LEXIUM MHDA1004, MHDA1008, MHDA1028, MHDA1017, MHDA1056 User Manual

Download

Lexium Servo Drive

17D Series User Guide

Version 2.0 June 2003 31001643_K01_000_04

Preface

Preface The data and illustratio ns found in this bo ok are not bindi ng. We reserv e the right to

modify our products in line with our policy of continuous product development. The information in this document is subject to change without notice and should not be construed as a commitment by Schneider Electric.

Schneider Electric assum es no res po ns ibi lit y for any e rrors that m ay appe ar in this document. If you have any suggestions for improvements or amendments or have found errors in this publication, please notify us.

No part of this document may be reproduced in any form or by any means, electronic or mechanical, including photocopying, without express written permission of the Publisher, Schneider Electric.

CAUTION!

All pertinent state, regional, and local safety regulations must be observed when installing and using this product. For reasons of safety and to assure compliance with documented s ystem dat a, repai rs to c ompo nents shou ld be performed only by the manufacturer.

Failure to observe this precaution can result in injury or equipment damage.

MODSOFT® is a registered trademark of Schneider Electric

The following are trademarks of Schneider Electric:

Modbus Modbus Plus Modicon 984 Quantum

DIGITAL® and DEC® are registered trademarks of Compaq Computer Corp.

IBM® and IBM AT® are registered trademarks of International Business Machines Corporation.

Microsoft® and MS-DOS® and Windows® are registered trademarks of Microsoft Corporation.

890 USE 120 00 iii

Preface

890 USE 120 00

Contents

Chapter 1 - Introduction 1

At a Glance...................................................................................................... 1

Document Scope ....................... ...... ...... ..... ...... ........................................ 1

What’s in this Chapter ............................................................................... 1

About this User Guide .................................................................................... 2

Who Should Use this User Guide ............................................................. 2

How this User Guide Is Organized ............................................................ 2

Related System Components ......................................................................... 4

Single-Axis Motion Control System ........................................................... 4

UniLink Commissioning Software for 17D ................................................ 4

Related Documentation .................................................................................. 5

Documents ................................................................................................ 5

Hazards, Warnings and Guidelines ................................................................ 6

Hazards and Warnings ............................................................................. 6

Additional Safety Guidelines ..................................................................... 9

Qualified Personnel ................................................................................... 9

Standards and Compliances ............................ ...... ........................................ 10

European Directives and Standards ......................................................... 10

EC Directive Compliance .......................................................................... 10

UL and cUL Compliance ........................................................................... 11

Conventions .................................................................................................... 12

Acronyms and Abbreviations .................................................................... 12

890 USE 120 00 v

Contents

Chapter 2 - Product Overview 15

At a Glance...................................................................................................... 15

Introduction ............................................................................................... 15

What’s in this Chapter ............................................................................... 15

The 17D Series Servo Drive Family ............................................................... 16

Introducing the 17D Drive Family ............................................................. 16

Drives Available ..................................... ..... ...... ...... .................................. 16

Implementing the Drives ........................................................................... 16

Applicable Servo Motor Types .................................................................. 16

Connection to different mains supply networks ........................................ 17

Electrical Considerations .......................................................................... 18

17D Drive Family Portrait .......................................................................... 19

17D Drives Front View .............................................................................. 20

Equipment Supplied .................................................................................. 21

Equipment Available ................................................................................. 21

17D System Configuration Diagram ......................................................... 22

Overview of Usability Features........................................................................ 23

Digital Control ........................................................................................... 23

Usability Enhancements ........................................................................... 24

Restart lock -AS- (A00 drives only) ........................................................... 25

Overview of 17D Internal Electronics.............................................................. 26

17D Internal Electronics Block Diagram ................................................... 26

General Characteristics ............................................................................ 27

Primary Power .......................................................................................... 27

Bias Power ................................................................................................ 27

EMI Suppression ............................. ...... ..... ...... ...... .................................. 27

Internal Power Section .............................................................................. 28

DC Link Capacitor Reconditioning ............................................................ 28

Integrated Safe Electrical Separation .......................... ...... ..... ...... ...... ...... 28

LED display ............................................................................................... 29

Overview of System Software ........................................................................ 30

Setup ........................................................................................................ 30

Setting Parameters ................................................................................... 30

Automatic Card Recognition ..................................................................... 30

Default Settings ............................... ...... ..... ...... ........................................ 30

UniLink Commissioning Software ............................................................. 31

890 USE 120 00

Contents

Chapter 3 - Mounting and Physical Dimensions 33

At a Glance...................................................................................................... 33

What’s in this Chapter................................................................................ 33

Installation Safety Precautions ....................................................................... 34

Power Supply Overcurrent Protecti on .... ..... ...... ...... ..... ............................. 36

Earth Connections .................................................................................... 36

Cable Separation ...................................................................................... 36

Air Flow ..................................................................................................... 36

Drive Mounting and Physical Dimensions ...................................................... 37

17D Height, Width and Depth Dimensions ............................................... 37

17D Drive and Mounting Area Dimensions ............................................... 38

External Regen Resistor Assembly Dimensions ....................................... 39

External regen resistor assembly .............................................................. 40

Motor Choke Assembly Dimensions ......................................................... 41

Chapter 4 - Wiring and I/O 43

At a Glance...................................................................................................... 43

Introduction 43

What’s in this Chapter................................................................................ 44

Wiring and I/O Initial Considerations .............................................................. 45

Initial Considerations ................................................................................. 45

Grounding ................................................................................................. 45

Wiring Overview ............................................................................................. 46

Overview of 17D Wiring Connections ....................................................... 46

Connection diagram for LEXIUM 17D ....................................................... 47

Pin assignments for LEXIUM 17D ............................................................ 48

Cable Shield Connections .............................................................................. 49

Connecting Cable Shields to the Front Panel ........................................... 49

Cable Shield Connection Diagram ............................................................ 50

Power Wiring .................................................................................................. 51

AC Mains Power Supply Connection ........................................................ 51

Bias Supply Connection............................................................................. 51

Serial Power Connections.......................................................................... 52

External Regen Resistor Connection......................................................... 53

Regen Circuit Functional Description ........................................................ 53

Lexium BPH Servo Motor Connection (excluded BPH055) ...................... 54

Lexium BPH 055 Servo Motor Connection................................................ 55

890 USE 120 00 vii

Contents

Lexium SER Servo Motor Connection ...................................................... 56

Servo Motor (with Optional Dynamic Brake Resistors and Contactor)

Connection................................................................................................ 57

Servo Motor Holding-Brake Control Functional Description ..................... 58

Signal Wiring .................................................................................................. 60

Lexium BPH Resolver Connection (excluded BPH055) ........................... 60

Lexium BPH055 Resolver Connection ..................................................... 61

Lexium SER Resolver Connection ........................................................... 62

Lexium BPH Encoder Connection ............................................................ 63

Lexium SER Encoder Connection ............................................................ 64

Incremental Encoder Emulation ............. ................................................... 65

Incremental Encoder Output Functional Description ................................ 65

SSI Encoder emulation ............................................................................. 66

SSI Encoder Output Functional Description ............................................. 66

Diagram of master-slave operation ........................................................... 67

Incremental encoder emulati on .............................................. ...... ...... ..... . 67

SSI encoder emulation ............................................................................. 67

External Incremental encoder connection ................................................ 68

External SSI encoder connection ............................................................. 69

Analog I/O Connection ................................................................................... 70

Analog Inputs .............................................. ...... ...... ..... ............................. 70

Servo Motor Rotation Direction ................................................................. 70

Analog Outputs ........................................... ...... ...... ..... ...... ..... .................. 71

Fault Relay and Digital I/O Connection .......................................................... 72

Digital Inputs and Outputs ........................................................................ 72

Using Functions Pre-programmed into the Drive ...................................... 73

Serial Communications Connection................................................................ 74

Serial Communications Connection Diagram ........................................... 74

CANopen Interface ................................................................................... 75

CAN bus cable ................................. ...... ................................................... 76

Stepper Motor Control Interface Connection................................................... 77

Stepper-Motor Control Interface Connection Functional Description ....... 77

Stepper-Motor Control Interface Connection Diagram ............................. 77

Stepper-Motor Speed Profile and Signal Diagram .................................... 78

viii

890 USE 120 00

Contents

Chapter 5 - System Operation 79

At a Glance...................................................................................................... 79

What’s in this Chapter................................................................................ 79

Powering Up and Powering Down the System ............................................... 80

Power-on and Power-off Characteristics .................................................. 80

Stop Function ............................................................................................ 81

Emergency Stop strategies ....................................................................... 82

Wiring example ......................................................................................... 83

Description of the restart lock -AS- (MHDA••••A00 drives only) ..................... 84

Advantages of the restart lock .................................................................. 84

Description of the restart lock -AS- ................................................................. 85

Functional description ............................................................................... 85

Block diagram............................................................................................ 86

Signal diagram (sequence)........................................................................ 87

Installation / Commissioning...................................................................... 88

Connection diagram .................................................................................. 89

Application examples ................................................................................ 90

Control circuit example ................................................ ...... ..... .................. 91

Procedure for Verifying System Operation ..................................................... 92

Overview ................................................................................................... 92

Quick Tuning Procedure ........................................................................... 93

Parameter setting ...................................................................................... 95

Multi-axis system ....................................................................................... 95

Front Panel Controls and Indicators ............................................................... 96

Keypad Operation...................................................................................... 96

LED Display .............................................................................................. 97

Chapter 6 - Troubleshooting 99

At a Glance...................................................................................................... 99

What’s in this Chapter ............................................................................... 99

Warning Messages ......................................................................................... 100

Warning Identification and Description ..................................................... 100

Error Messages ........................................... ..... ...... ...... ..... ...... ....................... 101

Error Identification and Description............................................................ 101

Troubleshooting .............................................................................................. 105

Problems, Possible Causes and Corrective Actions ................................. 105

890 USE 120 00 ix

Contents

Appendix A - Specifications 107

At a Glance...................................................................................................... 107

What’s in this Appendix ............................................................................ 107

Performance Specifications ............................................................................ 108

Performance Specifications Table............................................................. 108

Environmental and Mechanical Specifications ............................................... 109

Environmental Specifications Table .......................................................... 109

Mechanical Specifications Table .............................................................. 110

Electrical Specifications .................................................................................. 111

What’s in this Section ............................................................................... 111

Electrical Specifications - Power..................................................................... 112

