ECODRIVE03/DURADRIVE Drives for General Automation with SERCOS and Parallel Interface. Functional Description: SGP 20VRS SYSTEM200

Transcription

1 ECODRIVE03/DURADRIVE Drives for General Automation with SERCOS and Parallel Interface Functional Description: SGP 20VRS SYSTEM200

2 About this Documentation SGP-20VRS Title ECODRIVE03/DURADRIVE Drives for General Automation with SERCOS and Parallel Interface Type of Documentation Functional Description: SGP 20VRS Document Typecode Internal File Reference Box 72-V20-EN Basis: SGP-01VRS Document Number, B310-01/EN Purpose of Documentation The following documentation describes the functions of the firmware FWA-DRIVE*-SGP-20VRS. Record of Revisions Description Release Date Notes First Release Copyright 2001 Rexroth Indramat GmbH Copying this document, giving it to others and the use or communication of the contents thereof without express authority, are forbidden. Offenders are liable for the payment of damages. All rights are reserved in the event of the grant of a patent or the registration of a utility model or design (DIN 34-1). Validity The specified data is for product description purposes only and may not be deemed to be guaranteed unless expressly confirmed in the contract. All rights are reserved with respect to the content of this documentation and the availability of the product. Published by Rexroth Indramat GmbH Bgm.-Dr.-Nebel-Str. 2 D Lohr a. Main Telephone +49 (0)93 52/40-0 Tx Fax +49 (0)93 52/ Dept. ED (sa/th) Note This document has been printed on chlorine-free bleached paper.

3 (6-:),)04 SGP-20VRS About this Documentation Functional Description: Summary of Documentation - Overview Description of all implemented Function based on SERCOS-Parameters FK Order designation: Parameter Description: A description of all parameters used in the firmware PA Order designation: DOK-DRIVE*- SGP -20VRS**-PA01-EN-P Troubleshooting Guide: -Explanation of the diagnostic states -How to proceed when eliminating faults WA Order designation: DOK-DRIVE*- SGP -20VRS**-WA01-EN-P Firmware Version Notes: FV Description of new and changed functions in terms of the derivatives: FWA-ECODR3- SGP 01VRS-MS Order designation: DOK-DRIVE*- SGP-20VRS**-FV01-EN-P Order designation DOK-DRIVE*- SGP -20VRS**-7201-EN-P CD: DRIVEHELP Collection of Windows help systems which contains documentation on firmware types Order designation: DOK-GENERL-DRIVEHELP**-GExx-MS-D0600

4 About this Documentation SGP-20VRS Notes

5 SGP-20VRS Contents I Contents 1 System overview ECODRIVE03/DURADRIVE the universal drive solutions for automation The ECODRIVE03/DURADRIVE drive families Drive controllers Command communication interface Supported motor types Supported measuring systems Function overview: FWA-DRIVE*-SGP-20VRS-MS Operating modes Basic drive functions Optional drive functions Important directions for use Appropriate use Introduction Areas of use and application Inappropriate use Safety Instructions for Electric Drives and Controls Introduction Explanations Hazards by Improper Use General Information Protection Against Contact with Electrical Parts Protection Against Electric Shock by Protective Low Voltage (PELV) Protection Against Dangerous Movements Protection Against Magnetic and Electromagnetic Fields During Operation and Mounting Protection Against Contact with Hot Parts Protection During Handling and Mounting Battery Safety Protection Against Pressurized Systems General instructions for commissioning Definition of terms, introduction Parameters Data storage Password Commands

6 II Contents SGP-20VRS Operating modes Warnings Errors IDN lists of parameters Parameterization mode - operating mode Checks in the transition commands Commissioning guidelines Diagnostics Overview of diagnostics Drive-internal diagnostics Diagnostic message composition Permanently-configured collective indication Language selection Firmware update with the "Dolfi" program Communication through the SERCOS interface Overview of SERCOS interface communication Signals with inactive SERCOS communication Cyclic data transfer through SERCOS interface Master control word Drive enable Drive Halt Drive status word Acknowledgment of drive enable Real-time control and status bits Transfer of non-cyclical data through SERCOS interface Commissioning the SERCOS interface Settings of the SERCOS interface Connecting the fiber optic cables of the SERCOS interface Setting the drive address of the SERCOS interface Checking the distortion indicator of the SERCOS interface Using the distortion indicator Setting the transmission rate of the SERCOS interface Setting the optical transmission power Checking the fiber optic cables SERCOS telegram configuration Configuration of the telegram send and receive times Configuration of telegram contents SERCOS interface error Diagnostics of the interface status Error counter for telegram interrupts Multiplex channel Overview Pertinent parameters Functional principle multiplex channel Diagnostic messages

