SD Drive.
• Wide Current Loop Bandwidth: For high positioning accuracy and
response.
• Velocity and Torque Monitor: High quality velocity monitor and torque
monitor signals are provided to simplify system testing.
• Small Package: ServoWire SD Drives have a small footprint to conserve
panel space.
• Shunt Regulation: All Models except SAC-SD_203 and SAC-SD_205 have
shunt regulation circuitry. If an application requires regenerative operation,
regenerative discharge resistors can be mounted external to the servodrive.
• Serial Encoder: The motor encoder interface supports several serial
encoder types. Yaskawa Sigma II 13 and 17-bit incremental and 16, 17 and
20-bit absolute encoders are supported. The Tamagawa TS56xx series of
absolute encoders is also supported. The drive battery option is required to
maintain multiturn information for absolute encoders.

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ServoWire SM Drive Manual Installation

SAC-SD 01c page 5

Installation ServoWire SD Drive Manual

2.1.1 ServoWire SD Drive Model Number Description

SAC-SD M 2 03 - S B A P 0

Pacer Support (optional)

P = adds incremental pacer support
0 = no pacer support

Analog I/O (optional)

A = Analog I/O included
0 = option not included

Absolute Encoder Support (optional)

B = adds backup battery for absolute enc. (-S only)
0 = no battery added
Primary Feedback
R = Resolver Support
S = Serial & Incremental Encoder support

Maximum Continuous Current

03 = 2.4 Arms/∅ (115/230 VAC model)
3.0 Arms//∅ (24-96 VDC model)
05 = 4.2 Arms/∅ (115/230 VAC model)
05 = 5 Arms/∅ (460 VAC model)
10 = 8.2 Arms/∅ (115/230 VAC model)
10 = 10 Arms/∅ (460 VAC model)
17 = 13.9 Arms/∅ (115/230 VAC model)
17 = 17 Arms/∅ (460 VAC model)
20 = 16.3 Arms/∅
25 = 25 Arms/∅
35 = 35 Arms/∅
50 = 50 Arms/∅
60 = 60 Arms/∅

Bus Voltage
2 = 115/230 VAC
4 = 460/230 VAC

Controller (Firmware)
M = SMLC & MotionObjects applications.
Blank = Orion Motion Controller (MotionBASIC)

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ServoWire SM Drive Manual Installation

ServoWire Drive logo's Model Number

SD ..... Used with ORION Motion Controller.

MotionDESK is used to upgrade the drive firmware.

Yellow Logo

SDM.... Used with SMLC & MotionObjects applications.

ServoWire Pro is used to upgrade the drive firmware.

Blue Logo

2.1.2 Differences between SAC-SW / SAC-SM / SAC-SD Drives.

The SD line of ServoWire drives has different features and functionality from
the SW and SM series of drives, as shown in Table 1.

Feature SW Servodrive SM Servodrive SD Servodrive

ServoWire Soft Motion Soft Motion
1394 Comm. Speed 200 Mbit/sec maximum 400 Mbit/sec maximum 1394a or 1394b with 800
Mbit/sec maximum
I/O Connectors Pluggable terminal block Pluggable header Pluggable terminal blocks
Field Oriented Control No Yes, firmware 3.0.1 or later Yes, firmware 3.0.1 or later
High-Speed Sensors 3 – ASEN, BSEN & 2 – ASEN & BSEN 2 – ASEN & BSEN
CSEN
High-Speed Sensor Pull- 3 choices – none (PNP), 2 choices – none (PNP) or 2 choices – none (PNP) or
up Resistor 2.38k (NPN) or 20k 2.7k (NPN) 2.7k (NPN)
(NPN)
Digital I/O (optically 2 Inputs, 6 Outputs 3 Inputs, 4 Outputs, 3 Inputs, 4 Outputs,
isolated) 1 Bi-directional I/O. 1 Bi-directional I/O.
Brake Output OUT 6 OUT 3 OUT 3
Drive Ready Output OUT 2 OUT 4 OUT 4
Hardware Travel IN1 & IN2 IN1 & IN2 IN1 & IN2
Limits
Encoder Reference Z Z Out OUT 5 OUT 5
Output
Delay Counter DELAY
Output
Option Module None Support for Feedback and Support for Feedback and
Interfaces I/O Option Modules I/O Option Modules
Analog I/O 2 Outputs 1 Output, 1 Input

SAC-SD 01c page 7

Installation ServoWire SD Drive Manual

Feature SW Servodrive SM Servodrive SD Servodrive

ServoWire Soft Motion Soft Motion
ID/Status Displays 2-digit seven segment Single digit seven segment 2-digit seven segment
display, 6 I/O status display and Bus Power display, 11 I/O status LEDs
LED's and Bus Power LED and Bus Power LED
LED
Auxiliary Encoder Input Drive Option ( / P ) Drive Option ( / P ) Drive Option ( -P )
Delay Counter Drive Option ( / D)
Yaskawa Absolute Drive Option ( /A ) Drive Option ( /A ) adds Drive Option ( -B ) adds
Encoder Support battery. Sigma II support battery. Sigma II support
always present on /S. always present on -S.
Resolver Feedback None Option Module Integral on –R version.
Option SAC-SD-RES

Table 1, Differences between SAC-SW_, SAC-SM_ and SAC-SD_ Drives.

2.1.3 SAC-SD Drives 1394 Cable change.

In the first half of 2009 the SAC-SDx series drives were transitioned to use
locking ServoWire 1394 connectors. The original drive had 3 connectors. The
new drives have 2 connectors, each capable of securing the new 1394 cables with
locking screws.
To take full advantage of the new locking cables you will need to order cables
CBL-SW-BL-x, where the L specifies the locking screws. The locking cables are
only available for 1394 b to 1394 b connections. Such connections are available
on the SAC-SD servodrives and the SMLC controller. Therefore, connections
between the SMLC and the SAC-SD drive and from SAC-SD drive to SAC-SD
drive can use the locking cables. Ormec’s Orion controller uses 1394 a style
connectors which are not supported with locking cables. A system with an Orion
and multiple SAC-SD drives must use a CBL-SW-BA for the Orion to drive
connection and then can use CBL-SW-BL locking cables from drive to drive.
In this manual pictures of the face of the drives show both versions, 3 connector
and 2 connector. Use the drawing which matches your drive.

2.1.4 SAC-SD Drives changes marked by version 1.2.

In the first half of 2009 the SAC-SDx series of drives version 1.2 was released.
The changes included:
1) ServoWire 1394 connectors now support screw locking cables and changed
from 3 to 2 connectors. See section above for more details.
2) The –S version OUT3 and OUT4 current capability increased. It now
matches the higher current capabilities always available on the –R version.

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ServoWire SM Drive Manual Installation

Chapter 3
Installation
3 Installation

3.1 Receiving and Inspection

ORMEC Servodrives and their associated accessories are put through rigorous
tests at the factory before shipment. After unpacking, however, check for
damage, which may have been sustained in transit. The bolts and screws should
all be tight, and motor output shafts should rotate freely by hand. Check the
servodrive and any accessories for bent or broken components or any other
physical damage before installation.

3.2 ServoWire SD Drive Panel and Environment Considerations

ServoWire SD Drives are designed for panel mounting, with the panel in turn
mounted in a metallic enclosure (supplied by the machine builder). For optimal
EMC (Electromagnetic Compatibility) shielding, the enclosure should have
continuous ground continuity maintained between all metal panels.
For high quality servo performance, proper wiring, grounding and shielding
techniques must be considered.
¾ Refer to the “Shielding and Grounding Electrical Panels” Application Note,
which is included as an Appendix to this manual and can also be downloaded
from ORMEC's site on the World Wide Web at [Link]
The servodrive environment should be maintained as follows:
• Ambient operating temperature should be above 0oC & below 50oC.
• If the electrical panel is subjected to vibration, mount the units on shock
absorbing material. Be sure to maintain a good electrical connection.
• Avoid use in corrosive atmospheres, which may cause damage over time.
• Select a location with minimum exposure to oil, water, hot air, high
humidity, excessive dust, or metallic particles.
• The proper mounting orientation for the servodrive is vertical on a panel
using the mounting holes on the base plate.
3 holes with SD_203 through SD_220, and SD_405 through SD_410
4 holes with SD_225 through SD_260, and SD_417 through SD_450

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Installation ServoWire SD Drive Manual

• Allow sufficient clearance around servodrive for airflow, and provide proper
ventilation. Section 3.3 shows the minimum clearance between drives.
• External regenerative discharge resistors should be mounted in an enclosure
separate from the ServoWire SD Drive enclosure, if possible. Regenerative
discharge resistors can become extremely hot, so proper ventilation must be
provided.

page 10 SAC-SD 01c

ServoWire SM Drive Manual Installation

3.3 ServoWire SD Drives Outline Drawings

Note: Add 1-inch [25-mm] width the -P option and for each optional plug-in module.

3.3.1 Mounting Information for SAC-SD_203, 205, 210, 217, 220

Figure 1, ServoWire SD Drives 203 - 220 Outline Drawings

Figure 2, ServoWire SD Drives 203 - 220 with 1394 locking connectors, Outline Drawings

SAC-SD 01c page 11

Installation ServoWire SD Drive Manual

3.3.2 Mounting Information for SAC-SD_225, 235, 260, 417 & 425

Figure 3, ServoWire SD Drives 225-260 & 417-425 w/o locking connectors, Outline Drawings

Figure 4, ServoWire SD Drives 225-260 & 417-425 with 1394 locking connectors, Outline Drawings

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ServoWire SM Drive Manual Installation

3.3.3 Mounting Information for SAC-SD_405 & 410

Figure 5, ServoWire SD Drives 405 & 410 w/o locking connectors, Outline Drawings

Figure 6, ServoWire SD Drives 405 & 410 w/ 1394 locking connectors, Outline Drawings

SAC-SD 01c page 13

Installation ServoWire SD Drive Manual

3.3.4 Mounting Information for SAC-SD_435 & 450

Figure 7, ServoWire SD Drives 435 & 460 w/o locking connectors Outline Drawings

Figure 8,
ServoWire SD
Drives 435 & 460
w/ 1394 locking
connectors,
Outline
Drawings

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ServoWire SM Drive Manual Installation

Additional clearance above, below and to the sides of the ServoWire SD Drives is
also required for heat dissipation:
SAC-SD_203, SAC-SD_205 and SAC-SD_210
Add 2” (51 mm) clearance top and bottom.
Add 1” (25 mm) clearance each side.
SAC-SD_217 and SD_405
Add 2” (51 mm) clearance top and bottom.
Add 1.2” (31 mm) clearance each side.
SAC-SD_220 and SD_410
Add 2” (51 mm) clearance top and bottom.
Add 1” left-side, 2” (51 mm) right-side clearance.
SAC-SD_225, SAC-SD_235 , SAC-SD_260, SAC-SD_417, SAC-SD_425, SAC-
SD_435 and SAC-SD_450
Add 2” (51 mm) clearance.
Add 4” (102 mm) clearance bottom.
Add 1” (25 mm) clearance each side.

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Installation ServoWire SD Drive Manual

3.4 Software Configuration Setup

The following motor parameters and drive settings are software configurable:
• Motor Model Number / name
• Continuous Stall Current
• Peak Current
• Motor Torque (Peak, Continuous, Rated)
• Maximum Speed of motor
• Resistance measured phase-to-phase
• Inductance measured phase-to-phase
• Inertia of motor
• Number of Poles of motor
• Feedback Offset in degrees (Hall or Resolver offset)
• Maximum Drive Input Voltage based on motor’s rating
• Commutation Type: (Sine-Brushless/Trap-Brushless/DC-Brush)
• Commutation Feedback Type:
Incremental encoder with separate U,V,W hall inputs -or-
Yaskawa Sigma I incremental encoder -or-
Yaskawa Sigma II Serial encoder-or-
Resolver
• Feedback Resolution (Counts per revolution)
• Thermal Switch in motor is present/not present
• Thermal Time Constant of motor.
• Motor Over Temperature Handling (Ignore/Error/Drive Fault)
• Hardware Travel Limit Inputs (Enable/Disable)
• Input Voltage for Drive (115/230/460 VAC)
• Pull-up Resistors for ASEN & BSEN:
2.7 KΩ (8.9 mA at 24 VDC) for NPN sensor -or-
No pull-up resistor for PNP sensor
• ASEN & BSEN gating (Enable/Disable)
• ASEN, BSEN, ZREF trigger (Rising/Falling/High/Low)
• ZOUT (primary or auxiliary axis)
• Regen Resistor Resistance (Ohms)
• Regen Resistor Rated Power (Watts)
The ServoWire icon, shown at the left, will be displayed in this manual wherever
one of these drive parameters is discussed, to indicate that the functionality of
the drive will depend on the Software Configuration setting.

SAC-SDM ..............................used with SMLC or MotionObjects software.

These configuration settings are stored as part of your ServoWire Pro software project file
( [Link] ), and are downloaded to the drive by the application program.

SAC-SD..................................used with ORION Motion Controller.

These configuration settings are stored as part of your MotionDESK software project file
( [Link] ), and are downloaded to the drive by the Orion MotionBASIC application
program.

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ServoWire SM Drive Manual Installation

3.5 ServoWire SD Drives Power Considerations

3.5.1 Supply Power for 115/230 VAC (SAC-SD_2__) Drives

ServoWire SD 115/230 VAC Drives (SAC-SD_2__) can be operated, through
line filters or an isolation transformer, on commercial power lines supplying
either 115 (+15%, -20%) or 230 (+15%, -20%) VAC, 50/60 Hz. The Drives are
suitable for use on a circuit capable of delivering not more than 5000 RMS
symmetrical amperes, 240 VAC maximum.
To prevent power line accidents due to grounding error, contact error, or to
protect the system from a fire, circuit breakers or fuses must be installed
according to the number and size (current capacity) of ServoWire SD Drives
used. Slow-blow circuit breakers or fuses should be used because the servodrive
draws substantial inrush current at power up.

3.5.2 Supply Power for 460 VAC (SAC-SD_4__) Drives

ServoWire SD 460 VAC Drives (SAC-SD_4__) have different limits for control
power and motor power. This section deals with control power.
Control power (terminals r & t on TB2) for ServoWire SD 460 VAC Drives
models 405 through 425 (5 A through 25 A) can be operated, through line
filters or an isolation transformer, on commercial power lines supplying either
115 (+15%, -20%) or 230 (+15%, -20%) VAC, 50/60 Hz. The Drives are suitable
for use on a circuit capable of delivering not more than 5000 RMS symmetrical
amperes, 240 VAC maximum.
Control power (terminals r & t on TB2) for ServoWire SD 460 VAC Drives
models 435 and 450 (35 A and 50 A) must be operated at 230 VAC ONLY. It
can be operated, through line filters or an isolation transformer, on commercial
power lines supplying 230 (+15%, -20%) VAC, 50/60 Hz. The Drives are suitable
for use on a circuit capable of delivering not more than 5000 RMS symmetrical
amperes, 240 VAC maximum.
To prevent power line accidents due to grounding error, contact error, or to
protect the system from a fire, circuit breakers or fuses must be installed
according to the number and size (current capacity) of ServoWire SD Drives
used. Slow-blow circuit breakers or fuses should be used because the servodrive
draws substantial inrush current at power up.

3.5.3 Shielding, Power Line Filtering & Noise Suppression

The Servodrive uses high voltage switching power transistors in the main DC
Bus circuit. When these transistors are switched, the di/dt or dv/dt switching
noise may sometimes prove objectionable depending on the wiring and/or
grounding method. The Servodrive also utilizes a DSP, which can be susceptible
to power line interference caused either by the output switching transistors or
other equipment on the power line, such as welders, electrical discharge
machines, induction heating equipment, etc. Careful layout of wiring and power
line filtering will help prevent noise interference. Recommendations with
respect to wiring and grounding are described later in this section.
¾ Further information is available in the "Shielding & Grounding Electrical
Panels" Application Note, which is included as an Appendix to this manual

SAC-SD 01c page 17

Installation ServoWire SD Drive Manual

and can also be, downloaded at ORMEC's Web Site

([Link]
It is recommended that line filters be installed to eliminate electro-magnetic
interference coming into the system from the power line, as well as block
switching noise from being transmitted back out to the power line from the
servodrives.

3.5.4 Sizing Fuses, Line Filters, and Transformers for 115/230 VAC (SAC-SD_2__) and 460 VAC
(SAC-SD_4) Drives
To determine current requirements for fuses, line filters and transformers for
main power; use the following conservative formulas:

Required Power (in KVA) = 1.1 * Rated Power of Motor (in Watts)
1000

Required Current (in Amps) = 1.1 * RatedPower of Motor (in Watts)

Incoming Line Voltage (in Volts AC)

Note: Rated Power of Motor can be found in Chapter 6, Specifications.

In cases where the motor is substantially over-sized for an application, consider
substituting the actual power required by the application into the above
formulas, instead of the motor’s rated power.
Branch circuit short protection used should be suitable for use on a circuit
capable of delivering not more than 5000 rms symmetrical amperes, 240 V or
480 V maximum depending on drive and input.

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ServoWire SM Drive Manual Installation

3.5.5 Power Dissipation

Use the following table to determine cabinet cooling requirements:

Dissipated Power (Watts)

Control Power External
Regen Resistor
Max Typical Main Power (if used)
SAC-SD_203 45 20 55 ⎯
SAC-SD_205 45 20 90 ⎯
SAC-SD_210 45 20 180 800 max.
SAC-SD_217 45 20 300 1200 max.
SAC-SD_220 55 30 350 2400 max.
SAC-SD_225 55 30 450 3000 max.
SAC-SD_235 55 30 600 4175 max.
SAC-SD_260 55 30 900 7100 max.
SAC-SD_405 45 20 120 1200 max.
SAC-SD_410 45 20 240 2400 max.
SAC-SD_417 55 30 405 4000 max.
SAC-SD_425 55 30 600 5970 max.
SAC-SD_435 60 35 835 8350 max.
SAC-SD_450 60 35 1200 12000 max.
Table 2, Power Dissipation

Main power dissipation is shown in Table 2 for the rated output power of the
drive. The actual dissipated main power may be lower, depending on the motor
and/or application requirements. To more closely estimate main power
dissipation, use the conservative formula: 0.1*(rated power of the motor). In
cases where the motor is substantially oversized for the application, use 0.1*(the
power required by the application).
Actual power dissipated in the regen resistor is dependent on the application
requirements. Table 2, column “External Regen Resistor” shows the rated
regen capacity of the ServoWire SD Drive.

3.5.6 Line Filters

Once the incoming power service is determined, the appropriate main power line
filter can be selected from Table 3. In the case of a system using multiple
ServoWire SD Drives, they may share one line filter per cabinet.

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Installation ServoWire SD Drive Manual

Total
ServoWire SD Main Power Continuous Main Power
Drive Input Voltage Current Line Filter
SAC-SD_203 Up to 15 Amps SAC-LF215U
Single phase
SAC-SD_205 Up to 30 Amps SAC-LF230U
SAC-SD_210 Up to 30 Amps
SAC-LF30C
SAC-SD_217
SAC-SD_220
SAC-SD_225 30 – 55 Amps SAC-LF55C
SAC-SD_235
SAC-SD_260
Three-phase
SAC-SD_405
SAC-SD_410
55 – 100 Amps
SAC-SD_417 SAC-LF100C
SAC-SD_425
SAC-SD_435
SAC-SD_450
Table 3, Line Filter Recommendations

The following methods are recommended for proper installation of line filters:
1. The filter must be mounted on the same panel as, and as close as possible to
the ServoWire SD Drive(s).
2. Paint or other panel covering material should be removed before mounting
the filter.
3. All SAC-LF___C line filter ground connections should be tied to earth
ground with a single wire (preferably braid), and the filter must be
grounded before connecting the ServoWire SD Drives.
4. Line filters should not be touched for a minimum of 10 seconds after removal
of the supply power.
5. Separate the input and output leads by a minimum of 10 inches (250 mm).
Do not bundle them or run them in the same duct or wireway.
Do not bundle the ground lead with the filter output lines or other
signal lines, and do not run them in the same duct.

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ServoWire SM Drive Manual Installation

3.5.7 Terminal Block Wiring Guidelines

All ServoWire SD terminal block wiring should be UL listed copper wire with at
least an 80C-temperature rating (wiring to regen resistors should be heat
resistant, non-combustible insulation). The maximum wire gauge and screw
terminal torque for each terminal block is indicated in Table 4. Wiring for TB1
should be twisted pair, shielded with the drain wire connected to earth ground
(NOTE: the SHIELD connections at various points on the ServoWire SD Drive
are connected to the frame ground).

Wire Gauge Screw Torque

(AWG) (in-lb)
[mm2] [N-m]
Terminal Block - TB1 - Power

SAC-SD_203 to SD_220 22 to 12 7.0 to 9.0

SAC-SD_405 to SD_410 [0.64 to 2.1] [0.8 to 1.0]

SAC-SD_225 to SD_260 18 to 4 16
[1.0 to 5.2] [1.8]
SAC-SD_417 to SD_450
Terminal Block - TB2 – Power

(SAC-SD_225 to SD_260 only) 24 to 10 4.4 to 5.3

[0.51 to 2.6] [0.5 to 0.6]
Terminal Block – TB3 – Analog I/O

All models 30 to 14 1.95

[0.14 to 1.5] [.22]
Terminal Block – TB4 – Drive I/O

All models 30 to 14 1.95

[0.14 to 1.5] [.22]
Terminal Block – TB5 – Drive I/O

All models 30 to 14 1.95

[0.14 to 1.5] [.22]

Table 4, Terminal Block Wiring Gauge and Screw Torque

NOTE: Install all power wiring (including ground wiring) according to NEC
(National Electric Code) or UL (Underwriters Laboratories)
specifications and in compliance with local ordinances.

SAC-SD 01c page 21

 Installation ServoWire SD Drive Manual

3.6 ServoWire SD Drive Connections

This section describes the ServoWire SD Drive. Signal descriptions are given in
Table 6 through Table 12. The remainder of Section 3.5.7 shows additional
wiring information. Detailed electrical specs are in Section 6.1, ServoWire SD
Drive Specifications. Part numbers for these and mating connectors are in
Section 0 (page 89).

TB3 (page 27)

Analog I/O
1 FG

2 AOUT

3 AGND
4 AIN Control Power Input
115 or 230(+15%, -20%)
Single phase, 50/60 Hz
TB4
1 FG
(page 28)
2 ASEN ServoWire
Main Power Input
3 BSEN (J3 on ver. up
115 or 230(+15%, -20%)
to 1.2)
4 V+S Single or three phase, 50/60 Hz
5 V-S SAC-SD_203-205: 1φ (L1,L2)
SAC-SD_210-220: 3φ (L1,L2,L3)

TB5 Ground for Control &

1 V+S Main Power Input
2 V-S (page 23)
Drive I/O External Regen Resistor
3 IN1’
(if used)
4 IN2’ (No Regen shunt capability on
5 IN3’ SAC-SD_203 or SAC-SD_205)
(page 24)
IN4’/
6 Drive I/O
OUT4’
OUT4
7
RTN (page 30) J4 Motor Power & Ground
8 FG Motor Feedback
(Colors shown are for
9 OUT1’ Ormec-supplied cables.
10 OUT2’
See pages 44 for Cable
part numbers, and
11 OUT3’ Appendix E for Cable
drawings.)
OUT5’ /
12
ENCZ

Pacer Feedback J5. (page 31)

Located on bottom of drive.

