Lexium MDrive Motion Control with circular connectors Integrated Motor + Driver + Programmable Controller Product manual V1.00, 03.

Transcription

1 with circular connectors Integrated Motor + Driver + Programmable Controller Product manual IP65 Applicable to: LMDOM57xC LMDOM85xC LMDCM57xC LMDCM85xC

2 Manual Date Revision Changes 08/19/2014 V1.00, Initial release 03/18/2015 Added information on IP65 rating for NEMA 23 (57 mm) Lexium MDrive products. Minor corrections and updates.

3 Important information This manual is part of the product. Carefully read this manual and observe all instructions. Keep this manual for future reference. Hand this manual and all other pertinent product documentation over to all users of the product. Carefully read and observe all safety instructions and the chapter Before you begin - safety information. Some products are not available in all countries. For information on the availability of products, please consult the catalog. Subject to technical modifications without notice. All details provided are technical data which do not constitute warranted qualities. Most of the product designations are registered trademarks of their respective owners, even if this is not explicitly indicated.

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5 Table of Contents Table of Contents Important information... 3 Writing conventions and symbols Introduction About this manual Unit overview Components and interfaces Components Interfaces Name plate Part number identification Documentation and literature references Before you begin - safety information Qualification of personnel Intended use Hazard categories Basic information Standards and terminology Technical data Certifications Environmental conditions Mechanical data Degree of protection Mounting NEMA 23 (57 mm) dimensions NEMA 34 (85 mm) dimensions Electrical data Supply voltage VDC at P Multifunction interface at P2 a & b Service interface at P LED indicators Motor data LMD 57 (NEMA 23) specifications LMD 57 (NEMA 23) performance LMD 85 (NEMA 34) specifications LMD 85 (NEMA 34) performance Conditions for UL 508C Basics Functional safety Working with IEC Engineering External power supply units Supply voltage +VDC Auxiliary power supply Wiring and shielding Ground design Monitoring functions i

6 Table of Contents 6 Installation Electromagnetic compatibility, EMC Mechanical installation Electrical installation Overview of all connectors Connection of the supply voltage VDC Connection of the multifunction interface Connection of the service interface Checking wiring Configuration Preparing for Configuration Installing the Lexium MDrive Software Suite Operation Basics Overview hmtechnology (hmt) Overview of motor phase current Software operation modes Immediate mode Program mode Operation by hmt modes hmt off (bypass) (AS=0) hmt on (fixed current) (AS=1) hmt on (variable current) (AS=2) hmt on (torque mode) (AS=3) I/O operation General purpose inputs General purpose outputs Analog input Signal output Diagnostics and troubleshooting Error indication and troubleshooting Operation state and error indication Error codes Accessories and spare parts Accessories Service, maintenance and disposal Service address Maintenance Replacing units Shipping, storage, disposal Glossary Units and conversion tables Length Mass Force Power Rotation Torque Moment of inertia Temperature Conductor cross section Terms and Abbreviations ii

7 Table of Contents List of Figures Figure 1.1: Components and Interfaces... 4 Figure 1.2: Name plate... 6 Figure 1.3: Part numbering... 7 Figure 3.1: Mounting positions Figure 3.2: NEMA 23 (57 mm) Mounting hole pattern Figure 3.3: NEMA 34 (85 mm) Mounting hole pattern Figure 3.4: LMDxx57xC dimensions [inches (mm)] Figure 3.5: LMDxx85xC Dimensions [inches (mm)] Figure 3.4: Overview of connectors Figure 3.7: LMD 57 torque-speed performance curves Figure 3.8: LMD 85 torque-speed performance curves Figure 5.1: DC power supply cabling under 50 (15.24 m) Figure 5.2: AC power to full wave bridge Figure 5.3: AC power to DC supply Figure 5.4: System power wiring Figure 6.1: Overview of connectors Figure 6.2: Pin Assignment supply voltage Figure 6.4: Multifunction interface pin assignments Figure 6.8: Open collector sourcing Figure 6.9: Wiring example - mechanical switches Figure 6.10: Wiring example - NPN sensors Figure 6.11: Wiring example - PNP sensors Figure 6.12: Output sinking configuration Figure 6.13: Output sourcing configuration Figure 6.14: Output wiring examples Figure 6.15: Signal output Figure 6.16: ANALOG_IN signal input Figure 6.17: Analog input sample wiring Figure 6.18: Service interface pin assignments Figure 6.19: Full duplex interface, single mode (RS422) Figure 6.20: Half-duplex interface, party mode (RS485) Figure 6:21: Full-duplex interface, party mode (RS422) Figure 8.1: Control bounds for hmtechnology Figure 8.2: Overview of motor phase current Figure 8.3: Master-slave network architecture Figure 8.4: Distributed control architecture Figure 8.5: Motion block, hmt disabled Figure 8.6: Block diagram, hmt enable (AS=1/2) Figure 10.1: MD-CS pin M12 A-coded Figure 10.2: MD-CS pin M12 A-coded Figure 10.3: MD-CS pin M12 B-coded iii

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9 Writing conventions and symbols Writing conventions and symbols Work steps If work steps must be performed consecutively, this sequence of steps is represented as follows: Special prerequisites for the following work steps XX Step 1 YY Specific response to this work step XStep X 2 If a response to a work step is indicated, this allows you to verify that the work step has been performed correctly. Unless otherwise stated, the individual steps must be performed in the specified sequence. Bulleted lists The items in bulleted lists are sorted alphanumerical or by priority. Bulleted lists are structured as follows: Item 1 of bulleted list Item 2 of bulleted list Subitem for 2 Subitem for 2 Item 3 of bulleted list Making work easier Information on making work easier is highlighted by this symbol: Sections highlighted this way provide supplementary information on making work easier. Parameters Parameters are shown as follows RC Motor Run Current Units of measure Measurements are given US units, metric values are given in SI units in parenthesis. Examples 1.00 in (25.4 mm) 100 oz-in (70 N-cm) 1