Line Input Specifications Table ................................................................. 112

Bias Input Specifications Table ................................................................. 113

Limit supply values of the servodrive MHDA associated with a

BHP motor with brake .............................................................................. 113

External Fuse Specifications Table .......................................................... 114

Motor Output Specifications Table ............................................................ 115

Internal Power Dissipation Specifications Table ....................................... 116

Electrical Specifications - Regen Resistor ...................................................... 117

Regen Circuit Specifications ..................................................................... 117

Electrical Specifications - Signal .................................................................... 118

Motor Overtemperature Input Specifications Table .................................. 118

Resolver Input Specifications Table ......................................................... 118

Encoder Input Specifications Table .......................................................... 119

Emulated Encoder Output (Incremental Format) Specifications Table ..... 119

Encoder Output (Incremental Format) Timing Diagram ............................ 120

Encoder Output (SSI Format) Specifications Table .................................. 120

Encoder Input (Slave) Specifications Table .............................................. 121

Discrete Input Specifications Table .......................................................... 121

Discrete Output Specifications Table ........................................................ 122

Fault Relay Output Specifications Table ................................................... 122

Brake Output Specifications Table ........................................................... 122

Analog Input Specifications Table ............................................................ 123

Analog Output Specifications Table .......................................................... 123

Serial Communications Specifications Table ............................................ 124

Wire Specifications (Recommended) ............................................................. 125

Wire Specifications ................................................................................... 125

890 USE 120 00

Contents

Appendix B - Parts List 127

At a Glance...................................................................................................... 127

What’s in this Appendix ............................................................................. 127

Lexium 17D Drives ......................................................................................... 128

Drives Available ........................................................................................ 128

External 24 Vdc supply ................................................................................... 129

External 24Vdc supply .............................................................................. 129

Drive Cables ................................................................................................... 130

Drive to Motor Cables ............................................................................... 130

RS-232 Serial Communications Cable Part Table .................................... 130

Encoder Output Cables Parts Table ......................................................... 130

Regen Resistor Assemblies ............................................................................ 131

Regen Resistor Assembly Part Table........................................................ 131

Servo Motor Choke.......................................................................................... 132

Servo Motor Choke Part Table (when cable length exceeds 25m)............ 132

Spare Parts ..................................................................................................... 133

Spare Parts Table ..................................................................................... 133

Appendix C - Drive-to-Controller Wiring Diagrams 135

At a Glance...................................................................................................... 135

What’s in this Appendix ............................................................................. 135

Typical Motion Controller Interface Connections ............................................ 136

Motion Controller Interface Diagram ......................................................... 136

Wiring a 17D Drive to Premium CAY Motion Modules ................................... 137

Premium CAY Single Axis Drive Option Diagram ..................................... 137

Premium CAY Multi-Axis Breakout Module Wiring Diagram ..................... 138

Premium CAY Multi-Axis and Breakout Module Diagram, First of 4 Axes. 139

Wiring a 17D Drive to a MOT 201 Motion Module .......................................... 140

MOT 201 Control Wiring Diagram ............................................................. 140

MOT 201 Encoder Wiring Diagram: Option 1 ........................................... 141

MOT 201 Encoder Wiring Diagram: Option 2 ........................................... 142

Wiring a 17D Drive to Quantum 140 MSx Motion Modules ............................ 143

Quantum 140 MSx Control and Encoder Wiring Diagram ........................ 143

890 USE 120 00 xi

Contents

Wiring a 17D Drive to B885-11x Motion Modules .......................................... 144

B885-11x Control Wiring Diagram ............................................................ 144

B885-11x Encoder Wiring Diagram: Option 1 ........................................... 145

B885-11x Encoder Wiring Diagram: Option 2 ........................................... 146

Appendix D - Cable Connection Wiring Diagrams 147

At a Glance...................................................................................................... 147

What’s in this Appendix ............................................................................ 147

Wiring a Sub-D Connector with Shielding (drive side) .................................... 148

Wiring the Sub-D Connector .............................................. ..... .................. 148

Wiring the feedback connector of the motors ................................................. 150

Wiring the feedback connector of the BPH motors (excluded BPH055) ... 150

Wiring the feedback connector of the BPH055 motors ............................. 151

Wiring the feedback connector of the SER motors ................................... 152

Wiring the Motor Power Connector (Drive end).............................................. 153

Wiring the Motor Power Connector ................... ...... ..... ............................. 153

Wiring the BPH Motor Power Connector (excluded BPH055 )................... 154

Wiring the BPH055 Motor Power Connector ...................................... ...... 155

Wiring the SER Motor Power Connector ............................................ ..... . 156

Serial Communication Interface Connection (X6) RS 232 ............................. 157

Serial Communication Interface Cable Connectors .................................. 157

Appendix E - Servo Loop Diagrams 159

At a Glance...................................................................................................... 159

What’s in this Appendix ............................................................................ 159

17D Current Controller Overview ................................................................... 160

17D Current Controller Diagram................................................................ 160

17D Velocity Controller Loop .......................................................................... 161

17D Velocity Controller Loop Diagram ..................................................... 161

17D Analog Input Loop Diagrams................................................................... 162

Overview ................................................................................................... 162

17D Analog Input Mode 0 Loop Diagram.................................................. 162

17D Analog Input Mode 1 Loop Diagram ................................................. 163

17D Analog Input Mode 3 Loop Diagram.................................................. 164

17D Analog Input Mode 4 Loop Diagram ................................................. 165

17D Analog Input Mode 5 Loop Diagram ................................................. 166

xii

890 USE 120 00

Contents

Appendix F - Expansion Options 167

At a Glance...................................................................................................... 167

What’s in this Appendix ............................................................................. 167

Expansion Cards ............................................................................................ 168

Overview ................................................................................................... 168

Fitting expansion card................................................................................ 168

I/O Expansion Cards ...................................................................................... 169

24 Vdc Discrete I/O Expansion Card......................................................... 169

IConnector and LED Location Diagram..................................................... 169

Light-Emitting Diodes (LEDs)..................................................................... 170

Terminal Assignments .............................................................................. 170

Controlling Pre-programmed Motion Tasks............................................... 172

Programming the PLC .............................................................................. 172

Motion Task Coordination.......................................................................... 172

Motion Task Application Examples ........................................................... 1 73

Example of a Motion Task Number............................................................ 173

Connection Diagram ................................................................................. 174

Appendix G - External Regen Resistor Sizing 175

At a Glance...................................................................................................... 175

What’s in this Appendix ............................................................................. 175

Overview ................................................................................................... 176

Determining When Energy Is Absorbed .................................................... 176

Determining External Regen Resistor Size..................................................... 177

Power Dissipation Calculatio n Proce dure .......................... ..... ...... ...... ..... . 177

Drive Energy Absorption Capability .......................................................... 178

Example Regen Resistor Power Dissipati on Ca lc ula tio n.......................... ..... . 179

Example Motor and Drive Specific ati ons ........................... ..... ...... ...... ..... . 179

Example Step 1...................... ..... ...... ...... ................................................... 180

Example Step 2 .......................... ...... ...... ..... .............................................. 181

Example Step 3 .......................... ...... ...... ..... .............................................. 181

Example Step 4 .......................... ...... ...... ..... .............................................. 182

Example Step 5 .......................... ...... ...... ..... .............................................. 182

Example Step 6 .......................... ...... ...... ..... .............................................. 182

Example Step 7 .......................... ...... ...... ..... .............................................. 182

Example Step 8 .......................... ...... ...... ..... .............................................. 183

890 USE 120 00 xiii

Contents

xiv

890 USE 120 00

Introduction

At a Glance

Document Scope This user guide contains complete installation, wiring interconnection, power

application, test and maintenance information on the Lexium 17D series servo drive.

What’s in this Chapter

This chapter provides general information about this user guide and contains the following topics:

Topic Page

About this user guide 2 Related system components 4 Related documentation 5 Hazards, warnings, and guidelines 6 Standards and compliances 10 Conventions 12

About this User Guide

Who Should Use this User Guide

This user guide is written for any qualified person at your site who is responsible for installing (mounting and interconnecting), operating, testing and maintaining your Lexium 17D servo drive and the servo system equipment with which it int erfaces. In addition, the following precautions are advised:

l Transportation of the servo drive to, or from, an installation site should only be

performed by personnel knowledgeable in handling electrostatically sensitive components.

l Commissioning of the equipment should only be performed by personnel

having extensiv e know ledg e of, and experi ence wi th, elec trical and se rvo dri ve technologies .

Y ou a re expec ted to h ave some overall u nderst anding of what your 17D servo drive does and how it will function in a high-performance, single-axis motion control system. Accordingly, be sure you read and understand the general information, detailed descriptions and associated procedures presented in this manual, as well as those provided in other relevant manuals, before installing your 17D. (See

Related System Components

later in this chapter.)

If you have questions, please consult your Schneider Electric customer representative.

How this User Guide Is Organized

This manual is organized as follows.

Chapter/Appendix Description

Chapter 1

About this User Guide

Chapter 2

Lexium 17D Product Overview

Chapter 3

Mounting and Physical Dimensions

An introduction to this manual — who should use this manual, how this manual is organized, related publications, hazards and warnings.

General descriptions of the 17D servo drives, descriptions of components that are supplied by Schneider in a typical 17D system, and a block diagram for internal electronics.

Physical dimensions and information for mounting the servo drive, Regen resistor and servo motor choke.

Continued on next page

About this User Guide, cont inued

How this User Guide Is Organized,

continued

Chapter/Appendix Description

Chapter 4

Wiring and I/O

Chapter 5

System Initialization, Commissioning and Operation

Chapter 6

Troubleshooting

Appendix A

Specifications

Wiring diagrams for the power connections and wiring diagrams and descriptions for all signal

wiring connections — encoder, resolver, analog I/O, discrete I/O, and serial communications cable.

Detailed procedures and associated descriptions on how to initialize, commission and operate a typical 17D system.

Description of faults, probable causes and recommended corrective actions.

Specifications for the servo drives, including general, electrical, signal, and power specifications.

Appendix B

Parts List

Appendix C

Drive to Controller Wiring Diagrams

Appendix D

Cable Connection Wiring Diagrams

Appendix E

Servo Loop Diagrams

Appendix F

Expansion Options

Appendix G

External Regen Resistor Sizing

Part numbers related to the 17D servo drive system.

Wiring diagrams that show signal wiring between a 17D servo drive and MOT 201, Quantum MSx, B885-11x, and Premium CAY motion modules.