7 SGP-20VRS Contents III 6 Command communication using parallel interface Overview Pertinent parameters How it works Drive control Configurable outputs Configurable inputs Applications Positioning block mode with parallel interface Switch of modes of operation with parallel interface Motor configuration Characteristics of the different motor types Motor feedback data memory Linear motor rotary motor Synchronous motor asynchronous motor Temperature monitoring Load default feature Setting the motor type Automatic setting of the motor type for motors with feedback data memory Setting of the motor type through P , Motor type Asynchronous motors Basics on the asynchronous motor Torque evaluation User-defined parameterization of the asynchronous motor Synchronous motors Commissioning synchronous kit motors Determining commutation offset Field weakening for synchronous motors Motor holding brake Pertinent parameters Setting the motor brake type Setting the motor brake control delay Setting maximum braking time Command "Release motor holding brake" Monitoring the motor holding brake Activation and monitoring of an external brake Connecting the motor holding brake Operating modes Setting the operating mode parameters Determining/detecting the active operating mode Operating mode: torque control Pertinent parameters Torque controller Diagnostic messages

8 IV Contents SGP-20VRS 8.4 Operating mode: velocity control Pertinent parameters Command value processing in velocity control Velocity controller Current controller Diagnostic messages Operating mode: Position control Command value processing in position control Drive-controlled command value processing in position control Position controller Position command value monitoring Position command value monitoring - setting Operating mode: drive internal interpolation Pertinent parameters Functional principle Monitoring and diagnosing Status messages during the operating mode "drive internal interpolation" Operating mode: drive controlled positioning Pertinent parameters Functional principle Acknowledging command value strobe Monitoring and diagnoses Status messages Positioning block mode Pertinent parameters How it works Activating positioning blocks Positioning block modes Parameterization notes for positioning blocks Acknowledging positioning block selected Status messages during the operating mode "positioning block mode" Diagnostic messages Hardware connections Operating mode: jogging Pertinent parameters How it works Diagnostic messages Hardware requirements for operating mode jogging Operating mode: velocity synchronization with virtual master axis Pertinent parameters Command value preparation for velocity synchronization with virtual master axis Operating mode: velocity synchronization with real master axis Pertinent parameters Functional principle Operating mode: phase synchronization with virtual master axis Pertinent Parameters

9 SGP-20VRS Contents V Command value preparation with phase synchronization with virtual master axis Operating mode: phase synchronization with real master axis Pertinent parameters Functional principle Operating mode: electronic cam shaft with virtual master axis Pertinent parameters Command value preparation for electronic cam shaft Operating mode: electronic cam shaft with real master axis Pertinent parameters Functional principle Basic drive functions Physical values display format Adjustable scaling for position, velocity and acceleration data Display format of position data Velocity data display format Acceleration data display format Command value polarities and actual value polarities Mechanical transmission elements Modulo feature Setting the measuring systems Motor encoder Optional encoder Position feedback values of non-absolute measuring systems after initialization Drive-internal format of position data Supplementary settings for absolute measuring systems Encoder types and relevant interfaces Absolute encoder range and absolute encoder evaluation Absolute encoder monitor Modulo evaluation of absolute measuring systems Position feedback values of absolute measuring systems after initialization Drive limitations Current limit Torque/force limit Velocity limit Travel range limits Master axis feedback analysis Functional principle of master axis feedback analysis Parameterizing the master axis feedback Drive error reaction Best possible deceleration Power off on error NC response in error situation E-Stop function Control loop settings General information for control loop settings

10 VI Contents SGP-20VRS Load default Setting the current controller Setting the velocity controller Velocity control loop monitoring Position controller Setting the position controller Position control loop monitoring Setting the acceleration feed forward Setting the velocity mix factor Automatic control loop settings General comments Prerequisites for starting the automatic control loop settings Executing automatic control loop settings Chronological sequence of automatic control loop settings Results of automatic control loop settings Drive halt Pertinent parameters Functional principle of drive halt Connecting the drive halt input Drive-controlled homing Pertinent parameters Setting the homing parameter Overview of the type and allocation of reference marks of non-absolute measuring systems Functional principle of drive-controlled referencing in non-absolute measuring systems Functional principle of drive-guided referencing with absolute measuring systems Functional sequence "drive-controlled homing" Commissioning with "Evaluation of reference mark/home switch edge" Commissioning with "Evaluation of distance-coded reference mark" Functions of the control during "Drive-controlled homing" Possible error messages during "Drive-controlled homing" Mounting of the home switch Connection of the home switch Homing of Gantry axes Set absolute measuring Pertinent parameters Functional principle Position feedback values after setting the absolute measurement Position feedback values of absolute encoders after power on Diagnostic messages Hardware connections Optional drive functions Configurable signal status word Pertinent parameters Configuration of the signal status words

