rel-series

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Control Modes
• Cyclic Synchronous Position-Velocity(CSP, CSV)
• Profile Position-Velocity-Torque, Interpolated Position, Homing
• Camming, Gearing
• Indexer
Command Interface
• CANopen over EtherCAT (CoE)
• ASCII and discrete I/O
• Stepper commands
• ±10V position/velocity/torque (2 inputs)
• PWM velocity/torque command
• Master encoder (Gearing/Camming)
Communications
• EtherCAT
• RS-232
Accessories
• external regen resistors
• external edge filter
Feedback
• Digital quad A/B encoder
• enDat, Hiperface, BiSS, SSi, Yaskawa & Panasonic encoders
• Aux. encoder / encoder out
• Analog sin/cos encoder
• resolver option
• Digital Halls
Safety Disable
• Two active inputs enable power stage
• one output confirms power stage status
i/o Digital
• 15 inputs, 6 outputs
i/o Analog
• 2, 16 bit inputs
• 1, 12 bit input Model Vac Ic Ip
• 1, 12 bit output REL-230-18 100 - 240 6 18
Dimensions: in [mm] REL-230-36 100 - 240 12 36
• 7.9 x 5.5 x 2.3 [202 x 139 x 52]
REL-230-40 100 - 240 20 40
Add -R for resolver feedback option.
description
REL set new levels of performance, connectivity, and flexibility. Ethernet based EtherCAT operates
in CANopen over EtherCAT mode (CoE). A wide range of absolute interfaces are built-in including
EnDat, Hiperface, and BiSS.
High resolution A/D converters ensure optimal current loop performance. Both isolated and high-
speed non-isolated I/O are provided. For safety critical applications, redundant power stage enable
inputs can be employed.
Harmonic Drive LLC, 247 Lynnfield Street, Peabody, MA 01960 Tel: 978.532.1800 Fax: 978.532.9406
Web: www.harmonicdrive.net 800.921.3332 Page 1 of 25
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GENERAL SPECIFICATIONS
Test conditions: Wye connected load: 2 mH line-line. Ambient temperature = 25 °C. Power input = 230 Vac, 60 Hz, 1 Ø
MODEL REL-230-18 REL-230-36 REL-230-40

Output CURRENT
Peak Current 18 (12.7) 36 (25.5) 40 (28.3) Adc (Arms, sinusoidal)
Peak time 1 1 1 s
Continuous current (Note 1) 6 (4.24) 12 (8.5) 20 (14.1) Adc (Arms, sinusoidal)
INPUT POWER
Mains voltage, phase, frequency 100~240 Vac, ±10%, 1 Ø or 3 Ø, 47~63 Hz
Mains current 20 Arms
+24 Vdc Control power +20 to +32 Vdc, 500 mA max Required for operation
DIGITAL CONTROL
Digital Control Loops Current, velocity, position. 100% digital loop control
Sampling rate (time) Current loop: 16 kHz (62.5 µs), Velocity & position loops: 4 kHz (250 µs)
Bus voltage compensation Changes in bus or mains voltage do not affect bandwidth
Minimum load inductance 200 µH line-line
command inputs
Distributed Control Mode
CANopen over EtherCAT (CoE) Position, Velocity, Torque, Homing, Profile, Interpolated Profile, and Cyclic Synchronous modes
Stand-alone mode
Analog torque, velocity, position reference ±10 Vdc, 16 bit resolution Dedicated differential analog input
Digital position reference Pulse/Direction, CW/CCW Stepper commands (2 MHz maximum rate)
Quad A/B Encoder 2 M line/sec, 8 Mcount/sec (after quadrature)
Digital torque & velocity reference PWM , Polarity PWM = 0% - 100%, Polarity = 1/0
PWM 50% PWM = 50% ±50%, no polarity signal required
PWM frequency range 1 kHz minimum, 100 kHz maximum
PWM minimum pulse width 220 ns
Indexing Up to 32 programs can be launched from inputs or ASCII commands.
Camming Up to 10 CAM tables can be stored in flash memory
DIGITAL inputs
Number 15
[IN1,2] Non-isolated Schmitt trigger, 1 µs RC filter, 24 Vdc max, Vin-LO <= 1.25 Vdc, Vin-HI >= 3.5 Vdc,
Hysteresis = 0.66 Vdc minimum, 10 kΩ programmable per input to pull-up to +5 Vdc or pull-down to ground
[IN3~6] Non-isolated line receiver, 100 ns RC filter, +12 Vdc max, programmable as 4 single-ended, or 2 differential
Single-ended: [IN3,4] or [IN5,6]: Vin-LO <= 2.3 Vdc, Vin-HI >= 2.7 Vdc, Vhysteresis = 400 mVdc
Differential: [IN3/4] or [IN5/6]: Vin-LO <= -200 mVdc, Vin-HI >= 200 mVdc, Vhysteresis = ±200 mVdc
[IN7~14] Isolated: Opto-isolated, ±15~30 Vdc compatible, bi-polar, 2 groups of 4 with common for each group
[ENCFLT] Encoder fault; same electrical specs as [IN1,2,15] except 10 kΩ fixed pull-up to +5 Vdc
analog inputs
Number 3
[AIN1~2] Differential, ±10 Vdc, 5 kW input impedance, 16-bit resolution
[AIN3] Single-ended, motor temperature sensor, 4.99 kW pulled-up to +5 Vdc, 12-bit resolution
digital outputs
Number 6
[OUT1~2] Current-sinking MOSFET with 1 kΩ pullup to +5 Vdc through diode
1 Adc max, +40 Vdc max; external flyback diode required if driving inductive loads
[OUT3] High-speed CMOS buffer, ±32 mA
[OUT4~5] Opto-isolated Darlingtons with 36V Zener flyback diodes, 50 mA max
[OUT6] Motor brake control: opto-isolated, current-sinking with flyback diode to +24 Vdc, 1 Adc max
analog output
Number 1
Range ±5 Vdc single-ended, 12-bit resolution
multi-mode encoder port
As Input Secondary digital quadrature encoder (A, /A, B, /B, X, /X), 121 Ω terminating resistors
18 M-counts/sec, post-quadrature (4.5 M-lines/sec)
As Output Quadrature encoder emulation with programmable resolution to 4096 lines (65,536 counts) per rev
from analog sin/cos encoders or resolvers. Buffered signals from digital quad A/B/X primary encoder
A, /A, B, /B, X, /X, from MAX3032 differential line driver
RS-232 PORT
Signals RxD, TxD, Gnd in 6-position, 4-contact RJ-11 style modular connector
Mode Full-duplex, DTE serial communication port for drive setup and control, 9,600 to 115,200 Baud
Protocol Binary and ASCII formats
ethercat PORTS
Format Dual RJ-45 receptacles, 100BASE-TX
Protocol EtherCAT, CANopen over EtherCAT (CoE)
status indicators
Drive Status Bicolor LED, drive status indicated by color, and blinking or non-blinking condition
NET Status Bicolor LED, status of EtherCAT bus indicated by color and blink codes to CAN Indicator Specification 303-3
5V output
Two independent 5 Vdc @ 400 mA outputs: J8-20 and J10-6,17
Notes:
1. Heatsinking and/or forced-air cooling is required for continuous output power rating
2. Brake[OUT4] is programmable as motor brake, or as general purpose digital output
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REGENERATION
Operation Internal solid-state switch drives external regen resistor (see Ordering Guide for types)
Cut-In Voltage +HV > 390 Vdc Regen output is on, (optional external) regen resistor is dissipating energy
Drop-Out Voltage +HV < 380 Vdc Regen output is off, (optional external) regen resistor not dissipating energy
Tolerance ±2 Vdc For either Cut-In or Drop-Out voltage
protections
Mains power loss Interruption or loss of AC power is detected
HV Overvoltage +HV > 400 Vdc Drive PWM outputs turn off until +HV is less than overvoltage
HV Undervoltage +HV < 60 Vdc Drive PWM outputs turn off until +HV is greater than undervoltage
Drive over temperature IGBT > 80 °C ±3 °C Drive PWM outputs turn off until IGBT temperature is below threshold
Short circuits Output to output, output to ground, internal PWM bridge faults, regen resistor fail-shorts
I T Current limiting
2
Programmable: continuous current, peak current, peak time
Motor over temperature Drive shuts down when motor over-temperature switch changes to high-resistance state, or opens
Feedback power loss Fault occurs if feedback is removed or +5 V is <85% of normal
MECHANICAL & ENVIRONMENTAL
Size 7.55 in (191,8 mm) X 5.57 in (141,5 mm) X 2.57 in (65,3 mm)
Weight 3.0 lb (1.36 kg) for drive without heatsink
3.1 lb (1.40 kg) for XEL-HS heatsink, 1.86 lb (0.84 kg) for XEL-HL heatsink
Ambient temperature 0 to +45 °C operating, -40 to +85 °C storage
Humidity 0% to 95%, non-condensing
Contaminants Pollution degree 2
Vibration 2 g peak, 10~500 Hz (sine), IEC60068-2-6
Shock 10 g, 10 ms, half-sine pulse, IEC60068-2-27
Environment IEC68-2: 1990
Cooling Heat sink and/or forced air cooling required for continuous power output
agency standards conformance

