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Series HSV-180AS AC Spindle Drive. User Manual (V1.00 2012.4) - page 1

1.2 Meaning of Safety Precaution Symbols

Safety precaution signage

Warning

！

z Danger! High Voltage

z Don’t move cables or

touch terminals while

applying power

z Disconnect incoming

power and wait

5

minutes

before

connecting cables or

The meaning of each

opening

terminal

symbol

cover

Symbols of Safety

Precaution

1.3 Explanation of Safety Precaution Symbols

Danger

It indicates a potentially hazardous situation which, if not avoided,

will result in death.

Caution

！

It indicates a potentially hazardous situation which, if not avoided,

will result in minor or moderate injury or death and damage to the

machine.

1.4 Safety Regulations

1. Products Confirmation

Caution

！

Do not install damaged drive units.

Failure to follow this instruction could result in injury.

2. Installation

Caution

！

z Hold the bottom of the machine.

If only hold the panel，the main engine may fall off which may

result in injury.

z Fit to noncombustible such as metal.

Failure to follow this instruction could result in fire hazard.

z If necessary, set a cooling fan and keep the inlet air at 45℃ or

less.

Overheating may result in fire and other hazards.

z Don’t block the inlet and outlet. Avoid foreign matter entering

into the internal part of the machine.

It may cause the aging of internal components, which can result

in malfunction or fire hazard.

z When installing, make sure a specified intervals between drive

unit and control cabinet or other machines.

Failure to follow this instruction could result in fire hazard or

malfunction.

3.

Wiring

z Before wiring, confirm whether the power is off.

Failure to follow this instruction could result in electric shock

and fire hazard.

z Only electrical engineer can do the wiring.

Failure to follow this instruction could result in electric shock

and fire hazard.

z Make sure the ground terminal grounded.

Failure to follow this instruction could result in electric shock

and fire hazard.

z After the wiring of the emergency stop circuit, check whether the

wiring is effective.

Failure to follow this instruction could result in injury. (Users

shall be responsible for the wiring.)

z Do not touch the output terminal directly nor connect external

shield to the output wire of a spindle drive unit. Avoid short

circuit of output wires.

Failure to follow this instruction could result in electric shock

and short circuit.

Caution

！

z Confirm whether the power voltage of the main AC circuit is subject

to the rated voltage of the spindle drive unit.

Failure to follow this instruction could result in injury and fire

hazard.

z Do not make withstand test for the spindle drive unit.

Failure to follow this instruction could result in damage to

components such as semi-conductor.

z Do not connect power cable to the output U, V, W terminals so as

to avoid damage of spindle drive unit internal parts.

Caution

！

z Do not connect capacitance and LC or LR noise filter to the output

circuit so as to avoid damage of spindle drive.

z Do not connect electromagnetic switch and electromagnetic

contactor to the U, V, and W output circuit. When the spindle drive

running with load, surging current could activate over-current

protection of the spindle drive unit.

4. Testing and Commissioning

Dange

z Do not remove or modify anything when the external wirings are made,

or the power is on.

Failure to follow this instruction could result in electric shock.

z Do not approach to the machine on the trial-operations, after

resetting of spindle drive unit (Take physical safety into

consideration when perform electrical and mechanical design).

z Arrange an external emergency stop device.

Failure to follow this instruction could result in injury.

！

Cautio

z Before operating, reconfirm some information such as the use range

of the motor and machines.

Failure to follow this instruction could result in injury.

z Do not touch the machine while operating or just cut off the power,

because the radiator, brake resistor motor etc. may be at high

temperature.

Failure to follow this instruction could result in burn.

z If necessary, arrange external brake. Do not touch the machine.

Failure to follow this instruction could result in injury.

z Do not check signal while operating to avoid damage to the

equipment.

5. Troubleshooting

Danger

z Do not remove wiring within 5 minutes nor touch terminals after

power-off of a spindle drive unit, because the high voltage will

last for a while.

Failure to follow this instruction could result in electric shock.

z Operations (such as wiring, installation, operation, remove and

maintenance) must be performed by the specified professional

personnel.

Failure to follow this instruction could result in electric shock

and damage to the spindle drive unit.