Procedures and associated diagrams that show how to wire Sub-D and power cable connectors as well as the serial communication cable used with the drive.

Illustrations of the 17D servo drive and singleaxis motion module servo loops.

Description and procedure for using the I/O expansion card with the drive.

Description and procedure for determining the power dissipation requirement for the external Regen resistor.

Related System Components

Single-Axis Motion Control System

UniLink Commissioning Software for 17D

The 17D servo drive is typically only one component in a larger, single-axis motion control system. A single axis comprises one motion module, one servo drive, and one motor.

Compatible Schneider motion modules include:

l Quantum 140 MSx series motion modules l Compact MOT 201 motion modules l B885-11x series motion modules l Premium CAY motion modules

To configure your single-axis system, you will be using the UniLink

axis

commissioning software, which Schneider supplies. UniLink allows you to configure your 17D servo drive axis and tune the motor

quickly and easily. With its graphical user interface and oscilloscope tuning features, UniLink provides an easy point-and-click method for configuring motion setup parameters. UniLink minimizes or eliminates cumbersome programming tasks.

For complete information on UniLink, please see the UniLink online help.

Related Documentation

Documents Related documentation that covers all these system components is illustrated

below.

You will need these:

Unilink

Online Help

(included

in software)

Depending on which motion module you have, you will also need one of these:

MOT 201,

202 Motion

Modules

User Guide

GI-BMOT-20X

If you have a Premium motion module CAY, you will also need this:

PL7 Junior/Pro Premium PLCs

Specific

Functions

TLX DS 57 PL7 40

If you have a BPH motor, you will also need this:

Quantum

140MSx 101

Single Axis

Motion

Module

Reference

Guide

840 USE 105 X

Premium PLCs

Installation

Manual

TSX DM 57 40

Lexium BPH

Serie

servo motors

Motors Reference

Guide

B885-1xx

Motion

Modules

User Guide

GI-B885-1XX

* included in AM0 CSW 001V•00 (CDROM)

*AMOMAN001U

Hazards, Warnings and Guidelines

Hazards and Warnings

Read the following precautions very carefully to ensure the safety of personnel at your site. Failure to c ompl y will re sult in dea th, seri ous in jury o r equipm ent da mage.

DANGER! ELECTRIC SHOCK HAZARDS

l During operation, keep all covers and cabinet doors closed. l Do not open the servo drives; depending on degree of enclosure protection,

the servo drives may have exposed components.

l Control and power connections on the drive may be energized even if the

motor is not rotating.

l Never attempt to disconnect the electrical connections to the servo drive with

power applied. Failure to comply may result in arcing at the contacts.

l Wait at least five minutes after disconnecting the servo drive from the mains

supply voltage before touching energized sections of the equipment (for example, contacts ) or discon necting el ectrical con nections . Capacitors can st ill have dangerous voltages present up to five minutes after switching off the supply voltages. To ensure safety, measure the voltage in the DC Link circuit and wait until it has fallen below 40V before proceeding.

l Check to ensure all energized connecting elements are protected from

accidental contact. Lethal voltages up to 900V can be present. Never disconnect any electrical connections to the servo drive with power applied; capacitors can retain residual and dangerous voltage levels for up to five minutes after switching off the supply power.

Failure to follow any one of these instructions will result in death, serious injury or equipment damage.

Continued on next page

Hazards, Warnings and Guidelines, continued

WARNING! THERMAL HAZARD

During operation, the front panel of the servo drive, which is used as a heat sink,

can become hot and may reach temperatures above 80°C. Check (measure) the heat sink temperature and wait until it has cooled below 40°C before touching it.

Failure to observe this precaution can result in severe injury.

WARNING! OVERCURRENT, OVERLOAD AND OVERHEATING PROTECTION

Separate motor overcurrent, overload and overheating protection is required to be provided in accordan ce wit h the Ca nad ian Elec tric al Code, Part 1 and the National Electrical Code.

Failure to observe this precaution can result in severe injury.

Continued on next page

Hazards, Warnings and Guidelines, continued

CAUTION! SAFETY INTERLOCKS

Schneider recommends the installation of a safety interlock with separate contacts

for each motor. Such a system sh ou ld be hard wired with over–travel lim it s w itc he s and a suitable emergency stop switch. Any interruption of this circuit or fault indication should:

l Open the motor contacts l Shunt dynamic braking resistor s across each motor, if they are present.

Failure to observe this precaution can result in equipment damage.

CAUTION! ELECTROSTATIC COMPONENTS

The servo drives contain electrostatically sens itive components that may be damaged by improper handling. Appropriately discharge yourself before touching the servo drive and avoid contact with highly insulating materials (artificial fabrics, plastic film, and so on). Place the ser vo drive o n a conductive surface.

Failure to observe this precaution can result in equipment damage.

Continued on next page

Hazards, Warnings and Guidelines, continued

Additional Safety Guidelines

Qualified Personnel

Read this documentation and adhere to the safety guidelines contained herein before engaging in any activities involving the servo drives.

l Ensure that all wiring is in a ccorda nce with the Nati ona l Ele ctr ica l Code (NEC)

or its nationa l equiv alent (CSA, C ENELEC , etc.), as well a s in ac cordan ce wi th all prevailing local codes.

l Exercise extreme caution when using instruments such as oscilloscopes, chart

recorders, or volt–ohm meters with equipment connected to line power.

l Handle the servo drives as prescribed herein. Incorrect handling can result in

personal injury or equipment damage.

l Adhere to the technical information on connection requirements identified on

the nameplate and specified in the documentation.

l The servo drives may only be operated in a closed cabinet or enclosure.

Nevertheless, operating co nditions must be always respected ( as defined in Appendix A):

- operating temperature range

- pollution degree 2 as defined in EN 50178

- assembly.

Only properly qualified personnel having extensive knowledge in electrical and servo drive technologies should install, commission and/or maintain the Lexium 17D servo drives.

Standards and Compliances

European Directives and Standards

EC Directive Compliance

The Lexium 17D servo drives are incorporated into an electrical plant and into machinery for industrial use.

When the servo drives are built into machines or a plant, do not operate the servo drive until the machine or plant fulfills the requirements of these European Standards:

l EC Directive on Machines 89/392/EEC l EC Directive on EMC (89/336/EEC) l EN 60204 l EN 292

In connection with the Low Voltage Directive 73/23/EEC, the associated standards of the EN 50178 series in conjunction with EN 60439-1, EN 60146 and EN 60204 are applied to the servo drives.

The manufacturer of the machine or plant is responsible for meeting the requirements of the EMC regulations.

Compliance with the EC Directive on EMC 89/336/EEC and the Low Voltage Directive 73/23/EEC is mandatory for all servo drives used within the European Community.

The Lexium 17D servo drives were tested by an authorized testing laboratory and determined to be in compliance wi th the directives identified above.

Continued on next page

Standards and Compliances, continued

UL and cUL Compliance

UL Listed (cUL Certified) servo drives (Underwriters Laboratories Inc.) comply with the relevant American and Canadian standards (in this case, UL 840 and UL 508C).

This standard describes the minimum requirements for electrically operated power conversion equipment (such as frequency converters and servo drives) and is intended to eliminate the risk of injury to personnel from electric shock or damage to equipment from fire. Conformance with the United States and Canadian standard is determi ned by an i nde pe nde nt U L (cUL) fire inspector through the type testing and regular checkups.

UL 508C

UL 508C describes the minimum requirements for electrically operated power conversion equipment (such as frequency converters and servo drives) and is intended to eliminate the risk of fire caused by that equipment.

UL 840

UL 840 describ es air a nd insu lation c reepage spacing s for ele ctrical equip ment and printed circuit boards.

Conventions

Acronyms and Abbreviations

The acronyms and abbreviations used in this manual are identified and defined in the table below.

Acronym or Abbreviation Description

CE European Community (EC) CLK Clock signal COM Serial communication interface for a PC-AT cUL Underwriters Laboratory (Canada) DIN German Institute for Norming Disk Magnetic storage (diskette, hard disk) EEPROM Electrically erasable programmable read only memory EMC Electromagnetic compatibility EMI Electromagnetic Interference EN European norm ESD Electrostatic discharge IEC International Electrotechnical Commission IGBT Insulated Gate Bipolar Transistor ISO International Standardization Organization LED Light Emitting Diode MB Megabyte MS-DOS Microsoft Disk Operating System for PC-AT PC-AT Personal computer in AT configuration PEL V Protected extra low voltage PWM Pulse-width modulation RAM Random Access Memory (volatile) Regen Regen resistor RFI Radio Frequency Interference

Continued on next page

Conventions, continued

Acronyms and Abbreviations,

continued

Acronym or Abbreviation Description

PLC Programmable Logic Controller SRAM Static RAM SSI Synchronous Serial Interface UL Underwriters Laboratory Vac Voltage, Alternating Current Vdc Voltage, Direct Current

Product Overview

At a Glance

Introduction This chapter contains a product overview of the Lexium 17D series servo drives

and includes:

l Available drive models and related system components l Feedback and performance information l Power and signal electronics l Software and axis configuration

What’s in this Chapter

This chapter contains the following topics:

Topic Page

The 17D series servo drive family 16 Overview of usability features 23 Overview of 17D internal electronics 26 Overview of system software 30

The 17D Series Servo Drive Family

Introducing the 17D Drive Family

Drives Available

Each member of the Lexium 17D series family is comprised of a three-phase brushless servo amplifier, power supply and high-performance digital controller all housed in a single enclosure.

The 17D drives are available in five models which are correlated to different output current levels as identified in the following table.

Output Current Intermittent (Peak) 17D Drive

4A 8A 17A 28A 56A Note:

A00 means that restart lock -AS- is included. N00 standard version

MHDA1004 MHDA1008 MHDA1017 MHDA1028 MHDA1056

•00

Implementing the Drives

The Lexium 17D servo drives are intended for incorporation into electrical equipment or ma ch ine r y a nd can only be commissioned as in tegral components of those types of devices.

Applicable Servo Motor Types

The Lexium 17D se rvo drives are intended to drive BPH and SER series brushless servo motors.

Continued on next page

The 17D Series Servo Drive Family, continued

Connection to different mains supply networks

On this page you’ll find all possible connection variations to different mains supply networks.

WARNING ! An isolating transformer is always required for 400...480V mains networks

without earth(ground) and for networks with asymmetrical earth(ground).

