HA-800A Servo Drive Debugging Guide

HA-800A Servo Drive Debugging Guide

Introduction

The HA-800A series is an AC servo drive designed by Harmonic Drive Systems specifically for high-precision harmonic reduction actuators, such as the SHA, FHA-C, FHA-Cmini, RSF/RKF series. It supports three control modes: position, speed, and torque, and integrates 17 bit/13 bit absolute encoders and incremental encoder interfaces. The driver adopts advanced functions such as modular I/O signal distribution, automatic tuning, and feedforward control, which can significantly shorten the positioning stability time.

This article is based on the original factory technical manual, and provides engineers with a direct reference debugging guide by summarizing the installation points, initial encoder settings, manual/automatic gain adjustment, parameter configuration, and troubleshooting process of HA-800A from a practical perspective.

Installation and wiring points

1.1 Environment and Mechanical Installation

The driver must be installed in the control cabinet, with an ambient temperature of 0-50 ℃ and humidity ≤ 95% without condensation. The installation direction must be vertical, and sufficient heat dissipation space must be left around (up and down ≥ 50mm, left and right ≥ 30mm). For HA-800A and above models, there is an internal cooling fan, and it is necessary to ensure good ventilation.

1.2 Wiring of main circuit and control circuit

Driver model Main circuit power supply Recommended wire diameter for control power supply (mm ²)

HA-800A single-phase/three-phase 200V single-phase 200V 0.75

HA-800A-3 three-phase 200V single-phase 200V 1.25

HA-800A-6 three-phase 200V single-phase 200V 2.0

HA-800A 24 three-phase 200V single-phase 200V 5.5

Attention when wiring:

Main circuit terminals R, S, T (three-phase) or R, S (single-phase); Control the power supply r and s.

The power lines U, V, and W of the motor must correspond one-to-one with the actuator terminals. Phase sequence errors will not trigger an alarm but may cause runaway.

The grounding wire (FG) must be independently grounded with a grounding resistance of ≤ 100 Ω.

The encoder cable uses twisted pair shielded wire (above 0.3mm ²) with a length of ≤ 10m (it is recommended to use original extension cable).

1.3 Anti interference measures

The driver adopts PWM modulation, which will generate switch noise. To comply with CE/EMC requirements, noise filters (such as RASMI RF3020 series) and ferrite magnetic rings (such as JFE MA070R) should be installed at the power input end. The signal line and power line should be wired separately (with a spacing of ≥ 30cm) and grounded at one end.

Power on and initial inspection

2.1 First Power On Process

Only connect the control power supply (r, s). The panel LED should light up, and if an alarm is displayed (such as AL81, AL53, UA99), it belongs to the normal initial state.

Confirm that the actuator combination is correct. Panel d13 will display the currently matched actuator code; If UA99 is displayed, it indicates that the driver and actuator do not match and need to be replaced with the model specified on the nameplate.

Perform multiple rounds of zeroing. For absolute encoders, AL81 (17 bits) or AL53 (13 bits) may appear after the first power on or battery replacement. It is necessary to enter test mode T08, perform multi revolution clear, and then power off and on again.

Connect the main circuit power supply (R, S, T). At this point, the CHARGE light is on and the DC bus voltage is established.

Input the servo ON signal (CN2-2). Normally, the excitation sound of the actuator should be heard, and the panel should display the "S-ON" status.

2.2 Common initialization alarms and their handling

Solution to the meaning of alarm codes

UA99 actuator model mismatch replaced with actuator corresponding to nameplate

AL81 (17 bits)/AL53 (13 bits) system failure (multiple data loss) execution T08 multiple round zeroing

UA91 Absolute Encoder Battery Voltage Low Replacement Battery (HAB-ER17/33)

AL50 encoder wire breakage inspection CN1 connector and cable

Encoder system configuration

HA-800A supports three types of encoders and needs to be set correctly according to the actuator model.

3.1 17 bit absolute encoder (SHA series FHA‑Cmini）

Resolution: 131072 pulses per revolution (motor shaft).

Multi circle range: -32768 to+32767.

Battery backup: Keep the location after power failure.

Parameter settings:

SP61: Encoder monitors the number of output pulses (default 8192).

SP66:0=used as an absolute encoder; 1=Used as an incremental encoder (battery free).

SP67: Output axis indexing function (used for SHA-CG series angle unit commands).

Origin setting steps:

Move the output shaft to the mechanical origin through JOG or manually.

Perform T08 multiple rounds of zeroing, and then power on again.