Caution

！

z The control circuit board adopts the CMOS IC. When maintaining,

do not touch it directly with your fingers, because electrostatic

induction could damage the control circuit board.

6. System Configuration

Caution

！

z The rated torque of the spindle motor must be larger than

continuous effective load torque. Otherwise, the spindle motor

could be damaged by long-time overload operation.

z The ratio of load inertia and spindle motor inertia must be less

than the recommended value.

z Make sure that the motor is properly matching the spindle drive

unit.

Failure to follow this instruction could result in damage of the

equipment.

7. Others

Danger

z Do not make alterations independently.

Failure to follow this instruction could result in electric shock

and injury.

2 Overview

Series HSV-180AS AC spindle motor drive is a new generation of full

digital AC servo spindle drive developed by Wuhan Huazhong Numerical

Control Co., Ltd.. This product features high performance, compact

structure, easy-to-use operation, and high reliability.

HSV-180AS-□□□

Spindle drive current type

035

050

075

100

150

200

300

450

3.1.2 Current Type of HSV-180AS

Table 3-1 Current Types of HSV-180AS spindle drives

Type

HSV-180AS-035

HSV-180AS-050

HSV-180AS-075

Maximum power of

3.7KW

5.5KW

5.5KW

7.5KW

7.5KW

11KW

applicable Motor（KW）

Rated output current (A)

16.8

21.9

31.4

Short-time Peak Current

22

28

42

(A)

Circute breaker（A）

25

32

32

40

40

63

conector（A）

18

25

25

32

32

40

Input

Current

10

15

15

20

20

30

exchange

(A)

reactor

Inductance

1.4

0.93

0.93

0.7

0.7

0.47

(mH)

Input filter(A)

10

15

15

20

20

30

Maximum braking

25

25

40

resistor (A)

Resistor

51Ω

51Ω

27Ω

Recommended

(Ω)

Braking

Power (W)

1500W

1500W

2000W

resistor

Quanlity

1

1

1

Recomand value of main

4

4

4

4

4

10

circute cable （mm²）

Type

HSV-180AS-100

HSV-180AS-150

Maximum power of

11KW

15KW

18.5KW

22KW

applicable Motor（KW）

Rated output current (A)

43.8

62.8

Short-time Peak Current

56

84

(A)

Circute breaker（A）

63

63

100

100

conector（A）

40

50

63

80

Input

Current

30

40

50

60

exchange

(A)

reactor

Inductance

0.47

0.35

0.28

0.24

(mH)

Input filter(A)

40

50

65

Maximum braking

75

resistor (A)

Resistor

33Ω

27Ω

Recommended

(Ω)

Braking

Power (W)

1500W

2000W

resistor

Quanlity

2

2

Recomand value of main

10

16

16

25

circute cable （mm²）

Type

HSV-180AS-200

HSV-180AS-300

HSV-180AS-450

Maximum power of

30KW

37KW

51KW

75KW

applicable Motor（KW）

Rated output current (A)

85.7

125

170

Short-time Peak Current

110

168

224

(A)

Circute breaker（A）

125

160

200

400

conector（A）

95

115

150

250

Input

Current

80

90

150

250

exchange

(A)

reactor

Inductance

0.17

0.16

0.095

0.056

(mH)

Input filter(A)

100

150

250

Maximum braking

100

150

resistor (A)

Resistor

30Ω

30Ω

30Ω

Recommended

(Ω)

Braking

Power (W)

2500W

2500W

2500W

resistor

Quanlity

3

4

6

Recomand value of main

70

120

circute cable （mm²）

3.1.3 Technical Specification of HSV-180AS

The following table describes the technical specification of

HSV-180AS

Table 3-2 Technical specification of HSV-180AS spindle drives

Rated

150A and below specifications：Three-phase

AC380V

-15%～+10%

50/60Hz

voltage、

200A and above Specifications：

Rangeof

Input

1.Single phase AC220V control power

-15%～+10%

voltage

power

50/60Hz

fluctuation

2.Three-phase AC380V strong power

-15%～+10%

Frequency

50/60Hz

Position control、External speed control、JOG

Control modes

control、Internal speed control

Speed

frequency

300Hz or higher

response

Charac

Speed

terist

Lower than 5r/min (load 0%～100%)