EN 55011 : 1998 CISPR 11 (1997) Edition 2/Amendment 2:
Limits and Methods of Measurement of Radio Disturbance Characteristics of Industrial, Scientific, and
Medical (ISM) Radio Frequency Equipment
EN 61000-6-1 : 2001 Electromagnetic Compatibility Generic Immunity Requirements
Following the provisions of EC Directive 89/336/EEC:
EN 61010-1 2nd Ed.: 2004 Safety Requirements for Electrical Equipment for Measurement, Control, and Laboratory use
Following the provisions of EC Directive 2006/95/EC:
UL 508C 3rd Ed.: 2002 UL Standard for Safety for Power Conversion Equipment
DIMENSIONS
Inches (mm) 7.92 201.17
Chassis Grounding:
7.54 191.52
.19 4.83
For CE compliance and machine safety
an electrically conductive grounding
R.094 2.37 TYP
tab is provided. This connects to the
1.29 32.69 heatplate and to the frame ground
pins on J1-3, J2-1, J3-5, J5-1, J8-1,
J9-1, and J10-1.
5.12 130.07
3.00 76.20
.190 4.83
.24 6.12
Chassis 7.54 191.52

.19 4.83
grounding
tab
1.00 25.40 2.31 58.67
.76 19.18
.31 7.92
7.92 201.17 5.51 139.88
5.72 145.35
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feedback specifications
Digital quad a/b Encoder

Type Quadrature, differential line driver outputs
Signals A, /A, B, /B, (X, /X, index signals optional)
Frequency 5 MHz line frequency, 20 MHz quadrature count frequency
Analog Encoder
Type Sin/cos/index, differential line driver outputs, 0.5 Vpeak-peak (1.0 Vpeak-peak differential)
centered about 2.5 Vdc typical. Common-mode voltage 0.25 to 3.75 Vdc
Signals Sin(+), sin(-), cos(+), cos(-), index(+), index(-)
Frequency 230kHz maximum line (cycle) frequency
Interpolation 10 bits/cycle (1024 counts/cycle)
Digital Halls
Type Digital, single-ended, 120° electrical phase difference
Signals U, V, W
Inputs 10 kW pullups to +5 Vdc, 1 µs RC filter to Schmitt trigger inverters
multi-mode encoder port
As Input Secondary digital quadrature encoder (A, /A, B, /B, X, /X), 121 Ω terminating resistors
18 M-counts/sec, post-quadrature (4.5 M-lines/sec)
As Emulated Output Quadrature encoder emulation with programmable resolution to 4096 lines (65,536 counts) per rev
from analog sin/cos encoders or resolvers.
A, /A, B, /B, X, /X, from MAX3032 differential line driver
As Buffered Output Digital encoder feedback signals from primary digital encoder are buffered by MAX3032 line driver
Resolver (-R option)
Type Brushless, single-speed, 1:1 to 2:1 programmable transformation ratio
Resolution 14 bits (equivalent to a 4096 line quadrature encoder)
Reference frequency 7.5 kHz
Reference voltage 2.8 Vrms, auto-adjustable by the drive to maximize feedback
Reference maximum current 100 mA
Maximum RPM 10,000+
ENCODER Power Supplies
Number 2
Ratings +5 Vdc @ 400 mA from J10-6 and J8-20
Protection Current-limited to 750 mA @ 1 Vdc if overloaded
Encoder power developed from +24 Vdc so position information is not lost when AC mains power is removed
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Ethercat communications
EtherCAT is the open, real-time Ethernet network developed by Beckhoff based on the widely used 100BASE-TX cabling system. EtherCAT enables high-
speed control of multiple axes while maintaining tight synchronization of clocks in the nodes. Data protocol is CANopen over EtherCAT (CoE) based on
DSP-402 for motion control devices.
Ethercat connections
Dual RJ-45 sockets accept standard Ethernet cables. The IN port connects to a master, or to the OUT port of a device that is ‘upstream’, between the
REL and the master. The OUT port connects to ‘downstream’ nodes. If REL is the last node on a network, only the IN port is used. No terminator is
required on the OUT port.
J7: EtherCAT PORTS ethercat LEDs (on j7)

RJ-45 receptacles, Green and yellow LEDs indicate the state of the EtherCAT interface:
8 position, 4 contact Green is the “Link” indicator: Yellow is the “Activity” indicator:
On = Good Link On = Activity
Off = No Link Blinking Off = No Activity
net status LED (ON j6)

8
OUT (B)
A bi-color LED indicates the state of the EtherCAT bus.
1
Green and red colors alternate, and each color has a separate meaning:
ACTIVITY Green is the “RUN” or EtherCAT State Machine: Red is the “ERR” indicator:
(yellow)
Off = INIT state Blinking = Invalid configuration
8
IN (A) Blinking = PRE-OPERATIONAL Single Flash = Unsolicited state change

LINK Single Flash = SAFE-OPERATIONAL Double Flash = Application watchdog timeout
1
(green) On = OPERATIONAL
amp status LED

Pin signal
A bi-color LED gives the state of the Xenus Plus drive.
1 TX+ Colors do not alternate, and can be solid ON or blinking:
Green/Solid = Drive OK and enabled. Will run in response to reference inputs
2 tx-
or EtherCAT commands.
3 rx+ Green/Slow-Blinking = Drive OK but NOT-enabled. Will run when enabled.
Green/Fast-Blinking = Positive or Negative limit switch active.
6 rx- Drive will only move in direction not inhibited by limit switch.
Red/Solid = Transient fault condition. Drive will resume operation when fault is removed.
Red/Blinking = Latching fault. Operation will not resume until drive is Reset.
EtherCAT Address (station alias) EtherCAT

In an EtherCAT network, slaves are automatically assigned addresses based on their Address Switch
position in the bus. But when the device must have a positive identification that is Decimal values
independent of cabling, a Station Alias is needed. In the REL, this is provided by two
16-position rotary switches with hexadecimal encoding. These can set the address of the S1 S2
drive from 0x01~0xFF (1~255 decimal). The chart shows the decimal values of the hex Hex Dec
settings of each switch.
0 0 0
Example 1: Find the switch settings for decimal address 107:
1 16 1
1) Find the highest number under S1 that is less than 107 and set S1 to the hex value in
the same row: 2 32 2
96 < 107 and 112 > 107, so S1 = 96 = Hex 6 3 48 3
2) Subtract 96 from the desired address to get the decimal value of switch S2 and set S2 4 64 4
to the Hex value in the same row:
5 80 5
S2 = (107 - 96) = 11 = Hex B
6 96 6
S1 S2 7 112 7
8 128 8
9 144 9
A 160 10
B 176 11
C 192 12
D 208 13
E 224 14
F 240 15
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COMMUNICATIONS
RS-232 communications
REL is configured via a three-wire, full-duplex DTE RS-232 port that operates from 9600 to 115,200 Baud, 8 bits, no parity, and one stop bit. Signal format
is full-duplex, 3-wire, DTE using RxD, TxD, and Gnd. Connections to the REL RS-232 port are through J7, an RJ-11 connector. The REL Serial Cable Kit
(SER-CK) contains a modular cable, and an adapter that connects to a 9-pin, Sub-D serial port connector (COM1, COM2, etc.) on PC’s and compatibles.
SER-CK serial cable kit J6: RS-232 Port