11 SGP-20VRS Contents VII Diagnostic messages / error messages Configurable signal control word Pertinent parameters Configuring the signal control word Diagnostic messages / error messages Analog output Possible output functions Direct analog output Analog output of existing parameters Outputting pre-set signals Bit and byte outputs of the data memory Terminal assignment of analog output Analog inputs Pertinent parameters Functional principle of the analog inputs Terminal assignment of analog inputs Digital inputs/outputs Pertinent parameters Assignment of digital outputs Assignment of digital inputs Oscilloscope feature Functional principle of the oscilloscope feature Parameterizing the oscilloscope feature Probe input feature Pertinent parameters probe analysis Main function of the probe analysis Signal edge selection for the probe inputs Signal selection for the probe inputs Continuous measurement Measurement with expectation window Connecting the probe inputs Command - Detect marker position Functional principle of command detect marker position Command parking axis Pertinent parameters Functional principle Programmable limit switch Pertinent parameters Function diagram for the programmable limit switch Parameterizing the limit switch Encoder emulation Pertinent parameters Activating encoder emulation Functional principle: incremental encoder emulation Diagnostic messages with incremental encoder emulation Functional principle: absolute encoder emulation

12 VIII Contents SGP-20VRS Measuring wheel mode Pertinent parameters Functional principle Diagnostic messages Position feedback value monitor Master axis generator Master axis of master axis feedback Master axis of master drive Virtual master axis generator DISC - Drive macros EcoX Expansion interface for digital drives Overview Pertinent parameters Function Assignment drive controller I/O module Inputs and outputs Command value linkage Diagnostic messages Hardware dependence Serial communication Overview Pertinent parameters General information on the parameter structure Functional principle independent of protocol Basic state after switching control voltage on Setting the drive address Communication via RS232 interface Communication via RS485 interface Error messages Transmission protocols ASCII protocol Features Structure, telegram frame Communicating with an ASCII protocol Application example (changing position block data) Error with ASCII communication SIS protocol Features Structure, telegram frame Communicating with the SIS protocol Application examples (following telegrams) Error with SIS communication Connection technique Glossary 12-1

13 SGP-20VRS Contents IX 13 Index Service & Support Helpdesk Service-Hotline Internet Vor der Kontaktaufnahme... - Before contacting us Kundenbetreuungsstellen - Sales & Service Facilities

14 X Contents SGP-20VRS Notizen

15 SGP-20VRS System overview System overview 1.1 ECODRIVE03/DURADRIVE the universal drive solutions for automation The ECODRIVE03/DURADRIVE automation systems for universal use are particularly efficient solutions for control tasks. The characteristics of these systems are their excellent performance data, wide range of functions and favorable price-performance ratio. In addition, ECODRIVE03/DURADRIVE feature easy mounting and installation, as well as a high degree of plant availability, and allow saving system components. ECODRIVE03/DURADRIVE can be used to realize a multitude of drive tasks in most diverse applications. Typical applications are: Machine tools Printing and paper converting machines Handling systems Packaging and food processing machines Handling and mounting systems 1.2 The ECODRIVE03/DURADRIVE drive families For the ECODRIVE03/DURADRIVE family there are three firmware types for different applications: FWA-DRIVE*-SMT-2xVRS-MS FWA-DRIVE*-SGP-2xVRS-MS FWA-DRIVE*-FGP-2xVRS-MS Drives for Machine Tool Applications with SERCOS and Parallel Interface Drives for General Automation with SERCOS and Parallel Interface Drives for General Automation with Fieldbus Interfaces FWA-DRIVE*-SGP-20VRS-MS The present Functional Description refers to the firmware type: "Drives for General Automation with SERCOS and Parallel Interface" For the other firmware types mentioned there are separate documentations available.

16 1-2 System overview SGP-20VRS 1.3 Drive controllers Command communication interface Within the drive controller families ECODRIVE03 and DURADRIVE, you can choose from various devices. The differences between the devices are due to different current ratings and different device concepts (interfaces, supported motor types and measuring systems). Interfaces Apart from a serial interface, there are the following command communication interfaces available: Command communication interface DURADRIVE ECODRIVE03 DKCxx FW (*1) ECODRIVE03 DKCxx FW DKCxx FW DKCxx FW SERCOS yes yes yes Analog no no yes Parallel no yes yes INTERBUS yes yes yes PROFIBUS yes yes yes CANopen yes yes yes DeviceNet yes yes yes *1: With regard to the devices of the DKCxx FW type, please note the information in the glossary Fig. 1-1: Command communication interface Note: The command communication interfaces INTERBUS, PROFIBUS, CANopen and DeviceNet can only be operated with the FWA-DRIVE*-FGP-2xVRS-MS firmware. Supported motor types With the devices of the DURADRIVE family, you can operate all motors made by Rexroth Indramat. You can also operate all motors made by Rexroth Indramat with the devices of the ECODRIVE03 family, except for the 16-ampere device (product name DKCxx FW). On the DKCxx FW devices you can only operate Rexroth Indramat motors of the MKD type or third-party motors with resolver. Note: With regard to the devices of the DKCxx FW type, please note the information in the glossary.