volatility

ic

Speed range

1r/min～12000r/min

Constant

1：4

power range

Types of

① Direction + pulse train ②CCW pulse +CW pulse

pulse

③Two-phase A / B quadrature pulse

command

Positi

Form of

on

pulse

Non-insulated wire drive（about +5V）

contro

command

l

Frequency

of pulse

≤500kHz

command

Types of

② Direction + pulse train ②CCW pulse +CW pulse

pulse

③Two-phase A / B quadrature pulse

command

Form of

pulse

Non-insulated wire drive（about +5V）

command

Speed

Frequency

contro

of pulse

≤500kHz

l

command

Analog

DC 0～+10VorDC -10V～+10V

command

Acceleratio

n and

0.1～180seconds

deceleratio

n function

TTL composite incremental photoelectric

encoder:1024line、2048line、2500line

Type of spindle

Sine and cosine incremental encoder：256line

motor encoder

Absolute encoder：ENDAT2.1/2.2 Protocol encoder

（EQN1325/EQN1313）

Spindle encoder

Optical encoder (TTL)

encoder type

Sine and cosine analog signal（1Vpp）

Run enable

Alarm clear

Forward and reverse running enable

Control

Spindle orientation ready

input

Input

Control modes switch

and

Indexing incremental orientation ratio input

output

selection

Signal

Spindle ready

Spindle alarm

Control

Spindle orientation-finished

output

Speed-reached

Zero-speed reached

Spindle

Accuracy：±1pulse；Position adjustment：Parameter

Spindl

orientation

setting

e

Rigid

Tapping deviation：±2％

functi

tapping

on

Other

C-axis control，Thread cutting

function

Communication

RS232 use MODBUS protocol

function

Speed

Flux current

Torque current

Monitoring function

Motor load current

Switch-value input status display

Switch-value output status display

Control mode display

Provides protection against:

Over speed

Main power over-voltage and under-voltage

Over current

Protecting function

Overload

Motor over heat

Big speed error

IPM fault etc.

Six LED digital tubes, two light-emitting

Operation

diodes(LED), five bottoms

Adaptive motor

2.2KW～75KWAC servo spindle motor

Non-corrosive, flammable gas, prevent

Use place

conductive objects, metal dust, oil mist and

liquid from entering inside the drive unit.

Use

Use temperature :0℃～+40℃，More than 40 ℃

Temperature

shall be derated。

Storage

Storage temperature :-20℃～+60℃。

Temperature

Use

Use

Enviro

humidity

nment

Below 90% RH, non-condensing.

Storage

humidity

Below 1000m，Altitude above 1000m shall be

Altitude

derated。

Vibration /

Vibration Resistance 4.9m/S² ，Impact resistance

impact

19.6m/S²

resistance

3.1.4 Dimension and Size of Spindle Drive

The following figures show the installation dimension of series

HSV-180AS spindle drives.

1.Figure 3-2 Dimension and size of HSV-180AS-, 035, 050, 075 (without

auxiliary devices Unit: mm)

Figure 3-3 Dimension and size of HSV-180AS-025, 035, 050, 075 (with

auxiliary devices Unit: mm)

2、Figure 3-4 Dimension and size of HSV-180AS-,100, 150 (without auxiliary

devices Unit: mm)

Figure 3-5 Dimension and size of HSV-180AS-100,150 (with auxiliary

devices Unit: mm)

3、Figure 3-6 Dimension and size of HSV-180AS-,200, 300,450 (without

auxiliary devices Unit: mm)

Figure 3-7 Dimension and size of HSV-180AS-,200, 300,450 (with auxiliary

devices Unit: mm)

3.2 Specification of Spindle Motor

3.2.1 Introduction to Series GM7 AC Servo Spindle Motor

Series HSV-180AS spindle drive matched with the series GM7 AC servo

spindle motor which achieves the closed-loop control and has an

excellent performance. It is widely used in the fields that require

AC servo spindles such as machine tool, building material, textile,

light industry, machinery, and metallurgy industries.