208...230V

208...480V

L2 L3 PE

208V with 60Hz only

230...480V with 50Hz or 60Hz

1:1400...480V

L2 L3 PE

208...230V

L2 L3 PE

1:1400...480V

Continued on next page

L2 L3 PE

The 17D Series Servo Drive Family, continued

Electrical Considerations

The Lexium 17D family of servo amplifiers is to be used on earthed three-phase industrial mains supply networks (TN-system, TT-system with earthed neutral point, not more than 5000 rms symmetrical amperes).

Periodic overvoltages between outer conductor (L1, L2, L3) and housing of the servo amplifier ma y not exceed 1000V (peak value). Transient overvoltages (<

50µs) between the outer conductors may not exceed 1000V. Transient overvoltages (< 50µs) between outer conductors and housing may not exceed 2000V.

The Lexium 17D drives are incompatible with the IT system because interference suppression filters are inte rnal an d conne cted to earth. If th e user w ants to conne ct Lexium drives to an IT system, he may:

l use an in sulation star trans former in order to re-create a local TT or TN s ystem.

This way allows the rest of the wiring to stay an IT system (only warning in case of the first fault.)

l use a spec ial Residual C urrent Circ uit Breaker ( RCCB) that is able to w ork with

dc and high peak currents. This device detects unbalance of phases with regard to earth. Warnin g: W hen th e fi rst fau lt occ urs, the RCCB has to switch off qui ckly po w er of the drives. Set of the res idual curren t val ue mu st be carefu lly d one an d mus t

be started with the lowest available value (for example: 30mA.) Following equipment of Merlin Gerin can be used: l Vigirex, model RH328AF (Reference: 50055)

l One of these magnetic cores:

- model TA, 30mm in internal diameter (Reference: 50437)

- model PA, 50mm in internal diameter (Reference: 50438)

- model IA, 80mm in internal diameter (Reference: 50439)

If the servo amplifiers are used in residential areas, or in business or commercial premises, then additional filter measures must be implemented by the user.

The Lexium 17D family of servo amplifiers is only intended to drive specific brushless sync hron ous s erv om otors from the Lexium BPH series , w ith c los ed -loo p control of torque, speed and/or position. The dielectric withstand voltage of the

motors must be at least as hight as the DC-link voltage of the servo amplifier.

Use only copper wire. Wire size may be deter minate d from EN 60 204 (or table 3 1016 of the NEC 60°C or 75°C column for AWG size).

We only guarantee the conformance of the servo amplifiers w ith the standards for industrial areas, if the component s (mot ors, cables , ampli fiers etc ) are del ivered by Schneider Automation.

Continued on next page

The 17D Series Servo Drive Family, continued

17D Drive Family Portrait

The following photograph shows a representative member of the 17D drive family. The complete family consists of five models partitioned into two physical sizes. Models MHDA1004 have dimensionally identical physical housings while Model MHDA1056 wider housing. (See Chapter 3 for detailed dimensional information.)

•00, MHDA1008•00, MHDA1017•00 and MHDA1028•00

•00 has a

Model without AS function

Continued on next page

The 17D Series Servo Drive Family, continued

17D Drives Front View

The following photograph shows a typical 17D front view without AS function.

Continued on next page

The 17D Series Servo Drive Family, continued

Equipment Supplied

Equipment Available

Each 17D servo drive includes the following har dware. l Mating connectors X3, X4, X0

, X0B, X7 and X8

l Read me first. l Mating connector X10 for AS functi on, de livere d only w ith MH DA••••A 00 drive s.

Note: The mating Sub-D connectors and servo motor connector X9 are supplied with the appropriate cable.

The following items are optionally available to you from Schneider for use with the 17D servo drives:

l Lexium BPH series br ushless servo motors l Servo motor power and feedback cables

Note: Power and feedback cables are available in lengths from 5...75 m and are supplied by Schnei der w i th th e c onn ec tor fo r the se rvo mo tor a ttac he d to t he c ab le and with the connector for the drive unasse mbled and un attached to the cable. The 10 m length cable is supplied (from stock) by Schneider with connectors attached to each end of the cable.

l Optional S ervo motor choke (for motor power c able lengths exceeding 25m) l Optional External Regen resistor l Serial communications cable (between drive and PC) l Pre-configured cables for various Telemecanique and Modicon motion

controllers.

l Optional expansion cards. l Optional communication cards and accessories (SERCOS, MODBUS +,

FIPIO, PROFIBUS DP)

Continued on next page

The 17D Series Servo Drive Family, continued

17D System Configuration Diagram

The following illustration shows a typical 17D system configuration.

Overview of Usability Features

Digital Control The 17D drive provides complete digital control of a brushless servo system. This

includes:

l A digital field-oriented current controller operating at an update rate of 62.5 µs l A fully programmable digital PI-type speed controller operating at an update

rate of 250 µs

l If required by user application, an integrated, digital, position controller with

configurable trajectory generation operating at an update rate of 250 µs is also available. Up to 180 indep endent moti on tas ks c an be confi gured and s tored i n the drive depending upon the application requirements.

l An integral step/direction input is provided for use with an external indexer

which al lows the 17D drive and the applicable BPH motor to be used as a stepper motor/drive replacement.

l Full digital evaluation of motor position feedback (primary feedback) from

either a standard two-pole resolver or a high precision Sin-Cos type encoder (hiperface).

l Full digital emulation of either a standard incremental encoder or a SSI

encoder is also available fr om positio n information derived from the primary feedback device. The drive may also be configured as a slave to follow a master incremental encoder with a programmable gear ratio.

Continued on next page

Overview of Usability Features, continued

Usability Enhancements

The following features are incorporated into the 17D drive to facilitate the set-up and operation of the servo system:

l Two analog +/-10 V inputs can be programmed for a multitude of functions

depending upon the application. Both inputs incorporate automatic offset

compensation, dead-band limitation and slew-rate limitation. l T wo +/-1 0 V analog mo nitor outpu ts can be programm ed to support a multitu de

of internal drive control loop variables via the analog voltage output levels. l Four fully programmable 24 V discrete inputs; two of which are typically

defined as hardware limit swi tches. l Two fully programmable 24 V outputs and a separate 24 V brake output

capable of driving a maximum of 2 Amps. l An integrated and fully isolated RS-232 connection for communication with a

PC; used to set configur ati on par ameters and tune the system with the Unilink

configuration software.

l Integrated CANopen (default 500 kBauds) l A separate 24V bias supply input which may be connected through a UPS to

preserve system data in the event of an interruption in the AC mains supply. l Restart lock AS (A00 drives only).

Overview of Usability Features, continued

Restart lock -AS(A00 drives only)

The restart lock -AS- is exclusively intended to provide safety for personnel, by preventing the restart of a system. To achieve this personnel safety, the wiring of the safety circuits must meet the safety requirements of EN60204, EN292 and EN 954-1.

The -AS- restart lock must only be activated, l When the motor is no longer rotating

(setpoint = 0V, speed = 0rpm, enable = 0V). Drives with a suspended load must have an additional safe mechanical blocking (e.g. by a motor-holding brake).

l When the monitoring contacts (KSO1/2 and Fault RA/RB for all servo

amplifiers are wired into the control signal loop (to recognize a cable break).

The -AS- restart lock may only be controlled by a PLC if the control of the internal safety relay is arranged for redundant monitoring.

The -AS- restart lock must not be used if the drive is to be made inactive for the following reasons

l Cleaning, maint ena nc e and repai r opera tions l Long inoperative periods

In such cases, the entire system should be disconnected from the supply by the personnel, and secured (main switch).

l Emergency-stop situations.

In an emergency-stop situation, the main contactor is switched off (by the emergency-stop button or the Fault RA/RB contact in the safety circuit).

Overview of 17D Internal Electronics

17D Internal Electronics Block Diagram

The following block diagram illustrates the 17D internal electronics and depicts internal interfaces for power, signal I/O, and communication.

LEXIUM

Analog1 in + Analog1 in -

-AS-

Analog2 in + Analog2 in -

-AS-

17D

-AS-

+Rb ext +Rb int

- Rb

X10

KSI+

KSI-

KS01

KS02

-AS-

Continued on next page

Overview of 17D Internal Electronics, continued

General Characteristics

The Lexium 17D servo drives are available in five peak output current ratings (4.2,

8.4, 16.8, 28 and 56 A) that are partitioned into two groups based on the width of the package; the 70 mm drive s are rated to ha ndle cu rrents up to 28 A and the 120 mm wide drive is rate d to han dle current s up to 56 A. All Lexium drives o perate wi th an input voltage which may range from 208 V -10% 60 H z , 230 V -10% 50 Hz through 480 V +10% 50-60 Hz.

Each drive provides:

l Direct shield connection points l Two analog setpoint inputs l Integrated and electrically isolated RS-232 communications

Primary Power A single phase input supply may be used for commissioning and set-up and for

continuous operating with various smaller drive/motor combinations. See the Lexium 17/ BPH motor torque speed curves for details. Fusing (e.g. fuse cut-out) is provided by the user.

Bias Power The 17D drive requires 24 Vdc bias power from an external, electrically isolated

supply (SELV).

EMI Suppression EMI suppression for the 17D drives is integrally provided by filters on both the

primary power (EN550011, Class A, Group 1) input as well as on the 24 Vdc bias supply (Class A) input.

Continued on next page

Overview of 17D Internal Electronics, cont i nued

Internal Power Section

DC Link Capacitor Reconditioning

The Internal power section of the 17D drive includes the following: l Power input: A rectifier bridge directly connected to the three-phase earthed

supply system, integral power input filter and inrush current limiting circuit. l Motor power output: PWM current-controlle d voltage sou rce IGBT -inv erter with

isolated current measurement l Regen ci rcu it: D y nam ic d is trib uti on of Regen power between s ev eral drives on

the same DC Link circuit. An internal Regen resistor is standard; external

Regen resistors are available as required by your application. l DC Link voltage: 300...700 V dc, nominal (900 Vdc, intermittent) and can be

operated in parallel.

If the servo drive has been stored for longer than one year, then the DC Link capacitors will have to be reconditioned as follows:

Step Action

1 Ensure that all electrical connections to the drive are disconnected. 2 Provide 230 Vac, single-phase power to connector XO

L1 / L2) on the servo drive for about 30 minutes to recondition the capacitors.