The SER-CK provides connectivity between a D-Sub 9 male connector and the RJ-11 RJ-11 receptacle,
connector on the REL. It includes an adapter that plugs into the COM1 (or other) 6 position, 4 contact
port of a PC and uses common modular cable to connect to the REL. The connections
are shown in the diagram below.
Pin signal
2 RxD
1
6 3,4 Gnd
6 1
9 5 Txd
5
RJ-11
D-Sub 9F
2 5
RxD TxD
3 2
TxD RxD
5 3
Gnd Gnd
ASCII communications
The HDLLC ASCII Interface is a set of ASCII format commands that can be used to operate and monitor HDLLC DDP, DEP, RTL AND
REL series amplifiers over an RS-232 serial connection. For instance, after basic amplifier configuration values have been programmed
using HDM, a control program can use the ASCII Interface to:
• Enable the amplifier in Programmed Position mode.
• Home the axis.
• Issue a series of move commands while monitoring position, velocity, and other run-time
variables.
Additional information can be found in the ASCII Programmers Guide on the HDLLC website:
http://www.harmonicdrive.net/spport/documentdownloads/
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safe-OFF
description
The REL has a safety feature that is designed to function under the protocol of EN 954-1. Two opto-couplers are provided which, when de-energized,
prevent the upper and lower devices in the PWM outputs from being operated by the DSP. This provides a positive OFF capability that cannot be
overridden by the DSP, its’ firmware, or associated hardware components. When the opto-couplers are activated (current is flowing in the input diodes),
the DSP can control the operation and on/off state of the PWM outputs.
functional diagram
In order for the PWM outputs of the REL to be activated, current must be flowing through both opto-couplers that are connected to the ENH and ENL
terminals of J5, and the drive must be in an ENABLED state. The LED outputs on J5 connect an opto-coupler to an external LED and will conduct current
through the LED to light it whenever the PWM outputs can be activated, or the drive is in a diagnostic state. When the LED opto-coupler is OFF, the
drive is in a Safe state and the PWM outputs cannot be activated to drive a motor.
safe-OFF override
The diagram below shows connections that will energize both ENH and ENL opto-couplers. When this is done the SAFE-OFF feature is defeated and
control of the output PWM stage is under control of the DSP. This is the operating mode of CC drives that don’t have the SAFE-OFF feature.
functional diagram
REL
Safety Override
J5 +HV
Connections
ENH(+) High Side PWM
5.1V
ENH
2
4.99k
4.99k
ENH(-)
3
Motor
Low Side PWM Ouputs
ENL(+) 5.1V
ENL
4
4.99k
4.99k
ENL(-)
5
LED(+) 10
6 +V
LED(-) 36V ENH
7 ENL
DIAG-ON
+24V Output
9 From 24V input on J4-3
Signal ground
8
1 Frame Ground
safety connector J5 signals
Pin Signal Pin Signal

SAFETY
1 Frame Gnd 6 Enable LED(+)

2 Safe Enable HI(+) 7 Enable LED(-)
J5
3 Safe Enable HI(-) 8 24 Vdc Common
1
6
4 Safe Enable LO(+) 9 +24 Vdc Input

9
5 Safe Enable LO(-)

5
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command Inputs
NON-ISOLATED digital INPUTS

HS Inputs [IN1~2]
Inputs [IN1~2] are 24V tolerant
24 Vdc max
These are high-speed types with pull-up resistors to +5 Vdc and 1 µs RC filters when driven by
active sources. The active level is programmable on each input. Input [IN1] is dedicated to the +5.0 V
drive enable function. The remaining inputs [IN2~IN14] have programmable functions. Input
A
[IN11] is set up for the motor overtemperature function and connects to the feedback connector
J10. If not used as the Motemp input it can be programmed for other functions. All of the inputs
can operate from +5 to +24 Vdc sources.
74HC2G14
10k
[IN1]
[IN2]
10k
100pF
digital INPUTS [IN3~6]

These inputs have all the programmable functions of the GP inputs plus these additional functions on [IN8] & [IN9] which can be configured as single-
ended or differential:
• PWM 50%, PWM & Direction for Velocity or Current modes
• Pulse/Direction, CU/CD, or A/B Quad encoder inputs for Position or Camming modes
single-ended differential
12 Vdc max 12 Vdc max
+5V +5V
10k MAX3096 10k MAX3096

1k 1k
[IN3] [IN3]
100 pF 100 pF
2.5V
+5V + +5V
10k 10k
1k 1k
[IN4] [IN4]
100 pF 100 pF
MAX3096
+5V +5V
10k MAX3096 10k MAX3096

1k 1k
[IN5] [IN5]
100 pF 100 pF
2.5V
+5V + +5V
10k 10k
1k 1k
[IN6] [IN6]
100 pF 100 pF
MAX3096
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opto-isolated digital INPUTS

These inputs have all the programmable functions of the GP inputs plus opto-isolation. There are two groups of four inputs, each with
its’ own common terminal. Grounding the common terminal configures the inputs to work with current-sourcing outputs from controllers
like PLC’s. When the common terminal is connected to +24V, then the inputs will be activated by current-sinking devices such as NPN
transistors or N-channel MOSFETs. The minimum ON threshold of the inputs is ±15 Vdc.
[IN7~10] IN11~14
±30 Vdc max ±30 Vdc max
J9 J9
24V GND 24V GND
24V [COMM_A] 24V [COMM_A]

+ 2 + 7
4.7k 4.7k
[IN7] [IN11]
3 8
4.99k 5.1V 4.99k 5.1V
4.7k 4.7k
[IN8] [IN12]
4 9
4.99k 5.1V 4.99k 5.1V
4.7k 4.7k
[IN9] [IN13]
5 10
4.99k 5.1V 4.99k 5.1V
4.7k 4.7k
[IN10] [IN14]
6 11
+ +
4.99k 5.1V 4.99k 5.1V
24V 24V
J8
D/A
Analog Inputs F.G. 1 Frame Ground

Two differential analog inputs with ±10 Vdc range have
Ref1
programmable functions. As a reference input [AIN1] can ±10V 2 -
take position/velocity/torque commands from a controller. 5.36k
Vref
A second input [AIN2] is programmable for other functions. Ref1
3 +
The ratio of drive output current or velocity vs. reference
input voltage is programmable. 15 Sgnd 1.5V
11 -
5.36k
Vref
12 +
19 Sgnd 1.5V
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outputs
digital OUTPUTS [OUt1], [out2] J8

These are open-drain MOSFETs with 1 kΩ pull-up resistors in series with a diode
to +5 Vdc. They can sink up to 1 Adc from external loads operating from power
supplies to +30 Vdc. The output functions are programmable. The active state [OUT1]
of the outputs is programmable to be on or off. When driving inductive loads +5V 16 R-L
such as a relay, an external fly-back diode is required.
The internal diode in the output is for driving PLC inputs that are opto-isolated
and connected to +24 Vdc. The diode prevents conduction from +24 Vdc 100mA
through the 1 kΩ resistor to +5 Vdc in the drive. This could turn the PLC input
on, giving a false indication of the drive output state.
[OUT2]
+5V 17 R-L
+
100mA
Sgnd
15
+30V max
HIGH SPEED OUTPUT [OUT3] opto-isolated outputs [out4,5]

5V CMOS 30 Vdc max
J8 J9
[OUT4+]
+5V R-L 14
30V max +
[OUT3]
50mA
18 R [OUT4-]
15
NC7SZ125
±32mA [OUT5+]
Sgnd 12
R-L
15 30V max +
50mA
[OUT5-]
13
BRAKE OUTPUT [OUT6] Analog output