Series GM7 AC servo drive consists of stator, rotor, low-noise fans,

high-precision encoder and other components. Based on the structural

optimization design and magnetic circuit optimization, it adopts

class F insulation structure, machine processing and high-precision

dynamic balance technologies.

3.2.2 Features of Series GM7 AC Servo Spindle Motor

„ Compact structure, small size, light weight, high power density

„ Low magnetic vibration, low noise, high-precision rotation, large

speed range of constant torque and wide constant power speed range

„ Low rotor inertia and short response time

„ Uniform air gap, high-precision dynamic balance, and small torque

ripple

„ Sealed design and the protection grade reached IP54

„ Adopting class F insulation structure to preventing surge current

and corona so as to ensure reliable and long-life operation

„ High capability and low price

Figure 3-4 Series GM7 AC servo spindle motor

3.2.3 Technical index of Series GM7AC servo spindle motor

The following table describes the technical index of series AC GM7

servo spindle motor.

Table 3.3 Technical index of series GM7AC servo spindle motor

Item

Description

Motor type

Full-digital AC servo inverter motor

（squirrel-cage AC induction motor）

Insulation class

Class F insulation, special insulation structure

Feedback

Incremental square-wave encoder or incremental

component

sine-wave encoder

Temperature

positive temperature coefficient(PTC)

protection

thermistor

Force cooling

z Terminal in the terminal box

fun connection

optic-electrica

z Circular socket connector

l encoder

connection

Types of

z Types of mounting: IMB5 IMB35

mounting

z Protection level: IP54 Alternative：IP55

Protection level

z Cooling: forced air cooling and air flow from

Cooling

drive end to non-drive end

z Flat grey paint or customized color

Surface paint

Bearing

z Deep groove ball bearing double sealed

Shaft ends

z Standard model: with key way and key, or

determined by the customers' requirements

Vibration level&

Vibration level : Level N Alternative: level R

Rotation

Rotation accuracy: Level N Alternative: level R

accuracy

Noise

100 and 132 base ≤ 70dB (A)

160base ≤ 72dB (A)

110base ≤ 76dB (A)

225base ≤ 77dB (A)

3.2.4 Order information of series GM7 AC servo spindle motor

3.2.5 Technical index of series GM7 AC servo spindle motor

Adhere to the following principles when choosing the spindle drive：

„ Generally the maximum current or rated current is equal or greater

than 2.

„ For rigid tapping, the maximum current or rated current is equal

or greater than 3.

„ For the situation that requires low inertia loads and common

dynamic response characteristics, the maximum current or rated

current is equal or greater than 1.6.

The following table describes the technical index of series GM7 AC

servo spindle motor.

Table 3.4 Technical index of series GM7 AC servo spindle motor

Rated

Rated Rotary

Maximum

Rated

Rated

Power

speed

Speed

Torque

Curren

Adaptive Spindle

Motor Type

（r/min）

（r/min）

t

Drive

(KW

(Nm)

(A)

)

6000/

HSV-180AS-03

GM7101-4SB6

3.7

23.6

10

1500

9000

5

1

/2.2

6000/

HSV-180AS-03

9000

5

GM7103-4SB6

/1.7

5.5

35

13

1500

1

HSV-180AS-05

0

/2.1

6000/

HSV-180AS-05

8000

0

GM7105-4SB6

/1.5

7.5

47.8

18.8

1500

1

HSV-180AS-07

5

/2.2

6000/

HSV-180AS-07

8000

5

GM7109-4SB6

/1.7

11

70

25

1500

1

HSV-180AS-10

0

/2.2

6000/

HSV-180AS-10

8000

0

GM7133-4SB6

/1.6

15

95.5

34

1500

1

HSV-180AS-15

0

/2.5

6000/

HSV-180AS-15

GM7135-4SB6

18.

117.

42

1500

8000

0

1

5

8

/2

6000/

HSV-180AS-15

GM7137-4SB6

140.

22

57

1500

8000

0

1

1

/1.5

6500

HSV-180AS-20

GM7181-4SB6

30

191

72

1500

0

1

/1.5

6500

HSV-180AS-20

GM7183-4SB6

235.

37

82

1500

0

1

5

/1.4

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