Figure 9, ServoWire SD Drive Connections Overview (SD_203 – SD_220)

page 22 SAC-SD 01c

 ServoWire SM Drive Manual Installation

TB3 Analog I/O – Opt.

on top. (page 27)

TB1

TB2 (page 28) L1 Main Power Input

Control Power 115 or 230 VAC
115 or 230(+15%, -20%) (+15%, -20%)
L2
TB3 Single phase, 50/60 Hz Three phase, 50/60 Hz
1 FG J1 & J2 & J1 r L3
J3
2 AOUT
(page 28) t
3 AGND ServoWire J2 Main Power Input Ground

4 AIN
J3 Bus +
(J3 on ver. External Regen
TB4 up to 1.2) Resistor
RG (If Used)
1 FG
2 ASEN 1
TB4 (page 23) Bus -
3 BSEN Drive I/O
5
4 V+S
U
5 V-S
1
V
Motor Power & Ground
TB5 TB5 (page 24)
1 V+S Drive I/O (See pages 44 for Cable part
W
12
2 V-S numbers, and Appendix E for
3 IN1’ Cable drawings.)
4 IN2’
5 IN3’
SH
IN4’/ Motor Power Cable
6
OUT4’ J4 (page 30) Shield Connection
OUT4 Motor Feedback
7
RTN
8 FG

9 OUT1’
10 OUT2’
11 OUT3’
J5 Pacer Feedback – Opt. on
OUT5’ / bottom. (page 31)
12
ENCZ

Figure 10, ServoWire SD Drive Connections Overview(SD_225 – SD_260)

SAC-SD 01c page 23

Installation ServoWire SD Drive Manual

(page 27)
Analog I/O
TB3 - Top
TB3 TB1

1 FG
Control Power Input
2 AOUT
r 115 or 230(+15%, -20%)
3 AGND Single phase, 50/60 Hz
4 AIN t

L1
TB4 Main Power Input
230 or 460(+15%, -20%)
1 FG J1
L2 Three phase, 50/60 Hz
2 ASEN
(page 28)
3 BSEN ServoWire J2
L3
4 V+S (J3 on ver. up
Ground for Control &
5 V-S to 1.2)
J3 Main Power Input

TB5 Bus + External Regen Resistor

1 V+S (if used)
1
2 V-S RG
(page 23) TB4
3 IN1’ Drive I/O 5
4 IN2’ Bus--
1
5 IN3’
Motor Power & Ground
IN4’/ U- Red
6 (page 24) TB5
OUT4’ (Colors shown are for
Drive I/O
OUT4 V- Ormec-supplied cables.
7 White
RTN See pages 44 for Cable
12
8 FG W- Black part numbers, and
Appendix E for Cable
9 OUT1’ drawings.)
10 OUT2’ (page 30) J4
11 OUT3’ Motor
Feedback
OUT5’ /
12 J4
ENCZ

Pacer
Feedback J5.
(page 31)
Located on
bottom of drive. J 5- Bottom

Figure 11, ServoWire SD Drive Connections Overview (SD_405 – SD_410)

page 24 SAC-SD 01c

ServoWire SM Drive Manual Installation

TB3
1 FG
2 AOUT
3 AGND TB3 Analog I/O – Opt.
4 AIN on top. (page 27)

TB2 (page29) Control Power TB1

SD_405 to SD_425 115 or
230(+15%, -20%) L1 Main Power Input
Single phase, 50/60 Hz 115 or 230 VAC
SD_435 & SD_450 (+15%, -20%)
L2
230 VAC ONLY Three phase, 50/60 Hz

r L3
J1
TB4
t
1 FG J1 & J2 & Main Power Input Ground
J3
2 ASEN J2
(page 28)
3 BSEN ServoWire Bus +
4 V+S External Regen
J3 Resistor
5 V-S (J3 on ver. RG (If Used)
1 up to 1.2)

TB5 TB4 (page 23) Bus -

1 V+S 5
Drive I/O
2 V-S U Motor Power & Ground
3 IN1’
1 (Colors shown are for
4 IN2’ V Ormec-supplied cables. See
5 IN3’ TB5 (page 24) pages 44 for Cable part
Drive I/O W numbers, and Appendix E for
IN4’/
6 12 Cable drawings.)
OUT4’
OUT4
7
RTN
8 FG
SH
9 OUT1’ Motor Power Cable
J4 (page 30) Shield Connection
10 OUT2’
Motor Feedback
11 OUT3’
OUT5’ /
12
ENCZ

J5 Pacer Feedback – Opt. on

bottom. (page 31)

Figure 12, ServoWire SD Drive Connections Overview(SD_417 – SD_450)

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Installation ServoWire SD Drive Manual

3.6.1 Drive Sensor Connections for All Models (TB4)

Refer to the Table 38, I/O Specifications (TB4 and TB5) section (page 87) of the
Specifications chapter for further information.

Pin Signal Function Description

1 Shield Cable shield connection Connect the cable shield at one end only.
2 ASEN High Speed Sensor Inputs Software configurable for:
3 BSEN • 2.7KΩ pull-up resistor for NPN sensor (8.9 mA @ 24VDC)
• No pull-up resistor for PNP sensor

See Figure 17 (page 36) for a simplified schematic.

V+S and V-S must be connected to a DC Power Supply

(5 – 24 VDC) in order to use these inputs.
4 V+S I/O Power Supply Input Inputs for 5-24 VDC power supply used for:
5 V-S Common for I/O Power • High Speed Sensor inputs ASEN, BSEN

• Discrete Inputs IN1’ - IN4’

• Discrete Outputs OUT1’ – OUT5’
Note that V-S must be referenced to FG somewhere in the
system.

Table 5, Drive Sensor (TB4) Connections

3.6.2 Drive Input / Output Connections for All Models (TB5)

Refer to the Table 38, I/O Specifications (TB4 and TB5) section (page 87) of the
Specifications chapter for further information.

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ServoWire SM Drive Manual Installation

Pin Signal Function Description

1 V+S I/O Power Supply Input Inputs for 5-24 VDC power supply used for:
2 V-S Common for I/O Power • High Speed Sensor inputs ASEN, BSEN

• Discrete Inputs IN1’ - IN4’

• Discrete Outputs OUT1’ – OUT5’

3 IN1’ General Purpose Input 1 Software configurable for operation as general-purpose
4 IN2’ General Purpose Input 2 inputs,
5 IN3’ General Purpose Input 3 or Hardware Travel Limit switch inputs, an E-Stop/Quick
Stop input. Refer to the Discrete Inputs section of the
Operation chapter (page 52) for further information.
See Figure 18 (page 38) for a simplified schematic.
V+S and V-S must be connected to a DC Power Supply
(5 – 24 VDC) in order to use these inputs.

6 IN4’/ General Purpose Input 4 Usable as either a general purpose input or output and
OUT4’ or ServoWire Pro software-configurable for operation as a
General Purpose Output 4 Drive Ready indicator. Refer to the Discrete Outputs
7 OUT4 IN4/OUT4 Return section of the Operation chapter (page i) for further
RTN information.
See Figure 18 (page 38) for a simplified schematic.
8 Shield Cable shield connection Connect the cable shield at one end only.
9 OUT1’ General Purpose Output 1 Software configurable for operation as general purpose
10 OUT2’ General Purpose Output 2 outputs, as a Brake control output, isolated motor encoder
11 OUT3’ General Purpose Output 3 reference or isolated feedback option module output.
12 OUT5’ General Purpose Output 5 Refer to the Discrete Outputs section of the Operation
chapter (page 54) for further information.
See (page 39) for a simplified schematic.
V+S and V-S must be connected to a DC Power Supply
(5 – 24 VDC) in order to use these inputs.
Table 6, Drive Input / Output (TB5) Connections

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Installation ServoWire SD Drive Manual

3.6.3 ServoWire SD 115/230 VAC (SAC-SD_2__) Drive Power Terminal Block (TB1)
Terminal Function Description
r, t Input Control Power Single phase 115 (-20%) to 230 (+15%) VAC, 50/60 Hz control
(SD_203 – SD_220 logic input power.
only, for SD_225 – Once the ServoWire SD Drives in a network have control
SD_260 see Table 8 ) power applied, it is best to leave their control power on
continuously, while any of the drives is torque-producing.
L1, L2, L3 Input Main Bus Power (SAC-SD_210, 217, 220, 225, 235, 260): Three phase 115
– or – (+15%, -20%) or 230 (+15%, -20%) VAC, 50/60 Hz.
L1, L2 (SAC-SD_203, 205): Single phase 115 (+15%, -20%) to 230
(+15%, -20%) VAC, 50/60 Hz.
The input voltage should match the configuration software
setting, to ensure proper operation of low bus voltage faults
and inrush current limiting.
Ground Ground for input power. Must be connected to input
power ground.
Bus + DC Bus Power + Nominal bus voltage: 325 VDC for 230 VAC input
Bus - 163 VDC for 115 VAC input
These terminals can be used for connecting bus power
between servodrives. (SD_225 – SD_260 only).
RG Regen Resistor If an external regen resistor is used (SAC-SD_210, 217, 220,
225, 235, 260 only), it is connected between Bus + and RG.
See Section 4.10,

Figure 20, Schematic of Discrete Outputs OUT1'-OUT5', -R

version and –S version 1.2 or later
External Regen Resistor Wiring (RG) (page 39 ).
U,V,W Motor Power Single or Three-phase power to the motor. See:
• H-Series Servomotor Connections (page 49)
• G-Series Servomotor Connections (page 46)
• DE/DA/DB-Series Servomotor Connections (page 48)
• DC Servomotor Connections (page 49).
The motor type must match the configuration software
setting, to ensure proper operation.
Ground Ground connection for motor frame ground
SH Shield Connection Connection for motor shield drain (SD_225 – SD_260 only)
Table 7, ServoWire SD 115/230 VAC Drive (SAC-SD_2__) Power Connections (TB1)

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ServoWire SM Drive Manual Installation

3.6.4 ServoWire SD Drive (SAC-SD_225 – SD_260) Control Power Terminal Block (TB2)
Terminal Function Description
r, t Input Control Power Single phase 115 (-20%) to 230 (+15%) VAC, 50/60 Hz control
logic input power.
Once the ServoWire SD Drives in a network have control
power applied, it is best to leave their control power on
continuously, while any of the drives is torque-producing.
Ground Ground for control logic input power. Must be connected to
input power ground.
Table 8, ServoWire SD Drive (SAC-SD_225 – SD_260) Control Power Connections (TB2)

3.6.5 ServoWire SD 460 VAC (SAC-SD_4__) Drive Power Terminal Block (TB1)
Terminal Function Description
r, t Input Control Power Single phase 115 (-20%) to 230 (+15%) VAC, 50/60 Hz control
(SD_405 – SD_410 logic input power.
only, for SD_417 – Generally, once the ServoWire SD Drives in a network have
SD_450 see Table 10) control power applied, it is best to leave their control power
on continuously, while any of the drives is torque-producing.
L1, L2, L3 Input Main Bus Power (SAC-SD_405, 410): Three phase 230 (+15%, -20%) or 460
– or – (+15%, -20%) VAC, 50/60 Hz.
L1, L2 The input voltage should match the configuration software
setting, to ensure proper operation of low bus voltage faults
and inrush current limiting.
Ground Ground for input power. Must be connected to input
power ground.
Bus + DC Bus Power + Nominal bus voltage: 325 VDC for 230 VAC input
Bus - 650 VDC for 460 VAC input
These terminals can be used for connecting bus power
between servodrives.
RG Regen Resistor If an external regen resistor is used, it is connected between
Bus + and RG. See Section 4.10.1.
U,V,W Motor Power Single or Three-phase power to the motor. See:
• H-Series Servomotor Connections (page 49)
• G-Series Servomotor Connections (page 46)
• DE/DA/DB-Series Servomotor Connections (page 48)
• DC Servomotor Connections (page 49).
The motor type must match the configuration software
setting, to ensure proper operation.
Ground Ground connection for motor frame ground
SH Shield Connection Connection for motor shield drain (SD_417 – SD_450 only)
Table 9, ServoWire SD 460 VAC Drive (SAC-SD_4__) Power Connections (TB1)

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3.6.6 ServoWire SD Drive (SAC-SD_417 – SD_450) Control Power Terminal Block (TB2)
Terminal Function Description
r, t Input Control Power SD_417 & SD_425 - Single phase 115 (-20%) to 230 (+15%)
VAC, 50/60 Hz control logic input power.
SD_435 & SD_450 - 230 (-20%, +15%) VAC, 50/60 Hz control
logic input power.
Generally, once the ServoWire SD Drives in a network have
control power applied, it is best to leave their control power
on continuously, while any of the drives is torque-producing.
Ground Ground for control logic input power. Must be connected to
input power ground.
Table 10, ServoWire SD Drive (SAC-SD_225 – SD_260) Control Power Connections (TB2)

3.6.7 Drive Analog I/O Connections for All Models (TB3)

Refer to the Table 41, Analog I/O Specifications (TB3) section (page 90) of the
Specifications chapter for further information.

Pin Signal Function Description

1 Shield Cable shield connection Connect the cable shield at one end only.
2 AOUT Analog Output Provides an analog output from the drive. The signal
output is Software configurable. Torque command,
Velocity Monitor, Position Error, Bus Voltage, Phase U, V
or W current or a manual value can be selected.
3 AGND Analog Ground Ground reference for AOUT and AIN
4 AIN Analog Input Provides an analog input. This input can be used to close
a feedback loop in the drive when in tension mode or can
be used by the host controller. The input has a Software
configurable low pass filter.

Table 11, Drive Analog I/O (TB4) Connections

3.6.8 ServoWire Connectors for All Models (J1, J2 & J3)

The SD Drives have been enhanced with 1394b capabilities. They utilize
bilingual connectors and interface chips which allow communication in either
1394b or 1394a protocols. The 1394b protocol is an improvement over the 1394a
protocol, offering more digital communication, better noise immunity and the
possibility for faster communication.
The ServoWire bilingual connector has 9 pins: two for power, four for
communications and additional shield pins. The connectors are available only as
an integral part of an IEEE 1394 or ServoWire cable.
There is no ‘in’ or ‘out’ distinction between the J1, J2 and J3 connectors. Each
ServoWire network can be thought of as a bus.
In the first half of 2009 the SAC-SDx series drives were transitioned to use
locking ServoWire 1394 connectors. The original drive had 3 connectors. The
new drives have 2 connectors, each capable of securing the new 1394 cables with
locking screws.

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ServoWire SM Drive Manual Installation

To take full advantage of the new locking cables you will need to order cables
CBL-SW-BL-x, where the L specifies the locking screws. The locking cables are
only available for 1394 b to 1394 b connections. Such connections are available
on the SAC-SD servodrives and the SMLC controller. Therefore, connections
between the SMLC and the SAC-SD drive and from SAC-SD drive to SAC-SD
drive can use the locking cables. Ormec’s Orion controller uses 1394 a style
connectors which are not supported with locking cables. A system with an Orion
and multiple SAC-SD drives must use a CBL-SW-BA for the Orion to drive
connection and then can use CBL-SW-BL locking cables from drive to drive.
In this manual pictures of the face of the drives show both versions, 3 connector
and 2 connector. Use the drawing which matches your drive.

3.6.9 ServoWire Cable for All Models

With the addition of 1394b and the bilingual connector care must be made in the
selection of ServoWire cables. It is necessary to match the cable to the connector
on both ends. There are 3 choices available.
• 1394b – Cabling differences
• ServoWire Cables
• CBL-SW-A-x
• 6 pin to 6 pin
• 1394a to 1394a
• SW or SM drive to SW or SM drive
• CBL-SW-BA-x
• 9 pin to 6 pin
• 1394b to 1394a
• SMLC (30, 80, 160) to SW or SM drive
• Orion to SD drive
• SD drive to SW or SM drive
• CBL-SW-B-x
• 9 pin to 9 pin
• 1394b to 1394b
• SMLC (30, 80, 160) to SD drive
• SD drive to SD drive
• CBL-SW-BL-x
• 9 pin to 9 pin, with locking screws
• 1394b to 1394b
• SMLC (30, 80, 160) to SD drive
• SD drive to SD drive
• SMLC version 2.0 or later support locking cables
• SD drives version 1.2 or later support locking cables
• Without locking support the cables can be plugged into the SD drive
or SMLC, however the locking screws cannot be secured and will
overlap the neighboring connector, meaning that fewer cables can
be plugged.

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Figure 13, CBL-SW-A-x Figure 14, CBL-SW-BA-x

Figure 15, CBL-SW-B-x Figure 16, CBL-SW-BL-x

3.6.10 1394 network topology requirements

• Never exceed 63 nodes per bus
• Never create a loop in the ServoWire network
• Maximum of 16 cables between any 2 nodes
• Maximum of 72 meters (accumulated cable length) between any two
nodes
• Maximum single cable length 10 m. Use a repeater to span a
greater distance. (Repeater counts as a node.)
• SM and SD drives can be mixed on the same network. Doing so
will require a mix of cables.

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3.6.11 Motor Feedback Connector for Serial Encoder Models SAC-SDxxxx-S (J4)

Refer to the Table 39, SAC-SDxx-S version Motor Encoder Specifications (J4) section (page 89) of the
Specifications chapter for further information
.
Note: This table applies to the –S version drives with Quadrature and Serial Encoder
support
Pin Signal Description
1 ENCA Differential input, quadrature feedback channel A from the motor encoder.
2 ENCA’
3 ENCB Differential input, quadrature feedback channel B from the motor encoder.
4 ENCB’
Single ended quadrature encoders use ENCA and ENCB pins 1 & 3 only.
With an SMLC configure using ServoWire Pro and select feedback type
“single ended quadrature”. Not available in Orion configurations.

5 ENCZ Differential input, “once per revolution” marker signal from the motor
6 ENCZ’ encoder.
7 U Differential or single-ended input, commutation feedback channels U, V and
8 U’ W from the motor encoder. Use pin pairs for differential inputs.
9 V The U, V and W (pins 7, 9 & 11) inputs are intended for use with single
10 V’ ended commutation feedback. If the feedback signals are open collector
11 W outputs, external-biasing hardware may be required. The U’, V’ and W’ (pins
12 W’ 8, 10 & 12) inputs are internally biased and no connection or external
circuitry is required for use with single ended feedback. Refer to Appendix
B-4 for further information.
13,24,25 ENC PWR1 +5.3 VDC power supply output for the motor encoder (450 mA max).
This power is derived from the input control power.

16,17,18 DGND Common for the +5.3 VDC supply (ENC PWR1).
19 TEMP’ Motor Over Temperature input.
20 TEMP RET Configuration software settings determine the usage of this input.
Normally closed Contact wired to the ServoWire SD Drive:
• Open contact causes drive fault F4. (Immediately disables motor torque).

• or - Open contact causes application program error.

• or - Open contact is ignored. No fault or error occurs.

No Sensor exists at motor. Leave TEMP & TEMP RETURN unconnected.

•Contact is normally open. (This setting will cause an application program
configuration error if there is a closed contact).
See Section 4.10.8 (page 73) for a detailed explanation.
21 SHIELD Motor encoder shield termination point
22 BAT+ (Optional) Absolute encoder (3 VDC) backup power output.
23 BAT–
14 SDATA
Bi-directional differential signal pair for serial encoder communications.
15 SDATA'
Table 12, Encoder Motor Feedback Connector (J4) Descriptions (also see cable drawings in Appendix E)

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3.6.12 Motor Feedback Connector for Resolver Models SAC-SDxxxx-R (J4)

Refer to the Table 39, SAC-SDxx-S version Motor Encoder Specifications (J4) section (page 89) of the
Specifications chapter for further information
Note: This table applies to the –R version drives with Resovler Feedback support

Pin Signal Description

5, 7, 9 SHIELD Resolver shield termination points.
17 REF- Differential output, resolver excitation frequency.
18 REF+
The following resolver excitation parameters are specified in the
configuration software settings:
• Excitation Frequency: 2.5, 5.0 (default) & 10.0 kHz

• Excitation Amplitude: 0 to 6.5V RMS, 6V RMS at 100% set in the

configuration software. (The default is set for a transformation ratio of .5

with 100% indicating the setting for the default.) Due to variations in
resolver transformation ratios, the excitation amplitude may require
adjustment to meet the sine and cosine input voltage requirements.
19 COS- Differential Input, resolver feedback cosine channel from the motor resolver.
20 COS+ • Feedback Amplitude: 3V RMS, +/-15%

21 SIN- Differential Input, resolver feedback sine channel from the motor resolver.
22 SIN+ • Feedback Amplitude: 3V RMS, +/-15%

3 U Differential or single-ended input, commutation feedback channels U, V and

16 U’ W from the motor encoder. Use pin pairs for differential inputs.
6 V The U, V and W (pins 3, 6 & 11) inputs are intended for use with single
8 V’ ended commutation feedback. If the feedback signals are open collector
11 W outputs, external-biasing hardware may be required. The U’, V’ and W’ (pins
24 W’ 16, 8 & 24) inputs are internally biased and no connection or external
circuitry is required for use with single ended feedback. Refer to Appendix
B-4 for further information.
4 5.3v +5.3 VDC power supply output for the motor encoder (450 mA max).
This power is derived from the input control power.
25 GND Common for the encoder power, +5.3 VDC or +12 VDC supply.
12 +12v Encoder power – provides power for encoder, +12v, 400 mA maximum. This
power is derived from the input control power.
10 TEMP’ Motor Over Temperature input.
23 TEMP RET Configuration software settings determine the usage of this input.
Normally closed Contact wired to the ServoWire SD Drive:
• Open contact causes drive fault F4. (Immediately disables motor torque).

• or - Open contact causes application program error.

• or - Open contact is ignored. No fault or error occurs.

No Sensor exists at motor. Leave TEMP & TEMP RETURN unconnected.

•Contact is normally open. (This setting will cause an application program
configuration error if there is a closed contact).
See Section 4.10.8 (page 73) for a detailed explanation.
13 V+S Parallels V+S pins from TB5. Used to power additional devices.
2 SDATA Serial Data. Bi-directional differential signal pair for serial encoder
1 SDATA' communications.

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ServoWire SM Drive Manual Installation

15 SCLK
14 SCLK’ Serial Clock. Differential CLOCK pair for serial encoder communications.

Table 13, Resolver Motor Feedback Connector (J4) Descriptions (also see cable drawings in Appendix E)

3.6.13 Pacer Feedback Connector for All Models (J5 - mounted on bottom of drive)

Refer to the Table 39, SAC-SDxx-S version Motor Encoder Specifications (J4) section (page 89) of the
Specifications chapter for further information
.
Pin Signal Description
1 ENCA Differential input, quadrature feedback channel A from the pacer encoder.
14 ENCA’
2 ENCB Differential input, quadrature feedback channel B from the pacer encoder.
15 ENCB’
3 ENCZ Differential input, “once per revolution” marker signal from the pacer
16 ENCZ’ encoder.
5, 6, 18 ENC PWR1 +5.3 VDC power supply output for the motor encoder (450 mA max).
This power is derived from the input control power.

7, 19, 20 DGND Common for the +5.3 VDC supply (ENC PWR1).
9 SHIELD Motor encoder shield termination point
Table 14, Pacer Feedback Connector Descriptions (also see cable drawings in Appendix E)

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3.6.14 High Speed Sensor Inputs (ASEN, BSEN)

High speed sensor inputs ASEN and/or BSEN are individually software
configurable for:
• NPN sensor: 2.7K pull-up resistor (8.9 mA @ 24 VDC)
• PNP sensor: pull-up resistor removed from circuit.
V-S from external power supply must be referenced to FG
Figure 17 on the following page shows sensor wiring for types NPN (top) and
PNP (bottom).

NPN type Sensor Wiring

For ASEN, BSEN = true for sensor transistor ON (sinking current), set Axis Sensor Config = Falling Edge or Low Level
For ASEN, BSEN = true for sensor transistor OFF (floating), set Axis Sensor Config = Rising Edge or High Level

J3 (3, 4, 19) V+S

+24 V
NPN Sensor Use configuration
External software to select
Supply
(typical)
2.7K for 1.3K
this resistor
RTN
R*

Logic ASEN or
10K
J3 (1) ASEN or (motor) BSEN
or J3 (2) BSEN (for motor)

V+S
22

4.7K ASEN or
2.2K Logic
BSEN or
(aux)
(for aux edr)

J3 (5, 6, 20) V-S

ServoWire Drive Internal Circuitry
* Not all NPN sensors will provide this resistor

PNP type Sensor Wiring

For ASEN, BSEN = true for sensor transistor ON (sinking current), set Axis Sensor Config = Rising Edge or High Level
For ASEN, BSEN = true for sensor transistor OFF (floating), set Axis Sensor Config = Falling Edge or Low Level

J3 (3, 4, 19) V+S

+24 V Use configuration
PNP Sensor
External (typical) software settings to
Supply remove this resistor 1.3K
for PNP sensors
RTN
J3 (1) ASEN or
Or J3 (2) BSEN or
Logic ASEN or
10K (motor) BSEN or
(for motor)
V+S
External Pull-down
R* Resistor REQUIRED if
2 4.7K ASEN or
2.2K Logic
not internal to PNP sensor (aux) BSEN or

(for aux edr)

J3 (5, 6, 20) V-S

ServoWire Drive Internal Circuitry
* Not all PNP sensors will provide this resistor

Figure 17, Schematic of ASEN and BSEN wiring for NPN and PNP sensors

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ServoWire SM Drive Manual Installation

3.6.15 High Speed Sensor Inputs (ASEN, BSEN) (continued)

NOTE: ASEN and BSEN wiring should be shielded twisted pair cable, with a
foil shield. The DC Power Supply V-S connection should be connected
to the same ground as the ServoWire SD Drive frame ground (TB1,
ground pin or J7/J8 pin 1 on a Low Power Drive).
Configuration software is used to configure ASEN and BSEN for edge- or level-
sensitive triggering. Using level-sensitive (high or low) triggering
increases the susceptibility of your sensor inputs to noise.
ASEN and/or BSEN inputs can be software configured to operate in a gated
(masked) behavior by the ServoWire SD Drive outputs OUT1 and OUT2.