This output is an open-drain MOSFET with an internal The analog output is programmable and
flyback diode connected to the +24 Vdc input. It has an output voltage range of ±5 Vdc.
can sink up to 1A from a motor brake connected to An op-amp buffers the output of a 12-bit
the +24 Vdc supply. The operation of the brake is D/A converter.
programmable with HDM. It can also be programmed
as a general-purpose digital output.
J4 J8
100
+24V 9
3
BRK 15
Brk
2
+ 24V
0V
1
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MOTOR CONNECTIONS
Motor connections are of three types: phase, feedback, and thermal sensor. The phase connections carry the drive output currents that
drive the motor to produce motion. A thermal sensor that indicates motor overtemperature is used to shut down the drive to protect
the motor. Feedback can be digital quad A/B encoder, analog sin/cos encoder, resolver or digital Halls, depending on the version of the
drive.
quad a/b ENCODER with fault protection Encoder J10

Encoders with differential line-driver outputs provide incremental position feedback via the
A/B signals and the optional index signal (X) gives a once per revolution position mark. The FG 1 Frame Ground
MAX3097 receiver has differential inputs with fault protections for the following conditions:
A
Short-circuits line-line: This produces a near-zero voltage between A & /A which is below 13
the differential fault threshold. A 121 Enc. A
/A
12 MAX3097
Open-circuit condition: The 121W terminator resistor will pull the inputs together if either
side (or both) is open. This will produce the same fault condition as a short-circuit 11
B
across the inputs. B 121 Enc. B

/B
Low differential voltage detection: This is possible with very long cable runs and a fault will 10 MAX3097
occur if the differential input voltage is < 200mV. X

9
±15kV ESD protection: The 3097E has protection against high-voltage discharges using
Z 121 Enc. Index
the Human Body Model. 8
/X
MAX3097
Extended common-mode range: A fault occurs if the input common-mode voltage is
outside of the range of -10V to +13.2V +5V 6 +5V output @ 400 mA
0V 5 Signal Ground
ANALOG sin/cos incremental ENCODER Encoder J10

The sin/cos/index inputs are differential with 121 Ω terminating resistors and accept 1 Vp-p
signals in the format used by incremental encoders with analog outputs, or with Linear motors. FG 1 Frame Ground
Sin(+) 10k
19 -
sin 121 Sin
Sin(-)
18 +
10k
10k
Cos(+)
21 -
cos 121 Cos
Cos(-)
20 +
10k
Inx(+) 10k
23 -
indx 121 Indx
Inx(-)
22 +
10k
+5V 17 +5V output @ 400 mA
0V 5 Signal Ground
Resolver J10
FG 1 Frame Ground
RESOLVER (-R models) 19 Sin(+)
Connections to the resolver should be made with shielded cable that uses 18 Sin(-)
three twisted-pairs. Once connected, resolver set up, motor phasing, and other R/D
commissioning adjustments are made with HDM software. There are no hardware S3 Sin S1 Conversion
adjustments. S2
21 Cos(+)
Cos
20 Cos(-)
S4
R2 Ref R1
23 Ref(+)
22 Ref(-)
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MOTOR CONNECTIONS (Cont’d)
Ssi absolute Encoder BiSS absolute Encoder

The SSI (Synchronous Serial Interface) is an interface used to connect an BiSS is an - Open Source - digital interface for sensors and actuators.
absolute position encoder to a motion controller or control system. The XEL BiSS refers to principles of well known industrial standards for Serial
drive provides a train of clock signals in differential format to the encoder which Synchronous Interfaces like SSI, AS-Interface® and Interbus® with
initiates the transmission of the position data on the subsequent clock pulses. additional options.
The polling of the encoder data occurs at the current loop frequency (16 kHz). The
Serial Synchronous Data Communication
number of encoder data bits and counts per motor revolution are programmable.
Cyclic at high speed
The hardware bus consists of two signals: SCLK and SDATA. Data is sent
2 unidirectional lines Clock and Data
in 8 bit bytes, LSB first. The SCLK signal is only active during transfers.
Line delay compensation for high speed data transfer
Data is clocked out on the falling edge and clock in on the rising edge of
Request for data generation at slaves
the Master.
Safety capable: CRC, Errors, Warnings
Bus capability incl. actuators
J10 Bidirectional
Encoder
BiSS B-protocol: Mode choice at each cycle start
FG 1 Frame Ground
BiSS C-protocol: Continuous mode
Clk
9
A BiSS
Clk 121
B Clk Encoder
REL
/Clk
8 J3
MAX3362B 1
FG Frame Ground
Master
Dat MA+
15 9
A
Data 121 Data
121 Clk
MA-
/Dat B 8
14 MAX3362B MAX3362B
Slave
SL+
15
+5V 6 +5V output @ 400 mA
SL-
121 Data
14 MAX3362B
0V 5 Signal Ground
V+ 6 +5V output @ 400 mA
V- 5 Signal Ground
endat absolute Encoder

The EnDat interface is a Heidenhain interface that is similar to SSI in the use
of clock and data signals, but which also supports analog sin/cos channels
from the same encoder. The number of position data bits is programmable as
is the use of sin/cos channels. Use of sin/cos incremental signals is optional
in the EnDat specification. nikon-a absolute Encoder
The Nikon A interface is a serial, half-duplex type that is
electrically the same as RS-485
REL
Encoder
J10
FG 1 Frame Ground
Nikon-A
REL
9
Clk Encoder
A J10
Clk 121
B
Clk 5V
/Clk
8 1
1.2k
MAX3362B
SD+
15
Dat
15 A SD 220 121 Cmd
SD-
Data 121 Data 14
/Dat B
14 MAX3362B
D-R 1.2k D-R
Sin(+) 10k
19 -
SD
Cmd
sin 121 Sin +5V
6 5V output
Sin(-) V+
18 +
10k
MAX3362B 0V MAX3362B
V- 5 Signal Ground
Cos(+) 10k
21 -
cos 121 Cos
Cos(-)
22 +
10k
0V 5 Signal Ground
REL
WITH
EtherCAT RoHS
MOTOR CONNECTIONS (Cont’d)
motor phase connections J2

The drive output is a three-phase PWM inverter that converts the DC buss voltage
(+HV) into three sinusoidal voltage waveforms that drive the motor phase-coils.
Cable should be sized for the continuous current rating of the motor. Motor cabling F.G. 1
PWM
should use twisted, shielded conductors for CE compliance, and to minimize PWM
noise coupling into other circuits. The motor cable shield should connect to motor +HV
W
2
frame and the drive frame ground terminal (J2-1) for best results.
+ V Motor
3
3 ph.
U
0V 4
J10
Halls
10K
Hall A +5V
Hall U 10K
2
100p
digitAl HALL SIGNALS
10K
Hall signals are single-ended signals that provide absolute feedback within one Hall B
+5V
electrical cycle of the motor. There are three of them (U, V, & W) and they may be Hall V 10K
sourced by magnetic sensors in the motor, or by encoders that have Hall tracks as 3
100p
part of the encoder disc. They typically operate at much lower frequencies than the
motor encoder signals, and are used for commutation-initialization after startup, 10K
Hall C +5V
and for checking the motor phasing after the amplifier has switched to sinusoidal
Hall W 10K
commutation. 4
100p
0V 5 * Signal Ground
* Alternate Sgnd connections on J10 are pins 16, 25, 26
Motor Temperature Sensor encoder fault

Analog input Motemp, is for use with a motor overtemperature A high-speed (HS) non-isolated input with a pull-up resistor to +5 Vdc
switch or sensor. The input voltage goes through a low-pass and 1 µs RC filter when driven by active sources. The active level is
programmable. For encoders that output a FAULT signal in addition to
filter to a 12-bit A/D converter. The active level of the input, the other position data signals
Vset, is programmable generate an over-temperature fault if
the input voltage is <Vset, or >Vset.
J10 J10
+5V ENCODER +5.0 V