17 SGP-20VRS System overview 1-3 Supported measuring systems HSF Resolver Sine encoder with 1V pp signals Encoder with EnDat interface Resolver without feedback data memory Resolver without feedback data memory with incremental sine encoder Gearwheel encoder with 1V pp signals Square-wave encoder Note: You cannot connect an optional measuring system to DKCxx FW devices (with regard to the devices of the DKCxx FW type, please note the information in the glossary)! The combinations of optional encoder and motor encoder that are possible for all other drive controllers are described under "Setting the measuring systems". 1.4 Function overview: FWA-DRIVE*-SGP-20VRS-MS Operating modes Operating mode DURADRIVE ECODRIVE03 DKCxx FW (*1) Torque/force control Velocity control only possible via CCM (SERCOS) only possible via CCM (SERCOS) only possible via CCM (SERCOS) only possible via CCM (SERCOS) Position control yes yes yes Drive internal interpolation yes yes yes Jogging Positioning block mode only possible via CCM (SERCOS) only possible via CCM (SERCOS) Drive-controlled positioning yes yes yes Stepper motor mode no yes yes Synchronous operating modes with virtual master axis Synchronous operating modes with real master axis yes yes ECODRIVE03 DKCxx FW DKCxx FW DKCxx FW yes yes yes yes yes yes yes yes no yes *1: With regard to the devices of the DKCxx FW type, please note the information in the glossary CCM: command communication module Fig. 1-2: Operating modes

18 1-4 System overview SGP-20VRS Basic drive functions The following basic drive functions can be used by all drive controllers of the DURADRIVE and ECODRIVE03 product families: Diagnosis: extensive diagnostic functions Basic parameters: basic parameter set can be activated for defined setting of the drive parameters to default values. Customer password Error memory and hours-run meter Support of 5 languages for the parameter names and units, as well as for the diagnoses German English French Spanish Italian Adjustable drive-internal position resolution Evaluation of absolute measuring systems by setting absolute measurement Modulo function Torque/force limit to be parameterized Current limit Velocity limit Travel range limit: by means of travel range limit switches and/or position limit values Drive error reaction: Best possible deceleration "Velocity command value reset" Best possible deceleration "Disable torque" Best possible deceleration "Velocity command value to zero with filter and ramp" Power off on error NC response in error situation E-Stop function Position control loop setting Basic load (read feedback data memory) Acceleration feedforward Velocity feedforward Automatic control loop setting Velocity control loop monitoring Position control loop monitoring Drive halt

19 SGP-20VRS System overview 1-5 The following basic drive functions differ with regard to their availability for the drive controllers of the DURADRIVE and ECODRIVE03 product families: Basic drive function DURADRIVE ECODRIVE03 DKCxx FW (*1) Evaluation of optional (load-side) encoders for position and/or velocity control yes no yes Control loop setting with velocity mix factor yes no yes ECODRIVE03 DKCxx FW DKCxx FW DKCxx FW *1: With regard to the devices of the DKCxx FW type, please note the information in the glossary Fig. 1-3: Basic drive functions Optional drive functions Configurable system status word Configurable system control word Oscilloscope function Command "Parking axis" Dynamic position switch Command "Get mark position" DISC EcoX communication The following optional drive functions differ with regard to their availability for the drive controllers of the DURADRIVE and ECODRIVE03 product families: Optional drive function DURADRIVE ECODRIVE03 DKCxx FW (*2) ECODRIVE03 DKCxx FW DKCxx FW DKCxx FW Command "Drive-controlled homing procedure" yes yes *1) yes Command "Set absolute measurement" yes yes *1) yes Measuring probe function yes yes *1) yes Encoder emulation yes no yes Measuring wheel mode yes no yes Analog outputs yes no yes Analog inputs yes no yes *1): Availability restricted, because optional encoder cannot be connected *2): With regard to the devices of the DKCxx FW type, please note the information in the glossary Fig. 1-4: Optional drive functions