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3.6.16 Discrete Inputs (IN1’, IN2’, IN3’, IN4’/OUT4')

* Note: Input # 4 is Bi-directional & shares the same pin with Output # 4.
The four discrete inputs on the ServoWire SD Drive can be software configured
as general purpose inputs for use by the application program, or as Hardware
Travel Limits inputs and E-Stop/Quick Stop input.

SAC-SDM SAC-SD
MotionBASIC
required.

Hardware Travel Limit Forward IN1’ IN1'

Hardware Travel Limit Reverse IN2' IN2'
Refer to the Hardware Travel Limits
(IN1', IN2')
page 52
E-Stop / Quick Stop IN3' Not Available
Refer to the Quick Stop Input (IN3’)
page 52

Figure 18 shows a simplified schematic of the Discrete Inputs, TB5 pins 3, 4, 5

and 6 (IN1’ – IN4’) connected to a limit switch. Refer to the Hardware Travel
Limits on (page 52) and Quick Stop Input (page 53) sections of the Operation
chapter for further information.

The IN4’/OUT4’ pin is shared, with IN4’ indicating the state of the I/O point. If
OUT4’ is disabled, then this pin can be used as an input. If OUT4’ is enabled,
then this pin cannot be used as an input, though the state of IN4’ will still
correctly indicate the state of the I/O point.

External Internal
V+S

TB5 (1)

4.7 K 4.7 K
4.7 K
Current Current
Pullup
Limit Limit

IN1' – IN3'
Optocoupler

TB5 (3, 4, 5)
Limit Switch
(if used) IN4’/OUT4’

TB5 (6)

TB5 (7) OUT4

OUT4’ RTN

V-S

TB5 (2)

Figure 18, Schematic of IN1’, IN2’, IN3’ and IN4’/OUT4' Inputs

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ServoWire SM Drive Manual Installation

3.6.17 Discrete Outputs (OUT1’-OUT5’)

* Note: Output # 4 is Bi-directional & shares the same pin with Input # 4.
A ServoWire SD Drive provides five optically isolated general-purpose digital
outputs. By default these are controlled by the application program, but can be
software configured as hardware status and control signals.
Software configurable, OUT1’ through OUT5’ can be configured as general
purpose.

SAC-SDM SAC-SD
MotionBASIC
required.

Brake control OUT3’ OUT3’

Refer to the Brake Control Output
(OUT3’)
page 54
Drive Ready OUT4’ Not Available
Refer to the Drive Ready Output
(OUT4’)
page 54
Zero Reference OUT5' OUT5'
Refer to the Encoder Feedback Zero
Reference Output (OUT5’)
page 54

External Internal
V+S

TB5 (1)

4.7 K

OUT1’ – OUT3’
or
OUT5’
TB5 (9, 10, 11, 12)

V-S Optocoupler
TB5 ( 2)

Figure 19, Schematic of Discrete Outputs OUT1'-OUT5', -S version, prior to

version 1.2

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Installation ServoWire SD Drive Manual

V+S V+S V+S

TB5(1) TB5(1) TB5(1)

4.7k 4.7k 4.7k

OUT1’; OUT2’;’
OUT5’; OUT3’’ IN4’/OUT4’’ TO IN4’

TB5(9,10,12) TB5(11) TB5(6)

OPTOCOUPLER OPTOCOUPLER OPTOCOUPLER

V-S V-S OUT4’ RTN

TB5(2) TB5(2) TB5(7)

Figure 20, Schematic of Discrete Outputs OUT1'-OUT5', -R version and –S

version 1.2 or later

3.6.18 External Regen Resistor Wiring (RG)

Regenerative (regen) shunt circuitry, for use with external regen resistors, is
provided on ServoWire SD Drive models SAC-SD_210, SAC-SD_217, SAC-
SD_220, SAC-SD_225, SAC-SD_235, SAC-SD_260 and all 460 VAC drives,
SAC-SD_4xx. Regen resistors are connected between the Bus + and RG
terminals on TB1 (refer to Figure 21).
The following methods are recommended for proper installation of regen
resistors:
1. Regen resistors can become very hot as part of normal operation
and should be mounted in a ventilated, “touch safe” enclosure.
ORMEC SAC-SMRR/0700, SAC-SMRR/0845, SAC-SMRR/0846, and SAC-
SMRR/1700 regen resistors are supplied with enclosures. Mounting
enclosures for the SAC-SMRR/0055 and SAC-SMRR/0095 regen resistors are
not included and must be supplied by the user.
2. Regen resistor wiring should have heat resistant, non-combustible
insulation.
3. Regen resistor, and other system, wiring should be routed so that it is not in
contact with the regen resistors.
4. Switching voltages exceeding 400 VDC (230 V drives) or 800 VDC
(460 V drives) may be present on the Bus+ and RG terminals (and

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ServoWire SM Drive Manual Installation

across the regen resistor). Use appropriate high voltage safety wiring
methods.
5. Mounting and wiring practices should be in accordance with NEC (National
Electric Code) or UL (Underwriters Laboratories) specifications and in
compliance with local ordinances.

(on TB1)

(on TB1)

Figure 21, Regen Resistor Connection

For information on how the shunt circuitry operates, as well as information on

sizing regen resistors, see Section 4.10, Regenerative Loads (page 64).

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Installation ServoWire SD Drive Manual

3.6.19 Bus Sharing Wiring (230 V SD_225 – SD_260 and 460 V SD_405-SD_450)
DC Bus sharing is supported on 230 VAC ServoWire SD Drive models SAC-
SD_225, SAC-SD_235, and SAC-SD_260 only. DC Bus sharing is supported
on all 460 VAC ServoWire SD Drives, models SD_405 to SD_450. To configure
these drives for bus sharing, the Bus + and Bus – terminals are connected as
shown in Figure 22. Drives should be connected so that the highest power
drives are in the center of the bus-sharing chain. Bus wiring between drives
should be less than 12 inches in length to minimize oscillatory effects. As long as
the total system regenerative load can be dissipated, there is no limit to the
number of drives that can share the DC bus. NOTE: when bus sharing you
CANNOT mix 230 VAC and 460 VAC drives on the shared bus at 460 VAC.
Severe damage to the 230VAC drives will result.
For information on how the bus sharing operates, see Section 4.10.5, Bus
Sharing.
The following methods are recommended for proper configuration of bus sharing:
1. Wiring should have heat resistant, non-combustible insulation, rated at
1000V or more.
2. Switching voltages exceeding 400 VDC (230 V drives) and up to 900 VDC
(460 V drives) may be present on the BUS+ and BUS- terminals. Use
appropriate high voltage safety and noise suppression wiring methods.
3. Mounting and wiring practices should be in accordance with NEC
(National Electric Code) or UL (Underwriters Laboratories)
specifications and in compliance with local ordinances.
4. If an external regen resistor is to be used in conjunction with bus
sharing, it should be connected to the largest servodrive in the bus-
shared network. No more than one regen resistor may be used in
any bus sharing configuration. See 0 for more information on regen
resistor installation.

SD Drive #1 SD Drive #2 SD Drive #n

TB1 TB1 TB1

BUS + BUS + BUS +

Optional
regen
resistor

REGEN REGEN REGEN

BUS - BUS - BUS -

Figure 22, Bus Sharing Connections

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ServoWire SM Drive Manual Installation

3.7 ServoWire SD Drive ID

Each ServoWire SD Drive has a Drive Identification (ID) number, which is
shown on the ID/Status LED display on the front of the unit. ServoWire SD
Drives are shipped from the factory with Drive ID number set to 1.
The Drive ID is important because it establishes the axis ID of the motor being
controlled by the ServoWire SD Drive.
A push-button on the top of the ServoWire SD Drive allows setting of the Drive
ID. Once the Drive ID is being displayed, pressing the push-button will
increment the Drive ID by 1 each time it is pushed, up to a maximum value.
Pressing and holding down the push-button will cause the Drive ID to continue
incrementing. After reaching its maximum value, it will roll over back to 1, and
continue increasing again from there. This functionality is available after each
power-up, before torque has been enabled at the motor.

Figure 23, Drive ID Setup Flowchart

Figure 24, Top View of ServoWire
SD Drive showing Drive ID
Pushbutton
Standard Display
Long Release

Push to
Store ID
change the
Drive ID
(active only
Press Timeout
before torque
is enabled)
Release

Hold, auto Increment and display ID Display ID

increment

Press

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Installation ServoWire SD Drive Manual

3.8 Servomotor Installation

3.8.1 Motor Use and Environment

A standard G-Series Servomotor (IP65) is designed for use as described below:
• Either horizontal or vertical mounting orientation
• Indoors, clean and dry
• Free from corrosive and/or explosive gases or liquids
• If the location is subject to excessive water or oil, protect the motor with a
cover. The motor can withstand a small amount of splashed water or oil.
• Accessible for inspection and cleaning
• Face mounting: The structural integrity of the mounting can be critical to
obtaining the maximum performance from your Servomotor application.
• G-Series Servomotors: Rated Torque's/Currents are for 25oC; for ambient
temperatures above 25oC, use the formula given below in Figure 25. Note
that °CMax is 100oC for all G-Series Servomotors except models G006, G011,
G015, and G019; for these motors, °CMax is 85oC. The motor current is de-
rated by the same factor as the torque.

Torque Derated = Torque Rated * (oCMax – oCAmbient)

(oCMax – 25oC)

Figure 25, G-Series Torque Derating for High Ambient Temperature

3.8.2 Recommended Servomotor Wiring Methods

1. When the motor is mounted to the machine and grounded through the
machine frame, dv/dt current flows from the ServoWire SD Drive through the
floating capacity of the motor. To prevent the noise effects from this current,
and also for safety, the motor housing (terminal D of the motor connector)
should be connected to the frame of the ServoWire SD Drive ( TB1 pin FG
or pin 3 on J6 ), which should be directly grounded to the control panel frame
using copper wire.
2. When motor wiring is contained in metal conduits, the conduits and boxes
must be grounded. For ServoWire SD 115/230 VAC or 460 VAC Drives
(SAC-SD_2__, SAC-SD_4__), use wires of 12 AWG or heavier for grounding
to the case (preferably flat woven silver-plated copper braid).
3. If possible, route motor feedback and motor power cables in separate
conduits or ductwork, separated by a minimum of 10 inches (25 cm).

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3.8.3 Motors with Integral Fail-Safe Brakes

NOTE: The integral fail-safe brakes supplied on G-Series, H-Series and D-
Series motors are intended for holding purposes (preventing the
movement of a stopped motor) only and should not be used for braking
a motor in motion. Using an integral fail-safe brake to stop a motor in
motion may result in damage to the motor-brake unit. An external brake
should be used for fail-safe stopping a motor in motion.
Motors with brakes require special cables; see Table 17 (page 47) for G-Series
cable part numbers. Drawings for these cables are shown in Appendix E.
SAC-SDx-S drive versions prior to version 1,2 have a low current output
capability on OUT3’ and require an external relay to control the brake. All SAC-
SDx-R drive versions and SAC-SDx-S version 1.2 and later drives have a high
current output capability on OUT3’ and can directly drive many brakes 24VDC
brakes. Select the correct recommendation below.
For SAC-SDx-S drive versions prior to version 1.2 Figure 26 shows the
recommended safety and fault interlock wiring for motors with fail-safe brakes.
For all SAC-SDx-R drive versions and SAC-SDx-S versions 1.2 or later Figure
27shows the recommended safety and fault interlock wiring for motors with fail-
safe brakes.
• When the main power contactor opens, the brake engages.
• When OUT3’ is asserted, the brake disengages. OUT3’ can be software
configured to automatically control the brake when it needs to be engaged
and disengaged. OUT3’ can also be manually turned on and off to disengage
or engage the brake under the control of the application program. Refer to
the application software Help and the Brake Output section of the Operation
chapter (page 54) for further information.
Use a separate +24 VDC power supply for coil power from the
machine I/O power supply!

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Installation ServoWire SD Drive Manual

(Cable shown has brake leads in the

motor cable. Some cables have the
2 yellow brake leads in the feedback
cable)

ServoWire
+24VDC
V+ Drive
+24COM V+

Main Power Contactor

V-
Auxiliary Contacts

OUT 3 RE D +24 VD C
U
W HT
V
B LK Co mmon
W GRN
YEL
SH +24 VDC Power Supply
YEL or YEL/BLK (PSU-024/3.8A)
S H IE L D -
+
1 2

Coil Surge Optically Isolated

Suppressing Diode Solid State Relay
(see table below) (see table, below)

3 + 4

Figure 26, Fail-Safe Brake Interlock Circuit – SAC-SDx-S versions, versions before 1.2

Figure 27, Fail-Safe Brake Interlock Circuit – SAC-SDx-R versions and –S versions 1.2 and
later

Ormec P/N Manufacturer, P/N

Optically-Isolated Solid State Relay MIO-DC60S-3 Opto-22, DC60S-3
Coil Surge Suppressing Diode SEM029 Motorola, MUR410
Table 15, Additional Components for use with Fail-Safe Brakes G-Series Servomotor Connections

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3.8.4 G-Series Servomotor Connections

For G-Series motors without brakes, refer to the appropriate cable drawing(s) in Appendix E. The
motor and encoder cable part numbers and page numbers are shown in Table 16 (motors without
brakes) and Table 17 (motors with brakes).
MAC-G Motors Without Brakes Motor Power Cable Motor Encoder Cable
G005, G010, G006, G011, G015,G019
with SAC- SD_203 – SD_220 CBL-GMSW1 (p D-3)
G016, G030, G040, G055, G080, G115 CBL-GMSW2 (p D-4)
with SAC-SD_203 – SD_220
G080 & G115A2 CBL-GMSW
CBL-GMSWT2 (p D-5) (1-50 ft: p D-1)
with SAC-SD_225 & SD_235
(51-150 ft: p D-2)
G130 & G210 CBL-GMSW3 (p D-6)
with SAC-SD_210 – SD_220
G130A2 CBL-GMSWT3 (p D-7)
with SAC-SD_225
G210, G280A4 & G360A4 CBL-GMSWT5 (p D-7) CBL-GMSW
with SAC-SD_225 – SD_235
(1-50 ft: p D-1)
G280A2 & G360A2 CBL-GMSWT6 (p D-7) (51-150 ft: p D-2)
with SAC-SD_235 & SD_260
G640A2 CBL-GMSWT9 (p D-7)
with SAC-SD_260
Table 16, Cable Drawings for G-Series Motors Without Brakes

For G005, G006, G010, G011, G015, G019 motors, the brake leads are in the combined power/feedback cable.
For G016, G030, G040, G055, G080, and G115 motors, the brake leads are in the motor power cable.
For G130, G210, G280, G400 and G640 motors, the brake leads are in the motor feedback cable.

MAC-G Motors With Brakes Motor Power Cable Motor Encoder Cable
G005, G010, G006, G011, G015,G019
with SAC-SD_203 – SD_220 CBL-GMSWB1 (p D-3)
G016, G030, G040, G055, G080, G115 CBL-GMSWB2 (p D-10)
with SAC-SD_203 – SD_220 CBL-GMSW
(1-50 ft: p D-1)
G080 & G115A2 CBL-GMSWBT2 (p D-11) (51-150 ft: p D-2)
with SAC-SD_225 & SD_235
G130 & G210 CBL-GMSW3 (p D-6)
with SAC-SD_210 – SD_220
G130A2 CBL-GMSWT3 (p D-7)
with SAC-SD_225
G210, G280A4 & G360A4 CBL-GMSWB
CBL-GMSWT5 (p D-7) (1-50 ft: p D-8)
with SAC-SD_225 – SD_235
(51-150 ft: p D-9)
G280A2 & G360A2 CBL-GMSWT6 (p D-7)
with SAC-SD_235 & SD_260
G640A2 CBL-GMSWT9 (p D-7)
with SAC-SD_260
Table 17, Cable Drawings for G-Series Motors With Brakes

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3.8.5 D-Series Servomotor Connections

For D-Series motors without brakes, refer to the appropriate cable drawing(s) in
Appendix E. The motor and encoder cable part numbers and page numbers are
shown in Table 18 (motors without brakes) and Table 19 (motors with brakes).

MAC-D Motors Without Brakes Motor Power Cable Motor Encoder Cable
DE003, DE006, DE008, DE011, DE021,
DE042 with SAC- SD_203 – SD_220 CBL-DEMSW1 (p E-1)
DA030, DA055, DB025, DB055, DB080 CBL-DMSW1 (p F-3)
with SAC-SD_210 – SD_220
DA055 CBL-DMSWT1 (p F-4)
with SAC-SD_225
DA090, DA110, DB200 CBL-DMSWT2 (p F-4)
with SAC-SD_225 – SD_260
DA140, DB300 CBL-DMSW
CBL-DMSWT3 (p F-4) (1-50 ft: p F-1)
with SAC-SD_235 – SD_260
(51-150 ft: p F-12)
DB100 CBL-GMSW4 (p F-3)
with SAC-SD_220
DB100 CBL-GMSWT4 (p F-4)
with SAC-SD_225
DB330 CBL-DMSWT5 (p F-4)
with SAC-SD_260
DB465, DB700 CBL-DMSWT6 (p F-4)
with SAC-SD_235 – SD_260
Table 18, Cable Drawings for D-Series Motors Without Brakes

MAC-D Motors With Brakes Motor Power Cable Motor Encoder Cable
DE003, DE006, DE008, DE011, DE021,
DE042 with SAC- SD_203 – SD_220 CBL-DEMSWB1 (p E-1)
DA030, DA055, DB025, DB055, DB080 CBL-DMSWB1 (p F-5)
with SAC-SD_210 – SD_220
DA055 CBL-DMSWBT1 (p F-6)
with SAC-SD_225
DA090, DA110, DB200 CBL-DMSWBT2 (p F-6)
with SAC-SD_225 – SD_260
DA140, DB300 CBL-DMSW
CBL-DMSWBT3 (p F-6) (1-50 ft: p F-1)
with SAC-SD_235 – SD_260
(51-150 ft: p F-2)
DB100 CBL-DMSWB4 (p F-5)
with SAC-SD_220
DB100 CBL-DMSWBT4 (p F-6)
with SAC-SD_225
DB330 CBL-DMSWT5 (p F-4)
with SAC-SD_260 & CBL-DMACB (p F-7)
DB465, DB700 CBL-DMSWT6 (p F-4)
with SAC-SD_235 – SD_260 & CBL-DMACB (p F-7)
Table 19, Cable Drawings for D-Series Motors With Brakes

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3.8.6 H-Series Servomotor Connections

Serial encoder support requires SD Servo Drive with the "S" option.

MAC-D Motors Without Brakes Motor Power Cable Motor Encoder Cable
HA003, HA055,
HB025, HB055, HB080, HB100 CBL-HMSW1
HA110, HA140, HB200 CBL-HMSW2
CBL-HMSW
HB300 CBL-HMSW3 (1-50 ft: p G-1)
HA90 CBL-HMSW4 (51-150 ft: p G-5)
HB330, HB465 CBL-HMSW5
HB700 CBL-HMSW6
CBL-HEMSW
HE003, HE006, HE011, HE021, HE042 CBL-HEMSW1 (1-50 ft: p G-3)
(51-150 ft: p G-2)
Table 20, Cable Drawings for H-Series Motors Without Brakes

[Link] H-Series Motor Encoder Resolutions

Motor
Resolution using
Raw encoder
Model numder ORION SMLC
resolution
MAC-HE003A/ 2.8 lb-in, 5000 RPM max, 115 VAC
MAC-HE006A/ 5.6 lb-in, 5000 RPM max, 115 VAC
MAC-HE003B/ 2.8 lb-in, 5000 RPM max, 230 VAC
MAC-HE006B/ 5.6 lb-in, 5000 RPM max, 230 VAC 13-bit 8,192 8,192
MAC-HE011B/ 11 lb-in, 5000 RPM max, 230 VAC
MAC-HE021B/ 21 lb-in, 5000 RPM max, 230 VAC
MAC-HE042B/ 42 lb-in, 5000 RPM max, 230 VAC

MAC-HA030B/ 28 lb-in, 5000 RPM max, 230 VAC

MAC-HA055B/ 56 lb-in, 5000 RPM max, 230 VAC
131,072
MAC-HA090B/ 87 lb-in, 5000 RPM max, 230 VAC 17-bit 32,768 **
(17 bit)
MAC-HA110B/ 112 lb-in, 5000 RPM max, 230 VAC
MAC-HA140B/ 140 lb-in, 5000 RPM max, 230 VAC

MAC-HB025B/ 25 lb-in, 3000 RPM max, 230 VAC

MAC-HB055B/ 48 lb-in, 3000 RPM max, 230 VAC
MAC-HB080B/ 74 lb-in, 3000 RPM max, 230 VAC
MAC-HB100B/ 102 lb-in, 3000 RPM max, 230 VAC
131,072
MAC-HB200B/ 177 lb-in, 3000 RPM max, 230 VAC 17-bit 32,768 **
(17 bit )
MAC-HB300B/ 305 lb-in, 3000 RPM max, 230 VAC
MAC-HB330B/ 345 lb-in, 3000 RPM max, 230 VAC
MAC-HB465B/ 465 lb-in, 3000 RPM max, 230 VAC
MAC-HB700B/ 700 lb-in, 2000 RPM max, 230 VAC
Note: ** Orion's MotionBASIC limits the counts per revolution to 32,768.
The full 17-bit resolution is unattainable when using an Orion Motion Controller.

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3.8.7 DC Servomotor Connections

DC motors, voice coils and other actuators requiring single phase current output
can be connected to pins U and V on the High Power Terminal Block (TB1). The
Custom Motor editor can be used to configure the Drive for use with a DC motor
or single phase actuator, as well as for configuring the Low Bus Voltage fault
trip point.

3.8.8 Coupling the Servomotor to the Load

Good alignment of motor and the driven machine is essential to prevent
vibration, increase bearing and coupling life, and to prevent shaft and bearing
failures.
With a direct drive application a torsionally rigid flexible coupling should be
used. Timing belts and gearboxes are also commonly used in servo applications.
Shaft loading should be kept to a minimum. The allowable shaft bearing loading
is listed in the Specifications Section.
In either case, it is preferable to attach the coupling or pulley to the shaft with a
clamping arrangement rather than transmit torque through the keyway,
because of the reversing shock torque, which the Servomotor can generate. A
number of mechanical approaches afford this type of attachment including
tapered hubs, split hubs, ringfeder devices, etc.
Further information is available in Ormec Tech Note #27 - Coupling High
Performance Servos to Mechanical Loads, which is available from the ORMEC
Web Site ([Link]).

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Chapter 4
Operation
4 Operation

4.1 Power On and Off Sequencing

Appendix A shows the recommended interlock approaches for both single and
multiple axes. Note its features:
1) E-STOP interlocks
a) The recommended E-Stop switch is a maintained-contact red mushroom
head push-button, which must be manually pulled out (reset) after it has
been pressed (asserted). It should be powered by 115 or 230 VAC and
must conduct current for the Servomotor to provide output torque.
b) The E-Stop Reset should be a momentary contact pushbutton. It must be
asserted after all power is applied and the E-Stop switch is closed. It must
be closed long enough for the Main Power contactor auxiliary contact (MP-
AUX) to "pull-in", so that the main power contactor coil circuit is
energized.
c) If the E-Stop Switch is pressed (asserted), the main circuit power is
disconnected, and torque is prevented at the motor(s).
2) ServoWire Drive faults
a) If any fault condition occurs within a ServoWire SD Drive, the main circuit
power is disconnected because the Drive Ready (OUT4’) signal is
unasserted and the customer supplied relay contact in the main power
contactor coil circuit opens. In this case, the ServoWire SD Drive
ID/Status display will indicate the fault code. For the operation
described above, OUT4 must be configured for operation as the
Drive Ready output in the configuration software. Refer to the
Drive Ready Output section of this chapter for further information.
To reset a High Bus Voltage Fault, the main input power must be disabled
long enough for the power capacitors to discharge to a level below the High
Bus Voltage Fault limit.
To reset a Motor Over Temperature Fault, the motor must be sufficiently
cool. The application program can clear all other fault conditions.