FAULT
4.99k OUTPUT 74HC2G14
[ENCFLT] 10k
Motemp
27 Hz 12-bit 7
7 LPF A/D 10k
Thermistor,
100pF
Posistor,
* Sgnd
or switch * Sgnd 25
5
* Alternate Sgnd connections on J10 are pins 16, 25, 26
REL
WITH
EtherCAT RoHS
MOTOR CONNECTIONS (cont’d)

multi-MODE ENCODER PORT
This port consists of three differential input/output channels that take their functions from the Basic Setup of the drive.
With quad A/B encoder feedback, the port works as an output, buffering the signals from the encoder. With resolver or sin/cos encoder
versions, the feedback is converted to “emulated” quad A/B/X signals with programmable resolution. These signals can then be fed back
to an external motion controller that closes the position or velocity loops. As an input, the port can take quad A/B signals to produce
a dual-loop position control system or use the signals as master-encoder commands in camming mode. In addition, the port can take
stepper command signals (CU/CD or Pulse/Direction) in differential format.
Secondary
as buffered outputs from a digital quadrature Encoder Input
primary encoder MAX3097
When using a digital quadrature feedback encoder, the A/B/X signals drive
the multi-mode port output buffers directly. This is useful in systems that use
external controllers that also need the motor feedback encoder signals because
Input/Output
these now come from J8, the Control connector. In addition to eliminating “Y” Buffered A/B/X signals Select
cabling where the motor feedback cable has to split to connect to both controller from primary encoder
and motor, the buffered outputs reduce loading on the feedback cable that MAX3032
could occur if the motor encoder had to drive two differential inputs in parallel,
each with it’s own 121 ohm terminating resistor. Quad A/B/X primary
encoder
Secondary
Encoder Input
MAX3097
as emulated quad a/b/x encoder outputs from an

analog sin/cos feedback encoder
Analog sin/cos signals are interpolated in the drive with programmable Input/Output
Select
resolution. The incremental position data is then converted back into digital Emulated A/B/X signals
quadrature format which drives the multi-mode port output buffers. Some
analog encoders also produce a digital index pulse which is connected directly MAX3032
to the port’s output buffer. The result is digital quadrature A/B/X signals that Emulated Quad A/B
can be used as feedback to an external control system. signals from
analog Sin/Cos encoder
or resolver
MAX3097
as a master or camming encoder input from a
digital quadrature encoder
When operating in position mode the multi-mode port can accept digital Input/Output
A/B/X signals from
command signals from external encoders. These can be used to drive cam digital encoder Select
tables, or as master-encoder signals when operating in a master/slave
configuration.
MAX3032
as digital command inputs in pulse/direction, MAX3097
pulse-up/pulse-down, or
digital quadrature encoder format
The multi-mode port can also be used when digital command signals are in Input/Output
Pulse/Dir or CU/CD
Select
a differential format. These are the signals that typically go to single-ended differential commands
inputs. But, at higher frequencies these are likely to be differential signals in

MAX3032
which case the multi-mode port can be used.
REL
WITH
EtherCAT RoHS
Quad A/B Encoder
Frame
Gnd
Frame Ground 1 1
A A
A 26 13
Outputs Buffered
Quad A/B from /A /A
/A 25 Encoder 12
B B
Multi-Mode B 24 11 DIGITAL
Encoder ENCODER
/B /B
Port /B 23 10
X X
X 22 9
Control cable to J7
/X /X
/X 21 8
J9 +5 Vdc 6
Vcc
1 F.G.
(Note 1) 0V
Sgnd 5
2 [COMM_A]
3 [IN7] GPI 20 +5 Vdc @ 400 mA

±10 Vdc 2
Hall U
4 [IN8] GPI Analog 19 Signal Ground
Reference DIGITAL
Hall V 3
5 [IN9] GPI HALLS
3 Ain1(-)
6 [IN10] GPI Hall W 4
2 Ain1(+)
7 [COMM_B]
+5 Vdc 17 (Note 1)
8 [IN11] GPI 4 [IN1] Enable
Signal Ground 16
TEMP
9 [IN12] GPI 5 [IN2] GP
Motemp SENSOR
7
6 [IN3] GP [IN15]
10 [IN13] GPI
11 [IN14] GPI 7 [IN4] GP J10

12 [OUT5+] GPI 8 [IN5] HS
13 [OUT5-] GPI 10 [IN6] HS L3 4 L3

14 [OUT4+] GPI 11 Ain2(+)
Fuse AC MAINS:
FILTER
3 100 to 240 Vac

J1
LINE
1
15 [OUT4-] GPI 12 Ain2(-) 1Ø or 3Ø
L2 2 N L2 47 to 63 Hz
J8 L1 1 H L1
= Shielded cables required 9 Aout
for CE compliance Earth
15 Signal Ground
Mot U 4 U
BRAKE 16 [OUT1] * Fuse
Mot V 3 V BRUSHLESS
* Fuse MOTOR
17 [OUT2] J2 Mot W 2 W
Control Power Supply
18 [OUT3]
Required for Frame Ground 1
Drive Operation
DANGER: HIGH VOLTAGE
+ 3 +24V
REGEN+ 1 CIRCUITS ON J1, J2, & J3
+24 Vdc 2 * Fuse
BRAKE ARE CONNECTED TO
0.5 Adc J3 2
MAINS POWER
- 1 RTN J4 REGEN- 3
* Fuse
Drive mounting screw 4
Frame Ground 5
* Optional
Notes:
1) The total output current from the +5 Vdc supply to J7-20 cannot exceed 400 mAdc
2) Line filter is required for CE
REL
WITH
EtherCAT RoHS
Sin/Cos Encoder
Frame
Gnd
Frame Ground 1 1
Asin(+) Sin(+)
A 26 19
Outputs Buffered
Quad A/B from Asin(-) Sin(-)
/A 25 Encoder 18
Acos(+) Cos(+)
Multi-Mode B 24 21 Sin / Cos
Encoder ENCODER
Acos(-) Cos(-)
Port /B 23 20
Ainx(+) Index(+)
X 22 23
Control cable to J7
Ainx(-) Index(-)
/X 21 22
J9 +5 Vdc 6
Vcc
1 F.G.
0V
Sgnd 5
2 [COMM_A]
3 [IN7] GPI 20 +5 Vdc @ 400 mA

±10 Vdc 2
Hall U
Reference DIGITAL
Hall V 3
5 [IN9] GPI HALLS
3 Ain1(-)
2 Ain1(+)
7 [COMM_B]
+5 Vdc 17
Signal Ground 16
TEMP
9 [IN12] GPI 5 [IN2] GP
Motemp SENSOR
7
[IN15]
10 [IN13] GPI 6 [IN3] GP
11 [IN14] GPI 7 [IN4] GP J10

13 [OUT5-] GPI 10 [IN6] HS L3 4 L3

14 [OUT4+] GPI 11 Ain2(+)
Fuse AC MAINS:
3
FILTER
100 to 240 Vac

LINE
15 [OUT4-] GPI 12 Ain2(-)

J1 1
1Ø or 3Ø
L2 2 N L2 47 to 63 Hz
J8 L1 1 H L1
= Shielded cables required
9 Aout
for CE compliance
Earth
15 Signal Ground
Mot U 4 U
Mot V 3 V BRUSHLESS
* MOTOR
17 [OUT2] J2 Mot W 2
Fuse
W
18 [OUT3]
Drive Operation
+ 3 +24V
+24 Vdc 2 * Fuse
0.5 Adc J3 2
MAINS POWER
- 1 RTN J4 REGEN- 3
* Fuse
Frame Ground 5
* Optional
Notes:
REL
WITH
EtherCAT RoHS
Resolver
Frame
Gnd
Frame Ground 1 1
Asin(+) S3 Sin(+)
A 26 19
Outputs Buffered
Quad A/B from Asin(-) S1 Sin(-)
/A 25 Encoder 18
Acos(+) S2 Cos(+)
Multi-Mode B 24 21
Encoder Resolver
Acos(-) S4 Cos(-)
Port /B 23 20
Ainx(+) R1 Ref(+)
X 22 23
Control cable to J7
Ainx(-) R2 Ref(-)
/X 21 22
J9 +5 Vdc 6
1 F.G.
Sgnd 5
2 [COMM_A]
(Note 1)
3 [IN7] GPI 20 +5 Vdc @ 400 mA
±10 Vdc 2
Hall U
Reference
Hall V 3
5 [IN9] GPI
3 Ain1(-)
2 Ain1(+)
7 [COMM_B]
+5 Vdc 17
Signal Ground 16
TEMP
9 [IN12] GPI 5 [IN2] GP
Motemp SENSOR
7
[IN15]
10 [IN13] GPI 6 [IN3] GP
11 [IN14] GPI 7 [IN4] GP J10