20 1-6 System overview SGP-20VRS Notes

21 SGP-20VRS Important directions for use Important directions for use 2.1 Appropriate use Introduction Rexroth Indramat products represent state-of-the-art developments and manufacturing. They are tested prior to delivery to ensure operating safety and reliability. The products may only be used in the manner that is defined as appropriate. If they are used in an inappropriate manner, then situations can develop that may lead to property damage or injury to personnel. Note: Rexroth Indramat, as manufacturer, is not liable for any damages resulting from inappropriate use. In such cases, the guarantee and the right to payment of damages resulting from inappropriate use are forfeited. The user alone carries all responsibility of the risks. Before using Rexroth Indramat products, make sure that all the prerequisites for an appropriate use of the products are satisfied: Personnel that in any way, shape or form uses our products must first read and understand the relevant safety instructions and be familiar with appropriate use. If the product takes the form of hardware, then they must remain in their original state, in other words, no structural changes are permitted. It is not permitted to decompile software products or alter source codes. Do not mount damaged or faulty products or use them in operation. Make sure that the products have been installed in the manner described in the relevant documentation.

22 2-2 Important directions for use SGP-20VRS Areas of use and application Drive controllers made by Rexroth Indramat are designed to control electrical motors and monitor their operation. Control and monitoring of the motors may require additional sensors and actors. Note: The drive controllers may only be used with the accessories and parts specified in this document. If a component has not been specifically named, then it may not be either mounted or connected. The same applies to cables and lines. Operation is only permitted in the specified configurations and combinations of components using the software and firmware as specified in the relevant function descriptions. 2.2 Inappropriate use Every drive controller has to be programmed before starting it up, making it possible for the motor to execute the specific functions of an application. The drive controllers of the ECODRIVE03 family are designed for use in single or multiple-axis drive and control applications. To ensure an application-specific use, the drive controllers are available with differing drive power and different interfaces. Typical applications of drive controllers belonging to the ECODRIVE03 family are: handling and mounting systems, packaging and foodstuff machines, printing and paper processing machines and machine tools. The drive controllers may only be operated under the assembly, installation and ambient conditions as described here (temperature, system of protection, humidity, EMC requirements, etc.) and in the position specified. Using the drive controllers outside of the above-referenced areas of application or under operating conditions other than described in the document and the technical data specified is defined as inappropriate use". Drive controllers may not be used if they are subject to operating conditions that do not meet the above specified ambient conditions. This includes, for example, operation under water, in the case of extreme temperature fluctuations or extremely high maximum temperatures or if Rexroth Indramat has not specifically released them for that intended purpose. Please note the specifications outlined in the general safety instructions!

23 SGP-20VRS Safety Instructions for Electric Drives and Controls Safety Instructions for Electric Drives and Controls 3.1 Introduction Read these instructions before the initial startup of the equipment in order to eliminate the risk of bodily harm or material damage. Follow these safety instructions at all times. Do not attempt to install or start up this equipment without first reading all documentation provided with the product. Read and understand these safety instructions and all user documentation of the equipment prior to working with the equipment at any time. If you do not have the user documentation for your equipment, contact your local Rexroth Indramat representative to send this documentation immediately to the person or persons responsible for the safe operation of this equipment. If the equipment is resold, rented or transferred or passed on to others, then these safety instructions must be delivered with the equipment. WARNING Improper use of this equipment, failure to follow the safety instructions in this document or tampering with the product, including disabling of safety devices, may result in material damage, bodily harm, electric shock or even death! 3.2 Explanations The safety instructions describe the following degrees of hazard seriousness in compliance with ANSI Z535. The degree of hazard seriousness informs about the consequences resulting from noncompliance with the safety instructions. Warning symbol with signal word Degree of hazard seriousness according to ANSI Death or severe bodily harm will occur. DANGER Death or severe bodily harm may occur. WARNING Bodily harm or material damage may occur. CAUTION Fig. 3-1: Hazard classification (according to ANSI Z535)

24 3-2 Safety Instructions for Electric Drives and Controls SGP-20VRS 3.3 Hazards by Improper Use DANGER High voltage and high discharge current! Danger to life or severe bodily harm by electric shock! DANGER Dangerous movements! Danger to life, severe bodily harm or material damage by unintentional motor movements! WARNING High electrical voltage due to wrong connections! Danger to life or bodily harm by electric shock! WARNING Health hazard for persons with heart pacemakers, metal implants and hearing aids in proximity to electrical equipment! Surface of machine housing could be extremely hot! Danger of injury! Danger of burns! CAUTION CAUTION Risk of injury due to improper handling! Bodily harm caused by crushing, shearing, cutting and mechanical shock or incorrect handling of pressurized systems! Risk of injury due to incorrect handling of batteries! CAUTION