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All fault conditions, including E-Stop, must be cleared before

motor power can be restored. Also, the E-Stop Reset push-button
must be depressed long enough for all the drive power supplies to
charge and the Drive Ready (OUT4’) Relays to pull-up again.
b) If the E-Stop switch is pressed or another ServoWire SD Drive in the
system experiences a fault, the drive discrete input IN3 will be unasserted.
This will cause the drive to either disable the output or command zero
output (hold position, zero velocity or zero torque), depending on how the
drive is configured. For the operation described above, IN3 must be
software configured for E-Stop or Quick Stop operation.

4.2 Discrete Inputs (IN1’, IN2', IN3', IN4’/OUT4')

There are four optically isolated discrete inputs, IN1’ through IN4’.
* Note: Input # 4 is Bi-directional and shares the same pin with Output # 4.
See: I/O Schematic, Figure 18 (Page 38).
These inputs are available for use by the application program as general-
purpose inputs, or can be configured as Hardware Travel Limits inputs and/or
E-Stop/Quick Stop input. Refer to your application program documentation to
determine how the Discrete Inputs are being used.

4.2.1 Hardware Travel Limits (IN1', IN2')

Discrete input IN1’ and/or IN2' can be software configured to operate as
Hardware Travel Limits (HTL). IN1' is assigned HTL Forward. IN2' is assigned
HTL Reverse.
If a servo is in position, velocity or output mode and it's Hardware Travel Limit
is asserted, then it's commanded motion will be stopped, and a motion error will
be generated. The HTL must be reset before any motion can be commanded to
move off and away from the limit. Once the limit hardware has cleared and the
HTL input is conducting current, then the software variable can be successfully
cleared. Motion is again allowed in the direction of the HTL.

4.2.2 E-Stop Input (IN3’)

Using ServoWire Pro, Discrete input IN3’ can be software configured to operate
as an E-Stop input. When unasserted, this input causes the servodrive to
generate a drive fault and disable output power to the motor, as well as
generating a fault callback in the application program. Refer to Appendix A-1
for a diagram of how this input is connected to the machine e-stop interlock
circuit.

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4.2.3 Quick Stop Input (IN3’)

Using ServoWire Pro, Discrete input IN3’ can be software configured to operate
as a Quick Stop input. Unasserting IN3' in this mode generates an alarm
callback in the application program and has the effects indicated in Table 21,
which are dependent on the axis mode (torque, velocity or position), as
configured in ServoWire Pro (Axis Settings, Drive Input). Refer to Appendix A-1
for diagram of how this input is connected to the machine e-stop interlock
circuit.

Drive Input (Mode) Quick Stop Operation

Torque Generates an alarm callback in the application
program, output remains enabled and the drive
continues to receive torque commands. This
allows the motion controller to decelerate the load
under control.
Velocity/Position Generates an alarm callback in the application
program, output remains enabled, zero speed is
commanded 1 . Commanding zero speed may result
in commanded current to bring the motor to a stop.
When the drive is configured to use IN3 as a Quick
Stop input, missing phase detection is disabled
when IN2 is unasserted.
Table 21, Quick Stop Operation

4.3 Discrete Outputs (OUT1’ – OUT5’)

* Note: Output # 4 is Bi-directional and shares the same pin with Input # 4.
See: I/O Schematic, Figure 18 (Page 38).
There are five optically isolated discrete outputs, OUT1’ through OUT5’. These
outputs are available for use by the application program as general-purpose
outputs, or
(OUT3’) can be configured as a Brake Control Output,
(OUT4’) can be configured as a Drive Ready Output,
(OUT5’) can be configured as a Feedback Encoder Reference Output.
Refer to your application program documentation to determine how the Discrete
Outputs are being used.

1 The drive may command current as necessary to maintain zero velocity.

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4.3.1 Brake Control Output (OUT3’)

Discrete output OUT3’ can be software configured to operate as a Brake Output
for controlling a motor fail-safe brake. When asserted, this output can be used
to supply power to the coil of a motor fail-safe brake, keeping the brake
disengaged and allowing motor motion. Refer to Figure 26 for diagram of how
this output is connected to a fail-safe brake interlock circuit.
The user can configure the delay time between enabling motor power and
releasing the fail-safe brake, as well as the delay time between engaging the fail-
safe brake and disabling motor power. This is a very useful feature when
controlling vertical loads, it allows holding torque to be enabled before the brake
is released and vice versa. Refer to the diagram in Figure 28 for an explanation
of the Brake Output sequence of operation and the configurable delay
parameters.

Any Torque
Drive Producing
Mode
Enabled
Drive Output ON

Transistors
Brake Output
(OUT3') OFF

Motor Off Delay Brake Off Delay

Figure 28, Brake Output Sequence of Operation

4.3.2 Drive Ready Output (OUT4’)

Discrete output OUT4’ can be software configured to operate as a Drive Ready
Output. When asserted, this output indicates that the servodrive is operating
without any faults and the main bus is charged. Refer to Appendix A-1 for
diagram of how this output is connected to the machine e-stop interlock circuit.
On SAC-SDx-S drive versions (Quadrature, Serial Encoder) a limit of 3 drives
can be connected in series when configured as Drive Ready.
On SAC-SDx-R drive versions (Resolver feedback) a limit of 32 drives can be
connected in series when configured as Drive Ready.

4.3.3 Encoder Feedback Zero Reference Output (OUT5’)

Discrete output OUT5’ can be software configured to operate as a buffered
feedback encoder/resolver zero reference output. If no feedback option module is
present on the drive, the state of this output corresponds to the state of the
feedback (J4) zero reference signal. If one or more feedback option modules is
present, the configuration software can be used to specify which reference
signal’s state will be indicated by OUT5’.

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4.4 Status Indications

The servodrive status indication consists of a 2-digit 7-segment LED display
(ID/Status), several individual LEDs indicating the status of the I/O points and a
yellow LED indicating bus power.

If a fault condition (except for auxiliary encoder open wire F2 ) is present on the
ServoWire SD Drive, the output transistors are disabled, and an appropriate
fault code is displayed on the ID / Status display. The control power should be
maintained in case of a servodrive fault, so that the status indicators can display
the unit's status until the cause of the fault is determined.
If any wiring changes are necessary, turn off the control and main power circuits
then wait for the BUS POWER LED to go completely off to avoid possible
electrical shock.
Notes:
1. After the conditions causing a servodrive fault have been corrected, the
application program must reset the drive fault.
2. If the fault is due to the motor or drive being over temperature, the
servodrive fault will not reset until the component has cooled down.

Figure 29, ID/Status Indications

ID / STATUS

BUS POWER

Bus Power
LED
ServoWire
Comm.

Sensor LEDs
Torque
Enabled

Digital Input
LEDs

Digital
Output LEDs

A
x
I
s

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4.4.1 ServoWire Communications (Middle Dot of ID/Status Display)

During normal operation (e.g. when there are no faults), the middle dot of the
ID/Status Display flashes to indicate the state of ServoWire Network.
Slow Flash: (on for 1 second, off for 1 second) indicates that the drive is
functional, ServoWire power is detected on the ServoWire cable, but there is no
ServoWire communications.
Moderate Flash: (on for ½ second, off for ½ second) indicates that 1394
(ServoWire) communications are beginning and the drive is seeing cycle start
activity on the Network.
Rapid Flash: (on for 1/8 second, off for 1/8second) indicates that ServoWire
communications is functioning normally and the drive is sending and receiving
Isochronous communications..
Solid On or Off: indicates a drive failure that is recoverable only by cycling
control power. This should be reported to the Ormec Customer Service Dept.

4.4.2 Torque Enabled (Right lower dot of ID/Status Display)

Off: indicates that torque is not enabled at the motor.
On: indicates that torque is enabled at the motor.

4.4.3 Bus Power (Yellow LED above TB1)

Illuminated to indicate that the bus power supply voltage is greater than
approximately 24 VDC.

4.4.4 Sensor Status LED (to the side of TB4)

Illuminated to indicate that the sensor is sinking current. Note, in the case of a
sensor configured for PNP operation illumination does not indicate that the
sensor is active. The third LED in this section indicates that Sensor/IO power is
applied (i.e. a voltage is applied between V+S and V-S).

4.4.5 Digital Input LEDs (to the side of TB5 INx positions)
Illuminated to indicate that there is current in the digital input. For most
operation this indicates that the input is on.

4.4.6 Digital Output LEDs (to the side of TB5 OUTx positions)
Illuminated to indicate that the digital output is turned on.

4.4.7 Axis ID and Fault ID

When no drive alarms exist, the ID/Status will display the Drive ID, e.g. 1, 2,
etc. When a drive alarm exists, the ID/Status display will alternate between the
Drive ID and the alarm code (shown on the next page in Table 22, ServoWire
SD Drive Fault Codes.
Some errors have extended codes consisting of the general number followed by
an _n (underscore <value>). Extended error codes aid in diagnosing a problem

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ServoWire SD Drive Manual Operation

and are listed and explained in Section 7.2, ServoWire SD Drive Troubleshooting
Guide (page 94) and do not appear in the table below.
There is a more detailed table of fault codes, which shows cause-and-effect for
many of these faults in Section 7.2, ServoWire SD Drive Troubleshooting Guide
(page 94).
A Drive ID that is flashing alone (no alarm code) indicates two ServoWire Drives
with duplicate axis IDs on the same Controller. If the controller is an Orion
controller then the duplicate axis ID may belong to a pacer axis (ID = one less
than the displayed Drive ID).

With one exception (fault F2, Auxiliary Encoder Open Wire), all drive faults
cause torque to be disabled at the motor.

Drive faults 90 – 99 and 9A-9F may require cycling control power to clear the
fault. The application program can clear all other faults (after the cause of the
fault has been cleared).

Drive faults C0-CF are generated by the motion engine in the SMLC and then
displayed on the drive. Refer to the online help file [Link] for help in
identifying and resolving these fault conditions.

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Drive
Fault Fault
Condition Description
Indicator1 Code
1

Internal errors may require cycling the drive control power to clear
70-7F the fault. If the problem recurs or does not clear, contact ORMEC
112-159 Internal Drive Error Support at ( 585 ) 385-3520 or via e-mail at support@[Link].
90-9F Please have your Support ID available when you call or reference it in
your e-mail message.

90 144 Internal Drive Error This fault is normal during ServoWire 1394 network cable pulls.

70 112 Axis offline The drive has lost communications

Reference generation
71 113
conflict
Internal error

72 Not used

73 Not used

Unsupported feedback
74 116
device
The drive firmware does not support this feedback device type

75 117 Tension Max Tension has reached the OP_TEN_MAX limit

76 118 Tension Min Tension has reached the OP_TEN_MIN limit

77-7F Not used

The actual RMS current has exceeded the drives rated continuous
A0 160 Drive RMS Over Current
current longer than the allowed time (2 seconds at peak current).
A1 161 Peak Over Current The peak current rating for the drive was exceeded.
The Power Module’s self-protection has detected a short circuit, over
current, over temperature or control supply under voltage. - or-
A2 162 Power Module Fault
An SCR soft-start circuit error has been detected (SAC-SD_225,
SD_235 & SD_260 only).
The bus voltage is below the low voltage limit, which is calculated
A3 163 Low Bus Voltage based on the Drive Input Voltage specified in the configuration
software.
The bus voltage is above the high voltage limit, which is calculated
A4 164 High Bus Voltage based on the lessor of the motor rated voltage (as specified in
software) and the drive maximum voltage.
Drive hardware and The drive type or drive options does not match the software
A5 165 configuration software configuration settings. The application program has detected that the
mismatch. drive hardware does not match software configuration settings.
An attempt was made to enable torque before the drive’s setup
parameters have been configured. The drive setup parameters must
A6 166 Drive Not Configured
be configured each time the drive’s control power cycles on, before the
drive can be enabled.
An attempt was made to configure a drive parameter while the drive
A7 167 Illegal While Drive Enabled
was enabled.
An invalid commutation position was detected, possibly due to a
Invalid Commutation
A8 168
Position
discharged absolute encoder, or an encoder failure encoder.
(See ServoWire SD Drive Troubleshooting Guide, Fault Code A8)

1 Also see Section 7.2, ServoWire SD Drive Troubleshooting

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 ServoWire SD Drive Manual Operation

Drive
Fault Fault
Condition Description
Indicator1 Code
1

A9 169 Phase Loss The drive detected the loss of a main power phase or a soft-start error.
Inrush current greater than 0.5 amps or a low bus voltage (<50 VDC)
AA 170 Soft Start Error was detected when attempting to enable the drive (this is only
checked when enabling a drive).
Ab Not Used.
An over-temperature condition was detected in the drive powerblock,
AC 172 Drive Over Temperature
or a failure of the inrush current resistor.
A drive emergency stop was detected. This requires that the drive be
Ad 173 E-Stop
configured to use one of the general-purpose inputs as E-Stop input.
SAC-SDM Drive, SMLC or MotionObjects fault:
AE 174 Software upgrade.
Host PC driver software upgrade is required.
AF Not Used.
The checksum on the downloaded code was incorrect. The download
b0 176 Checksum error
has been aborted. Try again.
The download code was not recognized. The wrong file was used. The
b1 177 Bad file
drive firmware may be too old to recognize this format.
The downloaded code is not designed for this drive hardware, but
b2 178 Firmware not compatible rather for different drive hardware. Obtain the correct file and try
again.
b3 179 Firmware Checksum error Internal firmware program checksum error. Reload drive firmware.

The position following error exceeded the maximum amount

C0 192 Lag Fault
configured using ServoWire Pro.
The commanded speed exceeded the software configured axis speed
C1 193 Command Overspeed
limit.
The actual (feedback) speed exceeded the software configured axis
C2 194 Actual Overspeed
speed limit.
Motion was commanded further into a hardware travel limit while the
C3 195 Hardware Travel Limit
limit was still active.
C4 Not used
The available loop update time was insufficient to complete the loop
C5 197 Loop Rate Exceeded
processing
C6 198 Missing MotionData The MotionData from the master axis is not available.
C7 199 Motion Segment overflow
C8 200 Missing Motion table
C9 201 Unexpected Offline The SMLC is not receiving isochronous feedback from the drive.
The 1394 driver is no receiving its once-per-looprate update
CA 202 1394 Driver failure
information from the 1394 bus driver.
The pacer axis backed up far enough to overflow the backup
Cb 203 Pacer Backup Overflow
compensation.
CC 204 Invalid MotionData Config. The MotionData is configured in a loop, which is not valid.
CD-CF Not used
D0-DF Not used
ServoWire Protocol The ServoWire communications protocol in the drive is not compatible
E0 224
Incompatibility with the one used by the motion controller or PC.

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Drive
Fault Fault
Condition Description
Indicator1 Code
1

1394 network power loss (Host PC power lost or PC re-booted) or

E1 225 ServoWire Timeout Isochronous communications were lost. Example: Torque commands
from the Orion Motion Controller or Host PC are missing.
One possible cause is that the Loop Rate is set too high to allow all
Isochronous Arbitration
E2 226
Failure
the drives on the 1394 network to send there isochronous data
packets. Lower the Loop Rate.
ServoWire Watchdog The ServoWire Isochronous communications watchdog bit has not
E3 227
Timeout changed state within the allotted time.
ServoWire Initialization A hardware error was detected when initializing the IEEE 1394
E4 228
Error communications controller circuitry.
The drive internal watchdog has timed out due to either the loss of
E5 229 Drive Watchdog Timeout ServoWire network power (usually due to loss of PC power) or an
unexpected failure.
The drive is not detecting the 8-40 VDC on the ServoWire cable. No
No ServoWire
E6 230
Network Power
communication is possible until this is corrected. The error will
automatically clear itself when ServoWire power is applied.
E7 Not Used
The host has detected more than one drive with the same Axis ID. All
E8 232 Duplicate Drive ID
the drives with duplicate IDs should be displaying this error.

The motor’s rating for continuous current has been exceeded by the
F0 240 Motor RMS Over Current actual RMS current for longer than allowed by the thermal time
constant of the motor. ( Software configuration setting)
At least one motor encoder feedback channel (ENCA, ENCA’, ENCB,
F1 241 Motor Encoder Open Wire
ENCB’) is not connected properly. (J4 pins 1,2,3,4)
Auxiliary Encoder Open At least one channel (AUXENCA, AUX ENCA’, AUXENCB,
F2 242
Wire AUXENCB’) is not connected properly.
The hall track feedback from the motor is improperly wired.
F3 243 Invalid Hall State This fault can also occur if the feedback type in the drive
configuration software has been improperly identified.
F4 244 Motor Over Temperature Open contact at J4 pins 19-20. See Section 0, page 73.
The drive has detected an option board installed, but does not
F5 245 Unknown Option Board
recognize or support this board.
The motor configuration indicates that there is no over temperature
F6 246 Overtemp Config. Error.
sensor, but an over temperature sensor was detected by the drive.
F7 247 Serial Encoder Alarm. An alarm bit has been returned by the Sigma 2 encoder.
Unsupported Serial Unsupported encoder feedback type - or -
F8 248
Encoder detected. Not supported by the drive firmware

Table 22, ServoWire SD Drive Fault Codes (continued from previous page)

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ServoWire SD Drive Manual Operation

4.5 Commutation Modes

By default, ServoWire SD Drives are configured to control permanent magnet
brushless DC servomotors using sine-wave commutation. A commutation signal
is needed at initial startup to determine motor orientation. Serial encoders have
this information in serial data. With absolute encoders and resolvers the
information is derived from the absolute position and the Hall Offset value.
Quadrature encoders must provide the commutation information using the Hall
inputs, U, U’, V, V’ and W, W’.

4.6 Commutation Feedback Signals – Quadrature Feedback sources

With quadrature feedback sources the Drive can be configured for trapezoidal
commutation of brushless motors or DC output for brush motors using the
configuration software. This can be useful when integrating third party motors
or when controlling motors other than DC brushless servomotors.
Commutation position signals are illustrated below.
The U, V and W signals are “on” for 180o spaced 120o apart and allow the Drive
to determine motor position for commanding current. These signals are used to
determine rotor position whenever the Drive is operating in trapezoidal
commutation mode.

8 0 0 0
E n c o d e r c o u n ts E n c o d e r c o u n ts
0

E n c o d e r C h a n n e ls

7 9 9 2

7 9 9 6
O n e M o to r R e v o lu tio n Z - J 3 , P in 5
3 H a ll C y c le s (6 P o le M o to r)
4

E x a m p le : 8 0 0 0 C o u n t E n c o d e r (2 0 0 0 lin e ) A – J 3 , P in 1
C o u n te r-C lo c k W is e R o ta tio n
( Z c h a n n e l p h a s in g fo r re f o n ly * ) B – J 3 , P in 3

U – J 3 , P in 7

V – J 3 , P in 9

W – J 3 , P in 1 1

T B 1 - U
B e m f U -V
T B 1 - V
B e m f V -W
T B 1 - W
B e m f W -U

00 90
9 0 180
1 8 0 270
2 7 0 360
3 6 0 450
4 5 0 540
5 4 0 630
6 3 0 720
7 2 0 810
8 1 0 900
9 0 0 990
9 9 0 1080
1 0 8 0

Figure 30, Hall signals and Motor Back EMF waveforms

If the motor’s back EMF and commutation signals are not directly in phase, the
Hall Offset parameter can be used to compensate for the offset.

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4.7 ServoWire Drive Commutation Feedback ( Hall Signals )

NOTE: For the below procedure to work, the encoder must have hall support by providing integrated HALL
data tracks. Resolver motors & Serial encoders (Sigma II) do not have hall support.

Using ServoWire Pro (SMLC)

The state of the commutation signals can be displayed using the Monitor utility
in ServoWire Pro. To verify that the commutation feedback is correct, rotate the
motor shaft clockwise or counter-clockwise and confirm that the Hall sensors
proceed through the sequence indicated in this table.

Counter-Clockwise Clockwise Rotation

Rotation 010 011
110 001
W V U W V U 100 101
1 0 1 1 0 0 101 100
0 0 1 1 1 0 110
001
0 1 1 0 1 0
011 010
0 1 0 0 1 1
010 011
1 1 0 0 0 1 110 001
100 101
1 0 0 1 0 1
Note: Clockwise and Counter-Clockwise shaft rotation refers to
rotation when viewing the end of the motor shaft
Figure 31, Valid
Table 23, Valid Hall Signal Sequences
Hall States (6 Pole
Motor Example
diagram)

Using MotionDESK (Orion)

The state of the commutation signals can be displayed using the HALL@
MotionBASIC variable and the table below. To verify that the commutation
feedback is correct, " REPEAT PRINT HALL@(AxisNumber~) ", rotate the
motor shaft clockwise or counter-clockwise and confirm that the HALL@ value
proceeds through the sequence indicated below. Refer to the MotionBASIC Help
HALL@ variable section for further details. HALL@
W, V, U
Counter-Clockwise Clockwise Rotation 2 3
6 1
Rotation 4 010 011
110 001 5
W, V, U HALL@ W, V, U HALL@ 100 101
101 5 100 4 5 4
101 100
001 1 110 6 1 001 110 6
011 3 010 2 011 010
3 2
010 2 011 3 010 011
110 6 001 1 2 110 001 3
100 101
100 4 101 5 6 1
4 5
Note: Clockwise and Counter-Clockwise shaft rotation refers to
rotation when viewing the end of the motor shaft

Valid HALL@ Sequence Valid Hall States

(6 Pole Motor
Example diagram)

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ServoWire SD Drive Manual Operation

4.8 Quadrature Feedback Signals

Quadrature position signals for "Forward" and "Reverse" travel are illustrated in
Figure 32.
Channel A and Channel B are phase quadrature signals, which allow the
Servodrive and associated digital positioning electronics to determine both
travel distance and direction. Programmable motion controllers and
servodrives, such as ORMEC's, typically decode each transition of both encoder
channels, yielding a resolution of four times the linecount specification per
revolution e.g. A position encoder with 4096 linecount, when decoded by a
ServoWire SD drive yields a positioning resolution of 16,384 cnts/rev.

Figure 32, Quadrature Encoder Channel Description

4.9 Commutation Feedback Signals – Resolver Feedback drive

Configuration of the drive for a resolver is done using ServoWire PRO. Some
parameters are motor specific and are found in the motor properties definition.
Some parameters are drive specific and can be found on the drive properties
page, feedback tab.
A resolver works by receiving a reference sine wave of a given frequency and
amplitude. The resolver on the motor then couples this like a transformer into
two other windings, SIN and COS, which are 90 degrees apart. The SIN and
COS signals are returned to the drive where they are decoded and the position
determined.
There are design variations in resolvers which may need to be compensated.
ServoWire PRO will help you configure the servodrive for your specific resolver.
The servodrive has adjustments for:
• Excitation frequency – the frequency of the reference signal. Some
resolvers won’t handle high freqencies. As the frequency changes, the
impedance of the resolver changes and the ability of the resolver to couple
the signal to the output windings changes. In some cases getting low
enough that the resolver does not operate. Also, as the impedance goes
down the current in the reference signal will go up. With higher current
comes higher voltage drop. As long as it is within the limits of the drive
the system will work.
• Transformation Ratio – the gain of the resolver reference in to SIN and
COS out can vary, typically ranging from 0.5 to 2. The servodrive expects

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Operation ServoWire SD Drive Manual

SIN and COS to be 3 Vrms. The servodrive can be configured to meet

this requirement for transformation ratios of 0.25 to 2.

The REF signal is provided by the drive and sent to the resolver. The SIN and COS
signals are returned and are spaced 90o apart and allow the Drive to determine
motor position for commanding current.
If the motor’s back emf and commutation signals (SIN & COS) are not directly in
phase, the feedback offset parameter can be used to compensate for the offset.
The drive requires that the SIN and COS signals be phased such that the POS
command returns an increasing value when the motor is rotated counter-clockwise
as viewed from the shaft end. If the POS value is decreasing, reversing the SIN and
COS pairs will usually help. The signals labeled SIN and COS by the motor
manufacturer do not always have the same phasing from manufacturer to
manufacturer.