(terminals

Integrated Safe Electrical Separation

The 17D drive ensures safe electrical separation (in accordance with EN 50178) between the power input/motor connections and the signal electronics through the use of appropriate i ns ula tio n-c reep age dis tances and electrical isolation. Th e dri ve also provides so ft-start cha racteri stics, o vervoltage a nd over temperatu re detectio n, short-circuit protection and input phase-failure monitoring. When using BPH and

SER series servo moto rs in conjunction with Schneider’s pre-assembled cables, the drive also monitors the servo motor for overtemperature.

Continued on next page

Overview of 17D Internal Electronics, continued

LED display A three-character LED display on the front of the 17D drive indicates drive status

after the 24 Vdc bias supply is turned on. If applicable during operation, error and/ or warning codes are displayed.

Overview of System Software

Setup Configuration software is used for setting up and storing the operating parameters

for the Lexium 17D series driv es. The dri ve is co mmissi one d with the as sista nce of the UniLink software and, during this process, the drive can be controlled directly through this software.

Setting Parameters

You must adapt the servo drives to the requirements of your installation. This is

usually accomp lished by connect ing a PC (p rogrammin g unit) to th e drive’ s RS-2 32 serial interface the n runni ng the Schnei der-sup plied UniLink configu ration s oftw are.

The UniLink software and the associated documentation are provided on a CDROM. Use the UniLink software to alter parameter s; you can instantl y observe the effect on the drive when there is a continuous (online) connection to the drive. In addition, actua l values are simulta neously received from the drive and display ed on the PC monitor.

During the configu ration p roc ess, th e Unili nk sof tware wi ll sho w the motors that are correctly matched to the current rating of the drive being configured.

Automatic Card Recognition

Any interface modu le s (exp ansio n cards) tha t may be built in to the drive or that you install are automatically recognized by the drive’s internal firmware. Any additional parameters required for position control or motion-block definition are made available automatically in the UniLink configuration software.

Default Settings Motor-specific default settings for all the reasonable combinations of drive and

servo motor are incorpo rated into the drive’ s firmware. In mo st applicatio ns, you will be able to use thes e default values to get your drive running without any problems. (Refer to the UniLink online help for additional information on default values.)

Overview of System Software, continued

UniLink Commissioning Software

The minimum PC system requirements needed for the UniLink commissioning software are specified in the following table:

Item Minimum Requirement

Operating System Windows 95

Windows 98 Windows 2000 Windows ME Windows NT 4.0

Hardware:

Processor Graphics adapter RAM Hard drive space Communications

486 or higher VGA 8 Mbytes 5 Mbytes available One RS-232 Serial Port

At a Glance

Mounting and Physical Dimensions

What’s in this Chapter

This chapter provides information on the mounting requirements for, and physical dimensions of, the Lexium 17D series servo drives and includes the following topics:

Topic Page

Installation safety precautions 34 Installation considerations 36 Drive mounting and physical dimensions 37 External Regen resistor mounting and dimensions 39 Choke mounting and dimensions 41

Installation Safety Precautions

CAUTION! MECHANICAL STRESS

Protect the drive from physical impact during transport and handling. In particular, do not deform any exterior surfaces; doing so may damage internal components or alter critical insulation distances.

Failure to observe this precaution can result in injury or equipment damage.

CAUTION! ELECTRICAL STRESS

At the installatio n s ite , ensure the maximum permissi ble rate d v oltage at the Mains and bias input connectors on the drive are not exceeded. (See EN 60204-1, Section 4.3.1.) Excessive voltages on these terminals can result in destruction of

the Regen circuit and/or the drive’s electronics.

Failure to observe this precaution can result in injury or equipment damage.

CAUTION! ELECTRICAL CONNECTIONS

Never disconnect the electrical connections to the servo drive while power is applied.

Failure to observe this precaution can result in injury or equipment damage.

Continued on next page

Installation Safety Precauti ons, continued

CAUTION! CONTAMINATION AND THERMAL HAZARD

Ensure the 17D drive is mounted within an appropriately vented and closed switchgear cabinet that is free of conductive and corrosive contaminants. Ensure the ventilation clearances above and below the drive conform to requirements. (Refer to Chapter 3 for additional information.)

Failure to observe this precaution can result in injury or equipment damage.

DANGER! ELECTRIC SHOCK HAZARD

Residual voltages on the DC link capacitors can remain at dangerous levels for up to five minutes af ter switchin g off the mains su pply volt age. Ther efore, meas ure the voltage on the DC Link (+DC/-DC) and wait until the voltage has fallen below 40 V.

Control and power connections can still be energized, even when the motor is not rotating.

Failure to observe these instructions will result in death or serious injury.

Installation Considerations

Power Supply Overcurrent Protection

Earth

Y ou are responsible for prov iding over current protec tion (via circui t breakers and/ or fuses) for the Vac mains supply and the 24 Vdc bias supply that are connected to the drive.

Ensure the drive and associated servo motor are properly connected to earth.

Connections

Cable Separation Route power and control (signal) cables separately. Schneider recommends a

separation of at least 20 cm. This degree of separation improves the EMC performance of the system. If a servo motor power cable includes wires for brake control, those wires have a separate shield which must be connected to earth at both ends of the cable.

Air Flow Ensure that there is an adequate flow of cool, filtered air into the bottom of the

switchgear cabinet co ntai ning the drive.

Drive Mounting and Physical Dim ensions

17D Height, Width and Depth Dimensions

The following diagram shows height, width and depth dimensions for the 17D drive.

Model:

MHDA1004/00 MHDA1008/00 MHDA1017/00 MHDA1028/00

325 mm

Model:

MHDA1056/00

275 mm

(

)

(

275 mm

325 mm

* Dimensions with mating connectors installed

Continued on next page

Drive Mounting and Physical Dimensions, continued

17D Drive and Mounting Area Dimensions

The following diagram shows depth dimensions and mounting area requirements for the 17D drive.

Cable duct

45 mm 5 mm 305 mm

50 mm

MHDA1056

45 mm

MHDA1056

40 mm70 mm70 mm70 mm40 mm

MHDA1004

MKDA1008

MHDA1017

MHDA1028

MHDA1004

MKDA1008

MHDA1017

Cable duct

MHDA1028

Cabinet door

2,5 mm (min.)

273 mm

Mounting panel

265 (273 mm*) mm

Lexium 17D

* Dimensions with mating connecto rs installed

External Regen Resistor Mounting and Physical Dimensions

External Regen Resistor Assembly Dimensions

The following diagram shows the dimensions for all three external Regen resistor assemblies.

A B

+Rb

-Rb

ext

Regen Resistor

Assembly

Part Number

ext

AM0RFE001V025 AM0RFE001V050 AM0RFE 001V150

Power

Ω

33 33

1500

A B C D E F G Weight

mm mm mm mm mm mm mm Kg

342 352 410 64 45 4,8 x 8 77 1,5

250

413 428 485 93 64 6,5 x 12 120 4, 0

600

513 528 585 186 150 120 8,0

6,5 x 12

External Regen Resistor Mounting and Physical Dimensions, continued

External regen resistor assembly

CAUTION !

Surface t emperature can

exceed 20 0°C. Observe the requested free s pace. Do not moun t on combustible material !

100

Air flow

3030

Motor Choke Mounting and Dimensions

Motor Choke Assembly Dimensions

The following diagram shows the dimensions for the motor choke assembly.

250

153.3

160

113

N.B. : All dimensions are in millimeters (mm).

Réf. Irms max. F max. L AM0FIL001V056

3 x 20 A 8.3 kHz 1,2 mH

155

Wiring and I/O

At a Glance

Introduction This chapter describes and illustrates all power wiring connections, all signal wiring

connections, an d I/O wi rin g co nne ctions on the 17D drive. Power and signal wir ing connections are:

l AC mains power through a 4-position, plug-in, terminal block connector, X0 l Bias power through 4-position, plug-in, terminal block connector, X4 l Servo motor power throug h a 6-pos ition, plug-in, term inal bl ock conne ctor, X9 l Optional Regen power resistor through a 4-position, plug-in, terminal block

connector, X8

l Resolver feedback input through a 9-pin, plug-in, Sub-D connector, X2 l Encoder feedback input through a 15-pin, plug-in, Sub-D connector, X1 l Auxiliary encoder/command interface through a 9-pin, plug-in, Sub-D

connector, X5

l Master-Slave drive interface through a 9-pin, plug-in, Sub-D connector, X5 l Analog/digital I/O through an 18-position, plug-in terminal block connector, X3 l Serial communications interface through a 9-pin, plug-in, Sub-D connector,

l Stepper-motor control interface through an 9-pin, plug-in, Sub-D connector,

l Restart lock through a 4-position, plug-in, terminal block connector, X10 (A00

drives only)

Continued on next page

At a Glance, continued

What’s in this Chapter

This chapter contains the following topi cs.

Topic Page

Wiring and I/O initial considerations 45 Wiring overview 46 Cable shield connections 49 Power wiring 51 Signal wiring 60 Analog I/O connections 70 Fault Relay and Digital I/O connections 72 Serial communications connections 74 Stepper-motor control interface connections 77

Wiring and I/O Initial Consider ations

Initial Considerations

Some descriptions and illustrations contained in this chapter are provided as examples. Actual implementation depends on the application of the equipment; thus, appropriate variations are allowed provided they neither violate any safety precautions nor jeopardize the integrity of the equipment.

DANGER! ELECTRIC SHOCK HAZARD

Before you wire and connect cables, ensure the mains po wer supply, the 24 Vdc bias power supply and the power supplies to any other connected equipment, are OFF. Ensure any cabinet to be accessed is first electrically disconnected, secured with a lock-out and tagged with warning signs.

Failure to observe these safety instructions will result in death or serious injury.

Grounding Ensure the drive mounting plate, servo motor housing and Analog Com for the

controls are connected to common panel earth ground point.

Continued on next page

Wiring Overview

Overview of 17D Wiring Connections

The following diagram shows the wiring connections for the 17D drive.

CAUTION: Do not connect a Modbus serial port to the X6 connector!

Pin1 carries +8 Vdc which would be shorted out by a Modbus cable. Instead, use a 3-core cable (not a null-modem link cable) with only pins 2, 3 and 5 wired.

Failure to observe this precaution can result in equipment damage.

X0A, X0

B -

Note: The connectors descri bed above appea r in many wiring diagrams throug hout the remainder of this document and are identified in those diagrams by their alphanumeric designations only (for example, X4); the term

connector

is excluded.