25 SGP-20VRS Safety Instructions for Electric Drives and Controls General Information Rexroth Indramat GmbH is not liable for damages resulting from failure to observe the warnings provided in this documentation. Read the operating, maintenance and safety instructions in your language before starting up the machine. If you find that you cannot completely understand the documentation for your product, please ask your supplier to clarify. Proper and correct transport, storage, assembly and installation as well as care in operation and maintenance are prerequisites for optimal and safe operation of this equipment. Only persons who are trained and qualified for the use and operation of the equipment may work on this equipment or within its proximity. The persons are qualified if they have sufficient knowledge of the assembly, installation and operation of the equipment as well as an understanding of all warnings and precautionary measures noted in these instructions. Furthermore, they must be trained, instructed and qualified to switch electrical circuits and equipment on and off in accordance with technical safety regulations, to ground them and to mark them according to the requirements of safe work practices. They must have adequate safety equipment and be trained in first aid. Only use spare parts and accessories approved by the manufacturer. Follow all safety regulations and requirements for the specific application as practiced in the country of use. The equipment is designed for installation in industrial machinery. The ambient conditions given in the product documentation must be observed. Use only safety features and applications that are clearly and explicitly approved in the Project Planning Manual. For example, the following areas of use are not permitted: construction cranes, elevators used for people or freight, devices and vehicles to transport people, medical applications, refinery plants, transport of hazardous goods, nuclear applications, applications sensitive to high frequency, mining, food processing, control of protection equipment (also in a machine). The information given in this documentation with regard to the use of the delivered components contains only examples of applications and suggestions. The machine and installation manufacturer must make sure that the delivered components are suited for his individual application and check the information given in this documentation with regard to the use of the components, make sure that his application complies with the applicable safety regulations and standards and carry out the required measures, modifications and complements. Startup of the delivered components is only permitted once it is sure that the machine or installation in which they are installed complies with the national regulations, safety specifications and standards of the application.

26 3-4 Safety Instructions for Electric Drives and Controls SGP-20VRS Operation is only permitted if the national EMC regulations for the application are met. The instructions for installation in accordance with EMC requirements can be found in the documentation "EMC in Drive and Control Systems". The machine or installation manufacturer is responsible for compliance with the limiting values as prescribed in the national regulations. Technical data, connections and operational conditions are specified in the product documentation and must be followed at all times.

27 SGP-20VRS Safety Instructions for Electric Drives and Controls Protection Against Contact with Electrical Parts Note: This section refers to equipment and drive components with voltages above 50 Volts. Touching live parts with voltages of 50 Volts and more with bare hands or conductive tools or touching ungrounded housings can be dangerous and cause electric shock. In order to operate electrical equipment, certain parts must unavoidably have dangerous voltages applied to them. DANGER High electrical voltage! Danger to life, severe bodily harm by electric shock! Only those trained and qualified to work with or on electrical equipment are permitted to operate, maintain or repair this equipment. Follow general construction and safety regulations when working on high voltage installations. Before switching on power the ground wire must be permanently connected to all electrical units according to the connection diagram. Do not operate electrical equipment at any time, even for brief measurements or tests, if the ground wire is not permanently connected to the points of the components provided for this purpose. Before working with electrical parts with voltage higher than 50 V, the equipment must be disconnected from the mains voltage or power supply. Make sure the equipment cannot be switched on again unintended. The following should be observed with electrical drive and filter components: Wait five (5) minutes after switching off power to allow capacitors to discharge before beginning to work. Measure the voltage on the capacitors before beginning to work to make sure that the equipment is safe to touch. Never touch the electrical connection points of a component while power is turned on. Install the covers and guards provided with the equipment properly before switching the equipment on. Prevent contact with live parts at any time. A residual-current-operated protective device (RCD) must not be used on electric drives! Indirect contact must be prevented by other means, for example, by an overcurrent protective device. Electrical components with exposed live parts and uncovered high voltage terminals must be installed in a protective housing, for example, in a control cabinet.

28 3-6 Safety Instructions for Electric Drives and Controls SGP-20VRS To be observed with electrical drive and filter components: DANGER High electrical voltage on the housing! High leakage current! Danger to life, danger of injury by electric shock! Connect the electrical equipment, the housings of all electrical units and motors permanently with the safety conductor at the ground points before power is switched on. Look at the connection diagram. This is even necessary for brief tests. Connect the safety conductor of the electrical equipment always permanently and firmly to the supply mains. Leakage current exceeds 3.5 ma in normal operation. Use a copper conductor with at least 10 mm² cross section over its entire course for this safety conductor connection! Prior to startups, even for brief tests, always connect the protective conductor or connect with ground wire. Otherwise, high voltages can occur on the housing that lead to electric shock. 3.6 Protection Against Electric Shock by Protective Low Voltage (PELV) All connections and terminals with voltages between 0 and 50 Volts on Rexroth Indramat products are protective low voltages designed in accordance with international standards on electrical safety. WARNING High electrical voltage due to wrong connections! Danger to life, bodily harm by electric shock! Only connect equipment, electrical components and cables of the protective low voltage type (PELV = Protective Extra Low Voltage) to all terminals and clamps with voltages of 0 to 50 Volts. Only electrical circuits may be connected which are safely isolated against high voltage circuits. Safe isolation is achieved, for example, with an isolating transformer, an opto-electronic coupler or when battery-operated.

