Manual. MOVIDRIVE Flying Saw Application. Edition 04/2004 A5.J / EN

Transcription

1 Gearmotors \ Industrial Gear Units \ Drive Electronics \ Drive Automation \ Services MOVIDRIVE Flying Saw Application A.J6 Edition 4/ / EN Manual

2 SEW-EURODRIVE Driving the world

3 1 Important Notes System Description Application fields Application example Program identification Project Planning Prerequisites Functional description Determine material travel and web speed Process data assignment Installation Software MOVIDRIVE MDX61B Bus installation MOVIDRIVE MDX61B MOVIDRIVE compact MCH4_A I Startup General information Preliminary work Starting the "flying saw" program Parameters and IPOS variables Starting the drive Jog mode Reference travel Positioning....9 Automatic mode Operation and Service Timing diagrams Fault information Error messages Index MOVIDRIVE Flying Saw 3

4 1 Important Notes MOVIDRIVE 1 Important Notes This manual does not replace the detailed operating instructions! Installation and startup only by trained personnel observing applicable accident prevention regulations and the MOVIDRIVE operating instructions! Documentation Read this manual carefully before you commence installation and startup of MOVIDRIVE drive inverters with this application module. This manual was written assuming that the user has access to and is familiar with the MOVIDRIVE documentation, in particular the MOVIDRIVE system manual. In this manual, cross references are marked with ' '. For example, ( Sec. X.X) means: Further information can be found in section X.X of this manual. A requirement of fault-free operation and fulfillment of any rights to claim under guarantee is that you observe the information contained in the documentation. Safety and warning instructions Always observe the safety and warning instructions in this publication! Electrical hazard Possible consequences: Severe or fatal injuries. Hazard Possible consequences: Severe or fatal injuries. Hazardous situation Possible consequences: Slight or minor injuries. Harmful situation Possible consequences: Damage to the unit and the environment. Tips and useful information. 4 MOVIDRIVE Flying Saw

5 System Description Application fields 2 2 System Description 2.1 Application fields The "flying saw" application module is particularly suited to applications in which a moving endless material has to be cut to length. Other applications include synchronous material transport, filling stations, "flying punches" or "flying knives." The "flying saw" application module is especially suitable for the following sectors: Wood processing Paper, cardboard Plastic Stone Clay Two basic application types are possible: A parallel saw in which case one drive is needed for the saw carriage (traveling with the material) and another drive is required for the saw feed A diagonal saw in which case only one drive is necessary; the saw carriage moves diagonally in relation to the material direction The "flying saw" offers the following advantages in these applications: User-friendly operator interface Only the parameters required for the "flying saw" (cut length, engagement travel) need to be entered User-friendly application programs guide you through the process of setting parameters, so there is no need for complicated programming Monitor mode for optimum diagnostics You do not need any programming experience It doesn't take long to get to know the system MOVIDRIVE Flying Saw

6 System Description 2 Application example 2.2 Application example Flying saw The "flying saw" application module is often used in the wood processing industry. Long pressed particle boards have to be cut to length Figure 1: "Flying saw" in the wood processing industry 839BXX 1. Drive for the saw carriage feed along the longitudinal axis (material direction) 2. Drive for the saw feed 6 MOVIDRIVE Flying Saw

7 System Description Program identification Program identification You can use the MOVITOOLS software package to identify which application program was last loaded into the MOVIDRIVE unit. Proceed as follows: Connect MOVIDRIVE to the PC via the serial port Start MOVITOOLS Start "Shell" In Shell, select "Display/IPOS information..." Figure 2: IPOS information in Shell 671AEN The "IPOS Status" window appears. The entries in this window tell you what application software is stored in MOVIDRIVE. Figure 3: Display of the current IPOS program version 6711AEN MOVIDRIVE Flying Saw 7