Continued on next page

Connection diagram for LEXIUM 17D

Reference Safety Instructions and Use As Directed!

Sine-Cosine

Encoder

Resolver

Remove jumper if external regen resistor is connected

Regeneration

resistor

Max. 10A

Master contactor

thermal control included

U2 V2 W

B+ B-

FB2

FN1 FN2 FN3

supply unit

24Vdc

FH1

high resolution single / multiturn

Resolver

Brake+

Brake-

+RBint

-RB

n.c.

1 2

+24 Vdc

24 Vdc Com

L1 L2 L3 PE

1234 1234

Bext

X0A

X0B

Analog 1in + Analog 1 in -

Analog Com

Analog 2 in +

Analog 2 in Analog Out 1

Analog Com

Analog Out 2

I/O Com

Output 1

Output 2

Fault RA Fault RB

DC+ DC+DC- DC-

Input 3 Input 4 Input 1 Input 2

Enable

ROD

SSI

Ma./SI.

Pulse

CAN

14 11 12 15

5 1

6 7

2 3

PE-connection (protective earth) earth connection (panel)

shield connection via plug

shield connection at the front panel

+/-10V speed setpoint1 referenced to GND

GND

+/-10V speed setpoint2 referenced to GND

Analog 1

GND

Analog 2

GND

I/O-GND +24V referenced to 0V/GND

Digital1

Digital2

Safety

circuit

encoderevaluation, stepper motor control, slave/master amplifier

Can-Master

COM1/COM2

PEL1 L2 L3

shielding if cable is longer than 20cm

to other amplifiers

Wiring Overview, continued

Pin assignments for LEXIUM 17D

X6 PC/CAN X1 ENCODER

X2 RESOLVERX5 ROD/SSI pulse-direction master-slave

1 Reserved

2 RxD

Analog Com 1

Fault Ra 2 Fault Rb 3

Analog 1 In+ 4

Analog 1 In- 5

Analog 2 In+ 6

Analog 2 In- 7 Analog Out 1 8 Analog Out 2 9 Analog Com 10

Input 1 11 Input 2 12 Input 3 13 Input 4 14 Enable 15

Output 1 16 Output 2 17

I/O Com 18

KSO1 1 KSO2 2

KSI - 3 KSI+ 4

+24Vdc 1

+24Vdc 2

+24Vdc Com 3 +24Vdc Com 4

3 TxD

4 N.C.

CANL 6

X10

5 PGND

CANH 9

1 Pcom

2 M+

3 M-

B+ (DATA) 6

B- (/DATA) 7

4 A or CLK

5 A or CLK

N.C. 9

Reserved 8

5 R1

4 S2

3 S321 Shield

S4 8

R2 9

S1 7

V 6

8 Clock7 6 N.C.

5 DATA(+485)

Clock 15

Up SENSE 12

DATA (-485) 13

4 Up (8V)

3 B+ (COS)

2 0V(GND)

1 A+ (SIN)

0V SENSE 10

A- (REFSIN) 9

B- (REFCOS) 11

View: looking at the face of the built-in connectors

Coding

Cable Shield Connections

Connecting Cable Shields to the Front Panel

The following procedure and associated diagram describe how to connect cable shields to the front panel of the 17D drive:

Step Action

2 3

4 5

Remove a length of the cable’s outer covering and braided shield sufficient to expose the required length of wires.

Secure the exposed wires with a cable tie. Remove approximately 30 mm of the cable’s outer covering while ensuring the

braided shield is not damaged during the process. At the front panel of the drive, insert a cable tie into a slot in the shielding rail. Use the previously inserted cable tie to secure the exposed braided shield of

the cable firmly against the shielding rail.

Continued on next page

Cable Shield Connections, continued

Cable Shield Connection Diagram

The following diagram shows the cable shield connections at the front of the 17D drive.

Cable tie

30 30

Cable tie

ium

Cable tie

Power Wiring

AC Mains Power Supply Connection

Bias Supply Connection

The following diagram shows the connections for the AC mains power supply input to the 17D drive.

Lexium 17D

FN1

FN2

FN3

Three phase

50Hz

230... 480 Vac*

Three phase 60Hz

208... 480 Vac*

208...230V 60Hz

208...480V 60Hz

208...230V 60Hz

230...480V 50Hz

*3 x 230 V +10% max. with a BPH055 Servo motor

The following diagra m shows the connectio ns for the bias power su pply input to the 17D drive.

External 24 Vdc

supply (SELV)

FUS

+24 V

Lexium 17D

33V

+24 Vdc

(1)

Com +24 Vdc

(1)

The current must not exceed 10A through these pin.

Com +24 Vdc

(

)

Continued on next page

Power Wirin g , continued

Serial Power Connections

The following diagram shows the serial connections for the AC mains and bias power among multiple 17D drives.

AC supply

Lexium 17D

X4 +24 +24

COM COM

X0A

+DC

-DC

+DC

-DC

X0B

L1 L2 L3

To Next Drive

L1 L2 L3

~ =

Lexium 17D

X4 +24 +24

COM COM

X0A

+DC

-DC

+DC

-DC

X0B

L1 L2 L3

Lexium 17D

3 3

+24 +24

COM

X0A

L1 L2 L3

PE X7

+DC

-DC +DC

-DC

X0B

L1 L2 L3

DC supply

Lexium 17D

X4 +24 +24

COM COM

X0A

L1 L2 L3

+DC

-DC

+DC

-DC

X0B

L1 L2 L3

To Next Drive

POWER

SUPPLY

+DC

-DC

24 Vdc

Power Supply

Fuse

Max fuse: 20 A

schielded if length > 20 cm

Max. 10 A

Lexium 17D

X4 +24 +24

COM COM

X0A

+DC

-DC

+DC

-DC

X0B

L1 L2 L3

NCNC

Notes: -Inrush current must be limited to 20 A between power supply and drives.

- Drives have to be configured (see Unilink commands) to suppress faults.

Continued on next page

Power Wiring, continued

External Regen Resistor Connection

Regen Circuit Functional Description

The following d iag ram s ho w s the c onnections between the exte rnal Re gen resistor and the 17D drive. The drive is shipped with a jumper installed on connector X8, terminals R

and R

. If you are going to use an external Regen resistor, then

Bint

remove the jumper to disconnect (and thus disable) the internal Regen resistor

Fusing of the two lines to external Regen Resistor is mandatory.

-RB

+RBint

+RBext

N.C.

If using an external Regen resistor, disabl the internal Regen resistor by removing th jumper between -RB and +RBint.

FB1

RBext

FB2

Use high voltage AC/DC and fast fuses..

Lexium 17D

Bint

-DC

+DC

During braking, energy from the se rvo mo tor is returned to the drive and converted into heat in the Regen resistor. Operation of the Regen resistor is controlled by the Regen circuit using thresholds that are adjusted to the main supply voltage that is configured in the UniLink software. The following is an abbreviated functional description of the Regen circuit operation.

l Individual drive (not coupl ed thro ugh the DC Li nk c ircuit) - The c ircuit starts to

respond at a DC Link voltage of 40 0V, 720V or 840V (depending on the supply voltage). If the energy fed back from the servo motor is higher than the preset Regen power, then the drive issues a "Regen power exceeded" signal and the Regen circuit will be switched off. Upon the next internal check of the DC Link voltage, an overvoltage will be detected, the fault relay contact will be opened and the drive will be switched off with the error message "Overvoltage".

l Multiple drives (co up led thro ug h th e D C Lin k c irc ui t) - In t his c as e, the R ege n

energy is distributed equally among all the drives.

Continued on next page

Power Wirin g , continued

Lexium BPH Servo Motor Connection (excluded BPH055)

The following diagrams show the connections between a servo motor (excluded BPH055) and the 17D drive. When the interface cable length exceeds 25 m, a motor choke must be in stalled as shown and at a distance of one meter or less from the drive.

Connection between servo motor and drive when interface cable length is 25 m or less.

LEXIUM 17D

24 Vdc Com

24 Vdc

Connection between servo motor and drive when interface cable length exceeds 25 m..

LEXIUM 17D

24 Vdc Co m

24 Vdc

1 2

5 6

1 2

Brake- (Black)

Brake+ (White)

Gnd (Green)

W2 (3)

V2 (2) U2 (1)

Motor Choke

AMOFIL001V056

B-

B+

Brake -

(Black)

Brake +

(White)

Gnd

(Green)

Servo Motor

Note : The choke must be installed at a distance of one meter or less from the drive.

W V1 U1

W V2 U2

5 6

W2 (3)

V2 (2) U2 (1)

Servo Motor

Continued on next page

Lexium BPH 055 Servo Motor Connection

The following di agra ms show the connections betwe en a BPH055 servo motor and the 17D drive. When the interface cable length exceeds 25 m, a motor choke must be installed as shown and at a distance of one meter or less from the drive.

Connection between servo motor and drive when interface cable length is 25 m or less.

LEXIUM 17D

24 Vdc Com

Brake -

24 Vdc

5 6

Gnd (Green)

3 1

Brake +

BPH055

Servo

Motor

Connection between servo motor and drive when interface cable length exceeds 25 m..

24 Vdc

LEXIUM 17D

24 Vdc Com

1 2

5 6

Motor choke

AMOFIL001V056

B-

B+

Gnd

(Green)

3 1

BPH055

Servo

Motor

The choke must be installed at a distance of one meter or less from the drive.

Note :

WARNING!

With a BPH055 Servo motor, power supply of the 17D drive must be limited to 3 x 230 Vac +10%

Continued on next page

Power Wirin g , continued

Lexium SER Servo Motor Connection

The following diagrams show the conn ect ion s between a SER servo motor and the 17D drive. When the interface cable length exceeds 25 m, a motor choke must be installed as shown and at a distance of one meter or less from the drive.

Brake - (Grey)

Brake + (White)

Gnd (Green)

SER Servo Motor

(Grey)

SER

Servo

Motor

Note: The choke must be installed at a distance of one meter or less from the drive.

Continued on next page

Power Wiring, continued

Servo Motor (with Optional Dynamic Brake Resistors and Contactor) Connection

The following diagram shows the connections between a servo motor and the 17D drive when the optional dynamic brake rersistors and associated contactor are incorporated.

LEXIUM 17D

24 Vdc

Com 24 Vdc

1 2

5 6

RB RB

Brake -

Brake+

Gnd

(Green)

Servo Motor

Continued on next page

Power Wirin g , continued

Servo Motor Holding-Brake Control Functional Description

A 24V holding brake in the servo motor is controlled directly by the 17D drive through software-selectable BRAKE parameter settings. The time and functional relationships between the ENABLE signal, speed setpoint, speed and brak ing force are shown in the following diagram.