Read the current value data output by CN2-40/41 (or monitor d05/d06 feedback pulses through PSF-800), and store the value as the origin offset in the upper computer.

3.2 13 bit absolute encoder (FHA-C series)

Resolution: 8192 pulses per revolution.

Multi circle range: -4096 to+4095.

Battery backup is also required. Perform multiple rounds of zeroing when AL53 appears.

3.3 Incremental Encoder (FHA-Cmini/RSF, etc.)

No battery, feedback pulse accumulates from 0 after power on.

After each power outage, it is necessary to perform a return to origin operation (completed by the upper control).

I/O signal allocation and parameter setting

The input and output functions of HA-800A can be fully reassigned through system parameters, greatly improving flexibility.

4.1 Input signal (CN2, fixed pin+programmable pin)

Description of default signal programmable parameters for pins

2 S-ON (servo ON) fixed cannot be changed

3 Alarm reset SP01 can be changed to other inputs

4 Deviation counter reset SP02-

FWD prohibits SP03 NC logic (factory)

6 REV prohibits SP04 NC logic

7 FWD Enable SP05-

9 REV Enable SP06-

10 Control Mode Switching SP15 Default Switching Speed ↔ position

Example setting: Assign torque limit function to pin 10 (IN8): Set SP13=0008 and SP15=0000. At this point, when pin 10 is turned on, the internal torque limit value (AJ11) is enabled.

4.2 Output signal (pins CN2 16-22)

The assignable signals include: READY, ALARM, IN-POS, ZERO-SPD, etc. Logic options include normally open/normally closed.

Recommended output allocation:

16 feet: READY (normally open)

18 feet: ALARM (normally closed, output OFF when alarm)

19 feet: IN-POS (positioning completed)

21 feet: ZERO-SPD (zero speed, used for mode switching interlock)

4.3 Function Extension Parameters (SP40-SP79)

SP42: Command pulse input mode (2 pulses/single pulse/90 ° phase difference).

SP44-SP47: Electronic gear numerator/denominator (supports two sets of gears, selected by input signal).

SP50: Instruction polarity (0/1/2), affecting rotation direction, monitoring polarity, etc.

SP55: Dynamic braking enabled/disabled (recommended to be set to 1, enabled).

SP69: Feedforward control function setting (0=compatibility mode, 2-4=simple adjustment mode).

Gain adjustment and servo tuning

HA-800A provides two gain adjustment modes: manual and automatic.

5.1 Auto tuning

Automatically estimate load inertia and set appropriate gain through test mode T09.

Operation steps:

Ensure that the servo is ON (CN2-2 input ON) and there are no prohibited direction inputs.

Enter T09, press the SET key, display "- A.c.", and then press SET to start.

The actuator will rotate forward and backward by a certain angle (default 6000 ° motor shaft angle, can be modified through T10).

After completion, display "FINSH" and automatically write the position loop gain AJ00, velocity loop gain AJ01, velocity loop integral AJ02, and load inertia ratio AJ21.

Notes:

The speed limit and torque limit functions are disabled during automatic tuning.

If the mechanical limit of the system is small, the T10 angle can be reduced (1500-6000 °).

If there is still vibration after tuning, it can be manually adjusted.

5.2 Manual gain adjustment (position control)

Parameter name adjusts direction

AJ01 speed loop gain increases response but is prone to vibration, gradually increasing to the critical point and then decreasing by 5%

AJ02 speed loop integral compensation reduces the impact of load fluctuations by setting a larger value (such as 100) first, and then gradually reducing it to no vibration

The gain of AJ00 position loop decreases and the tracking error gradually increases after the velocity loop stabilizes

AJ03 feedforward gain reduction position deviation is usually set at 50-80, too high will cause impact

Recommended adjustment process:

Set AJ02 to a larger value (e.g. 100), increase AJ01 from small until slight vibration occurs, and then adjust it back by 10%.

Reduce AJ02 until vibration reappears, then increase by 5-10.

Increase AJ00, observe the completion time of positioning, and call back when overshoot occurs.

If using feedforward (SP69=3), then adjust AJ03.

5.3 Simple Adjustment of Feedforward Control (SP69=3)

This mode only requires setting AJ03 (feedforward gain) and AJ21 (load inertia ratio), with internal automatic matching filters. Suitable for most rigid connection systems. If high-frequency vibration occurs, you can try SP69=2 (stable mode) or SP69=5 (manual mode) and manually set AJ20 (filter frequency).

Test mode and trial operation

The test mode (T00-T11) is used for functional verification that does not rely on the upper system.