13 [OUT5-] GPI 10 [IN6] HS L3 4 L3

14 [OUT4+] GPI 11 Ain2(+)
Fuse AC MAINS:
3
FILTER
100 to 240 Vac

LINE
15 [OUT4-] GPI 12 Ain2(-)

J1 1
1Ø or 3Ø
L2 2 N L2 47 to 63 Hz
J8 L1 1 H L1
= Shielded cables required
9 Aout
for CE compliance
Earth
15 Signal Ground
Mot U 4 U
Mot V 3 V BRUSHLESS
* MOTOR
17 [OUT2] J2 Mot W 2
Fuse
W
18 [OUT3]
Drive Operation
+ 3 +24V
+24 Vdc 2 * Fuse
0.5 Adc J3 2
MAINS POWER
- 1 RTN J4 REGEN- 3
* Fuse
Frame Ground 5
* Optional
Notes:
REL
WITH
EtherCAT RoHS
Quad A/B Encoder
WARNING: Hazardous voltages exist on connections

to J1, J2, & J3 when power is applied, and for up to 30
seconds after power is removed.
J1 Mains Connections
J1 Cable Connector:
Signal Pin
Wago: 51118287 or 721-204/026-045/RN01-0000
Euro-style 7,5 mm pluggable female terminal block Mains Input L3 4
with preceding ground receptacle
Cable: AWG 12, 600 V recommended Protective Ground 3
for REL-230-36-R and REL-230-40-R models,
Mains Input L2 2 J1
AWG 14, 600V for REL-230-18-R
Shielded cable required for CE compliance Mains Input L1 1
J2 Motor Outputs
J2 Cable Connector:
Wago: 51118008 or 721-104/026-047/RN01-0000 Signal Pin J2
Euro-style 5,0 mm pluggable female terminal block
Motor Phase U 4
Cable: AWG 12, 600 V recommended
for REL-230-36-R and REL-230-40-R models, Motor Phase V 3
AWG 14, 600V for REL-230-18-R
Shielded cable required for CE compliance Motor Phase W 2
Cable Shield 1
J3
J3 Cable Connector:
Wago: 51111277 or 721-605/000-044/RN01-0000 J3 Regen Resistor
Euro-style 5,0 mm pluggable male terminal block
Cable: AWG 12, 600 V recommended Signal Pin
AWG 14, 600V for REL-230-18-R Regen Resistor 1
Shielded cable required for CE compliance
No Connection 2
J4
Regen Resistor 3
Wire Insertion/Extraction Tool: No Connection 4
Used on J1, J2, J3, & J4
Wago 231-131 Cable Shield 5
ISOLATED CIRCUIT
J5
NOTE: AN EXTERNAL J4 +24 VDC & Brake
+24 Vdc POWER SUPPLY
IS REQUIRED FOR OPERATION Signal Pin
+24 Vdc Control Power 3
J4 Cable Connector:
Brake Output [OUT6] 2
Wago: 51117974 or 721-103/026-047/RN01-0000
Euro-style 5,0 mm pluggable terminal block 0V (+24 Vdc Return) 1
ISOLATED CIRCUIT
REL
WITH
EtherCAT RoHS
Quad A/B Encoder
J8 Control Signals J8 Cable Connector:

High-Density
Pin Signal Pin Signal Pin Signal D-Sub male,
1 Frame Gnd 10 [IN6] HS 19 Signal Gnd 26 Position
2 [AIN1+] 11 [AIN2+] 20 +5 Vdc Out

3 [AIN1-] 12 [AIN2-] 21 Multi Enc /X2
4 [IN1] GP 13 Multi Enc /S2 22 Multi Enc X2
J6 5 [IN2] GP 14 Multi Enc S2 23 Multi Enc /B2

6 [IN3] HS 15 Signal Gnd 24 Multi Enc B2
7 [IN4] HS 16 [OUT1] 25 Multi Enc /A2
8 [IN5] HS 17 [OUT2] 26 Multi Enc A2
9 [AOUT] 18 [OUT3]
J7
J9 secondary I/O connector J9 Cable Connector:

High-Density
Pin Signal Pin Signal Pin Signal
D-Sub female,
1 Frame Gnd 6 [IN10] GPI 11 [IN14] GPI 15 Position
2 [COMM_A] 7 [COMM_B] 12 [OUT5+] GPI
3 [IN7] GPI 8 [IN11] GPI 13 [OUT5-] GPI
J8 4 [IN8] GPI 9 [IN12] GPI 14 [OUT4+] GPI
J10 feedback J10 Cable Connector:

High-Density
D-Sub female,
J9 1 Frame Gnd 10 Enc /B1 19 Sin1(+) 26 Position
2 Hall U 11 Enc B1 20 Cos1(-)
3 Hall V 12 Enc /A1 21 Cos1(+)
4 Hall W 13 Enc A1 22 Index1(-)
5 Signal Gnd 14 Enc /S1 23 Index1(+)
6 +5 Vdc Out 15 Enc S1 24 Enc Fault
7 Motemp 16 Signal Gnd 25 Signal Gnd
J10 8 Enc /X1 17 +5 Vdc Out 26 Signal Gnd

9 Enc X1 18 Sin1(-)
J5 safety disable J5 Cable Connector:

D-Sub male,
9 Position
4 Safe Enable LO(+) 9 +24 Vdc Output
5 Safe Enable LO(-)
REL
WITH
EtherCAT RoHS
Resolver
WARNING: Hazardous voltages exist on connections

to J1, J2, & J3 when power is applied, and for up to
30 seconds after power is removed.
J1 Mains Connections
J1 Cable Connector:
Signal Pin
Wago: 51118287 or 721-204/026-045/RN01-0000
Euro-style 7,5 mm pluggable female terminal block Mains Input L3 4
with preceding ground receptacle
Cable: AWG 12, 600 V recommended Protective Ground 3
Mains Input L2 2 J1
AWG 14, 600V for REL-230-18-R
Shielded cable required for CE compliance Mains Input L1 1
J2 Motor Outputs
J2 Cable Connector:
Wago: 51118008 or 721-104/026-047/RN01-0000 Signal Pin J2
Euro-style 5,0 mm pluggable female terminal block
Motor Phase U 4
Cable: AWG 12, 600 V recommended
for REL-230-36-R and REL-230-40-R models, Motor Phase V 3
AWG 14, 600V for REL-230-18-R
Shielded cable required for CE compliance Motor Phase W 2
Cable Shield 1
J3
J3 Cable Connector:
Wago: 51111277 or 721-605/000-044/RN01-0000 J3 Regen Resistor
Euro-style 5,0 mm pluggable male terminal block
Cable: AWG 12, 600 V recommended Signal Pin
AWG 14, 600V for REL-230-18-R Regen Resistor 1
Shielded cable required for CE compliance
No Connection 2
J4
Regen Resistor 3
Wire Insertion/Extraction Tool: No Connection 4
Used on J1, J2, J3, & J4
Wago 231-131 Cable Shield 5
ISOLATED CIRCUIT
J5
NOTE: AN EXTERNAL
+24 Vdc POWER SUPPLY J4 +24 VDC & Brake
IS REQUIRED FOR OPERATION Signal Pin
+24 Vdc Control Power 3
J4 Cable Connector:
Brake Output [OUT6] 2
Wago: 51117974 or 721-103/026-047/RN01-0000
Euro-style 5,0 mm pluggable terminal block 0V (+24 Vdc Return) 1
ISOLATED CIRCUIT
REL
WITH
EtherCAT RoHS
Resolver
J8 Control Signals J8 Cable Connector:

High-Density
Pin Signal Pin Signal Pin Signal D-Sub female,
1 Frame Gnd 10 [IN6] HS 19 Signal Gnd 26 Position
2 [AIN1+] 11 [AIN2+] 20 +5 Vdc Out

3 [AIN1-] 12 [AIN2-] 21 Multi Enc /X2
4 [IN1] GP 13 Multi Enc /S2 22 Multi Enc X2
J6 5 [IN2] GP 14 Multi Enc S2 23 Multi Enc /B2