Speed Setpoint Input

ENABLE Input

Internal Speed Setpoint

Actual Speed

ENABLE Internal

BRAKE Output

10ms

Ramp +

100ms

Bracking Force

SET t RELEASE

During the fixed ENABLE delay time of 100 ms, the internal speed setpoint of the drive is internally driven down a 10 ms ramp to 0 V. The 3 % region of actual speed is scaled to V

LIM

Note: The set and re lease times o f the ho lding brake vary wi th the s ervo mot or and thus must be considered when setting parameters.

Continued on next page

Power Wiring, continued

WARNING! IMPACT HAZARD

The off-the-shelf configuration of the holding-brake function does not ensure the safety of personnel. In order to make this function safe for personnel, a normallyopen contact and a user-installed suppressor device (Metal oxyde varistor or bidirectionnal transient voltage suppressor) must be incorporated into the brake circuit as shown in the following diagram.

Failure to observe this precaution can result in severe injury or equipment damage.

+24 Vdc

Lexium 17D

Com +24 Vdc

Square D

8501R5D41V53

or equivalent

Brake -

Brake +

Varistor or transient

voltage suppressor

Servo Motor

Signal Wiring

Lexium BPH Resolver Connection (excluded BPH055)

The following diagram shows the connections between the resolver and the 17D drive.

Note: The standard Lexium BPH series servo motors are equipped with two-pole, integral resolvers. The thermistor contact in the servo motor is connected via the resolver cable to the 17D drive.

1210

2 3

Continued on next page

Signal Wiring, continued

Lexium BPH055 Resolver Connection

The following diagram shows the encoder input connections between the encoder and the 17D drive.

Note: The BPH055 servo motors are equipped with two-pole, integral resolvers. The thermistor contact in the servo m otor is connected via the resol ver ca ble to the 17D drive..

BPH055

Continued on next page

Signal Wiring, continued

Lexium SER Resolver Connection

The following diagram shows the connections between the resolver and the 17D drive.

Note: The standard Lexium SER series servo motors are equipped with two-pole, integral resolvers. The thermistor contact in the servo motor is connected via the resolver cable to the 17D drive.

1210

2 3

Green

Yellow

White

9 5

7 3

Brown

Grey

Pink Black

Grey/Pink

6 7

1 2

5 9

2 6

Continued on next page

Signal Wiring, continued

Lexium BPH Encoder Connection

The following diagram shows the encoder input connections between the encoder and the 17D drive.

Note: The BPH series servo motors can be optionally fitted with a single-turn or multi-turn sine-cosine encoder, which is used by the 17D positioning or extremely smooth running. In addition, the thermistor contact in the servo motor is connected via the encoder cable to the 17D drive.

Encoder

HIPERFACE

Connector

Pinout

1210 9 8

1316

Continued on next page

Signal Wiring, continued

Lexium SER Encoder Connection

The following diagram shows the encoder input connections between the encoder and the 17D drive.

Note: The SER series servo motors can be optionally fitted with a single-turn or multi-turn sine-cosine encoder, which is used by the 17D positioning or extremely smooth running. In addition, the thermistor contact in the servo motor is connected via the encoder cable to the 17D drive.

Encoder

White Brown

Green Yellow

Grey Pink

8 4

9 5

6 7

HIPERFACE

Connector

Pinout

1210

7 6

Red/Blue

Blue

Black

Grey/Pink

10 11

1 2

Gnd

Continued on next page

Signal Wiring, continued

Incremental Encoder Emulation

The following diagram shows the incre mental enc oder output c onnection s between the 17D drive and the motion controller.

Note: The drivers are supplied from an internal supply voltage.

must always be connected to the controller ground.

Com

Use a cable with twisted pairs and shield (max. length: 10m.)

Lexium 17D

RS-485

= =

RS-485

5 4

2 3

8 1

6 7

Reserved

A+

A-

M+

M-

Com

B+

B-

Motion Controller

RS-485

Gnd

RS-485

Chan A

Marker

Chan B

Incremental Encoder Output Functional Description

The position of the servo motor shaft is calculated using the cylic-absolute signals from the resolver or encoder. The calculated position information is used to

generate two incremental-encoder compatible signals (A and B) with a 90° phase difference and a marker pulse.

Continued on next page

Signal Wiring, continued

SSI Encoder emulation

SSI Encoder Output Functional Description

The following diagram shows the connections between a motion controller and the 17D drive.

Note: The drivers are supplied from an internal supply voltage. P

must always

Com

be connected to the controller ground.

Lexium 17D

RS-485

= =

RS-485

6 7

4 5

Data +

Data -

Com

Clock +

Clock -

Motion Controller

RS-485

Gnd

RS-485

Data

Clock

The SSI interface is synchronous serial absolute-encoder emulation. The position of the servo motor shaft is calculated using the cyclic-absolute signals from the resolver or encoder. This calculation is then used to generate a synchronous, serial, cyclic-absolute 12-bit information output that is compatible with the data format of normal commercial SSI absolute encoders. A total of 24 bits are transmitted as follows:

l The upper 12 bits contain the number of turns (multi-turns) or are fixed at zero

(single turn) l The lower 12 bits contain the cyclic absolute position information. The signal sequence can be output in either:

l Gray code l Binary code

The count increments positively when the motor shaft is rotating clockwise (when viewed from the shaft end).

Continued on next page

Signal Wiring, continued

Diagram of master-slave operation

Incremental encoder emulation

The encoder int erfac e ca n be used to link one or more 17 D HP d riv es to gether in a master-slave operation, as shown in the following diagram. The UniLink software allows you to setup the parameters for the slave drive(s).

Note: In this configuration, the analog setpoint inputs are disabled, a Analog Com and I/O Com (connector X3) must be connected together.

Slave

Lexium 17D

RS-485

PCom

RS-485

+5 V

5 4

1 6

A +

A -

B+

B-

5 4

1 6

Master

Lexium 17D

Com

RS-485

Chan A

Chan B

RS-485

Note: Up to 16 slaves drives can be controlled by the master drive.

SSI encoder emulation

Lexium 17D

Note: Only one slave drive can be controlled by the master drive.

Slave

RS-485

+5 V

PCom

RS-485

Master

Com

Lexium 17D

RS-485

Chan A

Chan B

RS-485

6 7

1 5

Data +

Data -

CLK+

CLK-

6 7

1 5

Signal Wiring, continued

External Incremental encoder connection

The following diagram shows the incremental encoder input connections between the 17D drive and an external incremental encoder.

Note: The receivers are supplied from an internal supply voltage.

must always be connected to the encoder ground.

Com

Incremental encoder is powered by an external Power Supply.

Lexium 17D

RS-485

= =

RS-485

5Vdc

5 4

2 3

8 1

6 7

Reserved

A+

A-

M+

M-

Com

B+

B-

Power Supply

+ Vdc

Gnd

Incremental encoder

Chan A

Marker

Gnd

Chan B

Vdc Gnd

RS-485

Signal Wiring, continued

External SSI encoder connection

The following diagram shows the connections between an external SSI encoder and the 17D drive.

Note: The drivers are supplied from an internal supply voltage.

must always be connected to the encoder ground.

Com

SSI encoder is powered by an external Power Supply

Lexium 17D

RS-485

= =

* See Telemecanique XCC range

5Vdc

RS-485

6 7

Reserved

5 4

Data+

Data -

Com

Clock +

Clock -

Power Supply

+Vdc

Gnd

SSI encoder *

RS-485

Gnd

RS-485

Vdc Gnd

Analog I/O Connection

Analog Inputs The following diagram s hows the connect ions bet ween th e two fu lly prog rammable,

differential analog inputs on the 17D drive and a user device. (Refer to the list of pre-programmed functions contained in the UniLink online help.)

Note: The Analog Com must always be connected to the user device Com as a ground reference.

Servo Motor Rotation

The standard setting for direction of positive rotation of the servo motor shaft is clockwise (looking at the shaft end) and is achieved as follows:

Direction

l Positive voltage on connector X3, between terminals 4 (+) and 5 (-), or l Positive voltage on connector X3, between terminals 6 (+) and 7 (-)

To reverse the directio n o f ro tation, change the ROT. DIRECTION param ete r in th e "Speed controller" window; this window is accessed via the UniLink Configuration software.

Continued on next page

Analog I/O Connection, continued

Analog Outputs The following diagram shows the connections between the two programmable,

analog outputs on the 17D drive and a typical user device. (Refer to the list of preprogrammed functions in the UniLink online help.)

The outputs (+/-10V wi th 10-bit resol ution) can be configur ed for various monitori ng functions such as current or actual speed. The default settings are:

l Analog Out 1: Tachometer voltage (speed). The output delivers ±10V at the

preset limit speed.

l Analog Out 2: Current setpoint (torque). The output delivers ± 10V at the

preset peak current (effective RMS value).

Note: Output impedance of the analog outputs (2K2) must be taken into account when there is a c onnec tion to an us er devi ce: di vider due to the input imped ance of the user device.

Fault Relay and Digital I/O Connection

Digital Inputs and Outputs

The following diag ram shows th e connecti ons betw een the faul t relay, the four fullyprogrammable, digi tal inputs, dedicated enable input and two digital outputs on the 17D drive and typical user devices. (A list of pre-programmed functions is contained in the UniLink online help.)

100nF

25Ω

Continued on next page

Fault Relay and Digital I/O Connection, continued

Using Functions Pre-programmed into the Drive

Fault Relay- The isolated fault relay contacts are closed during normal operation

and open when a fault condition exists. Th e relay sta te is not af fected by the e nable

signal, I

t limit or warnings. All faults cause the Fault RA/RB contact to open and the switch-of f of the output sta ge. A list of error messages can be found in chapter Troubleshooting.

Digital Inputs 1, 2, 3 and 4 - You can use the four digital inputs to initiate preprogrammed functions that are stored in the drive.

Normally, the Input 3/Input 4 terminal s (X3/13 and X3/14) are programmed for the connection of limi t-switches. When they are connected as limit-switch positive/ negative (PSTOP/NSTOP), a low PSTOP signal (open) on input terminal X3-13, inhibits the positive direction of axis rotation and a low NSTOP signal (open) on input terminal X3-14, inhibits the negative direction of axis rotation. In both cases, the ramp function remains effective.