8 Project Planning 3 Prerequisites 3 Project Planning 3.1 Prerequisites PC and software The "flying saw" application module is implemented as an IPOS plus program and forms part of the SEW MOVITOOLS software package. To use MOVITOOLS, you must have a PC with one of the following operating systems: Windows 9, Windows 98, Windows NT 4., Windows Me or Windows 2. Inverters, motors and encoders Inverters The "flying saw" can only be implemented on MOVIDRIVE units in application version (...-T). In MOVIDRIVE MDX61B, the inverter can be controlled either using terminals or a bus. Terminal control is not possible with MOVIDRIVE compact MCH4_A. You can use the system bus provided as standard, the PROFIBUS-DP interface (MCH41A), the INTERBUS FO interface (MCH42A) or a fieldbus gateway. It is essential for the "flying saw" to have encoder feedback, and consequently it cannot be implemented with MOVIDRIVE MDX6B. Possible with MOVIDRIVE Control via MDX61B compact MCH41A compact MCH42A Terminals Yes, with DIO11B option No No System bus Yes, without option Yes, without option Yes, without option PROFIBUS-DP Yes, with DFP21B option Yes, without option No INTERBUS FO Yes, with DFI21B option No Yes, without option INTERBUS Yes, with DFI11B option Yes, with UFI11A option Yes, with UFI11A option CANopen Yes, with DFC11B option No No DeviceNet Yes, with DFD11B option Yes, with UFD11A option Yes, with UFD11A option In MOVIDRIVE MDX61B with bus control: The optional "I/O card type DIO11B" is not to be connected for operation with bus control. If the DIO11B option is connected, the virtual terminals cannot be addressed via the bus. Motors and encoders For operation on MOVIDRIVE MDX61B with DEH11B or MOVIDRIVE compact MCH4_A: CT/CV asynchronous servomotors (encoder installed as standard) or DR/DT/DV/ AC motors with encoder (Hiperface, sin/cos or TTL). For operation on MOVIDRIVE MDX61B with DER11B: CM/DS synchronous servomotors with resolver. Permitted operating modes (P7): Asynchronous motor (CT/CV/DR/DT/DV): CFC operating modes, the "flying saw" cannot be operated in VFC-n-CONTROL operating modes Synchronous motor (CM/DS): SERVO operating modes Important: No slip may occur in the slave drive. 8 MOVIDRIVE Flying Saw

9 Project Planning Functional description Functional description Functional characteristics The "flying saw" application offers the following functional characteristics: Control via terminals, system bus or fieldbus: In MOVIDRIVE MDX61B, the "flying saw" can be controlled either using binary input terminals, the system bus or a fieldbus. Only the system bus or a fieldbus is possible with MOVIDRIVE compact MCH4_A. Cut length control with/without material sensor or cutting mark control: You can select either cut length control or cut length control with label sensor. For cut length control, you can additionally use a material sensor that starts length control. In cut length control with/without material sensor, a master encoder measures the cut length of the material to be cut. This information is processed by the inverter and used for starting the saw carriage. There is no need to have any cutting marks on the material. Figure 4: Cut length control without material sensor 73AXX In cut length control with material sensor, a master encoder also measures the cut length of the material to be cut, but additionally a material sensor is evaluated. Cutting length control starts when the material to be cut reaches this sensor. There is no need to have any cutting marks on the material. However, the material sensor may have to detect a mark on the front edge of the material. Figure : Cut length control with material sensor 71AXX MOVIDRIVE Flying Saw 9

10 Project Planning 3 Functional description In cut length control with label sensor, a sensor detects the cutting marks on the material. This sensor signal is processed as an interrupt in the inverter and is used for starting the saw carriage. Figure 6: Cut length control with label sensor 7AXX Protecting the cut edge and "pulling a gap": The "pulling a gap" function causes the saw carriage to move ahead of synchronism with the material before the saw blade is pulled out. The result is a gap in between the cut edge and the saw blade, thereby preventing the saw blade from leaving any traces on the cut edge. This function is suitable for use in protecting the cut edge of sensitive material. This function can also be used for separating material that has already been cut. Immediate cut function by manual interrupt: The saw carriage is started immediately by a ""-"1" edge on a binary input. Extensive diagnostics: During operation, the monitor will display all important data, such as current cut length, material speed and speed of the saw drive. Simple connection to the machine control (PLC). Operating modes The functions are implemented with three operating modes: Jog mode (DI1Ø = "" and DI11 = "") A "1" signal on binary input DI13 "Jog +" causes the saw carriage motor to turn "clockwise." A "1" signal on binary input DI14 "Jog -" causes the saw carriage motor to turn "counterclockwise." Bear in mind whether you are using a 2 or 3- stage gear unit. A "" signal on binary input DI1 "Rapid speed" results in jog mode at slow speed. A "1" signal on binary input DI1 "Rapid speed" results in jog mode at rapid speed. Reference travel (DI1Ø = "1" and DI11 = "") The reference position is defined by reference travel to one of the two limit switches. Reference travel is started with a "1" signal on binary input DI12 "Start." The "1" signal must be present at DI12 for the entire duration of the reference travel. You can enter a reference offset during startup. The reference offset can be used for altering the machine zero point without having to adjust the limit switches. The following formula applies: Machine zero = reference position + reference offset 1 MOVIDRIVE Flying Saw