29 SGP-20VRS Safety Instructions for Electric Drives and Controls Protection Against Dangerous Movements Dangerous movements can be caused by faulty control of the connected motors. Some common examples are: improper or wrong wiring of cable connections incorrect operation of the equipment components wrong input of parameters before operation malfunction of sensors, encoders and monitoring devices defective components software or firmware errors Dangerous movements can occur immediately after equipment is switched on or even after an unspecified time of trouble-free operation. The monitoring in the drive components will normally be sufficient to avoid faulty operation in the connected drives. Regarding personal safety, especially the danger of bodily injury and material damage, this alone cannot be relied upon to ensure complete safety. Until the integrated monitoring functions become effective, it must be assumed in any case that faulty drive movements will occur. The extent of faulty drive movements depends upon the type of control and the state of operation.

30 3-8 Safety Instructions for Electric Drives and Controls SGP-20VRS DANGER Dangerous movements! Danger to life, risk of injury, severe bodily harm or material damage! Ensure personal safety by means of qualified and tested higher-level monitoring devices or measures integrated in the installation. Unintended machine motion is possible if monitoring devices are disabled, bypassed or not activated. Pay attention to unintended machine motion or other malfunction in any mode of operation. Keep free and clear of the machine s range of motion and moving parts. Possible measures to prevent people from accidentally entering the machine s range of motion: - use safety fences - use safety guards - use protective coverings - install light curtains or light barriers Fences and coverings must be strong enough to resist maximum possible momentum, especially if there is a possibility of loose parts flying off. Mount the emergency stop switch in the immediate reach of the operator. Verify that the emergency stop works before startup. Don t operate the machine if the emergency stop is not working. Isolate the drive power connection by means of an emergency stop circuit or use a starting lockout to prevent unintentional start. Make sure that the drives are brought to a safe standstill before accessing or entering the danger zone. Safe standstill can be achieved by switching off the power supply contactor or by safe mechanical locking of moving parts. Secure vertical axes against falling or dropping after switching off the motor power by, for example: - mechanically securing the vertical axes - adding an external braking/ arrester/ clamping mechanism - ensuring sufficient equilibration of the vertical axes The standard equipment motor brake or an external brake controlled directly by the drive controller are not sufficient to guarantee personal safety!

31 SGP-20VRS Safety Instructions for Electric Drives and Controls 3-9 Disconnect electrical power to the equipment using a master switch and secure the switch against reconnection for: - maintenance and repair work - cleaning of equipment - long periods of discontinued equipment use Prevent the operation of high-frequency, remote control and radio equipment near electronics circuits and supply leads. If the use of such equipment cannot be avoided, verify the system and the installation for possible malfunctions in all possible positions of normal use before initial startup. If necessary, perform a special electromagnetic compatibility (EMC) test on the installation. 3.8 Protection Against Magnetic and Electromagnetic Fields During Operation and Mounting Magnetic and electromagnetic fields generated near current-carrying conductors and permanent magnets in motors represent a serious health hazard to persons with heart pacemakers, metal implants and hearing aids. WARNING Health hazard for persons with heart pacemakers, metal implants and hearing aids in proximity to electrical equipment! Persons with heart pacemakers, hearing aids and metal implants are not permitted to enter the following areas: - Areas in which electrical equipment and parts are mounted, being operated or started up. - Areas in which parts of motors with permanent magnets are being stored, operated, repaired or mounted. If it is necessary for a person with a heart pacemaker to enter such an area, then a doctor must be consulted prior to doing so. Heart pacemakers that are already implanted or will be implanted in the future, have a considerable variation in their electrical noise immunity. Therefore there are no rules with general validity. Persons with hearing aids, metal implants or metal pieces must consult a doctor before they enter the areas described above. Otherwise, health hazards will occur.

32 3-10 Safety Instructions for Electric Drives and Controls SGP-20VRS 3.9 Protection Against Contact with Hot Parts CAUTION Housing surfaces could be extremely hot! Danger of injury! Danger of burns! Do not touch housing surfaces near sources of heat! Danger of burns! After switching the equipment off, wait at least ten (10) minutes to allow it to cool down before touching it. Do not touch hot parts of the equipment, such as housings with integrated heat sinks and resistors. Danger of burns! 3.10 Protection During Handling and Mounting Under certain conditions, incorrect handling and mounting of parts and components may cause injuries. CAUTION Risk of injury by incorrect handling! Bodily harm caused by crushing, shearing, cutting and mechanical shock! Observe general installation and safety instructions with regard to handling and mounting. Use appropriate mounting and transport equipment. Take precautions to avoid pinching and crushing. Use only appropriate tools. If specified by the product documentation, special tools must be used. Use lifting devices and tools correctly and safely. For safe protection wear appropriate protective clothing, e.g. safety glasses, safety shoes and safety gloves. Never stand under suspended loads. Clean up liquids from the floor immediately to prevent slipping.