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11 1 Introduction 1 Introduction About this manual This manual is valid for all standard products. This chapter lists the type code for this product. The type code can be used to identify whether your product is a standard product or a customized model. 1.2 Unit overview The consists of a stepper motor and integrated electronics. The product integrates interfaces, drive and control electronics and the power stage. Operating modes The is a fully programmable motion control system allowing for complex program and I/O interaction. Operating modes may be used interchangeably: Immediate mode: In immediate mode, also known as streaming commands, the device will respond to 1 and 2 character ASCII commands sent via the RS-422/485 fieldbus interface Program mode: In program mode the device may be programmed with multiple functions, subroutines and process interactions using the MCode programming language, which is made up of 1 and 2 character ASCII mnemonics. Stored programs may be executed using an input, by labeling a program SU to run it on start up, or via an immediate mode command. All setup parameters are set via the service interface. 3

12 1 Introduction 1.3 Components and interfaces NEMA 23 (57 mm) product shown below, the NEMA 34 (85 mm) has identical components and interfaces A C G B F D E Warranty void if removed. Figure 1.1: Components and Interfaces (A) Electronics housing (B) Two phase stepper motor (C) DC power interface (D) Multifunction interface (E) Service interface (F) Protective earth (G) LED indicators Components Motor The motor is a two phase brushless stepper motor. The motor has a high torque density due to the use of the latest magnetic materials and enhanced design. The step angle of the motor is 1.8. Electronics housing The electronics system is comprised of control electronics and power stage. The drive system is controlled by streaming commands via the service interface, embedded programming, or by pulse and direction input signals. 4

13 1 Introduction Interfaces Standard available interfaces connect using standard M12 circular connectors. DC power supply voltage The supply voltage VDC supplies the drive and control electronics and the power stage. This connector also contains the 12 to 24V Aux-Power input to supply power to logic circuits in the event of main supply loss. The ground connections of all interfaces are galvanically connected. For more information see chapter 5.2 Ground design. This chapter also provides information on protection against reverse polarity. Multifunction interface The multifunction interface operates at the following signal levels: 24V input signals are opto-isolated 24V output signals are opto-isolated and current limited 0 to 10V analog signal is not isolated The 24V input signals are programmable as general purpose or to predefined functions. Input 1 also has the alternate high speed function of being configured as a capture input. Two 24V output signals are programmable as general purpose or to a set of predefined functions. One output is special function as a high speed trip output. The reference voltage or current is applied to the analog input can be used for a number of programmatically defined operations. Interface is accomplished via a 12-position M12-M connector. Service interface The service interface provides a connection to the RS-422/485 bus. A PC may be connected to the interface via a USB to RS-422/485 converter via a 5-position M12-F connector. The commissioning software may then be used for tasks such as parameterization and monitoring the status of the device. The service interface is also used for firmware upgrades. Protective earth Protective earth provides a means of grounding to the device chassis. 5

14 1 Introduction 1.4 Name plate The name plate has the following information 7 1 C IP Figure 1.2: Name plate (1) Part number (2) Nominal voltage (3) Nominal torque (4) Max required input current (5) Serial number (6) Date of manufacture (7) CE mark (8) Communication interface (9) Data matrix (10) Ingress Protection rating 6

15 1 Introduction 1.5 Part number identification LMD O M 57 1 C Product Lexium MDrive Control type O = Open loop (no encoder) C = Closed loop (with encoder) Communication interface M = Motion Control RS-422/485 Size 57 = 57 mm / NEMA = 85 mm / NEMA 34 Length 1 = 1 stack 2 = 2 stacks 3 = 3 stacks Options C = M12 circular industrial connectors Figure 1.3: Part numbering 1.6 Documentation and literature references This document should be used in conjunction with the MCode Programming and Reference software manual. MCode is an ASCII language used to commission, parameterize, program and control the Lexium MDrive Motion Control. Source product manuals The current product manuals are available for download from the Internet. 7

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17 2 Before you begin - safety information 2 Before you begin - safety information Qualification of personnel 2.2 Intended use The information provided in this manual supplements the product manual. Carefully read the product manual before using the product. Only appropriately trained persons who are familiar with and understand the contents of this manual and all other pertinent product documentation are authorized to work on and with this product. In addition, these persons must have received safety training to recognize and avoid hazards involved. These persons must have sufficient technical training, knowledge and experience and be able to foresee and detect potential hazards that may be caused by using the product, by changing the settings and by the mechanical, electrical and electronic equipment of the entire system in which the product is used. All persons working on and with the product must be fully familiar with all applicable standards, directives, and accident prevention regulations when performing such work. This product is a motor with an integrated drive and intended for industrial use according to this manual. The product may only be used in compliance with all applicable safety regulations and directives, the specified requirements and the technical data. Prior to using the product, you must perform a risk assessment in view of the planned application. Based on the results, the appropriate safety measures must be implemented. Since the product is used as a component in an entire system, you must ensure the safety of persons by means of the design of this entire system (for example, machine design). Operate the product only with the specified cables and accessories. Use only genuine accessories and spare parts. The product must NEVER be operated in explosive atmospheres (hazardous locations, Ex areas). Any use other than the use explicitly permitted is prohibited and can result in hazards. V1.00, Electrical equipment should be installed, operated, serviced, and maintained only by qualified personnel. 9