11 Project Planning Functional description 3 Positioning (DI1Ø = "" and DI11 = "1") The "positioning" mode is used for position-controlled movement of the saw drive between the home position and the parking position. A "" signal on binary input DI13 selects the home position. A "1" signal on binary input DI13 selects the parking position. Positioning is started with a "1" signal on binary input DI12 "Start." The "1" signal must be present on DI12 for the entire duration of positioning. The drive immediately moves to its new position if DI12 remains "1" and a new position is specified using DI13. Automatic mode (DI1Ø = "1" and DI11 = "1") During startup, you specify whether cut length control with/without material sensor is active or if cut length control with label sensor is active. Cut length control without material sensor: A ""-"1" edge on binary input DI12 "Start" (process output data PO1:1) starts automatic mode. The "1" signal must be present at DI12 (PO1:1) for the entire duration of automatic mode. The material length is counted starting from the ""-"1" edge on DI12 "Start." Terminal control: From the cut length table ( Startup), select the required cut length in binary coded form via binary inputs DI1... DI17. The operating mode (cut length control with/without material sensor, or cut length control with label sensor) is set at startup and cannot be changed during running operation. To set another operating mode, you have to perform startup again. Bus control with one process data word (1 PD): From the cut length table ( Startup), select the required cut length in binary coded form via process output data PO1:13... PO1:1. The operating mode (cut length control with/without material sensor, or cut length control with label sensor) is set at startup and cannot be changed during running operation. To set another operating mode, you have to perform startup again. Bus control with three process data words (3 PD): You can set any cut length via fieldbus. Via fieldbus, you can also switch to another operating mode (cut length control with/without material sensor, cut length control with label sensor) during running operation. Cut length control with material sensor: A ""-"1" edge on binary input DI12 "Start" (process output data PO1:1) starts automatic mode. The "1" signal must be present at DI12 (PO1:1) for the entire duration of automatic mode. The material length is counted starting from the ""-"1" edge on DIØ2 "Sensor" (= material sensor). Terminal control: From the cut length table ( Startup), select the required cut length in binary coded form via binary inputs DI1... DI17. The operating mode (cut length control with/without material sensor, or cut length control with label sensor) is set at startup and cannot be changed during running operation. To set another operating mode, you have to perform startup again. MOVIDRIVE Flying Saw 11

12 Project Planning 3 Functional description Bus control with one process data word (1 PD): From the cut length table ( Startup), select the required cut length in binary coded form via process output data PO1:13... PO1:1. The operating mode (cut length control with/without material sensor, or cut length control with label sensor) is set at startup and cannot be changed during running operation. To set another operating mode, you have to perform startup again. Bus control with three process data words (3 PD): You can set any cut length via fieldbus. Via fieldbus, you can also switch to another operating mode (cut length control with/without material sensor, cut length control with label sensor) during running operation. Cut length control with label sensor: A "1" signal on binary input DI12 "Start" (process output data PO1:1) starts automatic mode. The "1" signal must be present at DI12 (PO1:1) for the entire duration of automatic mode. Following the sawing process, the "pulling a gap" function can be used to move the saw blade away from the cut edge. A "1" signal on binary input DI13 (process output data PO1:11) starts the "pulling a gap" function. You set the size of the gap during startup. Repositioning can be initiated once the drive reaches the reversing position. A "1" signal on binary input DI14 "Repositioning" (process output data PO1:12) moves the drive back to the home position. This "1" signal can remain permanently set. The saw carriage is started again once the cut length is reached or with the next signal edge on binary input DIØ2 "Sensor." Inputs Jog mode Reference travel Positioning Automatic mode PA1:8 / DI1 "" "1" "" "1" PA1:9 / DI11 "" "" "1" "1" PA1:1 / DI12 - Start reference Start positioning Start automatic mode travel PA1:11 / DI13 Jog + - Start park positioning Pulling a gap PA1:12 / DI14 Jog Repositioning PA1:13 / DI1 Rapid speed - - Cut length 2 PA1:14 / DI Cut length 2 1 PA1:1 / DI Cut length MOVIDRIVE Flying Saw