4.10 Regenerative Loads

Regenerative loading occurs when the direction of power flow is from the machine
to the motor: the motor is acting as a generator. Another way of describing this is
that the load torque is acting in a direction to ‘help’ the motor to move in the
commanded direction of motion. This can occur for a variety of reasons
including:
1. Decelerating the machine faster than it would coast, especially from high
speeds and with large inertial loads;
2. Using the motor to act as a brake on an unwind stand for a roll of material,
where the tension in the web causes the motor to brake while moving
forward; or
3. Using the motor to lower a vertical load that is not counterbalanced.
In many cases, this extra energy is dissipated by machine friction, or stored
temporarily in the drive’s power capacitors. However, if the amount of
regenerative energy is excessive, it must be shunted to an external regenerative
resistor, in order to prevent a high bus voltage condition. For assistance
determining if your application has a regenerative load component, contact your
ORMEC Sales and Applications Engineer.

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4.10.1 Shunt Regulator

ServoWire SD Drive models SAC-SD_210, SAC-SD_217, SAC-SD_220, SAC-
SD_225, SAC-SD_235, SAC-SD_260, SAC-SD_405, SAC-SD_410, SAC-SD_417,
SAC-SD_425, SAC-SD_435 and SAC-SD_450 have shunt regulator circuitry for
dissipating excessive regenerative voltage.
The shunt regulator consists of a voltage comparator and a switching transistor.
When the voltage comparator detects excess bus voltage, it turns on the shunt
regulator transistor, dissipating energy from the servodrive capacitors to the
external regen resistor. The ServoWire SD Drive controls the on-time duty
cycle, so that the average current is appropriate for the regen resistor specified
in the project software setting.

(on TB1)

(on TB1)

Figure 33, Simplified Schematic of Shunt Regulator

4.10.2 Sizing a Regen Resistor: Application-specific Formulas

Regardless of the type of application, the value of interest is Average
Regenerative Power.

V i1 V i1

V f1 V V f1
i2
V
V e lo c ity (R P M )

f2

V fn

V in

T
D is s ip a te d E n e r g y

c y c le
(J o u le s )

P 2 P n
P 1 P 1
E E E
1
2
n E 1

T T 2
T n T 1
1
T im e (s e c o n d s )

Figure 34, Regeneration during deceleration.

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[Link] Sizing a Regen Resistor: Regeneration Due To Decleration

Regeneration during a motor’s deceleration is due to the decreasing kinetic

energy of the rotating inertia. Not all of this energy will make it back to the DC
bus; some or all of it may be absorbed by machine friction and motor losses. In
the case of sizing regen resistors, neglecting frictional losses is a conservative
approach to sizing a regen resistor.

Each deceleration in a cycle results in a loss of kinetic energy at the motor.

Depending on frictional losses, some or all of this energy may make it back to
the drive as Regenerative Energy. Rotational kinetic energy at any velocity
can be calculated with the general equation E = 12 Iω2 . Applying the
appropriate units conversions:

E regen = 12 I ⋅ ( Vi − Vf2 ) ⋅ (0.00124)

2
(Equation 1)

where: Eregen is the loss of kinetic energy during a deceleration (Joules)

I is the total system inertia (motor + load) (in-lb-sec2)
Vi is the initial speed of the motor before deceleration (RPM)
Vf is the final speed of the motor after deceleration (RPM)
( 2 πrad / rev ) 2 ⋅( 4.448 N / lb )( 25.4 mm / in )
(0.00124) is a unit conversion: ( 60 sec/ min)2 (1000 mm / m )

Average Regenerative Power for the total cycle can be calculated as:

E1 + E 2 + E n
Pavg = (Equation 2)
Tcycle

where Pavg is the average dissipated power over the entire cycle (Watts)
E1 is the energy dissipated by the 1st decel in the cycle (Joules)
E2 is the energy dissipated by the 2nd decel in the cycle (Joules) …
En is the energy dissipated by the Nth decel in the cycle (Joules)
N is the number of decelerations in the cycle
Tcycle is the total repetitive cycle time (seconds)

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[Link] Sizing a Regen Resistor: Regeneration Due To Web Tension (motor acting as brake)

The regeneration in a tensioned-web application is due to the web tension

pulling the braking motor along in the same direction that it is moving.
Average Regenerative Power is calculated with the general formula:
P = Tω. Applying the appropriate units conversions:

Pavg = (0.0118) * T ⋅ V (Equation 3)

where Pavg is the continuous regenerated power (Watts)

T is the torque at the motor due to web tension (in-lb)
V is the velocity of the motor shaft (RPM)
( 2 πrad / rev )( 25.4 mm / in )( 4.448 N / lb )
(0.0118) is a conversion: ( 60 sec/ min)(1000 mm / m )

[Link] Sizing a Regen Resistor: Regeneration Due to Vertical Load

In an application where the motor is supporting the weight of a poorly

counterbalanced load, regeneration may occur when the load is being lowered.
This is due to gravity ‘helping’ the motor lower the load.
Instantaneous Regenerative Power can be calculated with the formula
P = Tω. Applying the appropriate units conversions:
Pinstant = (0.0118) * T *V (Equation 4)

where Pinstant is the instantaneous regenerated power (Watts)

T is the torque at the motor due to load weight (in-lb)
V is the speed of the motor during downward motion (RPM)
( 2 πrad / rev )( 25.4 mm / in )( 4.448 N / lb )
(0.0118) is a conversion: ( 60 sec/ min)(1000 mm / m )

Average Regenerative Power for the total cycle can be calculated as:

P1 ⋅ T1 + P2 ⋅ T2 + Pn ⋅ Tn
Pavg = (Equation 5)
Tcycle

where Pavg is the average dissipated power over the entire cycle (Watts)
P1 is the power dissipated by the cycle’s 1st downward move (Watts)
T1 is the time spent in the cycle’s 1st downward move (seconds)
P2 is the power dissipated by the cycle’s 2nd downward move (Watts)
T2 is the time spent in the cycle’s 2nd downward move (seconds)
…
Pn is the power dissipated by the cycle’s Nth downward move(Watts)
Tn is the time spent in the cycles Nth downward move (seconds)
n is the total number of downward moves in the cycle
Tcycle is the total repetitive cycle time (seconds)

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4.10.3 Sizing a Regen Resistor: Use Average Regenerative Power

Once Average Regenerative Power has been determined using one of the
methods in section 4.10.2, the sizing of the resistor is nearly complete.
The wattage of the regenerative resistor should be greater than or
equal to the application’s calculated Average Regenerative Power.
The next section shows the minimum resistance requirements, as well
additional limitations on the regen power that can be shunted, based on the
ServoWire SD Drive’s shunt transistor.

4.10.4 Sizing a Regen Resistor: Regen Transistor and Resistor Limitations

The amount of energy that can be dissipated by an external regen resistor may
be limited by the current capability of the switching transistor.
Table 24 below shows 1) the mimimum regen resistance allowed, 2) the
resulting current at that resistance and 3) the maximum average regen power
capability of the drive.
NOTE: Do not use a lower resistance than shown in the table below! Too low a
resistance may result in peak currents that are too high for the regen
transistor, and could result in damage to the transistor.

Drive Regen
Regen
Power Regen
Resistor
Output Transistor
Maximum
ServoWire Minimum Average Peak Bus
Drive Resistance(1) Power(3) Current(2) Capacitance
SAC-SD_203
Regen Transistor not available. 540 μF
SAC-SD_205
SAC-SD_210 50 Ω 800 W 8.5 A 1,170 μF

SAC-SD_217 1200 W
35 Ω 12 A 1,410 μF
SAC-SD_220 1700 W
SAC-SD_225 3000 W
7.8 Ω 50 A
SAC-SD_235 4175 W 3,360 μF
SAC-SD_260 5.0 Ω 7100 W 75 A

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ServoWire SD Drive Manual Operation

Drive Regen
Regen
Power Regen
Resistor
Output Transistor
Maximum
ServoWire Minimum Average Peak Bus
Drive Resistance(1) Power(3) Current(2) Capacitance
SAC-SD_405 70 Ω 1200 W 11.4 A
560 uF
SAC-SD_410 40 Ω 2400 W 20 A
SAC-SD_417 40 Ω 4000 W 20 A
840 uF
SAC-SD_425 25 Ω 5970 W 32 A
SAC-SD_435 20 Ω 8350 W 40 A
1120 uF
SAC-SD_450 15 Ω 12000 W 53.3 A
1 Minimum resistance – limited by drive transistor.
2 Calculated using minimum resistance at maximum voltage.
3 Average Regen Output Power which the drive can sustain over time without failure

Table 24, Regen Resistor Selection Requirements

The actual resistance of the regen resistor determines the current in the
resistor. Using Ohms law the current when the regen transistor turns on will be
I = V/R. V will be 395 V or 775 V depending on the drive bus voltage setting.
The table shows what the current will be for the minimum resistance allowed.
When using the minimum resistance value the power output (dissipated in the
resistor) will be much higher than the drive and usually the resistor can sustain.
Having this peak capability allows the drive to remove a large amount of energy
quickly. For example, using the SAC-SD_425 values: P = V2 /R. With V = 775 V
and R = 25 ohms the instantaneous power is 7752/25 = 24,025 W. For a short
time the drive and resistor (properly sized) can tolerate this power. The column
“Maximum Average Power” shows how much average regen power the drive can
sustain without damage. Verfying that the Average Power requirements are
met is accomplished by analysis of the application.
The resistors current and power ratings may also limit the amount of energy
that can be dissipated by a regen resistor. The peak current that will be seen by
the resistor is shown in Table 25. This current is limited by the regen resistor’s
resistance value, so if a higher resistance is used, the peak current will be lower.
The ServoWire SD Drive using an on-off duty cycle limits the average current
that will be seen by the resistor. This limits the average current so that neither
the wattage of the resistor (configuration software setting) nor the continuous
current of the regen transistor is exceeded on a continuous basis.

Peak Current Peak Current

on 230 V drive on 460 V drive
Regen Resistor Resistance Wattage (425 VDC max) (800 VDC max)
SAC-SMRR/0055 50 Ω 55 W 8.5 A 16 A
SAC-SMRR/0095 40 Ω 95 W 11 A 20 A

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Peak Current Peak Current

on 230 V drive on 460 V drive
Regen Resistor Resistance Wattage (425 VDC max) (800 VDC max)
SAC-SMRR/0700 54 Ω 700 W 7.9 A 14.8 A
SAC-SMRR/0845 40 Ω 845 W 11 A 20 A
SAC-SMRR/0846 10 Ω 846 W 43 A Not supported on
SAC-SMRR/1700 6.5 Ω 1,700 W 65 A 460 V drives

Table 25, Standard Regen Resistor Specifications

The regen resistors are voltage rated for up to 1000 VDC allowing them to be
used on both the 230 VAC and 460 VAC drives. When applying the resistor the
minimum resistance supported by the drive must not be exceeded. Table 26
shows which regen resistors are compatible with which drives. Entries with a
Pk indicate that the combination provides regen output at or near the peak
regen capacity of the drive, however, the power rating of the resistor is not rated
for continuous operation at that output level.

Regen Resistor Drive Model SAC-SD_

Model Resis- Power 210 217, 225, 260 405 410, 425 435 450
Number tance Rating 220 235 417
SAC-
SMRR/0055 50 Ω 55 W Pk Y Y Y Y Y Y Y
SMRR/0095 40 Ω 95 W Pk Y Y Pk Y Y Y
SMRR/0230 81 Ω 230 W Y Y Y Y Y Y Y Y Y
SMRR/0650 72 Ω 648 W Y Y Y Y Pk Y Y Y Y
SMRR/0700 54 Ω 700 W Pk Y Y Y Y Y Y Y
SMRR/0825 26 Ω 825 W Y Y Pk Pk Y
SMRR/0845 40 Ω 845 W Pk Y Y Pk Y Y Y
SMRR/0846 10 Ω 846 W Pk Y
SMRR/1650 15 Ω 1650 W Y Y Pk
SMRR/1700 6.5 Ω 1,700 W Pk
Y = combination acceptable, Pk = acceptable and at or near peak regen output capacity of the
drive
Table 26, Standard Regen Resistor Drive Compatibility

The voltage seen by the resistor will range between the Turn-On level and the
High-Bus level, as shown below in Table 27.

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ServoWire SD Drive Manual Operation

Nominal Input Nominal Bus Turn On Regen High Bus

Voltage Voltage Transistor Voltage Fault
(VAC) (VDC) (VDC) (VDC)
230 325 395 425
460 650 775 800

Table 27, Regen Transistor Turn-On and other Bus Voltage Levels

4.10.5 Bus Sharing

The extra energy generated by regenerative loads can also be dissipated through
bus sharing. In a shared-bus configuration, the bus capacitors are all connected
in parallel, magnifying the total bus capacitance by the number of drives present
(see Figure 35). Also, the regenerative energy generated by one drive can be
used to reduce the input power requirements of any other active drives on the
shared bus. However, if the amount of regenerative energy available is
excessive, it must be still be shunted to an external regenerative resistor, in
order to prevent a high bus voltage condition. For assistance in determining how
to use bus sharing in your application, contact your ORMEC Sales and
Applications Engineer.

4.10.6 Bus Sharing Limitations

Bus sharing is supported by most ServoWire SD drives. However, all drives
connected to bus share must be operating off the same AC power supply. That
is, connecting a 230 V drive to share the bus with a 460 V drive operating at 460
VAC will cause permanent damage to the 230 V drive.
On 230 VAC drives bus sharing is supported by ServoWire SD Drive models
SAC-SD_225, SAC-SD_235, and SAC-SD_260 only.
On 460 VAC drives bus sharing is supported by all 460 V models, ServoWire SD
Drive models SAC-SD_405, SAC-SD_410, SAC-SD_417, SAC-SD_425, SAC-
SM435 and SAC-SD_450.
In both cases the drive is subject to the following restrictions:
• Drives that are sharing the DC bus must also be connected to a main
input power source and a control input power source. The same source
must be used for all drives connected together.
• Main input power should be applied to all shared-bus drives within 0.1
seconds to prevent possible damage to internal drive control circuits.
• Bus wiring between drives should be less than 12 inches in length to
minimize oscillatory effects.
• Only one regen resistor may be used in a bus-sharing network.
That regen resistor must be sized to handle the regenerative power
produced by all of the drives in a shared bus configuration. See Section
4.10, Regenerative Loads for more information on sizing regen resistors.

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SD Drive # 1 SD Drive # 2 SD Drive # n

BUS + BUS + BUS +

Optional
regen
resistor
REGEN Bus
Capacitors

BUS - BUS - BUS -

Figure 35, Shared Bus Capacitors

4.10.7 Shunt Regulator Overload

If regenerated voltage is excessive, a High Bus Voltage fault (A4) may occur. A
High Bus Voltage fault will not reset until the voltage level has dropped to an
acceptable level. This will occur faster if you disable main power.
If High Bus Voltage faults recur, one of the following actions may resolve the
problem:
• Increase the wattage of the external regenerative discharge resistor.
For this change to be effective, you must also change the
software configuration settings for the ServoWire SD Drive:
Regen Resistor Power.
• Reduce the commanded current limit for the Controller.
• Reduce the commanded deceleration.
• Decrease the maximum motor speed.
• Reduce the inertial load seen by the motor, either by removing part of
the load, or by increasing the gear ratio (motor-to-load).

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4.10.8 Servomotor Temperature Protection

The thermostat contact wiring is part of the Motor Feedback Cable. When the thermal contact
opens, the behavior of the ServoWire SD Drive will depend on the ServoWire SD Drive’s software
configuration setting:

Host PC & SMLC/MotionObjects

Motor Thermal ServoWire Pro Behavior of
Switch state. configuration ServoWire SDM Drive &
setting. SMLC/MotionObjects.
Open An open contact will not cause any error or drive fault.
Closed Ignore A closed contact will cause an application program,
temperature sensor configuration error.
An open contact will cause an OnAlarm callback. NO
Generate Drive Fault will occur. The motor can still have torque.
Opens
Alarm It is up to the application’s program to respond to the
over temperature warning condition.
An open contact will cause an OnFault callback. If the
Generate
Opens drive torque is enabled, a drive fault F4 will immediately
Fault
disable torque to the motor.

Orion Motion Controller

Motor Thermal MotionDesk Behavior of
Switch state. configuration ServoWire SD Drive &
setting. MotionBASIC
An open contact will not cause any error or drive alarm.
Open
Ignore A closed contact will cause the MotionBASIC Configuration
Closed
Error 1629 = Temperature sensor configuration error.
An open contact will cause MotionBASIC ERR=1628 "Over
Generate temperature condition exists". NO Drive Alarm will occur.
Opens
Motion Error The motor can still have torque. It is up to the application’s
error handler to respond to the over temperature condition.
When the motor is too hot, causing the contact to open, the
SD Drive will generate an alarm. If the drive torque is
Generate enabled, a drive alarm F4 will immediately disable torque to
Opens
Drive Alarm the motor.
MotionBASIC generates an ALARM@=244 and ERR=1628 "
Over temperature condition exists".
The status of the thermal contact can be monitored with MotionBASIC variable [Link]@.
Table 28, Motor Over-Temperature Input
G-Series Servomotors have embedded thermostats, which open when the motor
winding temperature exceeds 155oC.
DE/DA/DB-Series Servomotors do not have embedded thermostats.

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4.11 Tuning - Loop Diagram

Loop Rate
Loop Rate defines the number of times per second (Hz) that the ISO commands will be sent to the drive.

Position Actual
Position Actual ( POS_ACT ) returns the value of, or assign a value to, the actual real-time position of an axis
feedback device (encoder or resolver in axis position user units). See: Axis Position for more detail.

Position Gain Factor ( Kp )

The position loop gain factor ( Kp ) is set by the motion controller as a function of the Velocity Loop Time
Constant ( VLTC ) and Kp. With Kp set to the default 100%, the position loop is adjusted for a critically
damped position response. Adjusting this factor higher, results in an under-damped response and adjusting
it lower results in an over-damped response.
Default = 100%, range 1 to 500% ( Note: 100% meets the requirements of most applications.)

Position Integral Factor ( Kpi )

The Position Loop Integral gain factor ( Kpi ) is set by the motion controller as a function of the position loop
characteristics. Position loop integral gain is normally required only in applications where position error
during motion is critical, such as electronic gearing or in the control of continuous web systems. It may also
be required to eliminate static position errors in applications with analog velocity loops, such as axes using
distributed feedback or velocity mode servodrives. With Kpi = 100% and Position Gain Factor (Kp) properly
adjusted, the servo axis is adjusted for critically damped position response. Adjusting this factor higher result
in an under-damped response and adjusting it lower results in no improvement in response.
Default = 0%, range 0 to 500%.

Velocity Observer
The velocity observer is software running in the drive, which derives velocity information from the axis
feedback signals ( encoder or resolver )

Velocity Feedforward Factor ( Kvf )

The Velocity Feedforward Factor ( Kvf ) allows the drive to directly command velocity as well as position in
response to a motion command from the motion controller. This enhances servo response and accuracy
because the velocity loop has significantly greater bandwidth than the position loop. The use of velocity
feedforward is a major factor in the elimination of position following error while the axis is moving.
Default = 100%, range 0 to 200%.

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Velocity Observer Sensitivity ( Kva )

The Velocity Observer Sensitivity ( Kva ) determines how the velocity observer responds to changes in
motor speed. Lower values will smooth low speed motion, but increase settling times on quick stops.
Default = 100%, range 40 to 200%

Velocity Loop Time Constant ( VLTC )

The Velocity Loop Time Constant ( VLTC ) is used to indirectly set the velocity proportional gain Kv. The
Velocity Loop Proportional Gain (Kv) is not available as a variable. The velocity proportional gain is set by
the motion controller to achieve the velocity loop time constant objective established by VLTC.
The performance characteristics of the servo motion control system are highly dependent on Velocity Loop
Time Constant ( VLTC ), should be set as small as the system dynamics allow. A realistic goal is 0.7 to 3
msec for loads, which are tightly coupled to the motor.
Default = 3 milliseconds, range 0.3 to 30 msecs.

Velocity Loop Integral Gain ( Kvi )

The velocity loop integral gain factor ( Kvi ) is set by the motion controller as a function of the velocity loop
characteristics. With Kvi set to the default 100%, the servo axis is adjusted for a critically damped velocity
response. Adjusting this factor higher result in an under-damped response and adjusting it lower results in
no improvement in response.
Default = 100%, range 0 to 1000% ( Note: 100% meets the requirements of most applications.)

Velocity Derivative Gain ( Kvd )

Velocity derivative gain ( Kvd ) sets the gain at which the velocity loop responds to feedback rate changes.
Velocity derivative gain is inherently noisy and will increase step-input responsiveness. The default
adjustment (0% of nominal) should be satisfactory for achieving stability.
Default = 0%, range 0 to 600%

Velocity Monitor Time Constant

The Velocity Monitor Time Constant ( VEL_MONTC ) sets the time constant of the filter on the velocity
monitor. This filter affects reporting only, not motion performance. Velocity Monitor TC is a decimal value,
with a higher value increasing filtering on the velocity-monitoring variable Velocity Monitor.
Default = 20.0 milliseconds, range 0.0 to 200.0 msecs.

Velocity Monitor
Velocity Monitor ( VEL_MON ) is a read only variable that returns the filtered observed (actual) velocity of the
servo axis in user units. The Velocity Monitor TC controls the amount of filtering.

Velocity Actual
Velocity Actual ( VEL_ACT ) is a read only variable, which returns the current real-time instantaneous
velocity of the servo axis, as determined by the velocity observer in user units. This filtered value is
operating internally at the ServoWire Drive, and its resultant filtered value is returned to the velocity-summing
junction.

Acceleration Feedforward Factor ( Kaf )

Acceleration feedforward ( Kaf ) allows the drive to directly command acceleration (and therefore torque) as
well as position in response to a motion command from the application program. This can enhance servo
response and accuracy because the current (torque) loop has significantly greater bandwidth than the
position and velocity loops. Acceleration feedforward has limited application, and is not used (disabled) in
electronic gearing applications. Increasing its value will improve motions that command short, quick
acceleration / decelerations.
Default = 0%, range 0 to 200%

Inertia
The total inertia of this axis is the combination of Motor and Load Inertia at the Motor Shaft, measured in in-
lbs-sec². When an assignment is made to the INERTIA value, an additional range check is made to insure
that: Axis Peak Torque [ in-lbs. ] X Torque Gain [ % ] / OP_LOOP_INERTIA [ in-lb-sec²] >=12800.
If it is less than 12800, an error will be generated, and the parameters will not be changed in the drive.

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Default = Motor Inertia only (in-lb-sec²), range 0.000001 to 99 in-lb-sec²

IMPORTANT:
For optimal performance, the value of INERTIA needs to match the total inertia on the axis as seen by
the motor.
You can use MotionDESK's Axis Tune or ServoWire Pro's Inertia Calculator to accurately calculate
total system Inertia by monitoring successive motor indexes.

Current Maximum
Current maximum ( CUR_MAX ) is the maximum drive current output that will limit the current command. It is
expressed as a percent of Peak Current, multiplied by 1000.
Ex: Current Max = 67450 then its value is 67.45% of peak.
Range = 0 to 100,000

Current Command
Current command ( CUR_CMD ) returns the instantaneous real-time value for the current command output
of an axis control loop. The valid range is from ± Current Max or responding to the desired servo drive
current command output. The ±100,000 maximum range is expressed as a percent of Peak Current,
multiplied by 1000, and is positive for "forward" output. Users desiring to limit output to values less than ±
peak would lower current max.
Range = 0 to 100,000

Current Monitor Time Constant

Current Monitor Time Constant ( CUR_MONTC ) sets the time constant of the filter on the current command
monitor. A higher value increases filtering on the current command monitoring variable. This filter affects
reporting only, not motion performance.
Default = 4, range 0 to 200 milliseconds.