18 2 Before you begin - safety information 2.3 Hazard categories Safety instructions to the user are highlighted by safety alert symbols in the manual. In addition, labels with symbols and/or instructions are attached to the product that alert you to potential hazards. Depending on the seriousness of the hazard, the safety instructions are divided into 4 hazard categories. DANGER indicates an imminently hazardous situation, which, if not avoided, will result in death or serious injury. WARNING indicates a potentially hazardous situation, which, if not avoided, can result in death, serious injury, or equipment damage. CAUTION indicates a potentially hazardous situation, which, if not avoided, can result in injury or equipment damage. CAUTION used without the safety alert symbol, is used to address practices not related to personal injury (e.g. can result in equipment damage). V1.00,

19 2 Before you begin - safety information 2.4 Basic information UNINTENDED CONSEQUENCES OF EQUIPMENT OPERATION When the system is started, the drives are usually out of the operator s view and cannot be visually monitored. Only start the system if there are no persons in the hazardous area. Failure to follow these instructions will result in death or serious injury. UNEXPECTED MOVEMENT Drives may perform unexpected movements because of incorrect wiring, incorrect settings, incorrect data or other errors. Interference (EMC) may cause unpredictable responses in the system. Carefully install the wiring in accordance with the EMC requirements. Ensure the BRIDGE ENABLE input is inactive to avoid an unexpected restart of the motor before switching on and configuring the drive system. Do NOT operate the drive system with unknown settings or data. Perform a comprehensive commissioning test. Failure to follow these instructions can result in death or serious injury. V1.00,

20 2 Before you begin - safety information LOSS OF CONTROL The designer of any control scheme must consider the potential failure modes of control paths and, for certain critical functions, provide a means to achieve a safe state during and after a path failure. Examples of critical control functions are emergency stop, overtravel stop, power outage and restart. Separate or redundant control paths must be provided for critical functions. System control paths may include communication links. Consideration must be given to the implication of unanticipated transmission delays or failures of the link. Observe all accident prevention regulations and local safety guidelines. 1) Each implementation of the product must be individually and thoroughly tested for proper operation before being placed into service. Failure to follow these instructions can result in death or serious injury. 1) For USA: Additional information, refer to NEMA ICS 1.1 (latest edition), Safety Guidelines for the Application, Installation, and Maintenance of Solid State Control and to NEMA ICS 7.1 (latest edition), Safety Standards for Construction and Guide for Selection, Installation and Operation of Adjustable-Speed Drive Systems. UNEXPECTED BEHAVIOR AND DESTRUCTION OF SYS- TEM COMPONENTS When you work on the wiring and when you unplug or plug in connectors, this may cause unexpected behavior and destruction of system components. Switch the power supply off before working on the wiring. Failure to follow these instructions can result in injury or equipment damage. V1.00,

21 2 Before you begin - safety information 2.5 Standards and terminology TAMPER SEAL Opening Lexium MDrive heat sinks can affect factory-set encoder alignment and impact hmtechnology performance. Tamper seals are to ensure factory hardware settings remain unaltered and match the encoder alignment set during the manufacturing process. If a seal is broken, the LMD product warranty is void. If experiencing faulty or erratic operation, contact the factory for support. Failure to follow these instructions can result in injury or equipment damage. Technical terms, terminology and the corresponding descriptions in this manual are intended to use the terms or definitions of the pertinent standards. In the area of drive systems, this includes, but is not limited to, terms such as safety function, safe state, fault, fault reset, failure, error, error message, warning, warning message, etc. Among others, these standards include: IEC series: Adjustable speed electrical power drive systems IEC series: Adjustable speed electrical power drive systems - Part 7-1: Generic interface and use of profiles for power drive systems - Interface definition IEC series: Industrial communication networks - Fieldbus specifications IEC series: Industrial communication networks - Profiles IEC series: Functional safety of electrical/electronic/programmable electronic safety-related systems V1.00,

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23 3 Technical data 3 Technical data 3 This chapter contains information on the ambient conditions and on the mechanical and electrical properties of the device family and the accessories. 3.1 Certifications Product certifications: Certification Regulation # Validity RoHS 2011/65/EU 08/01/2014 EMC 2004/108/EC 08/01/2014 REACH EC 1907/ /19/ Environmental conditions Ambient operating conditions The maximum permissible ambient temperature during operation depends on the distance between the devices and the required power. Observe the pertinent instructions in the chapter Installation. The following relative humidity is permissible during operation. Operating temperature 1) [ C] (no icing) Temperature variation [ C/min] 0.5 Humidity [%] (non-condensing) 1) If the product is to be used in compliance with UL 508C, note the information provided in chapter 3.6 Conditions for UL 508C. Ambient conditions: transportation and storage The environment during transport and storage must be dry and free from dust. The maximum vibration and shock load must be within the specified limits. Temperature [ C] Temperature variation [ C] Humidity [%] (non-condensing) 15