13 Project Planning Determine material travel and web speed Determine material travel and web speed The web speed must be known to set the cut length for the sawing process. The web speed can be determined in two ways: A slip-free encoder is mounted on the material web as closely as possible to the "flying saw." This encoder is connected as external encoder (= master encoder ) to X14: of the saw carriage drive. The incremental distance information from the external encoder is used for measuring the speed and the material travel. The ratio between the travel resolution of the motor encoder and the external encoder must be less than 2:1 to determine the web speed and the material travel with sufficient accuracy. The incremental travel information of the motor encoder on the material feed drive is used for determining the web speed and the material travel. For this purpose, an X14-X14 connection is required from the MOVIDRIVE drive inverter on the web drive to the MOVIDRIVE drive inverter on the saw carriage drive. MOVIDRIVE Flying Saw 13

14 Project Planning 3 Process data assignment 3.4 Process data assignment You can also control the "flying saw" application module via a bus. All MOVIDRIVE fieldbus options as well as the system bus (Sbus) provided as standard are supported. The virtual terminals in control word 2 are used for bus control ( MOVIDRIVE Fieldbus Unit Profile). Please note: The MOVIDRIVE option "I/O card type DIO11B" must not to be installed for bus control! Special characteristics of operation with three process data words: The values of PO2 "Setpoint cut length" and PO3 "Minimum reversing position" are transferred to the inverter with the scaling ".1 user travel unit." PA PA1 PA2 PA3 E Q PE1 PE2 PE3 PE Figure 7: Data exchange via process data 4427AXX PO = Process output data PI = Process input data PO1 = Control word 2 PI1 = Status word 2 PO2 = Setpoint cut length (IPOS PO DATA) PI2 = Actual cut length (IPOS PI DATA) PO3 = Min. reversing position (IPOS PO DATA) PI3 = Actual saw drive position (IPOS PI DATA) Minimum reversing position: Earliest possible position of the saw carriage at which the drive can be decoupled and it is possible to move back to the home position. Process output data Assignment of the process output data words: PO1: Control word 2 Virtual terminal 8 DI17 P617 Virtual terminal 7 DI16 P616 Virtual terminal 6 DI1 P61 Virtual terminal DI14 P614 Virtual terminal 4 DI13 P613 Virtual terminal 3 DI12 P612 Virtual terminal 2 DI11 P611 Virtual terminal 1 DI1Ø P61 Virtual input terminals Fixed assignment Controller inhibit/ Enable Enable/ Rapid stop Enable/Stop /Hold control Ramp switchover Parameter set switchover Fault reset Reserved 14 MOVIDRIVE Flying Saw

15 Project Planning Process data assignment 3 PO2: Setpoint cut length PO2 Setpoint cut length [.1 user unit] PO3: Minimum reversing position PO3 Minimum reversing position [.1 user unit] Process input data Assignment of the process input data words: PI1: Status word 2 Virtual terminal 8 DO17 P637 Virtual terminal 7 DO16 P636 Virtual terminal 6 DO1 P63 Virtual terminal DO14 P634 Virtual terminal 4 DO13 P633 Virtual terminal 3 DO12 P632 Virtual terminal 2 DO11 P631 Virtual terminal 1 DO1Ø P63 Virtual output terminals Fixed definition Output stage enabled Inverter Ready PO data enabled Current ramp generator set Current Parameter set Fault/warning Right limit switch active Left limit switch active PI2: Actual cut length PI2 Actual cut length [.1 user unit] PI3: Actual saw drive position PI3 Actual saw drive position [.1 User unit] MOVIDRIVE Flying Saw 1