Current Monitor
Current Monitor ( CUR_MON ) returns a filtered current value for the current command output, of an axis
current control loop. The amount of filtering is determined by the value of Current Command Time Constant.
The value is positive for "forward" output.
Range -100,000 to 100,000

Current Loop DC Gain ( Kdc )

This value is adjusted to the drive's current-loop DC gain. The DC Gain ( Kdc ) is a function of motor
characteristics, impedance, drive bus-voltage, and drive size. This parameter is calculated for a rapid
current response with low ringing. In a few cases it is possible to improve current loop response by raising or
lowering this value. Doing so in conjunction with the Final Output Stage Gain may also provide an
improvement in responsiveness.
Default = 100%, range 0 to 3000%

Current to Voltage Gain ( Kiv )

This value is adjusted to the drive's final output stage gain. The final Output Stage Gain is a function of
motor characteristics, impedance, drive bus-voltage, and drive size. This parameter is calculated for a rapid
current response with low ringing. In a few cases it is possible to improve current loop response by raising or
lowering this value. Doing so in conjunction with the Open-Loop DC Gain may also provide an improvement
in responsiveness.
Default = 100%, range 0 to 3000%

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4.12 Filter … Low-Pass Current Cutoff

The Current Filter sets the cutoff frequency ( Hertz ) of a recursive low-pass filter on the Current Command.
This digital filter is operating internally at the ServoWire Drive, and its resultant filtered value is not returned
to the motion controller current loop. A value of zero ( 0 ) will disable the filter.
Default = 500 Hz, range 20 to 2500 Hz ( In 1 Hertz increments)

4.13 Filter … Digital Notch

The Notch filter is used to reject (remove) one band of frequencies and passes both higher and lower
frequencies. This feature is only available in SAC-SD servo drives with firmware version 1.6.0 and later.
You must enable the filter.
Default = Disabled

NOTCH FREQUENCY is the center

frequency of the current loop's notch filter in
Hertz. The center frequency of the notch
measures the frequency at which the filter’s
magnitude reaches it’s minimum value.
Default = 300, range 1 to 2500.

NOTCH DEPTH is the depth of the current

loop's notch decibel's (dB). The depth of the
notch measures the filter’s minimum
magnitude.
Default = -4, range – 4 to – 40.

NOTCH WIDTH is the width of the notch (Hz).

The width of the notch measures the distance
between the two frequencies where the filter’s
magnitude is –3dB.
Default = 50, range 1 to 1250 Hz

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Chapter 5
Getting Started
5 Getting Started

5.1 Test Run

Before doing a test run, check the following points listed in this section. Correct
any problems before proceeding.

5.1.1 Servomotor Check

Before test run, check the following.
Motor mounting and grounding are correct.
Bolts and nuts are tight.
For motors with oil seals (IP67), the seals are not damaged and are properly
lubricated.
Motor Power and Feedback Cables are properly attached.

5.1.2 ServoWire SD 115/230 VAC Drive Check (SAC-SD_2__)

The control and main power voltage should be 115 (+15%, -20%) or 230 (+15%, -
20%) VAC, 50/60 Hz. The absolute maximum is 265 VAC.
The main power voltage depends on the servomotor:
MAC-G005A1, G006A1, G010A1, G010B1, G011A1, G015A1, DE003A1, DE-
006B1 and DE008C1 servomotors are rated for 115 VAC – not 230 VAC.
CHECK POWER BEFORE APPLYING IT TO THE SERVODRIVE.
• Check that feedback connector(s) J4 (and option modules) is/are firmly seated
• Check that Power terminal block connections r, t, L1, L2, L3,
BUS+, RG, BUS-, U, V, W, and ground ) are tight.
Note: The Ormec standard motor cable is color-coded:
RED= U, WHITE= V, BLACK= W, Green & Silver= GROUND.
• Motor wiring is correct.
• The main power interlock circuit disables main power under a ServoWire SD
Drive fault condition.

5.1.3 ServoWire SD 460 VAC Drive Check (SAC-SD_4__)

The control power voltage should be 115 (+15%, -20%) or 230 (+15%, -20%) VAC,
50/60 Hz. except on the 35A and 50A models (SAC-SD_435 and SAC-SD_450)

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where the control power is limited to 230 (+15%, -20%) VAC only. The
absolute maximum is 265 VAC.
The main power voltage is normally 460 (+15%, -20%) VAC, however, operation
at 230 (+15%, -20%) VAC, 50/60 Hz. is acceptable. The absolute maximum is
529 VAC.

The main power voltage depends on the servomotor. Do not choose a main
power voltage higher than that supported by the motorl.

CHECK POWER BEFORE APPLYING IT TO THE SERVODRIVE.

• Check that feedback connector(s) J4 (and option modules) is/are firmly seated
• Check that Power terminal block connections r, t, L1, L2, L3,
BUS+, RG, BUS-, U, V, W, and ground ) are tight.
Note: The Ormec standard motor cable is color-coded:
RED= U, WHITE= V, BLACK= W, Green & Silver= GROUND.
• Motor wiring is correct.
• The main power interlock circuit disables main power under a ServoWire SD
Drive fault condition.

5.1.4 Preparation for Test Run

During test run, the driven machine should not be attached to the Servomotor.
If it is necessary to start with the driven machine connected to the motor,
proceed with great care.
• After checking items above, turn on the control power.
• Enable the main power circuit and measure main DC Bus voltage.

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ServoWire SD Drive Manual Specifications

Chapter 6
Specifications
6 Specifications

Ormec products covered by this manual:

ServoWire SD Drives
SAC-SD_203 SAC-SD_205 SAC-SD_210 SAC-SD_217 SAC-SD_220
SAC-SD_225 SAC-SD_235 SAC-SD_260
SAC-SD_405 SAC-SD_410 SAC-SD_417 SAC-SD_425 SAC-SD_435
SAC-SD_450

6.1 ServoWire SD Drive Specifications

6.1.1 Environmental Specifications
Operating Temperature: 0 to +50oC
Storage Temperature: -20 to +70o C
Operating and Storage Humidity 10 to 90%, non-condensing
Table 29, Environmental Specifications

6.1.2 Mechanical Specifications

Mounting Method: Vertical panel mounting, two, three or
Also see outline drawings in Figure 1, ServoWire four 10-32 (M5) screws.
SD Drives 203 - 220 Outline Drawings (page 11).

Dimensions:

SAC-SD_203, SAC-SD_205 and SAC-SD_210

Height: add 2” (51 mm) clearance top and bottom 9.0 inches (229 mm)
Width: add 1” (25 mm) clearance each side 2.6 inches (76 mm)
Depth: includes clearance for attached cables 10.5 inches (267 mm)
Weight: SAC-SD_203 & SAC-SD_205 3.7 lbs. (1.7 kg)
SAC-SD_210 4.1 lbs. (1.9 kg)
SAC-SD_405 and SAC-SD_410

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Specifications ServoWire SD Drive Manual

Height: add 2” (51 mm) clearance top and bottom 11.0 inches (279 mm)
Width: SD_405 add 1” (25 mm) clearance each side 4.2 inches (107 mm)
SD_410 add 1” (25 mm) clearance each side 4.4 inches (112 mm)
Depth: includes clearance for attached cables 10.5 inches (267 mm)
Weight: SAC-SD_405 7.9 lbs. (3.7 kg)
SAC-SD_410 8.3 lbs. (3.9 kg)
SAC-SD_217
Height: add 2” (51 mm) clearance top and bottom 9.0 inches (229 mm)
Width: add 1.2” (31 mm) clearance each side 3.8 inches (97 mm)
Depth: includes clearance for attached cables 10.5 inches (267 mm)
Weight: 5.8 lbs. (2.7 kg)
SAC-SD_220
Height: add 2” (51 mm) clearance top and bottom 9.0 inches (229 mm)
Width: add 1” left-side, 2” (51 mm) right-side clearance 4.0 inches (112 mm)
Depth: includes allowance for attached cables 10.5 inches (267 mm)
Weight: 6.6 lbs. (3.1 kg)
SAC-SD_225, SAC-SD_235, SAC-SD_260, SAC-SD_417
and SAC-SD_425
Height: add 2” (51 mm) top, 4” (102 mm) bottom clearance 12.0 inches (305 mm)
Width: add 1” (25 mm) clearance each side 6.72 inches (187 mm)
Depth: includes allowance for attached cables 11.1 inches (282 mm)
Weight: 17.7 lbs. (8.1 kg)
SAC-SD_435 and SAC-SD_450
Height: add 2” (51 mm) top, 4” (102 mm) bottom clearance 14.0 inches (356 mm)
Width: add 1” (25 mm) clearance each side 7.8 inches (198 mm)
Depth: includes allowance for attached cables 12.1 inches (307 mm)
Weight: 22.0 lbs. (10. kg)
1

Table 30, Mechanical Specifications

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6.1.3 General Electrical Specifications for 115/230 VAC Drives (SAC-SD_2__)

Incoming Main Power Line Voltage – TB1 pins L1, L2, L3
WARNING: Use the servomotor’s voltage rating to determine the maximum input
voltage for the servodrive. MAC-G005A1, MAC-G006A1, MAC-G010A1, MAC-
DE003A1, MAC-DE006B1, and MAC-DE008C1 are rated for 115 VAC, not 230 VAC!
SAC-SD_203, SAC-SD_205: Single Phase, 50/60 Hz
115 (+15%, -20%) or 230 (+15%, -20%) VAC
SAC-SD_210, SAC-SD_217, SAC-SD_220, SAC- Three Phase, 50/60 Hz
SD_235, SAC-SD_260: 115 (+15%, -20%) or 230 (+15%, -20%) VAC
Incoming Control Power Line Voltage – TB1 or TB2 Single Phase, 50/60 Hz
pins r, t 115 (-20%) to 230 (+15%) VAC
0.5A max at 115 VAC, 0.25 A typ
Main DC Bus Voltage – TB1 pins BUS+, BUS-
115 VAC nominal input power: 163 VDC nominal level
230 VAC nominal input power: 325 VDC nominal level
Shunt Regulator Activation DC Bus Voltage1:
115 VAC motors: 207 VDC
230 VAC motors: 395 VDC
High Bus Voltage Fault Activation DC Bus Voltage1:
115 VAC motors: 237 VDC
230 VAC motors: 425 VDC
Low Bus Voltage Fault Activation DC Bus Voltage2:
115 VAC nominal input power: 94 VDC
230 VAC nominal input power: 205 VDC
Table 31, General Electrical Specifications for 115/230 VAC Drives (SAC-SD_2__)

6.1.4 General Electrical Specifications for 460 VAC Drives (SAC-SD_4__)

Incoming Main Power Line Voltage – TB1 pins L1, L2, L3
WARNING: Use the servomotor’s voltage rating to determine the maximum input
voltage for the servodrive.

SAC-SD_405, SAC-SD_410, SAC-SD_417, SAC- Three Phase, 50/60 Hz

SD_425, SAC-SD_435, SAC-SD_450 230 (+15%, -20%) or 460 (+15%, -20%) VAC
Incoming Control Power Line Voltage – TB1 or TB2
pins r, t
Single Phase, 50/60 Hz
SAC-SD_405, SAC-SD_410, SAC-SD_417, SAC-SD_425 115 (-20%) to 230 (+15%) VAC
0.5A max at 115 VAC, 0.25 A typ
Single Phase, 50/60 Hz
SAC-SD_435, SAC-SD_450
230 (+15%) VAC only
Main DC Bus Voltage – TB1 pins BUS+, BUS-
230 VAC nominal input power: 325 VDC nominal level

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Specifications ServoWire SD Drive Manual

460 VAC nominal input power: 650 VDC nominal level

Shunt Regulator Activation DC Bus Voltage1:
230 VAC motors: 395 VDC
460 VAC motors: 775 VDC
High Bus Voltage Fault Activation DC Bus Voltage1:
230 VAC motors: 450 VDC
460 VAC motors: 800 VDC
Low Bus Voltage Fault Activation DC Bus Voltage2:
230 VAC nominal input power: 205 VDC
460 VAC nominal input power: 325 VDC
Table 32, General Electrical Specifications for 460 VAC Drives (SAC-SD_4__)

6.1.5 ServoWire SD Drives Performance Specifications

Drive Model PWM Frequency Torque Loop

SAC-SD_203 to SAC-SD_210 20 kHz 10 kHz
SAC-SD_217 to SAC-SD_260 10 kHz 10 kHz
SAC-SD_405 to SAC-SD_450 10 kHz 10 kHz
Table 33, PWM Frequencies and Torque Loop Update Rates

SMLC Command Update Loop Update Rate

Rate(s) 1
Same as command update rate.
Position Loop 500 Hz - 2 kHz H Series motors = 2.5kHz
(same as Velocity Loop.)
Velocity Loop 500 Hz - 2 kHz 2.5 kHz
Torque Loop 500 Hz - 4 kHz 10 kHz
Table 34, SMLC/MotionObjects Command and Loop Update Rates

1 ServoWire command updates are made at multiples of the 125 usec base network update rate, up to 4 kHz.

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6.1.6 Output Specifications for 115/230 VAC Drives (SAC-SD_2__)

Single Phase 115 VAC Input Single Phase 230 VAC Input
Rated Cont. Peak Rated Cont. Peak
Output Current Current Output Current Current
Power 2 sec Power 2 sec
Drive Model (KVA) (Amps RMS/∅) (Amps RMS/∅) (KVA) (Amps RMS/∅) (Amps RMS/∅)

SAC-SD_203 0.29 2.5 4.4 0.59 2.5 4.2

SAC-SD_205 0.49 4.2 7.4 0.98 4.1 7.1
SAC-SD_210 0.58 5.1 8.8 1.17 4.9 8.5
SAC-SD_217 0.98 8.6 14.8 1.97 8.2 14.3
SAC-SD_220 1.09 9.5 16.5 2.19 9.1 15.8
SAC-SD_225
Single Phase Single Phase
SAC-SD_235
Not Available Not Available
SAC-SD_260
Table 35, Output (TB1 pins U, V, W) Specifications with Single Phase Input Power

Three Phase 230 VAC Input

Rated Output Cont. Peak Current
Power Current 2 sec
Drive Model (KVA) (Amps RMS/∅) (Amps RMS/∅)

SAC-SD_203
Three Phase Not Available
SAC-SD_205
SAC-SD_210 1.95 8.2 14.2
SAC-SD_217 3.32 13.9 24.1
SAC-SD_220 3.91 16.3 28.3
SAC-SD_225 5.98 25.0 50.0
SAC-SD_235 8.37 35.0 70.0
SAC-SD_260 15 60.0 120.0
Table 36, Output (TB1 pins, U, V, W) Specifications with Three Phase Input Power

Three Phase 460 VAC Input

Rated Output Cont. Peak Current
Power Current 2 sec
Drive Model (KVA) (Amps RMS/∅) (Amps RMS/∅)

SAC-SD_405 2.4 5.0 10.0

SAC-SD_410 4.7 10.0 20.0
SAC-SD_417 8.1 17.0 34.0
SAC-SD_425 11.9 25.0 50.0
SAC-SD_435 16.7 35.0 70.0
SAC-SD_450 23.9 50.0 100.0
Table 37, Output (TB1 pins, U, V, W) Specifications with Three Phase Input Power

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6.1.7 I/O Specification (TB4 & TB5)

V+S, V-S I/O Power Supply
TB4 pin 4, TB5 pin 1 (V+S)
TB4 pin 5, TB5 pin 2 (V-S)
Externally supplied voltage used by:
- High speed Sensor Inputs ASEN, BSEN
- Discrete Inputs IN1’, IN2’, IN3’, IN4’
- Discrete Outputs OUT1’-OUT5’
Max voltage between V+S and V-S ±27 VDC maximum
Max current V+S 85 mA
SAC-SDxx-S versions (Serial Encoder version) 240 mA
Max current V-S (return current on OUTPUTs uses V-S but not
V+S)
SAC-SDxx-R versions (Resolver version) 1300 mA
Max current V-S (return current on OUTPUTs uses V-S but not
V+S)

ASEN, BSEN High Speed Sensor Inputs

TB4 pins 2, 3
Input Current depends on software configuration:
NPN-type sensor with 2.7K pull-up resistor selected in drive: 8.9 mA @ 24 VDC
PNP-type sensor: current depends on pull-down resistance in
sensor (or external pull-down).
Max. voltage V+S
Minimum acceptance time 1 microsecond
Turn-on voltage Receiver Output
VIN > 0.5 * (V+S) + 0.4 VDC High
VIN < 0.5 * (V+S) + 0.1 VDC Low

IN1’, IN2’, IN3’, IN4’ Optically-coupled Digital Inputs

TB5 pins 3, 4, 5, 6
Note: Input #4 (TB5 pin 6) is Bi-directional and shares the same pin with Output #4.
Input should be normally sinking current to prevent an overtravel limit condition.

Current to turn on 0.7 mA minimum

7.0 mA maximum
Voltage max. 5V + V+S maximum

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OUT1’-OUT5’ Optically-coupled Digital Outputs

TB5 pins 9, 10, 11, 6, 12
Note: Output #4 (TB5 pin 6) is Bi-directional and shares the same pin with Input #4.
Applies to –S version drives and –R version drives except as noted below.
Max. sink current 33 mA
low level voltage 0.7 VDC maximum (Ic = 33 mA)
high level voltage V+S – 0.5 VDC
absolute maximum 27 VDC
max. sink current OUT3’ and OUT4’ on –R version and –S 900 mA
versions 1.2 and later drives
Table 38, I/O Specifications (TB4 and TB5)

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6.1.8 SAC-SDx-S drive version Motor Encoder Interface Specifications (J4)

This table applies to Quadrature/Serial encoder versions of the drive, identified by –S in part number, SAC-
SDxx-S.

ENCA, ENCA’, ENCB, ENCB’ Differential Digital Inputs

J4 pins 1, 2, 3, 4 Appendix B-1, B-3
J5 Pacer pins 1, 2, 14, 15
Common Mode Input -15 VDC to +15 VDC max.
Absolute Max. Input Voltage +/-25 VDC
Maximum Encoder Counts per Electrical Cycle 32,768 (after 4x decode) Orion
1,000,000 (after 4x decode) SMLC &
Softmotion
Maximum Encoder Data Rate: 4 MHz
Quadrature Specification 90o +/-45 o
Differential Turn On Voltage Receiver Output
VID > 0.7 V H
–0.7 V > VID > 0.7 V ?
VID < -0.7 V L
Where VID = (ENCx) – (ENCx’)

ENCZ, ENCZ’ Differential or Single-Ended

J4 pins 5, 6 Digital Input
J5 Pacer pins 3, 16 Appendix B-1, B-3
U, U’, V, V’, W, W’
J4 pins 7, 8, 9, 10, 11, 12
Common Mode Input -12 VDC to +12 VDC max.
Absolute Max. Input Voltage +/-25 VDC
Differential Turn On Voltage Receiver Output
VID > 0.2 V H
–0.2 V > VID > 0.2 V ?
VID < -0.2 V L
Where VID = (ENCx) – (ENCx’)
Single-Ended Turn On Voltage Receiver Output
VIS > 3 V H
2 V > VIS > 3 V ?
VIS < 2 V L

ENC PWR1, DGND

J4 pins 13, 24, 25 (Power)
J4 pins 16, 17, 18 (Digital Ground)
J5 Pacer pins 5, 6, 18 (Power) Encoder Power Supply
J5 Pacer pins 7, 19, 20 (Ground) Appendix B-1
+5 VDC for 115/230 VAC Drives (SAC-SD_2__) 5.3 VDC, +/-5%
450 mA max.
+5 VDC for Low Power Drives (SAC-SD_A__) 5.0 VDC, +/- 5%
450 mA max.

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TEMP’, TEMP RET Optically-isolated Digital Input

J4 pins 19, 20 Appendix B-1, B-4
Should be normally sinking current to prevent an over-temperature condition.
Current to turn on 2.5 mA
Voltage max. +12 VDC maximum
Table 39, SAC-SDxx-S version Motor Encoder Specifications (J4)

6.1.9 SAC-SDx-R drive version Motor Resolver Interface Specifications (J4)

This table applies to Resolver versions of the drive, identified by –R in part number, SAC-SDxx-R.

REF+, REF- Differential Resolver Reference

J4 pins 18, 17 Appendix

Output Frequency Configurable to 2441, 4882, 9765 Hz.

Amplitude RL = 1K Ohms 0 to 7.5 V RMS
Amplitude RL = 100 Ohms 0 to 6.5 V RMS
Output Current 70 mA max

COS+, COS-, SIN+, SIN- Differential Resolver Inputs

J4 pins 20, 19, 22, 21 Appendix

Input Voltage 3V RMS +/- 15%

U, U’, V, V’, W, W’ Differential or Single-Ended

J4 pins 3, 16, 6, 8, 11, 24 Digital Input
Appendix
Common Mode Input -12 VDC to +12 VDC max.
Absolute Max. Input Voltage +/-25 VDC
Differential Turn On Voltage Receiver Output
VID > 0.2 V H
–0.2 V > VID > 0.2 V ?
VID < -0.2 V L
Where VID = (ENCx) – (ENCx’)
Single-Ended Turn On Voltage Receiver Output
VIS > 3 V H
2 V > VIS > 3 V ?
VIS < 2 V L

5.3v Encoder Power, DGND

J4 pins 4 (Power) Encoder Power Supply
J4 pins 25 (Digital Ground) Appendix
+5 VDC 5.3 VDC, +/-5%
400 mA max.

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12v Encoder Power, DGND

J4 pins 124 (Power) Encoder Power Supply
J4 pins 25 (Digital Ground) Appendix
+12 VDC 12 VDC, +/-5%
400 mA max.

TEMP’, TEMP RET Optically-isolated Digital Input

J4 pins 10, 23 Appendix
Should be normally sinking current to prevent an over-temperature condition.
Current to turn on 2.5 mA
Voltage max. +12 VDC maximum
Table 40, SAC-SDx-R drive version Motor Encoder Specifications (J4)

6.1.10 Analog I/O Specificatoins (TB3)

AIN Single Ended Analog Input

TB3 pin 4 3
Common Mode Input -10 VDC to +10 VDC max.
Absolute Max. Input Voltage +/-12 VDC
Native ADC resolution 1 14 bits
Monotonic
Sample rate 2500 Hz
Filter – hardware 1 kHz anti-aliasing
Filter – software 0-500 Hz software configurable

AOUT Single Ended Analog Output

TB3 pin 2 3
Common Mode Output -10 VDC to +10 VDC max.
Output current drive +/- 10 mA max
Native DAC resolution1 14 bits
Update rate 10,000 Hz

Table 41, Analog I/O Specifications (TB3)

1The ADC and DAC have 14-bit resolution. The application quality of these I/O points is determined by the total system, not just
the circuitry in the drive. Care should be taken routing signals to and from the drive.

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6.1.11 Connector Part Numbers

Mating Connector 1 Drive Connector

Drive Manufacturer & Manufacturer &
Label Signal Description Part Number Ormec P/N Part Number
J1/J2 9 pin Available only as integral part of
ServoWire
/J3 IEEE 1394 IEEE1394 (ServoWire) cable
5-pin terminal
TB4 Drive I/O Phoenix 1803604 CON887 Phoenix 1803303
block
12-pin terminal
TB5 Drive I/O Phoenix 1803675 CON888 Phoenix 1803374
block
Encoder Amp 207464-1 (conn.) CON638
J4 Feedback Amp 745254-6 (pin) CON640 Kycon
25 pin male D-
Amp 206478-3 (shell) CON641 K22L-B255N
(-S) (-S drive sub
Amp 90406-1 (tool)
version)
Resolver Amp 207463-1 (conn.) CON650
J4 Feedback 25 pin female D- Amp 745253-6 (pin) CON649 Kycon
sub Amp 206478-3 (shell) CON641 K22B25PN
(-R) (-R drive
Amp 90406-1 (tool)
version)
Amp 207463-1 (conn.) CON650
Pacer 25 pin female D- Amp 745253-6 (pin) CON649 Kycon
J5
Feedback sub Amp 206478-3 (shell) CON641 K22B25PN
Amp 90406-1 (tool)
Analog I/O 4-pin terminal Phoenix 1803594 CON889
TB3 Phoenix 1829361
(top of drive) block
Table 42, Connector Part Numbers

1 The mating D-sub connectors for J3 and J4 are not provided as part of the ServoWire SD Drive.

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Chapter 7
Maintenance and Troubleshooting
7 Maintenance and Troubleshooting

7.1 ORMEC Product Support

• ORMEC Product Support relates to the functionality and proper operation of ORMEC supplied software
and equipment
• Product Service is provided by the ORMEC Service Department by phone at (585) 385-3520 or via
e-mail at support@[Link]
• Assistance installing and upgrading ORMEC supplied development software (e.g. CoDeSys), and
ServoWire Drive firmware, including necessary third-party supporting files (i.e. Microsoft Windows
Dial-Up Networking used for serial communication).
• Assistance configuring ORMEC development software communications.
• Explanation/clarification of the functionality and proper operation of ORMEC supplied hardware
and software, as provided in the various documentation available for those products (e.g. Windows
Help, Installation & Operation Manuals, Tech and App Notes, etc.)
• Troubleshooting assistance for ORMEC supplied hardware and firmware to insure the proper
operation of ORMEC supplied equipment. Assistance troubleshooting third-party equipment
connected to ORMEC equipment is not included.
• Providing return authorization (RA) numbers and replacement units (if appropriate) for defective
products.