24 3 Technical data Maximum operating temperatures Power stage 1) [ C] 85 Motor 2) [ C] 100 1) May be read via parameter 2) Measured on the surface Installation altitude The installation altitude is defined as height above sea level Installation altitude 3) [ft (m)] 3280 (1000) 3) Installation above 3280 (1000) may require derating output current and maximum ambient temperature. Vibration and shock Vibration, sinusoidal m/s 2 10 IEC Shock, non-sinusoidal m/s IEC EMC Emission IEC (Category C2) Noise immunity IEC Mechanical data Degree of protection IP degree of protection The product has the following IP degree of protection as per EN NEMA 23 (57 mm) NEMA 34 (85 mm) Degree of protection IP65 (1) IP20 (1) The motor shaft is not sealed against ingress of moisture/particulates. The total degree of protection is determined by the component with the lowest degree of protection. IP degrees of protection overview First digit Protection against intrusion of Second digit Protection against intrusion of water objects 0 No protection 0 No protection 1 External objects >50 mm 1 Vertically falling dripping water 2 External objects >12 mm 2 Dripping water falling at an angle ( ) 3 External objects >2.5 mm 3 Spraying water 4 External objects >1 mm 4 Splashing water 5 Dust-protected 5 Water jets 6 Dust-tight 6 Heavy sea 7 Immersion 8 Submersion 16

25 3 Technical data Mounting AXIAL AND RADIAL LOADING OF THE SHAFT Mounting of the load to the shaft must be done with regard to the radial and axial load limits of the motor Failure to follow these instructions can result in equipment damage. The following mounting positions are defined and approved as per EN : IM B5 drive shaft horizontal IM V1 drive shaft vertical, shaft end down IM V3 drive shaft vertical, shaft end up IM B5 Figure 3.1: Mounting positions IM V1 IM V3 NEMA 23 (57 mm) Mounting holes Mounting the LMDXX57X uses four (4) M5 x 0.5 screws on a bolt circle diameter (BCD) of (66.61 mm). The length of the screws will be determined by the thickness of the mounting material plus (4.7 mm) motor mounting flange thickness. Ø (66.61) Ø (38.1) (5.0) Thru 4 Places on a (66.61) Circle ( 47.10) Figure 3.2: NEMA 23 (57 mm) Mounting hole pattern (not to scale) 17

26 3 Technical data NEMA 34 (85mm) Mounting holes Mounting the LMDXX85X uses four (4) M5 x 0.8 screws on a bolt circle diameter (BCD) of (98.39 mm). The length of the screws will be determined by the thickness of the mounting material plus (10.6 mm) motor mounting flange thickness. Ø (98.39) Ø (73.0) (6.5) Thru 4 Places on a (98.39) Circle ( 69.57) Figure 3.3: NEMA 34 (85 mm) Mounting hole pattern (not to scale) 18

27 3 Technical data NEMA 23 (57 mm) dimensions 2.20 (55.9) 0.81 ±0.02 (20.56 ±0.51) 0.59 ±0.006 (15.0 ±0.20) Ø 1.50 ±0.002 (Ø ±0.05) 3.81 (96.8) 0.18 (4.57) L MAX 1 L MAX ±0.008 (1.6 ±0.20) shaft not sealed Ø / (Ø /-0.013) 0.23 ±0.004 (5.8 ±0.1) at shaft flat 4 x Ø /-0 (4 x Ø /-0) ±0.008 ( ±0.20) 2.22 ( 56.40) 2.59 (65.8) 1.28 (32.58) #6-32 x DP (For earth ground) (TYP) 3.81 (96.8) MAX C L L MAX 1 L MAX 2 LMD 571 in (mm) 3.22 (81.8) 3.83 (97.3) LMD 572 in (mm) 3.56 (90.4) 4.21 (106.9) LMD 573 in (mm) 4.44 (112.7) 5.06 (128.5) Figure 3.4: LMDxx57xC dimensions [inches (mm)] 19

28 3 Technical data NEMA 34 (85 mm) dimensions (50.12) (65.19) (29.45) (10.01) ±0.039 (37.1 ±1.0) Ø ±0.001 (Ø 73.0 ±0.025) ±0.01 (24.99 ±0.25) 4.65 (118.12) shaft not sealed Ø / (Ø /-0.010) ±0.004 (13.0 ±0.10) at shaft flat L MAX1 L MAX (2.0) 4 x Ø ±0.008 (4 x Ø 6.50 ±0.20) ( 69.57) ( 86.11) 3.59 (91.24) #6-32 x DP (For earth ground) (TYP) L MAX 1 L MAX 2 LMD (102.7) 4.65 (118.2) LMD (116.2) 5.18 (131.7) LMD (156.1) 6.75 (171.5) Figure 3.5: LMDxx85xC Dimensions [inches (mm)] 20

29 3 Technical data 3.4 Electrical data Overview of connectors LED 1 LED 2 4 P1 Chassis P2 P3 Figure 3.4: Overview of connectors Supply voltage VDC at P1 LDM 57 LDM 85 Nominal voltage 1). 2) [+V dc ] 24/48 24/48 Limit values min/max 1), 2) [+V dc ] 12/60 12/70 Ripple at nominal voltage [+V pp ] Max. current input [A] ) UL 508C rating to 48VDC, posted max ratings conforms to CE low voltage directive. 2) The actual power requirement is often significantly lower, because the maximum possible motor torque is usually not required for operation of a system. Auxiliary supply voltage VDC Aux power is used to maintain power to the logic circuits and retain information stored in counters, registers and user variable in the event of system power loss. It is not a required connection. Limit values min/max [+V dc ] Ripple at max voltage [+V pp ] 2.4 Max. current input [ma]