6 [IN3] HS 15 Signal Gnd 24 Multi Enc B2
7 [IN4] HS 16 [OUT1] 25 Multi Enc /A2
8 [IN5] HS 17 [OUT2] 26 Multi Enc A2
9 [AOUT] 18 [OUT3]
J7
J9 secondary I/O connector J9 Cable Connector:

High-Density
D-Sub male,
1 Frame Gnd 6 [IN10] GPI 11 [IN14] GPI 15 Position
2 [COMM_A] 7 [COMM_B] 12 [OUT5+] GPI
J8 4 [IN8] GPI 9 [IN12] GPI 14 [OUT4+] GPI
J10 feedback J10 Cable Connector:

High-Density
D-Sub male,
J9 1 Frame Gnd 10 Enc /B1 19 Sin1(+) S3 26 Position
2 Hall U 11 Enc B1 20 Cos1(-) S4
3 Hall V 12 Enc /A1 21 Cos1(+) S2
4 Hall W 13 Enc A1 22 Ref(-) R2
5 Signal Gnd 14 Enc /S1 23 Ref(+) R1
6 +5 Vdc Out 15 Enc S1 24 Enc Fault
7 Motemp 16 Signal Gnd 25 Signal Gnd
J10 8 Enc /X1 17 +5 Vdc Out 26 Signal Gnd

9 Enc X1 18 Sin1(-) S1
J5 safety disable J5 Cable Connector:

D-Sub male,
9 Position
4 Safe Enable LO(+) 9 +24 Vdc Output
5 Safe Enable LO(-)
REL
WITH
EtherCAT RoHS
Drive POWER SOURCES MAINS POWER

An external +24 Vdc power supply is Mains power drives the high-voltage All of the circuits on J1, J2, and J3 are mains-
required, and powers an internal DC/ section. It is rectified and capacitor-filtered connected and must never be grounded. The
DC converter that supplies all the control to produce +HV which the PWM stage ground terminals at J1-3, J2-1, and J3-5 all
voltages for drive operation. Use of converts into voltages that drive either connect to the drive chassis and are isolated
an external supply enables EtherCAT three phase brushless or DC brush motors. from all drive internal circuits.
communication with the drive when the An internal solid-state switch together Signal grounding references the drive
mains power has been removed. with an external power resistor provides control circuits to those of the control
Power distribution in REL is divided into four dissipation during regeneration when the system. These controls circuits typically
sections: +24 Vdc, signal, and high-voltage. mechanical energy of the motor is converted have their own earth connection at some
Each is isolated from the other and all are back into electrical energy that must be point. To eliminate ground-loops it is
isolated from the chassis. dissipated before it charges the internal recommended that the drive signal ground
capacitors to an overvoltage condition. All be connected to the control system circuit
EXTERNAL +24 Vdc
the circuits in this section are “hot”, that ground. When this is done the drive signal
The primary side of the DC/DC converter
is, they connect directly to the mains and voltages will be referenced to the same 0 V
operates directly from the external +24
must be considered high-voltages and a level as the circuits in the control system.
Vdc supply and is isolated from other drive
shock hazard requiring proper insulation Small currents flow between controller and
power sections. The Brake output [OUT4]
techniques during installation. drive when inputs and outputs interact. The
operates in this section and is referenced
signal ground is the path for these currents
to the +24 Vdc return (0V). It sinks current
GROUNDING to return to their power sources in both
from an external load connected to the
A grounding system has three primary controller and drive.
external +24 Vdc power source.
functions: safety, voltage-reference, and Shields on cables reduce emissions from the
INTERNAL SIGNAL POWER shielding. As a safety measure, the primary drive for CE compliance and protect internal
The signal power section supplies power for ground at J1-3 will carry fault-currents from circuits from interference due to external
the control circuits as well as logic inputs the mains in the case of an internal failure sources of electrical noise. Because of their
and outputs. Motor feedback signals such or short-circuit of electronic components. smaller wire gauge, these should not be
as Halls, encoder, and temperature sensor Wiring to this is typically done with the used as part of a safety-ground system.
operate from this power source. All signal green conductor with yellow stripe using the Motor cases can be safety-grounded either
circuits are referenced to signal ground. This same gauge wire as that used for the mains. at the motor, by earthing the frame, or by
ground should connect to the control system The pin on the drive at J1-3 is longer than a grounding conductor in the motor cable
circuit ground or common so that drive and the other pins on J1 giving it a first-make, that connects to J2-1. This cable should
controller inputs and output voltage levels last-break action so that the drive chassis is be of the same gauge as the other motor
work properly with each other. never ungrounded when the mains power is phase cables.
connected. This wire is a ‘bonding’ conductor For CE compliance and operator safety,
that should connect to an earthed ground the drive heatplate should be earthed to
point and must not pass through any circuit the equipment frame. An unplated tab is
interrupting devices. provided on the heatplate (near to J1) for
this connection.
SHIELD
FRAME GROUND REGEN(-) J3 REGEN(+)
J2
U
L1 2350 µF
~ +
DC BUS(+)
J1 L2 + PWM V REGENERATION
~ MOTOR
MAINS INVERTER
L3 DC BUS(-) The chart below shows the energy absorption
~ - W
in W·s for a REL drive operating at some
CASE
FRAME GROUND typical mains voltages. When the load
(SAFETY GROUND)
PWM mechanical energy is greater than these
STAGE
J4 +24 Vdc CONTROL
values an external regen resistor is available
POWER as an accessory.
ISOLATION BARRIER
+24 BRAKE SHIELD
BRAKE
VDC 200
DC/DC LOGIC Energy Absorption vs.
Cntrl &
RTN Mains Voltage
Energy Absorption (W·s)
SIGNAL
DC/DC
POWER
Converter
150
CONTROL +24 Vdc FEEDBACK

GROUND POWER &
SYSTEM +5 Vdc DECODING FEEDBACK
100
J8
ENABLE [IN1] CONTROL
LOGIC
SIGNAL GND 50
J10
CONTROL
SIGNAL
GROUND 0
100 120 140 160 180 200 220 240
Mains Voltage (Vac)
REL
WITH
EtherCAT RoHS
grounding & shielding for ce

Grounding and shielding are the means of
controlling the emission of radio frequency
energy from the drive so that it does not
interfere with other electronic equipment.
The use of shielded cables to connect the
drive to motors and feedback devices is a
way of extending the chassis of the drive
out to these devices so that the conductors
carrying noise generated by the drive
J8 J10
are completely enclosed by a conductive CONTROLLER FEEDBACK
shield.
The process begins at the mains connector
of the drive, J1. The ground terminal here
has a circle around it indicating that this is
the safety or “bonding” ground connection.
This should be connected with wire that is
the same gauge as that used for the mains.
In the case of a short-circuit in the drive
J2
MOTOR
the function of this ground connection is to
carry the fault current to earth ground until
the safety device (fuse or circuit breakers)
disconnects the drive from the mains. This
connection ensures that the heatplate of
the drive remains at earth potential and
REL
eliminating a shock hazard that could occur
of the chassis were allowed to float to the
potential of the mains. J1 LINE
While this connection keeps the heatplate MAINS
FILTER
at earth potential the high frequency noise
generated by switching circuits in the drive
can radiate from the wire used for the safety
ground connection. In order to keep the
path between the heatplate and earth as
short as possible it’s also recommended to
mount the drive to the equipment panel. An
unplated tab on the heatplate is provided for 24 V
POWER J4 J3 REGEN
this and will ground the heatplate directly
SUPPLY
to the equipment frame, further reducing
emissions.
The heatplate also connects directly to 3 TURNS
the frame ground terminals on the motor, AROUND
TOROID
feedback, and regen connectors. Note that INDUCTOR
the ground symbols for these do not have
a circle around them which indicates that Uplated tab for
these are for shielding and not not for heatplate
safety grounding. Motors and their feedback ground
devices (which are typically in the motor
case) should be grounded by mounting to
equipment that is grounded as a safety
ground. By connecting the shields for these Notes:
devices at the drive and at the device, the 1) Shielded cables required for CE are shown in the diagram
connection is continuous and provides a above.
return path for radio-frequency energy to 2) Line filter required for CE
the drive. 3) Ferrite core required for shielded cable to regen resistor
which must be in shielded enclosure.
REL
WITH
EtherCAT RoHS
MAXIMUM OPERATING TEMPERATURE VS HEATSINK TYPE & AIR CIRCULATION