Normal Product Support

Phone and e-mail support, available from 8 AM to 5 PM EST.

24-Hour Product Support

Phone support, available 24-hours a day, 7 days a week, 365 days per year.
There is an additional charge for this service.

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7.2 ServoWire SD Drive Troubleshooting Guide

Some of the error codes have been extended to provide additional troubleshooting assistance. The
extended error code will display as an _ <number> following the basic error code. For example, F3_4 will
display as 4 characters.

This extended code is currently only available by looking at the drive. ServoWire Pro, MotionDesk and
MotionBasic do not yet report the extended code.

Indication Code Status Description

70 112 Axis off-line

Indication Code Status Description

71 113 Reference Generation Internal error
Conflict
Defective hardware or software ⇒ Report error to Ormec Customer Service.

Indication Code Status Description

74 116 Unsupported Feedback The drive firmware does not support this feedback
device type.
Upgrade the drive firmware to the latest versions

Indication Code Status Description

75 117 Tension Max The actual measured tension is greater than
OP_TEN_MAX and the application
(OP_TEN_LIM_ACTION) is configured to generate
a fault if this occurs.
• Check the machine for binding or jamming
• Check the tension transducer for failure

Indication Code Status Description

76 118 Tension Min The actual measured tension is less than
OP_TEN_MIN and the application
(OP_TEN_LIM_ACTION) is configured to generate
a fault if this occurs.
• Check the machine for binding or jamming
• Check the tension transducer for failure

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Indication Code Status Description

90-99 144-153 Internal Drive Error An unexpected failure has occurred in the
ServoWire SD Drive software or hardware.
9A-9F 154-159

Defective hardware or software ⇒ Report error to Ormec Customer Service.

Indication Code Status Description

A0 160 Drive Over Current The maximum rating for the continuous current
(RMS) output of the drive has been exceeded.
When enabling axis with • Incorrect servomotor wiring ⇒ See Section 3.5.7 (page 21) for
Servomotor connected correct wiring.
• Defective Servomotor ⇒ Replace Servomotor
After applying control power • Defective Servodrive ⇒ Replace Servodrive
with Servomotor disconnected
Under load or during • Drive and/or motor may be undersized for the application.
acceleration.

Indication Code Status Description

A1 161 Drive Over Current The maximum rating for the peak current output of
(Peak) the drive has been exceeded.
When enabling axis with • Incorrect servomotor wiring ⇒ See Section 3.5.7 (page 21) for
Servomotor connected correct wiring.
• Defective Servomotor ⇒ Replace Servomotor
Under load or during • Drive and/or motor may be undersized for the application.
acceleration. • Wrong motor may be selected in configuration resulting in
poorly tuned current loop.

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Indication Code Status Description

A2 162 Power Module Fault The Power Module’s self-protection has detected a
short circuit, over current, over temperature,
control supply under voltage.
- or-
An SCR soft-start circuit error has been detected
(SAC-SD_225, SD_235, SD_260, SD_417, SD_425,
SD_435 & SD_450 only).
This fault is detected after the drive has been
enabled.

Indication Code Status Description

A3 163 Low Bus Voltage The bus voltage is below the low voltage limit,
which is calculated based on the Drive Input
Bus Power Voltage specified in the configuration software.
LED not on
• Input voltage does not match the software setting ⇒ Decrease
software setting or increase applied AC input voltage.
When the drive is being or has
• Main fuses blown or circuit breaker tripped ⇒ Correct main
been enabled
input power problem, and replace fuses or reset circuit breaker.
Defective Servodrive ⇒ Replace Servodrive

Indication Code Status Description

A4 164 High Bus Voltage The bus voltage is above the high voltage limit,
which is calculated based on the lessor of the motor
rated voltage and the drive maximum voltage.
When power is applied to the Applied voltage exceeds the Servomotor’s rating ⇒ Reduce applied
main circuit voltage.
The configuration software settings for ServoWire SD Drive Input
Voltage are lower than desired applied voltage ⇒ Increase setting
in the configuration software.
Defective Servodrive ⇒ Replace Servodrive
While motor is in regeneration, A regenerative discharge resistor is required by the application but
or when drives share bus is not present ⇒ Install regen resistor, reduce inertial load, or
power, if any of the motors is in reduce max speed and/or acceleration.
regeneration.
The regenerative resistor installed has been damaged and is no
Regeneration may exist during longer fully functional ⇒ Install higher-wattage regenerative
deceleration, or during resistor, and reduce inertial load, or reduce max speed and/or
downward motion in a non- acceleration.
counterbalanced vertical
application, or in a tensioned
unwind application.

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Indication Code Status Description

A5 165 Configuration Mismatch The drive type does not match the software
configuration settings.
SAC-SDM Drives: The SMLC or MotionObjects has detected that the drive hardware
does not match ServoWire Pro project settings. Either:
• Auxiliary feedback encoder is created in the user program but drive does not have
pacer (-P) hardware option. -OR-
• Axis is configured for drive type SAC-SW_ but actual drive type is SAC-SD_. -OR-
• Axis is configured for drive type SAC-SD_ but actual drive type is SAC-SW_.
SMLC/MotionObjects may also indicate this by the exception # 1031,
Error Message = Configured Drive type doesn't match actual drive hardware.

Indication Code Status Description

A6 166 Drive Not Configured An attempt was made to enable torque before the
drive’s setup parameters have been configured.
The drive setup parameters must be configured
each time the drive’s control power cycles on, before
the drive can be enabled.

Indication Code Status Description

A7 167 Illegal While Drive An attempt was made to write parameters for the
Enabled 'Number of Poles ' or ‘Resolution’ to the drive while
the drive was enabled. The drive must be disabled
before changing these parameters.

Indication Code Status Description

A8 168 Invalid Commutation A Drive configured for a motor with an absolute
Position encoder was commanded to enable when the
absolute encoder was discharged, or while the
commutation position was invalid, or the ABS
output was toggled on a Drive configured for an
incremental encoder.
The commutation position is invalid on a drive
configured for an absolute encoder motor when:

• The Drive is powered up, prior to drive

configuration
• An open encoder line is detected
• During trapezoidal commutation
• 'Number Of Poles' is written
• 'Resolution’ is written
The commutation position becomes valid when the
absolute encoder's position is read. Refer to the
SMLC/MotionObjects and ServoWire SM RTX
documentation for further information regarding
reading absolute encoder position.

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Indication Code Status Description

A9 169 Phase Loss The drive detected the loss of a main power phase.
L1, L2 and L3 are monitored for AC voltage. This
error indicates that no voltage or insufficient
voltage is or was not present.
Main fuses blown or circuit breaker tripped ⇒ Correct main input
When the drive is being or has power problem, and replace fuses or reset circuit breaker.
been enabled Loose wire or intermittent contact => Check all wire terminations
Defective Servodrive ⇒ Replace Servodrive

Indication Code Status Description

AA 170 Soft Start Not Complete – The drive inrush current is greater than 0.5 amps
general error. or there is a low bus voltage (<50 VDC). Note: This
is only checked when enabling the drive.
The hardware switch from soft start mode to full
power mode doesn’t take place until after startup is
complete, as evidenced by low inrush current and
sufficient bus voltage. This error may be caused
by:
• Enabling too soon after applying AC bus power
⇒ Wait longer between disabling and
reapplying AC bus power.
• Low AC bus power input voltage so that BUS+
never reaches 50 VDC ⇒ Correct the AC bus
power input voltage
• The load on BUS+ and BUS- is drawing
current as soon as AC bus power is applied ⇒
remove the load from BUS+ and BUS- (there
should not be a load on BUS+ and BUS-, regen
resistors are connected to BUS+ and RG.
AA_1 170 Soft Start Not Complete The drive does not see sufficient bus voltage to
due to low bus voltage. switch to full power mode. The minimum is set by
host software and is usually about 50% of the
expected DC bus voltage.
AA_2 170 Soft Start Not Complete The drive does not see all 3 input phases, L1, L2
due to phase loss. and L3. One or more may not be working or
sufficiently high. Check and correct any conditions
found.
AA_3 170 Soft Start Not Complete The drive is detecting current in the inrush
due to inrush current. resistor. The current needs to be less than 0.5 A.
This may be because inrush has not completed ~
wait longer after applying bus AC power to enable
~ or there is a load on the BUS+ terminal causing a
continuous current through the inrush resistor ~
correct the wiring to eliminate this load.

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AA_4 170 Soft Start Not Complete The drive waits approximately 750 msec after all of
due to time delay the above conditions are satisfied to switch to full
power mode. This error indicates that all of the
other conditions are ready, however, an attempt
was made to enable before the timeout completed.
Wait longer. Note, this delay increased
significantly in drive firmware version 3.3.2.

Indication Code Status Description

AC 172 Drive Overtemp or Soft An over-temperature condition was detected in the
Start Error drive powerblock, or a failure of the inrush current
resistor.
This fault is detected when the drive is being
enabled.

Indication Code Status Description

Ad 173 E-Stop A drive emergency stop was detected. This requires that
the drive be configured to use one of the general purpose
inputs as an E-Stop input

Indication Code Status Description

AE 174 Software upgrade. SAC-SDM Drive, SMLC/MotionObjects fault:
Host PC driver software upgrade is required.

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Indication Code Status Description

b0 176 Checksum error The checksum on the downloaded code was incorrect.
The download has been aborted. Try again.

Indication Code Status Description

b1 177 Bad file The download code was not recognized. The wrong file
was used. The drive firmware may be too old to
recognize this format.

Indication Code Status Description

b2 178 Firmware not compatible The downloaded code is not designed for this drive
hardware, but rather for different drive hardware.
Obtain the correct file and try again.

Indication Code Status Description

b3 179 Firmware Checksum error Internal firmware program checksum error, reload
drive firmware.

Note: Most of the drive faults are detected and generated in the drive. However, the “C” fault codes are
detected by the SMLC and sent via ServoWire to the Drive which disables the motor and displays the fault
code. Additional documentation and help on the “C” faults can be found in the ServoWire Pro and CoDeSys
Help.

Indication Code Status Description

C0 192 Lag Fault The position following error exceeded the maximum
amount configured using ServoWire Pro. See ServoWire
Pro or CoDeSys Help for further information.

Indication Code Status Description

C1 193 Command Overspeed The commanded speed exceeded the software configured
axis speed limit. See ServoWire Pro or CoDeSys Help for
further information.

Indication Code Status Description

C2 194 Actual Overspeed The actual (feedback) speed exceeded the software
configured axis speed limit. See ServoWire Pro or
CoDeSys Help for further information.

Indication Code Status Description

C3 195 Hardware Travel Limit Motion was commanded further into a hardware travel
limit while the limit was still active. See ServoWire Pro
or CoDeSys Help for further information.

Indication Code Status Description

C5 197 Loop Rate Exceeded The available loop update time was insufficient to
complete the loop processing. See ServoWire Pro or
CoDeSys Help for further information.

Indication Code Status Description

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C6 198 Missing MotionData The MotionData from the master axis is not available.
See ServoWire Pro or CoDeSys Help for further
information.

Indication Code Status Description

C9 201 Unexpected Offline The SMLC is not receiving isochronous feedback from
the drive. See ServoWire Pro or CoDeSys Help for
further information.

Indication Code Status Description

CA 202 1394 Driver failure The 1394 driver is not receiving its once-per-looprate
update information from the 1394 bus driver. See
ServoWire Pro or CoDeSys Help for further information.

Indication Code Status Description

Cb 203 Pacer Backup Overflow The pacer axis backed up far enough to overflow the
backup compensation. See ServoWire Pro or CoDeSys
Help for further information.

Indication Code Status Description

CC 204 Invalid MotionData The MotionData is configured in a loop, which is not
Configuration valid. See ServoWire Pro or CoDeSys Help for further
information.

Indication Code Status Description

E0 224 ServoWire Protocol The ServoWire communications protocol in the

Incompatibility drive is not compatible with the one in the SMLC or
Orion.
SMLC controller Either the drive’s firmware should be changed to a version that is compatible
with the SMLC firmware, or the SMLC firmware must be changed to a
version that is compatible with the servodrive firmware.
A SAC-SDM drive is required with an SMLC. Check drive model number.
Orion Controller The drive’s firmware should be changed to a version that is compatible with
the Orion controller and MotionBasic version.
A SAC-SD drive is required with an Orion. Check drive model number.

Indication Code Status Description

E1 225 ServoWire Timeout Isochronous communications (i.e. torque

commands, velocity commands, etc.) from the
motion controller or PC were lost (The ServoWire
dot will indicate if communications has been re-
established).
This normally occurs when the drive has control power, but the SMLC loses control power, or the
IEEE 1394 interface card fails. In either case, once the cause has been corrected, the fault can be
cleared by the application program (or by cycling power on the drive).

Indication Code Status Description

E3 227 ServoWire Watchdog The ServoWire Isochronous communications

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Timeout watchdog bit has not changed state within the

allotted time.

Indication Code Status Description

E4 228 ServoWire Initialization A hardware error was detected when initializing

Error the IEEE 1394 communications controller
circuitry.

Indication Code Status Description

E5 229 Drive Watchdog The drive internal watchdog has timed out due to
Timeout either the loss of ServoWire network power
(usually due to loss of motion controller power) or
an unexpected failure.

Indication Code Status Description

E6 230 No ServoWire Network The drive is powered up and is not detecting

Power ServoWire network power. Power for the
ServoWire interface is supplied by the SMLC or
Orion controller (8–40 VDC). Possible causes
include:
• The ServoWire cable is not connected to the
drive and/or the SMLC or Orion controller.
Be sure to verify that all the cables in the
network are properly connected.
• The SMLC or Orion controller is off and/or not
supplying power to the ServoWire network.

Indication Code Status Description

E8 232 Duplicate Drive ID The SMLC or Orion has detected more than one
drive with same Axis ID on the network.
Find the other drive with the flashing ID and
change one of them to a different value.

Indication Code Status Description

F0 240 Motor Over Current The motor’s rating for continuous current has been
(RMS) exceeded by the actual RMS current for longer than
allowed by the thermal time constant of the motor.

Indication Code Status Description

F1 241 Motor Encoder Open Wire At least one motor Encoder Feedback channel
(ENCA, ENCA’, ENCB, ENCB’ is not connected
properly. (J4 pins 1,2,3,4).
Quadrature Encoder At least one motor Encoder Feedback channel (ENCA, ENCA’, ENCB,
ENCB’ is not connected properly. (J4 pins 1,2,3,4).

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ServoWire SD Drive Manual Maintenance & Troubleshooting

H-Series Motor or other serial Loss of serial encoder communication or excessive errors. Check wiring
encoder and connections. (J4 pins 14, 15)

Indication Code Status Description

F2 242 Auxiliary Encoder Open At least one auxiliary Encoder Feedback channel
Wire (ENCA, ENCA’, ENCB, ENCB’ is not connected
properly. (J4 pins 1,2,3,4)

Indication Code Status Description

F3 243 Invalid Hall State An unexpected combination of Hall inputs has
occurred.

F3_1 243 Invalid Hall State on Drive is configured for differential Hall inputs and
Differential Inputs an invalid value has been detected.
Invalid states detected
Encoder Feedback Connector:
U,V,W (J4 pins 7, 9,11) all ON at the same
time.
U’,V’,W’ (J4 pins 8,10,12) all ON at the same
time.
U,V,W (J4 pins 7, 9,11) all OFF at the same
time.
U’,V’,W’ (J4 pins 8,10,12) all OFF at the same
time
F3_2 243 Invalid Hall State on D- Drive is configured for a D-Series motor and an
Series Motor interface invalid Hall state has been detected.
F3_3 243 Invalid Hall State on H- Drive is configured for a H-Series motor with a
Series Motor interface serial encoder and an invalid Hall state has been
detected.
When enabling axis • Bad feedback cable ⇒ Check pins above (see cable diagrams in
Appendix E)
• Wrong axis feedback type selected in ServoWire Pro or
MotionDesk Setup software settings ⇒ Correct software.

Indication Code Status Description

F4 244 Motor Over Temperature The thermal contact has opened indicating that the
motor is over temperature. This condition can not
be reset until the motor has sufficiently cooled.
Encoder connector (J4 pins 19 & 20)
Resolver connector ( SAC-SD-RES pins 10 & 23)
• Motor is overloaded ⇒ Reduce motor load
When the motor is hot • Excessive ambient temperature ⇒ Reduce ambient
temperature to 25oC

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Maintenance & Troubleshooting ServoWire SD Drive Manual

• Faulty motor feedback wiring ⇒ Check cable and all

termination points.
• Defective thermal switch in motor ⇒ Disconnect motor and test
When the motor is cool to the for continuity at motor pins. (See motor pinouts in Appendix E).
touch • Motor has no thermal switch, and ServoWire Setup software
settings are configured to expect a closed contact. ⇒ Disable
Thermal Contact in ServoWire Setup Axis Configuration
• Defective Servodrive ⇒ Replace Servodrive

Indication Code Status Description

F5 245 Unknown Option Module The drive has detected an installed option module,
but does not recognize and/or support that module
type.
• Not supported by the drive firmware ⇒ Verify
that the drive firmware revision supports the
option module, and update as needed.
• Improper option module installation ⇒
Reinstall the option module and verify it is
properly connected to the drive.
• Defective option module ⇒ Replace the option
module

Indication Code Status Description

F6 246 Overtemp Config. error. The motor configuration indicates that there is no
over temperature sensor, but an over temperature
sensor was detected by the drive.

Indication Code Status Description

F7 247 Serial Encoder Alarm. When using a H-Series motors
An alarm bit has been returned by the H-Series
serial encoder.
• Check connections & feedback cable for good
electrical connection.
• Try cycling the ServoWire Drive control power.
• Defective encoder feedback - Replace
Servomotor.
F7_1 247 Incremental encoder error When using a H-Series motor with an incremental
encoder the encoder has reported an error.
The error can only be cleared by power cycling the
motor which can only be done by power cycling the
drive.
F7_2 247 Absolute encoder When using a H-Series motor, the absolute
overspeed error encoder has reported an overspeed error.
The error can only be cleared by power cycling the

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motor which can only be done by power cycling the

drive.
F7_3 247 Absolute encoder When using a H-Series motor, the absolute
overspeed error encoder has reported an absolute error.
The error can only be cleared by power cycling the
motor which can only be done by power cycling the
drive.
F7_4 247 Absolute encoder backup When using a H-Series motor, the absolute
power error encoder has reported a backup power error.
Encoder backup power has failed and absolute
position lost. The error can be cleared by issueing
an Encoder Reset command, allowing operation to
continue without the need for a power cycle.
However, absolute position has been lost.
This can happen if the encoder cable is
disconnected for any time or if the battery has run
down.
F7_5 247 Absolute encoder generic When using a H-Series motor, the absolute
error encoder has reported a generic error.
The error can be cleared by issueing an Encoder
Reset command, allowing operation to continue
without the need for a power cycle.
F7_6 247 Absolute encoder over When using a H-Series motor, the absolute
temperature error encoder has reported an over temperature error.
The error can be cleared by issueing an Encoder
Reset command, allowing operation to continue
without the need for a power cycle. However, it is
recommended that the motor be allowed to cool
down before continuing.
This error is reported only once per power cycle of
the motor.
F7_7 247 Absolute encoder battery When using a H-Series motor, the absolute
low error encoder has reported a battery low error.
The error can be cleared by issueing an Encoder
Reset command, allowing operation to continue
without the need for a power cycle.
This error is reported only once per power cycle of
the motor.

Indication Code Status Description

F8 248 Unsupported Serial • Unsupported encoder feedback type detected -
Encoder detected. Replace servomotor to a supported type.
• Not supported by the drive firmware - Verify
that the drive firmware revision supports the
Serial Encoder, and update as needed.
F8_2 248 Unsupported Serial • An operational parameter defined in the

SAC-SD 01c page 105

Maintenance & Troubleshooting ServoWire SD Drive Manual

Encoder detected. encoder makes this encoder incompatible with

the drive. Contact Ormec Service for
assistance.

page 106 SAC-SD 01c

ServoWire SD Drive Manual Maintenance & Troubleshooting

7.3 Servomotor Troubleshooting Guide

Problem Cause What to do
Motor does not start Loose Connection ⇒ Tighten connection
Wrong wiring ⇒ Correct wiring
Overload ⇒ Reduce load or use a larger motor
Motor defective Measure voltage across motor terminals U, V,
& W on the Servodrive. If correct, replace
Servodrive Defective
motor, otherwise replace servodrive.
Locked Rotor Wrong order of U, V, W Check cabling.
Unstable Operation Wrong motor selected in the Check & correct that software matches motor.
configuration software.
Improper Tuning Check that Inertial load specified in the
configuration software is less than or equal to
the actual load seen by the motor.
Check other tuning parameters.
Wrong Wiring Inspect and correct wiring of motor terminals
U, V, & W and/or the encoder.
Motor Overheats Excessive ambient Reduce ambient temperature below 40oC, or
temperature use a larger motor.
Motor dirty Clean motor surface
Overload Reduce load or use a larger motor.
Unusual Noise Motor loosely mounted Tighten mounting bolts
Motor is mis-aligned Realign
Coupling out of balance Balance coupling
Noisy bearing Check alignment, loading of bearing,
lubrication.
Vibration of driven machine Check the machine's mechanical operation.
Improper grounding and/or Check the servomotor, servodrive, and power
shielding supply grounding and shielding.
Incorrect servo control loop Check the servo control loop tuning
tuning parameters.
Poor Velocity Single phase main power Use 3-phase power.
Regulation (L1 & L2 only) on a drive
expecting 3-phase power
(SAC-SD_210, SAC-
SD_217, SAC-SD_220)
WARNING!!!
Turn off power before working on the Servomotor

SAC-SD 01c page 107

ServoWire SD Manual Appendix A: System Wiring Diagram

115/230/460 VAC System Wiring Diagram

Main Power
(115 or 230 or 460 VAC)
Control
Main Contactor
Fuses or Power
Coil Power (115 or 230 VAC)
Circuit Breaker

Main Power LINE LINE

FILTER FILTER
Contactor

E-Stop Reset
E-Stop MP
(pulse)
MP- AUX
Relay
(customer + -
supplied)
(Select output rating
to match contactor
coil voltage.)
ServoWire Drive
(SAC- SDS/SDM)
J1 TB1
(High Power TB)
J2 r
J3
(TB5-Drive I/O) t
1 V+S I/O) L1
+ 2 V-S L2
24 Vdc 6 OUT4' (Drv Ready)
Power 7 OUT4' Return L3
Supply 5 IN3' (E-Stop OK)
PSU- 024/3.84 3 IN1' (Fwd HTL)
4 IN2' (Rev HTL) U
-
V
W
J4 (Feedback Encoder)

Brushless
Servomotor

ServoWire Drive
(SAC- SDS/SDM)
J1 TB1
( igh Power TB )
H
J2 r
J3
(TB5 -Drive I/O) t
1 V+S L1
2 V-S I/O) L2
6 OUT4' (Drv Ready)
7 OUT4' Return L3
5 IN3' (E-Stop OK)
3 IN1' (Fwd HTL)
4 IN2' (Rev HTL) U
V Notes:
Hardware Travel W 1) The E-Stop interlock configuration shown
Limits J4 (Feedback Encoder)
assumes that the drive(s) is/are configured in
ServoWire Pro to use IN3 as an E-Stop input and
( Customer Supplied )
OUT5 as a Drive Ready indicator. Refer to the
Operation chapter of ths manual and the ServoWire
Brushless Pro Help manual for further information.
Servomotor 2) The E-Stop indicator relay is customer supplied.
Refer to Note 1.
3) The Drive Ready relay is customer supplied.
The Interlock and I/O power should be provided
by separate power supplies to prevent inductive
in-rush from the Drive Ready relay.