30 3 Technical data Multifunction interface at P2 a & b Signal inputs The signal input functions are programmable in function. They may be used as sinking or sourcing based upon the bias of the INPUT_ REFERENCE Voltage range [+V dc ] input current (5V) [ma] 8.7 Input current (24V) [ma] 14.6 Input frequency [khz] 5 Isolation Galvanic Protection class III Analog input Voltage mode 0-5 [V dc ] Voltage mode 0-10 [V dc ] Current loop mode [ma] Resolution [Bits] 10 Impedance by mode 0-5 V [MΩ] V [kω] ma [Ω] 5 Isolation None Power outputs Voltage rating [V dc ] Current rating [ma] RDS ON [Ω] T ON (hardware) [ms] T OFF (hardware) [ms] O/C Level (±) [ma] S/C Peak (+ or [ma] 2.2 (max) Clamp voltage [V dc ]

31 3 Technical data Signal output Voltage open-collector [V dc ] 60 Voltage open-emitter [V dc ] 7 Current open-collector [ma] 5.5 Current open-emitter [ma] 5.5 Isolation Galvanic Service interface at P3 RS-422/485 RS-422/485 serial communications bus. Interface can be half-duplex (2 wire RS485) in party mode or full-duplex (4 wire RS422) in both single and party mode. Multi-drop addressable to 62 nodes. Bus is optically isolated. Characteristic of serial data lines RS485 Baud rate [kbps] Isolation Galvanic LED indicators The Lexium MDrive has two LEDs for status indication. LED 1: Status of the power supply LED 2: Status indication. Indication functions programmed using the AO command. See Lexium MCode manual. LED 1 power indication Color Status Off Green Flashing green Red Flashing red No Power +VDC supply in range +VDC off, drive on AUX power +VDC supply out of range +VDC off, AUX power out of range LED 2 status indication See the AO command of the Lexium MCode manual for available attention states. Color Off Green Red Status Not configured No attention state exists Attention state exists 23

32 3 Technical data 3.5 Motor data LMD 57 (NEMA 23) specifications LMD 571 LMD 572 LMD 573 Holding torque oz-in (N-cm) 103.4(73) (112) (171) Detent torque oz-in (N-cm) 3.89 (2.74) 5.55 (3.91) 9.72 (6.86) Rotor inertia oz-in-sec 2 (kg-cm 2 ) (0.18) (0.26) (0.46) Radial load limit End of shaft lb (kg) 10 (4.5) 10 (4.5) 10 (4.5) Center of shaft flat lb (kg) 15 (6.8) 15 (6.8) 15 (6.8) Center of shaft lb (kg) 20 (9.0) 20 (9.0) 20 (9.0) Axial load limit lb (kg)@1500rpm 20 (9.0) 20 (9.0) 20 (9.0) Weight oz (g) 26.4 (748) 31.2 (885) 44.0 (1247.3) LMD 57 (NEMA 23) performance Test condition: hmt OFF: 100% current 0.84 oz damper, inertia: oz-in 2 Single stack length Torque in Oz-In / N-cm Double stack length Torque in Oz-In / N-cm 225/ / VDC 48 VDC 60 VDC 225/ / VDC 48 VDC 60 VDC 75/53 75/ (600) 4000 (1200) 6000 (1800) Speed of rotation in full steps per second (rpm) (600) 4000 (1200) Speed of rotation in full steps per second (rpm) 6000 (1800) Triple stack length Torque in Oz-In / N-cm 225/ / VDC 48 VDC 60 VDC 75/ (600) 4000 (1200) 6000 (1800) Speed of rotation in full steps per second (rpm) Figure 3.7: LMD 57 torque-speed performance curves 24

33 3 Technical data LMD 85 (NEMA 34) specifications LMD 851 LMD 852 LMD 853 Holding torque oz-in (N-cm) 336(237) 480 (339) 920 (650) Detent torque oz-in (N-cm) 10.9 (7.7) (10.0) (14.0) Rotor inertia oz-in-sec 2 (kg-cm 2 ) (0.9) (1.35) (2.7) Radial load limit End of shaft lb (kg) 45 (20.4) 45 (20.4) 45 (20.4) Center of shaft flat lb (kg) 65 (29.4) 65 (29.4) 65 (29.4) Center of shaft lb (kg) 80 (36.3) 80 (36.3) 80 (36.3) Axial load limit lb (kg)@1500rpm 20 (9.0) 20 (9.0) 20 (9.0) Weight oz (gm) 4.45 (2.02) 5.65 (2.56) 9.00 (4.08) LMD 85 (NEMA 34) performance Test condition: hmt OFF: 100% current 3.7 oz damper, inertia: oz-in2 Single stack length Torque in Oz-In / N-cm Double stack length Torque in Oz-In / N-cm 900/ / VDC 48 VDC 70 VDC 900/ / VDC 48 VDC 70 VDC 300/ / (600) 4000 (1200) Speed of rotation in full steps per second (rpm) 6000 (1800) (600) 4000 (1200) Speed of rotation in full steps per second (rpm) 6000 (1800) Triple stack length Torque in Oz-In / N-cm 900/ / VDC 48 VDC 70 VDC 300/ (600) 4000 (1200) 6000 (1800) Speed of rotation in full steps per second (rpm) Figure 3.8: LMD 85 torque-speed performance curves 25