Typical uses of code functionality

T00 I/O signal monitoring check input/output wiring

T01 forced output signal ON/OFF test output circuit and external relay

T02 JOG speed setting 1-3000 r/min

T03 JOG acceleration and deceleration time 1~9999 ms

T04 JOG operation using UP/DOWN key jog

T05 parameter initialization restores factory settings (retains AJ16/AJ17)

T06/T07 speed/torque command offset automatic adjustment eliminates zero drift

Before setting the origin of the T08 multi turn zeroing absolute encoder, it must be executed

T09 automatic tuning, see previous section

T10 tuning stroke modification: rotation angle during automatic tuning

T11 tuning level selection is 1-5, the higher the value, the faster the response

Attention to JOG operation: In JOG mode, speed and torque limits are invalid and not constrained by external FWD/REV prohibition signals. It is necessary to confirm safety before operation.

Troubleshooting Quick Check

7.1 Common alarms and countermeasures

Main reasons and solutions for alarm code names

AL20 overload load is too large, friction torque is high, brake is not released. Check the load and release the brake; Reduce acceleration and deceleration speed

AL30 IPM overcurrent motor wire short circuit, regeneration resistor wiring error, acceleration and deceleration too fast check U/V/W insulation; Increase acceleration and deceleration time

AL40 overvoltage regeneration energy is too large, deceleration time is too short, and external regeneration resistor is connected; Extend deceleration time

AL41 regeneration resistor overheating regeneration resistor capacity insufficient external larger power resistor; Let SP64=1 (HA-800A -24)

AL50 encoder disconnected, CN1 poor contact, cable broken, re plug or replace encoder cable

If the deviation of AL60 is too large, the direction input is prohibited from being effective, the machine is stuck, and the gain is too low, check the FWD/REV inhibit signal; Increase AJ00 or SP49

AL81 (17 bit) system fault: Battery voltage is exhausted or the battery needs to be replaced after the first power on. Perform T08 multiple rounds of zeroing

UA91 battery voltage low, battery nearing end of life, battery replacement (HAB-ER17/33)

UA93 main circuit voltage low input voltage insufficient, phase loss check power supply voltage and wiring

7.2 Warning Handling

UA90 overload state: When the overload rate exceeds 50%, the output should be reduced or the gain adjusted.

UA97/UA98 FWD/REV disabled: Check the input signal logic. If not needed, set the logic to normally open (00) and do not allocate pins.

UA99 error actuator: The actuator code stored in the drive does not match the physical object, and the parameter (T05) needs to be replaced or reinitialized.

Maintenance and Drive Replacement

8.1 Battery replacement

The absolute encoder battery (model ER17/33) has a lifespan of approximately 1 year (in a power-off state). When UA91 appears, please replace it according to the following steps:

Open the panel cover and remove the old battery.

Insert the new battery with the positive pole facing downwards into the battery holder.

For 13 bit encoders or SHA20/FHA-Cmini, the alarm will automatically reset; For the other 17 bit encoders, an alarm reset and power on again are required.

If AL81 is still reported after replacing the battery, perform T08 multiple rounds of zeroing and reset the origin.

8.2 Driver replacement process

When the drive hardware fails and needs to be replaced, it is recommended to follow the following steps:

Record the parameters of the old drive (upload and save as a. psf file using PSF-800 software).

Record the positions of the rotary switch (SW5) and DIP switch (SW6).

Turn off the power and discharge all remaining electricity (wait for 15 minutes after the CHARGE light goes out).

Remove the old drive, install the new drive, and complete the wiring of the main circuit, control circuit, encoder, and motor wires.

First, connect the control power and use PSF-800 to write the previously saved parameter file.

Connect the main power supply, perform T08 multi turn zeroing, and reconfirm the origin position.

Conduct trial operation confirmation.

Key points for using communication software PSF-800

PSF-800 is an official Windows parameter setting and monitoring software (free download). Its main functions:

Real time status monitoring (speed, torque, overload rate, I/O status).

Parameter editing and batch reading and writing.

Waveform capture (speed, current, position error).

Automatic tuning and JOG testing.

Connection method: Use a dedicated cable EWA-RS03 to connect the driver CN3 port (RS-232C). Multiple drivers can be cascaded with RS-485, up to a maximum of 16.

Key operations:

After writing system parameters, it must be powered off and restarted to take effect.

When comparing parameter files, the difference in system reservation does not affect functionality.

The waveform data can be saved as CSV for easy import into Excel for analysis.