16 Installation 4 Software 4 Installation 4.1 Software MOVITOOLS The "flying saw" application module is part of the MOVITOOLS software package (version 3. and higher). Proceed as follows to install MOVITOOLS on your computer: Insert the MOVITOOLS CD into the CD ROM drive of your PC Select "Start\Run..." Type "{drive letter of your CD drive}:setup" and press the Enter key The MOVITOOLS setup menu appears. Follow the instructions of the installation wizard You can now use the Program Manager to start MOVITOOLS. If a MOVIDRIVE unit is connected to your PC, select the correct port (PC COM) and set peer-to-peer connection. Select <Update> to display the inverter in the "Connected Inverters" window. Figure 8: MOVITOOLS window 61BEN Application version The "flying saw" application module can be used on MOVIDRIVE units in application version (...-T). The application modules cannot be used with units in the standard version (-). 16 MOVIDRIVE Flying Saw

17 Installation MOVIDRIVE MDX61B MOVIDRIVE MDX61B SBus - 24 = V + X12: DGND 1 SC11 2 SC12 3 X13: DIØØ 1 /Controller inhibit DIØ1 2 CW/stop DIØ2 3 CCW/stop DIØ3 4 Enable/Rapid stop DIØ4 DIØ 6 /Endschalter Rechts /Endschalter Links DCOM 7 Reference X13:DIØØ...DIØ VO V output DGND 9 Ref. potential for binary signals ST11 1 RS-48 + ST12 11 RS-48 - TF1 DGND DBØØ DOØ1-C DOØ1-NO DOØ1-NC DOØ2 VO24 VI24 DGND X1: System bus ref. potential System bus high System bus low TF/TH input Ref. potential for binary signals /Brake Common relay contact Ready for operation Contact normally open Contact normally closed /fault +24V output +24V input Ref. potential for binary signals MOVIDRIVE MDX61B 24 V + = - X22: DI1Ø 1 DI11 2 DI12 3 DI13 4 DI14 DI1 6 DI16 7 DI17 8 DCOM 9 DGND 1 X23: DO1Ø 1 DO11 2 DO12 3 DO13 4 DO14 DO1 6 DO16 7 DO17 8 DGND 9 DEH11B DER11B IPOS input: mode 2^ IPOS input: mode 2^1 IPOS input: selection Dmin 2^ IPOS input: selection Dmin 2^1 IPOS input: set Dmin IPOS input: set Dmax IPOS input: reserved IPOS input: reset length counter Reference X22: DI1Ø...DI17 Reference potential for binary signals IPOS output: mode 2^ IPOS output: mode 2^1 IPOS output: selection Dmin 2^ IPOS output: selection Dmin 2^1 IPOS output: Dmax reached IPOS output: wrenched IPOS output: friction factor table read IPOS output: length reached Reference potential for binary signals X14: Input external encoder, Incremental encoder V TTL (Connection MOVIDRIVE MDX61B operating instructions) DIO11B X1: Motor encoder: Incremental encoder (DEH11B) or resolver (DER11B) (Connection MOVIDRIVE MDX61B operating instructions) DER11B 9 X14 X DEH11B 1 1 X14 X Figure 9: Wiring diagram MOVIDRIVE MDX61B with option DIO11B and DEH11B or DE11B. 61AEN MOVIDRIVE Flying Saw 17

18 Installation 4 MOVIDRIVE MDX61B Inputs Jog mode Reference travel Positioning Automatic mode DI1Ø "" "1" "" "1" DI11 "" "" "1" "1" DI12 - Start reference travel Start positioning Start automatic mode DI13 Jog + - Start park positioning Pulling a gap DI14 Jog Repositioning DI1 Rapid speed - - Cut length 2 DI Cut length 2 1 DI Cut length 2 2 Outputs Jog mode Reference travel Positioning Automatic mode DO1Ø "" "1" "" "1" DO11 "" "" "1" "1" DO12 Master and slave in synchronous operation Master and slave in synchronous operation Master and slave in synchronous operation Master and slave in synchronous operation DO13 Pulling a gap finished Pulling a gap finished Pulling a gap finished Pulling a gap finished DO14 Cut length 2^ Cut length 2^ Cut length 2^ Cut length 2^ DO1 Cut length 2^1 Cut length 2^1 Cut length 2^1 Cut length 2^1 DO16 Cut length 2^2 Cut length 2^2 Cut length 2^2 Cut length 2^2 DO17 Position reached Position reached Position reached Position reached 18 MOVIDRIVE Flying Saw