34 3 Technical data 3.6 Conditions for UL 508C If the product is used to comply with UL 508C, the following conditions must be met: Ambient temperature during operation Surrounding air temperature [ C] Pollution degree Use in an environment with pollution degree 2. Power supply Use only power supply units that are approved for over-voltage category III. Wiring Use only 60/75 C copper conductors. SIL PFH at high demand or continuous demand < < < <10-5 HFT and SFF Depending on the SIL for the safety system, the IEC standard requires a specific hardware fault tolerance HFT in connection with a specific proportion of safe failures SFF (safe failure fraction). The hardware fault tolerance is the ability of a system to execute the required safety function in spite of the presence of one or more hardware faults. The SFF of a system is defined as the ratio of the rate of safe failures to the total failure rate of the system. According to IEC 61508, the maximum achievable SIL of a system is partly determined by the hardware fault tolerance HFT and the safe failure fraction SFF of the system. SFF HFT type A subsystem HFT type B subsystem < 60% SIL1 SIL2 SIL3 SIL1 SIL2 60%... <90% SIL2 SIL3 SIL4 SIL1 SIL2 SIL3 90%... < 99% SIL3 SIL4 SIL4 SIL2 SIL3 SIL4 99% SIL3 SIL4 SIL4 SIL3 SIL4 SIL4 Fault avoidance measures Systematic errors in the specifications, in the hardware and the software, usage faults and maintenance faults of the safety system must be avoided to the maximum degree possible. To meet these requirements, IEC specifies a number of measures for fault avoidance that must be implemented depending on the required SIL. These measures for fault avoidance must cover the entire life cycle of the safety system, i.e. from design to decommissioning of the system. 26

35 4 Basics 4 Basics Functional safety Automation and safety engineering are two areas that were completely separated in the past but recently have become more and more integrated. Engineering and installation of complex automation solutions are greatly simplified by integrated safety functions. Usually, the safety engineering requirements depend on the application. The level of the requirements results from the risk and the hazard potential arising from the specific application Working with IEC IEC standard The standard IEC Functional safety of electrical/electronic/programmable electronic safety-related systems covers the safety-related function. It is not only one single component but the entire function chain (e.g. from the sensor through the logical processing unit to the actuator) that is considered as one single unit. This function chain must meet the requirements of the specific safety integrity level as a whole. Systems and components that can be used in various applications for safety tasks with comparable risk levels can be developed on this basis. SIL, Safety Integrity Level The standard IEC defines 4 safety integrity levels (SIL) for safety functions. SIL1 is the lowest level and SIL4 is the highest level. A hazard and risk analysis serves as a basis for determining the required safety integrity level. This is used to decide whether the relevant function chain is to be considered as a safety function and which hazard potential it must cover. Draft V PFH, Probability of a dangerous hardware failure per hour To maintain the safety function, the IEC standard requires various levels of measures for avoiding and controlling faults, depending on the required SIL. All components of a safety function must be subjected to a probability assessment to evaluate the effectiveness of the measures implemented for controlling faults. This assessment determines the PFH (probability of a dangerous failure per hour) for a safety system. This is the probability per hour that a safety system fails in a hazardous manner and the safety function cannot be correctly executed. Depending on the SIL, the PFH must not exceed certain values for the entire safety system. The individual PFH values of a function chain are added; the total PFH value must not exceed the maximum value specified in the standard. 27

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37 5 Engineering 5 Engineering 5 This chapter contains information on the application of the product that is vital in the design phase. 5.1 External power supply units MULTI-MODE OPERATION This device will operate differently in each mode of operation. It is critical that all documentation be read completely. A clear understanding of how the device is to be employed must be present before attempting to install or commission the device. Failure to follow these instructions can result in equipment damage. ELECTRIC SHOCK CAUSED BY INCORRECT POWER SUPPLY UNIT The VDC, AUX_PWR and INPUT_REFERENCE supply voltages are connected with many exposed signal connections in the drive system. z Use a power supply unit that meets the PELV (Protective Extra Low Voltage) requirements. z Connect the negative output of the power supply unit to PE (ground). Failure to follow these instructions will result in death or serious injury.! Caution GENERAL POWER SUPPLY PRACTICE Do not connect or disconnect the power supply while power is applied. Disconnect the AC side to power down the DC supply. For battery operated systems connect a transient suppressor across the switch to prevent arcs and high-voltage spikes. Failure to follow these instructions may result in damage to system components! 29

38 5 Engineering Supply voltage +VDC General The power supply unit must be rated for the power requirements of the drive. The input current can be found in the technical data. The actual power requirements are often significantly lower because the maximum possible motor torque is usually not required for normal operation of a system. When designing the system, note that the input current of the drive is higher during the motor acceleration phase than during constant movement. Regeneration condition (back EMF) Note the following for drives with large external mass moments of inertia or for highly dynamic applications: Motors return regeneration energy during deceleration. The DC bus can store a limited amount of energy in the capacitors. Connecting additional capacitors to the DC bus increases the amount of energy that can be stored. If the capacity of the capacitors is exceeded, the excess energy must be discharged via internal or external braking resistors. Overvoltage conditions can be limited by adding a braking resistor with a corresponding braking resistor controller. This converts the regenerated energy to heat energy during deceleration. LOSS OF CONTROL DUE TO REGENERATION CONDITION Regeneration conditions resulting from braking or external driving forces may increase the VDC supply voltage to an unexpected level. Components not rated for this voltage may be destroyed or cause malfunctions. Verify that all VDC consumers are rated for the voltage occurring during regeneration conditions (for example limit switches). Use only power supply units that will not be damaged by regeneration conditions. Use a braking resistor controller, if necessary. Failure to follow these instructions can result in injury or equipment damage. 30

39 5 Engineering Power supply cabling EMI and RFI! Caution These recommendations will provide optimal protection against EMI and RFI. The actual cable type, wire gauge, shield type and filtering devices used are dependent on the customer s application and system. The length of the DC power supply cable to an MDrive should not exceed 50 feet (15.2 m). Always use shielded/twisted pairs for the Lexium MDrive DC supply cable. Failure to follow these instructions may result in damage to system components! Cable length, wire gauge and power conditioning devices play a major role in the performance of your Lexium MDrive. Figure 5.1 illustrates the recommended cable configuration for DC power supply cabling under 50 feet (15.2 m) long. If cabling of 50 feet (15.2 m) or longer is required, the additional length may be gained by adding an AC power supply cable (see Figures 5.2 and 5.3). Correct AWG wire size is determined by the current requirement plus cable length. A B C D Supply GND +V GND - 50 (15.24 m) +VDC Output A B C D Type RFI Filter Required Current Ferrite Bead Shielded Twisted Pair (See AWG Table for Size) Electrolytic Capacitor, 500µF per Amp Shield to Earth (Supply End Only) Figure 5.1: DC power supply cabling under 50 (15.24 m) 31

40 5 Engineering B A C D To Cable in Figure (15.24 m) Shield to Earth (Supply End Only) A Type RFI Filter Required Current B Transformer: 10 to 28 VAC RMS C Shielded Twisted Pair (See AWG Table for Size) D Full Wave Bridge Rectifier, Rectifier Output Connects to Cable Shown in Figure 3.1 Figure 5.2: AC power to full wave bridge A B C To Cable in Figure (15.2 m) Shield to Earth (Supply End Only) A B C Type RFI Filter Required Current 120 or 240 VAC Dependant on DC Power Supply AC Input Requirement Shielded Twisted Pair (See AWG Table for Size) D D Unregulated DC Power Supply Figure 5.3: AC power to DC supply Recommended AWG (mm 2 ) per current and distance Length [ft (m)] 10 (3.0) 25 (7.6) 50 (15.2) 75 (22.9) 100 (30.5) Amps (peak) Minimum AWG (mm 2 ) 1 20 (0.5) 20 (0.5) 18 (0.75) 18 (0.75) 18 (0.75) 2 20 (0.5) 18 (0.75) 16 (1.5) 14 (2.5) 14 (2.5) 3 18 (0.75) 16 (1.5) 14 (2.5) 12 (4.0) 12 (4.0) 4 18 (0.75) 16 (1.5) 14 (2.5) 12 (4.0) 12 (4.0) 32

41 5 Engineering Auxiliary power supply The auxiliary logic supply is an optional power supply used to provide power to the logic circuitry of the Lexium MDrive in the event of main system power failure. This supply will retain data such as position. There are no special considerations required when choosing this supply beyond: Voltage to +24 VDC Current ma per Lexium MDrive Wiring and shielding Noise is always present in a system that involves high power and small signal circuitry. Regardless of the power configuration that you use in your system, there are some wiring and shielding rules that you should follow to keep your noise-to-signal ratio as small as possible. Rules of wiring Power Supply and Motor wiring should be shielded twisted pair, and these lines should not run parallel to signal carrying wires. For installations which utilize separate electric motor drives and stepper motors, wiring between the driver and motor should be shielded twisted pairs using 20 gauge wire for motor current less than 4.0 amps and 18 gauge or better for motor current 4.0 amps or higher. A common mode choke may be required in each of the motor phase lines to reduce shield current levels. Power ground return should be as short as possible. Power Supply wiring should be shielded twisted pairs. Use 18 gauge wires if load is less than 4 amps, or 16 gauge for more than 4 amps. Never use a daisy-chain power supply wiring scheme to system components. This type of power distribution will result in degraded system reliability and performance as a result of poor EMC and ground-loop issues. In cases where daisy-chaining is unavoidable, the systems engineer is responsible for final system reliability and performance. The use of conservatively selected wire gauge and the use of decoupling capacitors (i.e. a combination of capacitors to provide for acceptable low frequency and high frequency noise reduction) at each electronic drive should be considered as a minimum. Rules of shielding The shield must be tied to zero-signal reference potential. In order for shielding to be effective, it is necessary for the shield to be earthed or grounded. The shield must be connected so that shield currents drain to signal-earth connections. The shield should be tied to a single point to prevent ground loops 33

42 5 Engineering +VDC GND AUX GND +VDC Supply AUX Supply Figure 5.4: System power wiring 34

43 5 Engineering 5.2 Ground design The ground connections of all interfaces are galvanically connected, including the ground for the VDC supply voltage. The multifunction interface is an exception to this in the case of devices with galvanic isolation. The following points must be considered when you wire the drives in a system: The voltage drop in the VDC power supply lines must be kept as low as possible (less than 1 V). At higher ground potential differences between different drives, the communication / control signals may be affected. If the distance between the system components is greater, it is recommended to use decentralized power supply units close to the individual drives to supply the VDC voltage. However, the ground connections of the individual power supply units must be connected with the largest possible conductor cross section. If the master controller (e.g. PLC, IPC etc.) does not have galvanically isolated outputs for the drives, you must verify that the current of the VDC supply voltage has no path back to the power supply unit via the master controller. Therefore, the master controller ground may be connected to the VDC supply voltage ground at a single point only. This is usually the case in the control cabinet. The ground contacts of the various signal connectors in the drive are therefore not connected; there is already a connection via the VDC supply voltage ground. If the controller has a galvanically isolated interface for communication with the drives, the ground of this interface must be connected to the signal ground of the first drive. This ground may be connected to a single drive only to avoid ground loops. This also applies to a galvanically isolated CAN connection. Equipotential bonding conductors Potential differences can result in excessive currents on the cable shields. Use equipotential bonding conductors to reduce currents on the cable shields. The equipotential bonding conductor must be rated for the maximum current flowing. Practical experience has shown that the following conductor cross sections can be used: AWG 4 (16 mm 2 ) for equipotential bonding conductors up to a length of 650 ft (200 m) AWG 4 (20 mm 2 ) for equipotential bonding conductors with a length of more than 650 ft (200 m) 35

44 5 Engineering 5.3 Monitoring functions The monitoring functions in the product can help to guard the system and reduce the risks involved in a system malfunction. These monitoring functions may not be used to protect persons. The following monitoring functions are available and be monitored by two methods: 1) Software: may be monitored using software via the service interface 2) Hardware: may be monitored using the signal outputs via the multifunction interface. 36

45 6 Installation 6 Installation 6 LOSS OF CONTROL The designer of any control scheme must consider the potential failure modes of control paths and, for certain critical functions, provide a means to achieve a safe state during and after a path failure. Examples of critical control functions are EMERGENCY STOP, overtravel stop, power outage and restart. Separate or redundant control paths must be provided for critical functions. System control paths may include communication links. Consideration must be given to the implication of unanticipated transmission delays or failures of the link. Observe all accident prevention regulations and local safety guidelines. 1) Each implementation of the product must be individually and thoroughly tested for proper operation before being placed into service. Failure to follow these instructions can result in death or serious injury. 1) For USA: Additional information, refer to NEMA ICS 1.1 (latest edition), Safety Guidelines for the Application, Installation, and Maintenance of Solid State Control and to NEMA ICS 7.1 (latest edition), Safety Standards for Construction and Guide for Selection, Installation and Operation of Adjustable-Speed Drive Systems. RISK OF INJURY WHEN REMOVING CIRCUIT BOARD PLUGS z Always hold the plug to remove it (not the cable). Failure to follow these instructions can result in injury or equipment damage. Chapter 5, Engineering, contains basic information that you should now before starting the installation. 37

46 6 Installation 6.1 Electromagnetic compatibility, EMC SIGNAL AND DEVICE INTERFERENCE Signal interference can cause unexpected responses of device. Install the wiring in accordance with the EMC requirements. Verify compliance with the EMC requirements. Failure to follow these instructions can result in death or serious injury. This drive system meets the EMC requirements according to the standard IEC , if the described measures are implemented during installation. If it is operated outside this scope, note the following: HIGH-FREQUENCY INTERFERENCE In a domestic environment this product may cause highfrequency interference that may require action to suppress interference. Failure to follow these instructions can result in death or serious injury. EMC measures Keep cables as short as possible. Do not install unnecessary cable loops, use short cables from the star point in the control cabinet to the external ground connection. Ground the product via the motor flange or with a ground strap to the ground connection at the cover of the connector housing. Ground shields of digital signal wires at both ends by connecting them to a large surface or via conductive connector housings. Connect large surface areas of cable shields, use cable clamps and ground straps Effect Reduces capacitive and inductive interference. Reduces emissions, increases immunity. Reduces interference affecting the signal wires, reduces emissions Reduces emissions. The following cables must be shielded: Supply voltage VDC Multifunction interface Service interface 38

47 6 Installation Equipotential bonding conductors 6.2 Mechanical installation Potential differences can result in excessive currents on the cable shields. Use equipotential bonding conductors to reduce currents on the cable shields. The equipotential bonding conductor must be rated for the maximum current flowing. Practical experience has shown that the following conductor cross sections can be used: AWG 4 (16 mm 2 ) for equipotential bonding conductors up to a length of 650 ft (200 m) AWG 4 (20 mm 2 ) for equipotential bonding conductors with a length of more than 650 ft (200 m) HOT SURFACES Depending on the operation, the surface may heat up to more than 100 C (212 F). z Do not allow contact with the hot surfaces. z Do not allow flammable or heat-sensitive parts in the immediate vicinity. z Consider the measures for heat dissipation described. z Check the temperature during test runs. Failure to follow these instructions can result in injury or equipment damage. MOTOR DAMAGE AND LOSS OF CONTROL Shock or strong pressure applied to the motor shaft may destroy the motor. z Protect the motor shaft during handling and transportation. z Avoid shocks to the motor shaft during mounting. z Do not press parts onto the shaft. Mount parts to the shaft by gluing, clamping, shrink-fitting or screwing. Failure to follow these instructions can result in injury or equipment damage. 39

48 6 Installation MOTOR WITHOUT BRAKING EFFECT If power outage and faults cause the power stage to be switched off, the motor is no longer stopped by the brake and may increase its speed even more until it reaches a mechanical stop. Verify the mechanical situation. If necessary, use a cushioned mechanical stop or a suitable brake. Failure to follow these instructions can result in death or serious injury. LOSS OF BRAKING FORCE DUE TO WEAR OR HIGH TEMPERATURE Applying the holding brake while the motor is running will cause excessive wear and loss of the braking force. Heat decreases the braking force. Do not use the brake as a service brake. Note that EMERGENCY STOPS may also cause wear At operating temperatures of more than 80 C (176 F), do not exceed a maximum of 50% of the specified holding torque when using the brake. Failure to follow these instructions can result in death or serious injury. LOAD FALLS DURING SWITCHING ON When the brake of stepping motor drives is released and external forces are applied (vertical axes), the load may fall if the friction is low. In such applications, limit the load to a maximum of 25% of the static holding torque. Failure to follow these instructions can result in death or serious injury. To install a drive in locations difficult to access, it may be useful to carry out the electrical installation first and then install the fully wired drive. 40