33 SGP-20VRS Safety Instructions for Electric Drives and Controls Battery Safety Batteries contain reactive chemicals in a solid housing. Inappropriate handling may result in injuries or material damage. CAUTION Risk of injury by incorrect handling! Do not attempt to reactivate discharged batteries by heating or other methods (danger of explosion and cauterization). Never charge non-chargeable batteries (danger of leakage and explosion). Never throw batteries into a fire. Do not dismantle batteries. Do not damage electrical components installed in the equipment. Note: Be aware of environmental protection and disposal! The batteries contained in the product should be considered as hazardous material for land, air and sea transport in the sense of the legal requirements (danger of explosion). Dispose batteries separately from other waste. Observe the legal requirements in the country of installation Protection Against Pressurized Systems Certain motors and drive controllers, corresponding to the information in the respective Project Planning Manual, must be provided with pressurized media, such as compressed air, hydraulic oil, cooling fluid and cooling lubricant supplied by external systems. Incorrect handling of the supply and connections of pressurized systems can lead to injuries or accidents. In these cases, improper handling of external supply systems, supply lines or connections can cause injuries or material damage. CAUTION Danger of injury by incorrect handling of pressurized systems! Do not attempt to disassemble, to open or to cut a pressurized system (danger of explosion). Observe the operation instructions of the respective manufacturer. Before disassembling pressurized systems, release pressure and drain off the fluid or gas. Use suitable protective clothing (for example safety glasses, safety shoes and safety gloves) Remove any fluid that has leaked out onto the floor immediately. Note: Environmental protection and disposal! The media used in the operation of the pressurized system equipment may not be environmentally compatible. Media that are damaging the environment must be disposed separately from normal waste. Observe the legal requirements in the country of installation.

34 3-12 Safety Instructions for Electric Drives and Controls SGP-20VRS Notes

35 SGP-20VRS General instructions for commissioning General instructions for commissioning 4.1 Definition of terms, introduction It is helpful to explain the terms used in this document so that they will be better understood. Parameters Communication with the drive occurs (with a few exceptions) with the help of parameters. They can be used for Setting the configuration Parameterizing the controller settings Handling drive functions and commands Cyclical or acyclical (depending on requirements) transmission of command and actual values Note: All of the drive s operating data are identified by IDNs. The data status Each parameter is provided with a data status, which can also be read. It serves the following purposes: Identifying the validity/invalidity of the parameter Contains the command acknowledgement if the parameter acts as a command (see also chapter: "Commands") Parameter structure There are seven different data block elements for each parameter. These can be read/write accessed either via a user data interface by a higherranking control or a parameterization interface. Element No. Designation Remarks 1 ID Number parameter identification / reading of data status 2 Name can be changed in language selection 3 Attribute contains data length, type and decimal places 4 Unit can be changed in language selection 5 Minimum input value contains the minimum input value of the operating data 6 Maximum input value contains the maximum input value of the operating data 7 Operating data actual parameter value Fig. 4-1: Data block or parameter structure Write accessibility There is write access only for the operating data; all other elements can only be read.

36 4-2 General instructions for commissioning SGP-20VRS Data storage The operating data can be write-protected either continuously or temporarily. The write accessing of the operating data depends on the relevant communication phase or on whether a password has been activated. Possible error messages when reading and writing operating data see chapter "Error messages" Non-volatile parameter storage registers Various non-volatile parameter storage registers that buffer operating data are contained in the drive. The operating data apply to: setting the configuration and parameterizing the controller settings With each write access of an operating date the date is stored. The following modules contain non-volatile memories: Drive controller Motor feedback (optional) Programming module Parameters stored in the drive controller All operating data that refer only to the drive controller and that cannot be changed by the user are stored in the drive controller. This applies to the following parameters: S , Amplifier peak current S , Controller type P , Operating hours control section P , Operating hours power section P , Error recorder, diagnosis number P , Error recorder, operating hours control section P , Hardware code P , Current-zero-trim phase U P , Current-zero-trim phase V P , Current-amplify-trim phase U P , Current-amplify-trim phase V P , Test status P , Trim-current P , Intermediate DC bus voltage gain adjust P , Resolver input offset P , Resolver input, amplitude adjust P , Amplifier type data P , Brake resistor data P , Mains voltage gain adjust P , Serial number P , Production index