19 Installation Bus installation MOVIDRIVE MDX61B Bus installation MOVIDRIVE MDX61B Overview For the bus installation, please note the information in the relevant fieldbus manuals supplied with the fieldbus interfaces. Please refer to the operating instructions for information about installing the system bus (SBus). DFP21B PROFIBUS DP DFI21B INTERBUS DFI11B INTERBUS DFO11B CANopen PD(2) PD(1) PD() NA(6) DFD11B DEVICE-NET NA() NA(4) NA(3) NA(2) NA(1) NA() DR(1) DR() 11 S1 BUS OFF STATE GUARD Mod/ Net PIO ADRESS COMM NA() NA(4) NA(3) NA(2) BIO BUS- OFF 1 S1 nc R S2 3 NA(1) NA() DR(1) DR() S2 X3 PROFIBUS DP X3 CANopen X3 P R O F I PROCESS FIELD BUS B U S Device Net SBus Figure 1: Bus types 64AXX Please note: The MOVIDRIVE option "I/O card type DIO11B" must not be installed for bus control! MOVIDRIVE Flying Saw 19

20 Installation 4 Bus installation MOVIDRIVE MDX61B PROFIBUS (DFP21B) The PROFIBUS documentation package contains detailed information. This package can be ordered from SEW-EURODRIVE. The documentation package contains the GSD files and type files for MOVIDRIVE to help with project planning and to facilitate startup. Technical Data DFP PROFIBUS DP RUN BUS FAULT ON nc ADDRESS! Option PROFIBUS fieldbus interface type DFP21B Part number Resources for startup/diagnostics MOVITOOLS software and DBG6B keypad Protocol option PROFIBUS-DP to EN 17 V2 / DIN E 1924 T3 Supported baud rates Connection Bus termination Station address GSD file DP identity number Weight Automatic baud rate detection from 9.6 kbaud Mbaud 9-pin sub D socket Assignment according to EN 17 V2 / DIN 1924 T3 Not integrated, must be implemented in the PROFIBUS connector , can be set using DIP switch SEW_63.GSD 63 hex = 2479 dec.2 kg (.44 lb) " X3 PROFIBUS DP 1. Green LED: RUN 2. Red LED: BUS FAULT 3. DIP switch for setting the station address 4. 9-pin sub D socket: bus connection Pin assignment (1) RxD/TxD-P (B/ B) RxD/TxD-N (A/ A) CNTR-P DGND (MV) VP (PV) DGND (MV) (3) (2) Figure 11: Assignment of 9-pin sub D plug to EN 17 V2 66AXX (1) 9-pin sub D connector (2) Twist the signal wires together! (3) Conductive connection is necessary between the plug housing and the shield! 2 MOVIDRIVE Flying Saw

21 Installation Bus installation MOVIDRIVE MDX61B 4 INTERBUS with fiber optic cable (DFI21B) The INTERBUS FO documentation package contains detailed information. This package can be ordered from SEW-EURODRIVE. Technical data DFI INTERBUS 1. Option INTERBUS fieldbus interface type DFI21B (FO) Part number Resources for startup/diagnostics MOVITOOLS software, DBG6B keypad and CMD tool Supported baud rates kbaud and 2 Mbaud, can be selected via DIP switch Connection Weight Remote bus input: 2 F-SMA connectors Remote bus output: 2 F-SMA connectors Optically controlled FO interface.2 kg (.44 lb) DIP switch for process data length, PCP length and baud rate 2. Diagnostic LEDs 3. FO: Remote IN 4. FO: Incoming remote bus. FO: Remote OUT 6. FO: Outgoing remote bus Connection assignment Position Signal Direction Wire color of FO cable 3 FO remote IN Receive data Orange (OG) 4 Incoming remote bus Send data Black (BK) FO remote OUT Receive data Black (BK) 6 Outgoing remote bus Send data Orange (OG) MOVIDRIVE Flying Saw 21