WARNING! LIMIT SWITCH HAZARD

Once they are tripped, the limit switches must remain in that condition (PSTOP/ NSTOP signals low) in order to inhibit the corresponding direction of motion.

Failure to observe this precaution can result in severe injury .

Digital Outputs 1 and 2 - You can use the two digital outputs to send messages

from pre-programmed functions that are stored in the drive. Enable Input - This is a dedicated, level-sensitive (as opposed to edge-sensitive)

hardware input which will enable the output stage of the drive when 24 Vdc is applied and no fault conditions exist.

Note: The hardware enable is powered up upon detection of state sens e versus transition sensitiv ity. Refer to the UniLink on-line help for software enable information.

Serial Communications Connection

Serial Communications Connection Diagram

The following diagram depicts the RS-232 communication connection between the Lexium 17D and a PC.

Pcom

See wiring in Appendix D

The setting of the operating, position control, and motion-block parameters can be carried out with an ordinary commercial PC.

Connect the PC interface (X6) of the servo amplifier while the supply to the equipment is switched off via a normal commercial 3-core cable to a serial interface on the PC. Do not use a null-modem link cable!

The interface is electrically isolated through an optocoupler, and is at the same potential as the CANopen interface.

CANopen Interface

The interface for connection to the CAN bus (default 500 kBaud). The integrated profile is based o n the commu nication p rofile CANo pen DS301 and the driv e profi le DSP402.

The following functions are available in connection with the integrated position controller: Jogging with variable speed, reference traverse (zeroing), start motion task, start direct task, digital setpoint provision, data t rans mission functions and many ot hers .

Detailed information can be found in the CANopen manual. The interface is electr ically isolated by optocouplers, and is at the same potential as the RS232 interface. The analog setpoint inputs can still be used.

If the analog setpoint inputs are not used, then Analog Com and I/O Com (terminal X3) must be joined together !

= =

Lexium 17D

CAN +5

PGND

Analog Com

I/O Com

120Ω*

* according to line impedance

CAN ref. to ISO 11898

(when analog setpoints are not in use)

CANH

CANL

PGND

CAN-Server/Client

120Ω*

CAN

CAN bus cable To meet ISO 11898 you should use a bus cable with a characteristic impedance of

120 Ω. The maximum usable cable length for reliable communication decreases with increasing transmission speed. As a guide, you can use the following values which we have measured, but they are not to be taken as assured limits:

Cable data: Characteristic impedance 100-120Ω

Cable capacitanc e max. 60 nF/km Lead resistance (loop) 159.8 Ω/km

Cable length, depending on the transmission rate

Transmission rate (kBauds) max. cable lenght (m)

1000 20

500 70 250 115

Lower cable capacitance (max. 30 nF/km) and lower lead resistance (loop, 115 Ω/km) make it possible to achieve greater distances.

(Characteristic impedance 150 ± 5Ω =:> terminating resistor 150 ± 5Ω). For EMC reasons, the SubD connector housing must ful fill the following conditions:

l metal or metallized housing l shield connection to housing.

X6 X6 X6 X6

CANL CANH

PGND Shield

* about 120Ω according to line impedance

CANL

CANH PGND

Shield

Stepper Motor Control Interface Connection

Stepper-Motor Control Interface Connection Functional Description

Stepper-Motor Control Interface Connection Diagram

This interface can be us ed to co nnect th e servo drive to a third- party s tepper m otor controller. The parameters for the drive are set using the UniLink software and the number of steps are adjustable to allow the drive to correlate to the step-direction signals of any stepper-motor controller. In this configuration, the analog inputs are disabled and the drive can provide various monitoring signals.

The following diagram depicts the communication connection between the Lexium 17D and a stepper-motor controller.

Continued on next page

Stepper Motor Control Interface Connection , continued

Stepper-Motor Speed Profile and Signal Diagram

The following is the speed profile and signal diagram of the stepper-motor configuration.

At a Glance

System Operation

What’s in this Chapter

This chapter provid es inform ation on operatin g the Lexiu m 17D serie s servo dri ves and includes the following topics:

Topic Page

Powering up and powering down the system 80 Description of the restart lock -AS- 84 Procedure for verifying system operation 92 Front panel controls and indicators 96

890 USE 120 00 79

Chapter 5 System Operation

Powering Up and Powering Down the System

Power-on and Power-off Characteristics

The following diagram illustrates the functional sequence that occurs when the drive is turned on and off.

Continued on next page

890 USE 120 00

Chapter 5 System Operation

Powering Up and Powering Down the System, continued

Stop Function If a fault occurs the output stage of the servo a mplifier is switched off and the

Fault RA/RB contac t is opened . In addition, a g lobal error s ignal can be g iven out at one of the digital outputs (terminals X3/16 and X3/17). These signals can be used by the higher-level control to finish the current PLC cycle or to shut down the drive (with additional brake or simila r.).

For MHDAppppA00 only: The built-in restart lock -AS- can be used to switch off the drive via a positive action safety relay, so that personnel safety is ensured at the drive shaft.

Instruments which are equipped with a selected "Brake" function use a special sequence for switching off the output stage.

The Stop functions are defined in EN 60204 (VDE 0113), Para. 9.2.2, 9.2.5.3. There are three cat egories of Stop functions: l Category 0 : Shut down by immedia tely sw itching of f the s upply of en ergy to the

drive machinery (i.e an uncontrolled shut-down);

l Category 1: A controlled shut-down, during which the supply of energy to the

drive machine ry is maint ain ed to perform th e shut-down, and where th e energy supply is only interrupted when the shut-down has been completed;

l Category 2: A controlled shut-down, where the supply of energy to the drive

machinery is maintained.

Every machine must b e equipp ed with a S top function to Ca tegory 0. S top fun ctions to Categories I a nd/or 2 must be provided if the sa fety or functi onal r equirem ent s of the machine make this necessary.

890 USE 120 00 81

Chapter 5 System Operation

Powering Up and Powering Down the System, continued

Emergency Stop strategies

The Emergency Stop function is defined in EN 60204 (VDE 0113), Para. 9.2.5.4.

Implementation of the Emergency Stop function: l Category 0:

The controller is switched to "disable", the electrical supply (400VAC) is disconnected.

The motor must be held by an electromagnetic holding device (brake). In single axis or multiaxi s syste ms with co nnected DC-link b us (int ermediate circuit)

the motor leads have to be disconnected by a changeover switch and shortcircuited by resistors connected in a star configuration.

l Category 1: If hazardous conditions can result fr om an emergency stop switch-off with an

unbraked run-down, then the drive can be switched off by a controlled shut-down. Stop Category 1 permits electromotive braking with a switch -off when zero speed

has been reached. Safe shut-down can be achieved, when the loss of the mains supply is not rated as a fault and the control takes over the disabling of the servo amplifier.

In the normal situation, only the supply power is switched off in a safe manner. The 24V auxiliary supply remains switched on.

Continued on next page

890 USE 120 00

Powering Up and Powering Down the System, continued

Wiring example Stop and Emergency Stop function (Category 0)

L1 L2 L3

K10

Chapter 5 System Operation

XOA

3 2 1

LEXIUM 17

24 Vdc Com

24 Vdc

Enable

15 2 3

K10

K11

Fault RA/RB

Emergency-Off

OFFON

K10 K10

+24Vdc

B RB

K30

Brake-

Brake+

Gnd

(Green)

K20

Servo Motor

+24Vdc Com

890 USE 120 00 83

K30 K11K11

K20K10K30

K11 is normally closed (no fault of equipemen t)

Chapter 5 System Operation

Description of the restart lock -AS- (MHDA••••A00 drives only)

Advantages of the restart lock

A frequently required application task is the protection of personnel against the restarting of drives. This can not be achieved by an electronic inhibit, but must be implemented with mechanical elements (positively driven relay contacts).

To get round this problem, up to now either the main contactor in the mains supply line was switched off, or another contactor was used to disconnect the motor from the servo amplifier.

The disadvantages of this method are :

l the DC-link has to be charged up again at restart l wear on the contacts of the contactors, caused by switching under load l extensive wiring required, with additional switching components

The restart lock -AS- avoids these disadvantages. A safety relay in the servo amplifier is activated either by the PLC or manually. Positively driven contacts provide a safe disconnection of the amplifier, the setpoint input of the servo amplifier is inhibited, and a signal is sent to the safety circuit.

Advantages of the restart lock -AS- :

l the DC-link remains charged up, as long as the mains supply line remains

active

l only low voltages are switched, so there is no contact wear l very little w iring is required l the functionality and the personnel safety when using the circuit

recommendations in this documentation have been approved by the trade liability association.

Continued on next page

890 USE 120 00

Description of the restart lock -AS-

Chapter 5 System Operation

Functional description

The connector (X10) is mounted on the front panel of the Lexium 17 D. The coil connections and a make (n.o.) contact of a safety relay are available through 4 terminals on this connector.

Two contacts switch off the driver supply of the output stage in the servo amplifier, and short the internal setpoint signal to Analog Com (0 V).

The make (n.o.) contact used for monitoring is looped into the control circuit. If the safety relay is not energized, then the monitoring contact is open and the

servo amplifier is ready for operation. If the drive is elec tronically braked, the servo amplifier is disabled and the motor-

holding brake is on , th en the safety relay is energized (ma nu ally or by the controls). The supply voltage for the driver circuit of the output stage is switched off in a safe

manner, the internal setpoint is shorted to 0V, and the monitoring contact bridges the safety logic in the control circuit of the system (monitoring of protective doors etc.)

Even if the output stage or driver is destroyed, it is impossible to start the motor. If the safety relay itself is faulty, then the monitoring contact cannot bridge the

safety logic of the system. Opening the protective devices will then switch off the system.

890 USE 120 00 85

Chapter 5 System Operation

Description of the restart lock -AS-, continued

Block diagram

charging circuit

Mains

24Vdc

KSI+

KSI-

KSO1

KSO2

DC/DC converter

X10

4 3

1 2

monostable

AS relay

setpoint

Note: AS relay : Its main features are:

- according to EN 50205, IEC 255, IEC 664

- monostable

- high mechanical service life

- high switching reliability

- approvals TUV, UL and CSA.

223

DC link

control logic

6 activation

Continued on next page

890 USE 120 00

LEXIUM MHDA1004, MHDA1008, MHDA1028, MHDA1017, MHDA1056 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual