Schneider Electric 17S User Manual

Modicon

Lexium 17S Series SERCOS Servo Drive

User Guide

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Preface

Preface The data and illustratio ns f ound in this boo k are not bindin g. We reserve 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 assumes no responsibility for any errors that may appear 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 sy st em d ata , re pa irs to c om po nen ts s hou ld be performed o nly b y the manufacturer.

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

MODSOFT® is a registered trademark of Schneider Electric.

(SERCOS

interface is a tradema rk o f SERC O S Inte rfac e, I nc ., pro mot io n so ci ety. )

The following are trademarks of Schneid er Electric:

Modbus Modbus Plus Modicon Quantum 984 Concept

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

Microsoft® , MS-DOS®, Windows®, Windows 95®, Windows 98® and Windows NT® are registered trademarks of Microsoft Corporation.

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Preface

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Contents

Chapter 1 Introduction

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

SERCOS Multi-Axis Motion Control System ............................................ . 4

UniLink Commissioning Software for 17S ................................................. 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 .......................................................................... 1 0

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

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

SERCOS Standard .................... ............................................................... 11

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

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

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

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Contents

Chapter 2 Product Overview

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

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

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

The 17S Series SERCOS Drive Family ......................................................... 16

Introducing the 17S SERCOS Drive Family ............................................. 16

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

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

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

Electrical Considerations .......................................................................... 17

17S Drive Family Portrait .......................................................................... 18

17S Drives Front View ................................................. ...... ..... ...... ............ 19

Equipment Supplied .................................................................................. 20

Equipment Available ................................................................................. 20

17S System Configuration Diagram ......................................................... 21

Modicon Multi-Axis Motion SERCOS Network Configuration ......................... 22

Overview ................................................................................................... 22

Which Motion Controllers run a SERCOS Network .................................. 22

SERCOS Fiber- Optic Transmit and Receive Connectors........................ 22

Example of a Typical SERCOS Network Ring Configuration ................... 23

Benefits of Fiber-Optic Communication .................................................... 24

Two Types of Fiber-Optic Communication ............................................... 24

Digital Control ........................................................................................... 25

Usability Enhancements ........................................................................... 26

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Overview of 17S Internal Electronics ............................................................. 27

17S Internal Electronics Block Diagram ................................................... 27

General Characteristics ............................................................................ 28

Primary Power .......................................................................................... 28

Bias Power ................................................................................................ 28

EMI Suppression ........................................ ...... ...... .................................. 28

Internal Power Section .............................................................................. 29

DC Link Capacitor Reconditioning ............................................................ 29

Integrated Safe Electrical Separation ................................................. ..... . 29

Keypad ...................................................................................................... 29

LED Display and Discrete Indicators ........................................................ 30

Overview of System Software ........................................................................ 31

Setup ........................................................................................................ 31

Setting Parameters ..................................... ...... ...... ..... ............................. 31

Default Settings .......................................... ...... ........................................ 31

UniLink Commissioning Software ............................................................. 32

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Contents

Chapter 3 Mounting and Physical Dimensions

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

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

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

Power Supply Overcurrent Protection .... ..... ...... ...... ..... ............................. 36

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

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

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

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

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

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

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

Optional Motor Choke Assembly Dimensions ........................................... 40

Chapter 4 Wiring and I/O

At a Glance...................................................................................................... 41

Introduction ............................................................................................... 41

What’s in this Chapter ............................................................................... 42

Wiring and I/O Initial Considerations .............................................................. 43

Initial Considerations ................................................................................. 43

Grounding ................................................................................................. 43

Wiring Overview ............................................................................................. 44

Overview of 17S Wiring Connections........................................................ 44

Cable Shield Connections .............................................................................. 47

Connecting Cable Shields to the Front Panel ........................................... 47

Cable Shield Connection Diagram ............................................................ 48

Power Wiring .................................................................................................. 49

AC Mains Power Supply Connection ........................................................ 49

Bias Supply Connection ............................................................................ 49

Serial Power Connections ......................................................................... 50

Optional External Regen Resistor Connection ......................................... 51

Regen Circuit Functional Description......................................................... 51

Lexium BPH Servo Motor Connection (excluded BPH055) ...................... 52

Lexium BPH 055 Servo Motor Connection................................................ 53

Servo Motor (with Optional Dynamic Brake...............................................

Resistors and Contactor) Connection ....................................................... 54

Servo Motor Holding-Brake Control Functional Description ...................... 55

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Contents

Signal Wiring .................................................................................................. 57

Lexium BPH Resolver Connection (excluded BPH055) ........................... 57

Lexium BPH055 Resolver Connection ..................................................... 58

Encoder Input Connection ........................................................................ 59

Auxiliary Encoder Interface ....................................................................... 60

Analog Input Connection ................................................................................ 63

Analog Inputs .................................................... ...... ..... ...... ....................... 63

Fault Relay and Digital I/O Connection .......................................................... 64

Digital Inputs and Outputs ........................................................................ 64

Using Functions Pre-programmed into the Drive ...................................... 65

Serial Communications Connection ............................................................... 66

RS-232 Null Modem Type Communication Connection Diagram ............. 66

Chapter 5 System Operation

At a Glance...................................................................................................... 67

What’s in this Chapter ............................................................................... 67

Powering Up and Powering Down the System ............................................... 68

Power-on and Power-off Characteristics .................................................. 68

Stop Function ............................................................................................ 69

Emergency Stop strategies ....................................................................... 69

Wiring example ........................................... ...... ...... ..... ...... ....................... 70

Procedure for Verifying System Operation ..................................................... 71

Overview ................................................................................................... 71

Quick Tuning Procedure ........................................................................... 71

Front Panel Controls and Indicators ............................................................... 73

Keypad Operation ..................................................................................... 73

LED Display .............................................................................................. 73

SERCOS Communication LED Indicators ................................................ 74

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Chapter 6 Troubleshooting

At a Glance...................................................................................................... 75

What’s in this Chapter ............................................................................... 75

Warning Messages ......................................................................................... 76

Warning Identification and Description...................................................... 76

Error Messages ............................................................................................. . 77

Error Identification and Description ........................................................... 77

Troubleshooting............................................................................................... 81

Problems, Possible Causes and Corrective Actions.................................. 81

Appendix A Specifications

At a Glance...................................................................................................... 83

What’s in this Appendix ............................................................................. 83

Performance Specifications............................................................................. 84

Performance Specifications Table ............................................................ 84

Environmental and Mechanical Specifications................................................ 85

Environmental Specifications Table........................................................... 85

Mechanical Specifications Table ............................................................... 86

Electrical Specifications................................................................................... 87

What’s in this Section ................................................................................ 87

Electrical Specifications - Power .................................................................... 88

Line Input Specifications Table ................................................................. 88

Bias Input Specifications Table ................................................................. 89

External Fuse Specifications Table ........................................................... 89

Motor Output Specifications Table ............................................................ 90

Internal Power Dissipation Specifications Table........................................ 91

Electrical Specifications - Regen Resistor ...................................................... 92

Regen Circuit Specifications ..................................................................... 92

Electrical Specifications - Signal ..................................................................... 93

Motor Overtemperature Input Specifications Table .................................. 93

Resolver Input Specifications Table .......................................................... 93

Encoder Input Specifications Table........................................................... 94

Emulated Encoder Output (Incremental Format) Specifications Table...... 94

Encoder Output (Incremental Format) Timing Diagram ............................ 95

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Contents

Auxiliary Incremental Encoder Input Specifications Table ........................ 95

Discrete Input Specifications Table .......................................................... 96

Discrete Output Specifications Table ........................................................ 96

Fault Relay Output Specifications Table ................................................... 97

Brake Output Specifications Table ........................................................... 97

Analog Input Specifications Table ............................................................ 98

Serial Communications Specifications Table ............................................ 98

Wire Specifications ................................................................................... 99

Appendix B Parts List

At a Glance...................................................................................................... 101

What’s in this Appendix ............................................................................ 101

Lexium 17S Drives ......................................................................................... 102

Drives Available ..................................... ..... .............................................. 102

External 24Vdc supply .................................................................................... 103

External 24Vdc supply .............................................................................. 103

Drive Cables ................................................................................................... 104

Drive to Motor Cables .............................................................................. 104

RS-232 Serial Communications Cable Part Table .................................... 104

Encoder Output Cable Parts Table ........................................................... 104

Fiber Optic Cables Parts Table ......................... ...... .................................. 105

Optional External Regen Resistor Assemblies ............................................... 106

Optional Regen Resistor Assembly Part Table......................................... 106

Optional Motor Choke..................................................................................... 107

Optional Motor Choke Part Table.............................................................. 107

Spare Parts ..................................................................................................... 108

Spare Parts Table...................................................................................... 108

Appendix C Cable Connection Wiring Diagrams

At a Glance...................................................................................................... 109

What’s in this Appendix ............................................................................ 109

Wiring a Sub-D Connector with Shielding ...................................................... 110

Wiring the Sub-D Connector............................................... ....................... 110

Sub-D Connector Diagram ....................................................................... 111

Wiring the Motor Power Connector (Drive end) ............................................. 112

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Wiring the Motor Power Connector ........................................................... 112

Motor Power Connector (Drive end) Diagram (excluded BPH055) ........... 113

BPH055 Motor Power Connector (Drive end) Diagram ............................ 114

Serial Communication Interface Conne cti on (X6) .............................. ............ 115

Serial Communication Interface Cable Connectors .................................. 115

Appendix C Servo Loop Diagrams

At a Glance...................................................................................................... 117

What’s in this Appendix ............................................................................. 117

17S Current Controller Overview .................................................................... 118

17S Current Controller Diagram ............................................................... 118

17S Velocity Controller Loop .......................................................................... 119

17S Velocity Controller Loop Diagram .................................... .................. 119

17S Position Controller Loop .......................................................................... 120

17S Position Controller Loop Diagram....................................................... 120

Appendix D Optional External Regen Resistor Sizing

At a Glance...................................................................................................... 121

What’s in this Appendix.............................................................................. 121

Overview ................................................................................................... 122

Determining When Energy Is Absorbed .................................................... 122

Determining Optional External Regen Resistor Size ...................................... 123

Power Dissipation Calculation Proce dure .......................... ..... ...... ...... ..... . 123

Drive Energy Absorption Capability .......................................................... 124

Example Regen Resistor Power Dissipation Ca lc ula tio n ............................... 125

Example Motor and Drive Specifications................................................... 125

Example Step 1........................... ...... ...... ..... .............................................. 126

Example Step 2 ................................ ...... ..... ...... ........................................ 127

Example Step 3 ................................ ...... ..... ...... ........................................ 127

Example Step 4 ................................ ...... ..... ...... ........................................ 128

Example Step 5 ................................ ...... ..... ...... ........................................ 128

Example Step 6........................... ...... ...... ..... .............................................. 128

Example Step 7 ................................ ...... ..... ...... ........................................ 128

Example Step 8 ................................ ...... ..... ...... ........................................ 129

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Contents

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Introduction

At a Glance

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

application, test and maintenance information on the Lexium 17S series SERCOS 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 and standards 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

How this User Guide Is Organized

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 17S SERCOS drive and the servo system equipment with which it interfaces. In addition, the following precautions are advised:

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

performed by personnel knowledgeable in handling electrostatically sensiti ve components.

l Commissioning of the equipment should only be performed by personnel

having extensive knowledge of, and experience with, electrical and drive technologies.

You are expected to have some overall understanding of what your 17S SERCOS drive does and how it will function in a high-performance, multi-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 17S. (See

Related System Components

later in this chapter.)

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

This manual is organized as follows.

Chapter/Appendix Description

Chapter 1 About this User Guide

Chapter 2 Lexium 17S 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 17S SERCOS drives, descriptions of components that are supplied by Schneider in a typical 17S system, and a block diagram for internal electronics.

Physical dimensions and information for mounting the 17S SERCOS drive, optional Regen resistor and (if required) optional servo motor choke.

Continued on next page

About this User Guide, continued

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

Appendix B

Parts List

Appendix C

Cable Connection Wiring Diagrams

Appendix D

Servo Loop Diagrams

Appendix E

Optional External Regen Resistor Sizing

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

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

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

Description of faults, probable causes and recommended corrective actions.

Specifications for the 17S SERCOS drives, including general, electrical, signal, and power specifications.

Part numbers related to the 17S SERCOS drive system.

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 several servo loops within the 17S SERCOS drive system.

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

Related System Components

SERCOS MultiAxis Motion Control System

UniLink Commissioning Software for 17S

The 17S SERCOS drive is typically only one component in a larger, multi-axis motion control system. A multi-axis system is comprised of one motion controller and (depending on the controller) up to 32 drives. Each drive controls one servo motor.

To configure your multi-axis system, you will be using the UniLink axis commissioning software, which Schneider supplies.

UniLink allows you to configure and tune your 17S axis quickly and easily. With its graphical user interfa ce and osci lloscop e tuning feat ures, UniL ink provides an easy point-and-click me thod for confi guring moti on setup p arameters. U niLink mi nimizes or eliminates cumbersom e programming tasks.

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

Hazards, Warnings and Guidelines

Hazards and Warnings

Read the followi ng precautions very carefully to ensure the safety of personnel at your site. Failure to comply will result in death, serious injury or equipment damage.

DANGER! ELECTRIC SHOCK HAZARDS

l During operation, keep al l covers and cabine t doors closed. l Do not open the drives; depending on degree of enclosure protection, the

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 drive with power

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

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

voltage before touching energized sections of the equipment (for example, contacts) or disconnecting electrical connections. Capacitors can still 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 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 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 accordance wit h the Ca nad ian Elec tric al Code, Part 1 an d 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 should be hard w ire d wi th over–travel limit 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 resistors across each motor, if they are present.

Failure to observe this precaution can result in equipment damage.

CAUTION! ELECTROSTATIC COMPONENTS

The drives contain electrostatically sensitive components that may be damaged by improper handling. Appropriately discharge yourself before touching the drive and avoid contact with highly insulating materials (artificial fabrics, plastic film, and so on). Place the drive on 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 drives.

l Ens ure that al l wiri ng is in a ccorda nc e with the Nati ona l Ele ctr ical Cod e (NEC)

or its national equivalent (CSA, CENELEC, and so on), as well as in accordance with 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 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 drives may only be operated in a closed switchgear cabinet with

appropriate compensation for ambient conditions (as defined in Appendix A).

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

Standards and Compliances

European Directives and Standards

EC Directive Compliance

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

When the drives are b ui lt int o mac hines or a plant, do no t oper ate the d riv e 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 drives.

The manufacturer of the mach ine 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 drives used within the European Community.

The Lexium 17S SERCOS drives were tested by an authorized testing laboratory and determined to be in compliance with the directives identified above.

Continued on next page

Standards and Compliances, continued

SERCOS Standard

UL and cUL Compliance

If you want to reference the internatio nal SERCO S communic ations st andard , get a copy of:

International Standard IEC 1491,

Electrical Equipment of Industrial Machines –

Serial Data Link for Real-Time Communication between Controllers and Drives.

SERCOS is an industry standard term that refers to a special type of fiber–optic communication protocol, as defined by the SERCOS Interface, Inc., promotion society. (SERCOS® interface is a trade mark o f SERCO S Interf ace, I nc., pro motion

society.)

UL Listed (cUL Certified) 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 equipme nt (such as frequen cy con v erters and drive s) and is intended to eliminate the risk of inj ury to personnel fro m electric sh ock or d amage to eq uipment from fire. Conformance with the United States and Canadian standard is determined by an indepe nde nt UL (cU L ) fire in spe ct or th roug h th e ty pe tes tin g and regular checkups.

UL 508C

UL 508C describes the minimum requirements for electrically operated power conversion equipme nt (such as frequen cy con v erters and drive s) and is intended to eliminate the risk of fire caused by that equipment.

UL 840

UL 840 describes ai r and in sulat ion creep age spa cings f or electrical equipment 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 PELV Protected extra low voltage PWM Pulse-width modulation RAM Random Access Memory (volatile) Regen Regen resistor RBext External Regen resistor RBint Internal Regen resistor RFI Radio Frequency Interference

Continued on next page