The charts below show maximum ambient temperature vs. continuous output current for the REL Series. The cooling options are no
heatsink, standard heatsink, and low-profile heatsink. For each of these the drive can be operated with convection or forced-air cooling.
REL-230-18 REL-230-18
Mains: 120 Vac Mains: 240 Vac
60 2 Low Profile 60
2 Heatsink * 3 3 All other heatsink
and fan
combinations
Ambient Temperature (°C)

1 enable operation
50 1 No Heatsink 50
2 at 55 °C
1
40 * All other 40
heatsink and fan
2 Low Profile
combinations
Heatsink *
enable operation
at 55 °C
30 30
1 No Heatsink
20 20
1 2 3 4 5 6 1 2 3 4 5 6
Continuous Output Current (Adc) Continuous Output Current (Adc)
REL-230-36 REL-230-36
60 60
Standard 5 Standard
5 5
Heatsink w/fan Heatsink w/fan
5
4
4 Low Profile 4 Low Profile
50 50
3 Heatsink w/fan Heatsink w/fan
4
3 Standard 3 Standard
2 Heatsink
40 40 Heatsink
3
1 Heatsink or Heatsink or
2
no Heatsink no Heatsink
30 30
w/fan 1 w/fan
1 No Heatsink
1 No Heatsink
20 20
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12
REL-230-40 REL-230-40
60 5 Standard 60 5 Standard
Heatsink w/fan Heatsink w/fan

50 Heatsink w/fan 50 Heatsink w/fan

5
3 Standard 3 Standard
4 Heatsink 5 Heatsink
40 40
3
2 Low Profile 4 2 Low Profile
Heatsink or Heatsink or
1 2 no Heatsink 1 3 no Heatsink
30 w/fan 30 w/fan
2
1 No Heatsink 1 No Heatsink
20 20
2 4 6 8 10 12 14 16 18 20 2 4 6 8 10 12 14 16 18 20
REL
WITH
EtherCAT RoHS
Quad A/B Encoder
REL-230-18 REL with EtherCAT Servo Drive 6/18 Adc

Add “-R” to model number for resolver option
Accessories
Qty Ref Description Manufacturers Part Number

XEL-CK 1 J1 Plug, 4 position, 7.5 mm, female Wago: 51118287 or 721-204/026-045/RN01-0000
1 J2 Plug, 4 position, 5.0 mm, female Wago: 51118008 or 721-104/026-047/RN01-0000
Connector Kit
with 1 J3 Plug, 5 position, 5.0 mm, male Wago: 51111277 or 721-605/000-044/RN01-0000
Solder Cup 1 J4 Plug, 3 position, 5.0 mm, female Wago: 51117974 or 721-103/026-047/RN01-0000
Connectors
4 J1~4 Tool, wire insertion & extraction (for J1~4) Wago: 231-131
for
J5, J8, J9 & J10 1 Connector, D-Sub, 9-position, male, solder cup Norcomp: 171-009-103L001
J5
1 Backshell, D-Sub, RoHS, metallized, for above Norcomp: 979-009-020R121
1 Connector, high-density D-Sub, 26 position, female, solder cup Norcomp: 180-026-203L001
J8
1 Connector, high-density D-Sub, 15 position, male, solder cup Norcomp: 180-015-103L001
J9
1 Connector, high-density D-Sub, 26 position, male, solder cup Norcomp: 180-026-103L001
J10
HDM HDM Drive Configuration Software (CD-ROM)
J5
SER-CK RS-232 Cable Kit
Heatsink Kits for Field Installation (Optional)

1 Heatsink, low-profile
XEL-HL
Heatsink Kit 1 Heatsink thermal material
Low-Profile
4 Heatsink hardware
1 Heatsink, standard
XEL-HS
Heatsink Kit 1 Heatsink thermal material
Standard
4 Heatsink hardware
Regeneration Resistors (Optional)
XTL-RA-03 Regeneration resistor assembly (for REL-230-18), 30 W
XTL-RA-04 Regeneration resistor assembly (for REL-230-36 & REL-230-40 models), 15 W
Edge Filter (Optional)
XTL-FA-01 Edge filter
Edge Filter 1 Plug, 4 position, 5.0 mm, female Wago: 51118008 or 721-104/026-047/RN01-0000
Connector Kit
XTL-FK 1 Plug, 5 position, 5.0 mm, male Wago: 51111277 or 721-605/000-044/RN01-0000
2 Tool, wire insertion & extraction Wago: 231-131
Example: Order one REL drive, resolver version, 6/18 A with solder-cup connector Kit, HDM CD, serial cable kit and small heatsink fitted at the factory:
Qty Item Remarks
1 REL-230-18-R-HS REL servo drive
1 XEL-CK Connector Kit
1 HDM HDM CD
1 SER-CK Serial Cable Kit
Note: The heatsink can be fitted at the factory by adding an “-HS” or “-HL” to the drive part number to specify the standard or low-profile type. For fitting a
heatsink to an drive in the field, complete kits are available (XEL-HS and XEL-HL). These kits contain the heatsink, mounting hardware, and dry-film interface.
Note: Specifications are subject to change without notice Rev 4.02_th 1/08/2013

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REL

Add -R for resolver feedback option.

MODEL REL-230-18 REL-230-36 REL-230-40

agency standards conformance

Chassis 7.54 191.52

1.00 25.40 2.31 58.67

7.92 201.17 5.51 139.88

Digital quad a/b Encoder

J7: EtherCAT PORTS ethercat LEDs (on j7)

net status LED (ON j6)

IN (A) Blinking = PRE-OPERATIONAL Single Flash = Unsolicited state change

amp status LED

EtherCAT Address (station alias) EtherCAT

SER-CK serial cable kit J6: RS-232 Port

LED(-) 36V ENH

safety connector J5 signals

Pin Signal Pin Signal

1 Frame Gnd 6 Enable LED(+)

4 Safe Enable LO(+) 9 +24 Vdc Input

5 Safe Enable LO(-)

NON-ISOLATED digital INPUTS

digital INPUTS [IN3~6]

10k MAX3096 10k MAX3096

10k MAX3096 10k MAX3096

opto-isolated digital INPUTS

24V [COMM_A] 24V [COMM_A]

Analog Inputs F.G. 1 Frame Ground

digital OUTPUTS [OUt1], [out2] J8

HIGH SPEED OUTPUT [OUT3] opto-isolated outputs [out4,5]

BRAKE OUTPUT [OUT6] Analog output

quad a/b ENCODER with fault protection Encoder J10

across the inputs. B 121 Enc. B

occur if the differential input voltage is < 200mV. X

ANALOG sin/cos incremental ENCODER Encoder J10

+5V 17 +5V output @ 400 mA

RESOLVER (-R models) 19 Sin(+)

MOTOR CONNECTIONS (Cont’d)

Ssi absolute Encoder BiSS absolute Encoder

V+ 6 +5V output @ 400 mA

endat absolute Encoder

+5V 6 +5V output @ 400 mA

MOTOR CONNECTIONS (Cont’d)

motor phase connections J2

+5V 6 +5V output @ 400 mA

* Alternate Sgnd connections on J10 are pins 16, 25, 26

Motor Temperature Sensor encoder fault

+5V ENCODER +5.0 V

* Alternate Sgnd connections on J10 are pins 16, 25, 26

MOTOR CONNECTIONS (cont’d)

as emulated quad a/b/x encoder outputs from an

as digital command inputs in pulse/direction, MAX3097

inputs. But, at higher frequencies these are likely to be differential signals in

3 [IN7] GPI 20 +5 Vdc @ 400 mA

11 [IN14] GPI 7 [IN4] GP J10

13 [OUT5-] GPI 10 [IN6] HS L3 4 L3

3 100 to 240 Vac

3 [IN7] GPI 20 +5 Vdc @ 400 mA

11 [IN14] GPI 7 [IN4] GP J10