SAC-SD 01c page A-1

ServoWire SD Drive Manual Appendix B: Drive I/O Schematics

Resolver Option Board

SAC-SD 01c page B-1

Drive I/O Schematics Appendix B: ServoWire SD Drive Manual

SD Drive Logic Board - Sensor Interface

page B-2 SAC-SD 01c

ServoWire SD Drive Manual Appendix B: Drive I/O Schematics

SD Drive Logic Board - External Connection Pinout

SAC-SD 01c page B-3

Drive I/O Schematics Appendix B: ServoWire SD Drive Manual

SD Drive Logic Board - Encoder Interface

page B-4 SAC-SD 01c

ServoWire SD Drive Manual Appendix B: Drive I/O Schematics

SD Drive Logic Board - Optical Inputs & Outputs

SAC-SD 01c page B-5

Drive I/O Schematics Appendix B: ServoWire SD Drive Manual

page B-6 SAC-SD 01c

ServoWire SD Drive Manual Appendix C: Component Outline Drawings

Mounting Information for SAC-SD_203, 205, 210, 217, 220. Upper diagram for drives prior to rev 1.2, lower
diagram for drives rev 1.2 or later. Mounting holes are identical.

SAC-SD 01c page C-1

Component Outline Drawings Appendix C: ServoWire SD Drive Manual

Mounting Information for SAC-SD_225, 235, 260, 417 & 425. Upper diagram for drives prior to rev 1.2, lower
diagram for drives rev 1.2 or later. Mounting holes are identical

page C-2 SAC-SD 01c

ServoWire SD Drive Manual Appendix C: Component Outline Drawings

Mounting Information for SAC-SD_405 & 410. Upper diagram for drives prior to rev 1.2, lower diagram for
drives rev 1.2 or later. Mounting holes are identical

SAC-SD 01c page C-3

Component Outline Drawings Appendix C: ServoWire SD Drive Manual

Mounting Information for SAC-SD_435 & 450. Upper diagram for drives prior to rev 1.2, lower diagram
ram for
drives rev 1.2 or later. Mounting holes are identical

page C-4 SAC-SD 01c

ServoWire SD Drive Manual Appendix C: Component Outline Drawings

Additional clearance above, below and to the sides of the ServoWire Drives is also required for heat dissipation:
SAC-SD_203, SAC-SD_205 and SAC-SD_210
Add 2” (51 mm) clearance top and bottom.
Add 1” (25 mm) clearance each side.

SAC-SD_217 and SAC-SD_405

Add 2” (51 mm) clearance top and bottom.
Add 1.2” (31 mm) clearance each side.

SAC-SD_220 and SAC-SD_410

Add 2” (51 mm) clearance top and bottom.
Add 1” left-side, 2” (51 mm) right-side clearance

SAC-SD_225, SAC-SD_235, SAC-SD_260, SAC-SD_417, SAC-SD_425, SAC-SD_435 and SAC-SD_450

Add 2” (51 mm) clearance.
Add 4” (102 mm) clearance bottom.
Add 1” (25 mm) clearance each side.

SAC-SD 01c page C-5

Component Outline Drawings Appendix C: ServoWire SD Drive Manual

Regen Resistors

I.D. .31 [7.94] dia. I.D. .50 [12.70] dia.

Wire 14 AWG, 2 feet Wire 14 AWG, 2 feet

4.0 6.5
[102] [165]

SAC-SWRR/0055 SAC-SWRR/0095

All dimensions in inches [mm]

page C-6 SAC-SD 01c

ServoWire SD Drive Manual Appendix C: Component Outline Drawings

Mounting hole .50 [13] dia. Qty 4

13.00 11.00
[330] [279]

1.00
[25]

1.00
12.00 [305]
[25]

14.00 [356]

SAC-SWRR/1700
All dimensions in inches [mm]

SAC-SD 01c page C-7

Component Outline Drawings Appendix C: ServoWire SD Drive Manual

Line Filters: SAC-LF30C, 55C, & 100C

F
E

G
A

C D
B

G N D L u g

L in e F ilte r A B C D E F G U n its G N D L u g M a x . W ir e G a u g e
S A C -L F 3 0 C 1 3 .2 5 .9 2 .4 1 3 .9 1 2 .6 1 .4 0 .3 in c h e s M 5 6 A W G
3 3 5 1 5 0 6 0 3 5 4 3 2 0 3 5 6 .5 m m 1 0 m m 2
S A C -L F 5 5 C 1 3 .0 7 .3 3 .1 1 4 .8 1 2 .4 2 .2 0 .3 in c h e s M 6 3 A W G
3 2 9 1 8 5 8 0 3 7 7 3 1 4 5 5 6 .5 m m 2 5 m m 2
S A C -L F 1 0 0 C 1 4 .9 8 .7 3 .5 1 7 .2 1 4 .3 2 .6 0 .3 in c h e s M 1 0 1 /0 A W G
3 7 9 2 2 0 9 0 4 3 6 3 6 4 6 5 6 .5 m m 5 0 m m 2

L IN E L O A D
L 1 L 1 '

L 2 L 2 '

L 3 L 3 '

E E

page C-8 SAC-SD 01c

ServoWire SD Drive Manual Appendix C: Component Outline Drawings

Line Filters: SAC-LF215U

4.00 2.00

0.187
1.06 (6 p la c es)
2.12 SAC-LF215U 2.91

3.62 1/ 4" TAB

All dimensions in inches

Line Filters: SAC-LF230U

5.50 2.75

0.187
(4 places)
2.50 SAC-LF230U 3.00

4.87 #8-32 x 0.62

All dimensions in inches

SAC-SD 01c page C-9

ServoWire SD Drive Manual Appendix D: G-Series Cables

CBL-GMSW (1-50) Encoder Cable

SAC-SD 01c page D-1

G -Series Cables Appendix D: ServoWire SD Drive Manual

CBL-GMSW ( 51-150 ) Encoder Cable

page D-2 SAC-SD 01c

ServoWire SD Drive Manual Appendix D: G-Series Cables

CBL-QE25SW Pacer Encoder Cable

SAC-SD 01c page D-3

G -Series Cables Appendix D: ServoWire SD Drive Manual

CBL-GMSW1 / GMSWB1 Motor/Encoder Cable

page D-4 SAC-SD 01c

ServoWire SD Drive Manual Appendix D: G-Series Cables

CBL-GMSW2 Motor Cable

SAC-SD 01c page D-5

G -Series Cables Appendix D: ServoWire SD Drive Manual

CBL-GMSW3 Motor Cable

page D-6 SAC-SD 01c

ServoWire SD Drive Manual Appendix D: G-Series Cables

CBL-GMSWT2 Motor Cable

SAC-SD 01c page D-7

G -Series Cables Appendix D: ServoWire SD Drive Manual

CBL-GMSWTX Motor Cable

page D-8 SAC-SD 01c

ServoWire SD Drive Manual Appendix D: G-Series Cables

CBL-GMSWB Motor Cable

SAC-SD 01c page D-9

G -Series Cables Appendix D: ServoWire SD Drive Manual

CBL-GMSWB

page D-10 SAC-SD 01c

ServoWire SD Drive Manual Appendix D: G-Series Cables

CBL-GMSWBT2 Motor / Brake Cable

SAC-SD 01c page D-11

G -Series Cables Appendix D: ServoWire SD Drive Manual

CBL-GMSWB2 Motor / Brake Cable

page D-12 SAC-SD 01c

ServoWire SD Drive Manual Appendix D: G-Series Cables

BLANK

SAC-SD 01c page D-13

ServoWire SD Drive Manual Appendix E: DE-Series Cables

CBL-DEMSW1 Motor Cable

SAC-SD 01c page E-1

DE -Series Cables Appendix E: ServoWire SD Drive Manual

BLANK

page E-2 SAC-SD 01c

ServoWire SD Drive Manual Appendix F: D - Series Cables

CBL- DMSW Encoder Cable

SAC-SD 01c page F-1

D -Series Cables Appendix F: ServoWire SD Drive Manual

CBL-DMSW Encoder Cable

page F-2 SAC-SD 01c

ServoWire SD Drive Manual Appendix F: D - Series Cables

CBL-DMSWn Motor Cable

SAC-SD 01c page F-3

D -Series Cables Appendix F: ServoWire SD Drive Manual

CBL-DMSWTx Motor Cable

page F-4 SAC-SD 01c

ServoWire SD Drive Manual Appendix F: D - Series Cables

CBL-DMSWBn Motor / Brake Cable

SAC-SD 01c page F-5

D -Series Cables Appendix F: ServoWire SD Drive Manual

CBL-DMSWBTn Motor / Brake Cable

page F-6 SAC-SD 01c

ServoWire SD Drive Manual Appendix F: D - Series Cables

CBL-DMACB Brake Cable

SAC-SD 01c page F-7

ServoWire SD Drive Manual Appendix G: H-Series Cables

CBL-HMSW Encoder Cable

SAC-SD 01c page G-1

H-Series Cables Appendix G: ServoWire SD Drive Manual

CBL-HEMSW Encoder Cable

page G-2 SAC-SD 01c

ServoWire SD Drive Manual Appendix G: H-Series Cables

CBL-HEMSW Encoder Cable

SAC-SD 01c page G-3

H-Series Cables Appendix G: ServoWire SD Drive Manual

CBL-HEMSW1 Motor Cable

page G-4 SAC-SD 01c

ServoWire SD Drive Manual Appendix G: H-Series Cables

CBL-HMSW Encoder Cable

SAC-SD 01c page G-5

H-Series Cables Appendix G: ServoWire SD Drive Manual

CBL-HMSWn Motor Cable

page G-6 SAC-SD 01c

ServoWire SD Drive Manual Appendix H: Coupling Mechanical Lodes

Coupling High Performance Servos to Mechanical Loads

Application Note by Mick Oakley, Vice President, Customer Support Engineering

Introduction
Mechanical design for servos adds an additional set of constraints to
the design rules normally used for power transmission design. These
added constraints relate primarily to the stiffness of the system and
inertial matching. Decisions on speed reducers, couplings, shaft
configurations and many other critical aspects of the mechanical
design are often made very early in the design process. Once made,
these decisions can be very expensive and time consuming to
change.

The intent of this Application Note is to communicate some design

information and "rules of thumb" that we at ORMEC have found important in our many years of applying servos to
industrial automation. Are these guidelines universal truths? Obviously any set of design rules will from time to time
collide with a special case. However, the following guidelines will apply in the vast majority of cases and the prudent
designer will only violate them after careful analysis and with a thorough understanding of the risks involved.

Why Be Concerned About The Load?

Knowledgeable servo designers are wary of using a servomotor to drive mechanisms whose moment of inertia is many
times that of the motor itself. However, economic pressures and other technical advantages often cause engineers to
want to direct drive high inertia loads. The main advantages they seek are to eliminate the cost, maintenance and
inaccuracy of a reducer. While it is usually easier to avoid large inertia mismatches, with appropriate attention to detail,
they can be made to work. One reason many designers lean towards direct drive, is to avoid the cyclical inaccuracies
that gear reducers can introduce. The closed loop servo can monitor its actual speed and position and rapidly adjust for
load disturbances. When the load inertia is many times the motor inertia, the motor has only a very small amount of
kinetic energy compared to the load. To compensate for a sudden change in load, the servo amplifier must inject a large
amount of energy into the servomotor very quickly. This demands a high gain, high bandwidth system. When you
combine high gain, high bandwidth and large inertia mismatches, alarm bells should start to sound.

What constitutes a large inertia mismatch? At one time designers strove to achieve a 1:1 inertia match. They considered
anything above 5:1 to be a potential problem. The application of digital technology to servo control, digital signal
processors in particular, has relaxed that constraint. These days, mismatches of 100:1 or even 1000:1 can be made to
work with careful mechanical design.

While good mechanical design is always important, inertia mismatches of 10:1 and above,
can only work if the mechanical designer has paid careful attention to minimizing backlash
and compliance in the design.

SAC-SD 01c page H-1

Coupling Mechanical Lodes Appendix H: ServoWire SD Drive Manual

Backlash Effects
Backlash, sometimes called "lost motion", is a mechanical effect that allows you to turn the motor shaft without causing
any motion at the load. Generally, you can rotate the motor shaft back and forth over a limited range. If you release the
shaft, it will stay where it is.

Backlash, has the effect of temporarily uncoupling and re-coupling the load and the motor with changing speed and
direction. When stopped, if there are insufficient external forces acting on the load, the motor may for all intents and
purposes be disconnected from the load completely. If the servo is tuned to work well when the load is disconnected, it
will have extremely poor performance when the load is connected. Likewise, if the servo is tuned for adequate
performance, it will be unstable when the backlash disconnects the load.

The most common symptom of backlash is a "buzz" , often very loud, which occurs primarily when the motor is
stopped. Often you can eliminate the buzz by applying a torque at the load. If you tune the servo to eliminate the "buzz",
the system becomes very "soft". Sometimes the gain is so low that it cannot stabilize the position loop and the system
may oscillate wildly at a low frequency (1-5 Hz)

The only way to solve the problem is to mechanically eliminate the backlash. If you do not eliminate the buzz, over time
it may overheat the motor or ruin the mechanical system.

A common source of backlash is using a key-way or set screw to couple to the motor shaft. While key-ways are fine for
lawnmowers, they are inadequate for high performance servos! A clamp style coupling, preferably a taper lock bushing,
is the only acceptable way to couple to a servomotor shaft.

Another common cause of backlash is improperly adjusted spur gears or using gear reducers that are not designed for
servo applications. Properly selected precision planetary gearheads, such as those manufactured by Bayside Controls
Inc., Micron Instrument Corp. or Neugardt are generally quite good for servo applications. However, you must make
sure the gearhead and primary pinion are mounted and adjusted properly. If you are not careful, improper mounting will
introduce backlash into the system and it will deteriorate over time.

Compliance Effects
Compliance also allows you to rotate the input shaft without the load moving. However, with compliance you are
actually "winding up" the mechanical system like a spring. When you release the input shaft, it will spring back close to
its original position.

Compliance, or wind up, effects show up as a torsional resonant frequency which in turn causes the servo to be unstable.
The instability generally shows up as a medium to high frequency oscillation in the order of 100 to 500 Hz. Unlike the
"buzz" caused by backlash the sound is often a pure note and does not go away when the motor moves. The frequency
does not change as you manipulate the servo tuning however the amplitude may change. Applying a friction load may
also reduce the amplitude of the oscillation. As with the buzz caused by backlash, left uncorrected, this resonance will
overheat the motor and possibly damage the mechanism.

Long drive shafts, where the bulk of the load inertia is some distance from the motor, are a common
cause of this type of problem. It is often surprising how much windup can exist in what appears to be a
rather substantial shaft. Take for example a 1 inch diameter stainless steel shaft about 18 inches long.
When you apply a 500 in-lb. load the shaft will wind up almost 0.5 degrees.
Shaft Windup:
360T
θ= deg rees T is applied torque (in-lb.)
2πS S is the stiffness (in/rad)

page H-2 SAC-SD 01c

ServoWire SD Drive Manual Appendix H: Coupling Mechanical Lodes

Shaft Stiffness:
OD is the inside diameter and ID is the outside diameter
π(OD )G 4 in inches.
S= in − lb / rad G is the shaft shear modulus (lb/in2 )
32L for a stainless steel shaft it is (11x106).
L is the length of the shaft in inches.

Natural Frequency:
JM is the motor inertia (in-lb-sec2)
1 (J + J L )
f= S M Hz JL is the load inertia (in-lb-sec2)
2π (J M ⋅ J L )

If we take that same shaft and connect a MAC-DB200Q motor, with a moment of inertia of 0.0476 in-lb-s2 , on one end
and a load inertia of 100 times the motor inertia on the other end, the natural frequency of the system will be about 184
Hz.
Generally, if the natural frequency of the system is less than about 500 Hz, you may encounter resonance problems in
high performance systems. There is no magic about the number 500, it is simply a rule of thumb. With a mechanical
natural frequency above 500 Hz, you are unlikely to have a resonance problem. At frequencies below 500 Hz, the
probability of resonance problems increases. In the above example, to achieve a natural frequency of 500 Hz, you would
have to increase the shaft diameter to 1.6875 inches or decrease the shaft length to 2.5 inches.

The natural frequency will usually be determined by the least stiff portion of the drive train which is often the shaft
coupling. Be sure to obtain stiffness specifications for any coupling you expect to use and complete the necessary
calculations. If you have more than one "un-stiff" component in your drive train, the effects are additive in that the
resulting overall stiffness is given by:

Stiffness for ‘n’ components:

1
ST =
1 1 1 1
+ + + ...
S1 S2 S3 Sn
If the moment of inertia of components located between these couplings is significant compared to the overall load
inertia, the calculations become a lot more complex and usually result in multiple resonant frequencies.

Often times, choice of couplings, shaft dimensions and attachment methods have surprising effects. No designer should
approach the design of a servo driven mechanism, especially one with a significant inertial mismatch, without doing a
careful analysis of the natural frequency of the mechanical system. "Seat of the pants" engineering is almost guaranteed
to result in problems.

SAC-SD 01c page H-3

Coupling Mechanical Lodes Appendix H: ServoWire SD Drive Manual

Coupling Selection
In any servo mechanism, selection of mechanical couplings is critical. When there is a large inertia mismatch it is
doubly so. Many times it is the choice of coupling that causes the system to have a low resonant frequency. Helical style
couplings are almost never stiff enough to avoid problems unless the load inertia is so low as to be insignificant. The
best choice is a bellows style coupling with taper lock bushings.

If we take a typical inexpensive helical coupling rated for 500 in-lbs of torque, the stiffness will be approximately
72x103 in-lb/rad. If we use this coupling on the load system described earlier, it will limit the system natural frequency
to less than 197 Hz. Clearly this type of coupling would not be adequate. So instead, if we take a similarly rated bellows
coupling1, its stiffness will be 433x103 in-lb/rad. This coupling would have a natural frequency of 480 Hz, which is
much less likely to affect operation.

Generally, it is best to avoid helical, disc, oldham, split beam and jaw type couplers. Metal bellows will usually provide
the best results. In addition to the coupling type you must also pay careful attention to how it is attached to the shafts. A
clamping or taper lock is the best way to go. Always avoid keyways and set screws.

How to Tame Mechanical Load Problems

As said earlier, most mechanical load problems are really backlash and/or compliance problems. The solutions involve
changing the mechanical design to eliminate any backlash and to raise the natural frequency above 500 Hz. Increasing
the natural frequency can often be accomplished by selecting a stiffer coupling, increasing the diameter of shafts or
decreasing the lengths of shafts.

Another way to increase reduce the possibility of instability is to add a speed reducer. This step can reduce the reflected
inertia by the square of the reduction ratio. Adding speed reduction also increases resolution at the motor and improves
performance at low load speeds. It also allows the motor to run at a higher speed which gives it more kinetic energy to
overcome load disturbances. This in turn can reduce the gain and bandwidth requirements for the servo.

Obviously, adding a speed reducer adds the reducer's efficiency losses, in accuracy and compliance to the system so
careful selection of the reducer type is critical.

Another helpful technique, although one with its own disadvantages, is to add notch filtering in the servodrive
command. Ideally, a notch filter exactly counters the effect of the mechanical resonance and eliminates the system's
ability to respond at that frequency. When properly designed and implemented, they work well without requiring
mechanical changes. The disadvantages of notch filters are:
1. The filter will only work if the mechanism does not undergo significant changes overtime. As mechanisms wear or
heat up, their natural frequencies can change. The natural frequency will also change as the load inertia changes. A
once stable system may become unstable if the natural frequency shifts enough that the notch filter no longer
cancels it out.
2. Many resonant loads have several natural frequencies. If you design a notch filter with a wide enough notch to
cover all of the natural frequencies, you may end up with what is effectively a low pass filter which will reduce
servo response considerably.
While many mechanical problems can be resolved using notch filters, they don't address the root cause of
the problem and therefore are not a universal cure all.

page H-4 SAC-SD 01c

ServoWire SD Drive Manual Appendix H: Coupling Mechanical Lodes

Timing Belts
Timing belts are a very economical and surprisingly accurate way to provide modest speed reductions. For servo
applications, you should choose a belt with a high tensile stiffness and low backlash. Belts that use an aramid tensile
member and a modified curvilinear tooth profile are good in both qualities. Belt selection and design is a fairly
specialized process and the reader would be well advised to consult one of the many excellent application guides
published by belt manufacturers for assistance in this area. Another advantage of timing belts over other types of
reducer is their very high efficiency, 95% or better. A disadvantage of timing belts is the added inertia of the pulleys.
However, the added inertia can be minimized by modifying standard pulleys to reduce their mass. Custom pulleys can
be made from light weight materials such as aluminum and are available from most belt manufacturers.
Timing belts designed for precise positioning have a tensile member that uses fibers with a very high tensile strength.
These fibers are set at a diameter that is much larger than a typical direct drive shaft. If the belt system has been
properly sized the stiffness of the system can be better than a solid steel shaft. In the example shown on page 3, the
system had a shaft windup of 0.5 degrees with a 500 in-lb load. If you substitute a 37mm wide timing belt2 using 6 inch
pulleys3 on 18 inch centers, the windup will be less than 0.25 degrees. When a speed reduction is used rather than 1:1,
the windup decreases further.
To calculate the natural frequency of a timing belt system, you need to know the spring rate of the belt. This is available
from the belt manufacturer and is normally called the EA factor. The EA factor for a belt varies with the tension of the
belt and is usually shown on a chart that plots EA (lbs per inch width per unit strain) against belt load (lbs per inch
width).
Calculations to determine natural frequency of a timing belt system:
J1 is the total moment of inertia at the driving pulley (in-lb-s2 ). It
includes the inertia of the pulley and everything connected to it.
J1 J2 J2 is the total moment of inertia at the load pulley(in-lb-s2 ). It
M1 = ,M2 = includes the inertia of the pulley and everything connected to it.
R 12 R 22
R1 is the radius of the driving pulley (inches).
R2 is the radius of the driven pulley (inches).
S is the belt stiffness (lb/inch). span is the belt span, which is the
distance the belt spans between the initial contact points on the
EA ⋅ width pulleys on the tension side of the belt (inches). width is the belt
S= width (inches).
span
span is the belt span, which is the distance the belt spans between
1 (M 1 + M 2 ) the initial contact points on the pulleys on the tension side of the belt
F= S Hz (inches).
2π (M 1 ⋅ M 2 )
width is the belt width (inches).
EA Belt spring rate in (lbs/inch width per unit strain).
The calculations for windup and resonant frequency of a timing belt system can get quite tricky since you must take belt
tension and load forces into account when deciding what EA value to use4 . Unless you are already familiar with the
techniques, you should seek the assistance of your belt supplier. For the purpose of this Tech Note it is sufficient to say
that it is not difficult to design a timing belt drive that is as stiff or stiffer than a typical direct coupled load. The main
advantage of a timing belt system is not that it significantly increases the natural frequency but rather it changes the
amplitude of the resonance. A timing belt system adds considerable damping to the system and for a given natural
frequency, will allow higher gain settings before resonance becomes a problem. Another advantage is that it allows you
to run the motor at a higher speed which, if the motor inertia is small compared to the load, will provide better
operation.

SAC-SD 01c page H-5

Coupling Mechanical Lodes Appendix H: ServoWire SD Drive Manual

One thing to remember is that resonances are usually a greater problem when the system is stopped that when it is
moving under load. By reducing belt tension slightly, you can provide a measure of decoupling between the motor and
load. This decoupling and the damping provided by the belt will often reduce resonance problems. Be careful not to
reduce the tension too much or accuracy will suffer. A good rule of thumb is to make sure the "slack" side of the belt is
always under some tension.
Another thing to remember is that too much belt tension can easily generate a radial load on the motor shaft which will
drastically reduce bearing life. When belt tension must be high, always use a jack shaft with its own bearings to isolate
the motor shaft from the radial load.

Summary
In summary, if you have a load to motor inertia mismatch greater than 10:1, or have a significant portion of the load
inertia coupled through long shafts, you will need to carefully analyze your mechanical design. You will need to make
sure there is no backlash and that the natural frequency is higher than 500 Hz. If you cannot achieve that, gear or belt
reduction are the best alternatives for making it work. As a last resort, notch filtering may be practical in some special
cases.

References
1. Rimtec, type ADK 60.
2. Gates Rubber Co. Poly Chain GT (Part # 14M-1400-37) [Link]
3. Gates Rubber Co. (Part # 14M-34S-37).
4. Selecting Synchronous Belts for Precise Positioning, A.W. Wallin - Applications Engineer, Synchronous Drives
Div., The Gates Rubber Co., Denver CO.

Copyright 1997-98 ORMEC Systems Corp and/or its suppliers.

All rights reserved. Revised: October 28, 1998

page H-6 SAC-SD 01c