22 Installation 4 Bus installation MOVIDRIVE MDX61B INTERBUS (DFI11B) The INTERBUS documentation package contains detailed information. This package can be ordered from SEW-EURODRIVE. Technical data DFI11B INTERBUS 1. Option INTERBUS fieldbus interface type DFI11B Part number Resources for startup/diagnostics MOVITOOLS software and DBG6B keypad Connection Module ID Weight Remote bus input: 9-pin sub D connector Remote bus output: 9-pin sub D socket RS-48 transmission technology, 6-core shielded and twisted-pair cable E3 hex = 227 dec.2 kg (.44 lb) DIP switch for setting the number of process data 2. 4 green LED: Diagnostic LEDs 3. 1 red LED: Diagnostic LED 4. 9-pin sub D plug: Remote bus input. 9-pin sub D socket: Remote bus output Pin assignment Conductor color abbreviations to IEC 77. (1) (4) GN YE PK GY BN (2) (3) /DO DO /DI DI COM E Q /DO DO /DI DI COM () (2) (3) GN YE PK GY BN 443AXX Figure 12: Assignment of the 9-pin sub D socket of the incoming remote bus cable and the 9-pin sub D plug of the outgoing remote bus cable (1) 9-pin sub D socket of the incoming remote bus cable (2) Twist the signal wires together! (3) Conductive connection is necessary between the plug housing and the shield! (4) 9-pin sub D plug of the outgoing remote bus cable () Jumper pin with pin 9! 22 MOVIDRIVE Flying Saw

23 Installation Bus installation MOVIDRIVE MDX61B 4 CANopen (DFC11B) The CANopen documentation package contains detailed information. This package can be ordered from SEW-EURODRIVE. Technical data DFO CANopen PD(2) PD(1) PD() NA(6) NA() NA(4) NA(3) NA(2) NA(1) NA() DR(1) DR() S1 11 BUS OFF STATE GUARD Option CANopen fieldbus interface type DFC11B Part number Resources for startup/diagnostics MOVITOOLS software and DBG6B keypad Supported baud rates Can be selected via DIP switch: 12 kbaud 2 kbaud kbaud 1 kbaud 9-pin sub D connector Connection Assignment to CiA standard 2-core twisted cable to ISO Bus termination Can be switched on using DIP switch (12 Ω) Address range , can be selected using DIP switch Weight.2 kg (.44 lb) COMM nc R 3 3. S2 4. X3 CANopen 1. DIP switch for process data length, module ID and baud rate 2. Display and diagnostic LEDs 3. DIP switch for switching the bus terminating resistor on and off 4. 9-pin sub D plug: bus connection Pin assignment (1) (2) (3) DGND CAN High CAN Low DGND Figure 13: Assignment of 9-pin sub D socket of the bus cable 67AXX (1) 9-pin sub D socket (2) Twist the signal wires together! (3) Conductive connection is necessary between the plug housing and the shield! MOVIDRIVE Flying Saw 23

24 Installation 4 Bus installation MOVIDRIVE MDX61B DeviceNet (DFD11B) The DeviceNet documentation package contains detailed information. This package can be ordered from SEW-EURODRIVE. Technical data DFD DEVICE-NET Mod/ Net PIO BIO BUS- OFF 1. Option DeviceNet fieldbus interface type DFD11B Part number Resources for startup/diagnostics MOVITOOLS software and DBG6B keypad Supported baud rates Connection Permitted line cross section Bus termination Address range that can be set (MAC-ID) Weight Can be selected using DIP switch: 12 kbaud 2 kbaud kbaud -pin Phoenix terminal Assignment according to DeviceNet specification (Volume I, Appendix A) According to DeviceNet specification Use of bus connectors with integrated bus terminating resistor (12 Ω) at the start and finish of a bus segment , can be selected using DIP switch.2 kg (.44 lb) NA() NA(4) NA(3) NA(2) NA(1) NA() DR(1) DR() 1 S1 S X3 1. LED display 2. DIP switch for setting node address (MAC-ID) and baud rate 3. -pin Phoenix terminal: bus connection Terminal assignment The assignment of connecting terminals is described in the DeviceNet specification Volume I, Appendix A. Terminal Meaning Color X3:1 V- (V24) Black (BK) X3:2 CAN_L Blue (BU) X3:3 DRAIN Bright X3:4 CAN_H White (WH) X3: V+ (+24 V) Red (RD) 24 MOVIDRIVE Flying Saw

25 Installation Bus installation MOVIDRIVE MDX61B 4 Connection of system bus (SBus 1) Only if P816 "SBus baud rate" = 1 kbaud: MOVIDRIVE compact MCH4_A units must not be combined with other MOVIDRIVE units in the same system bus combination. The units may be combined at baud rates 1 kbaud. SBus wiring diagram Max. 64 CAN bus stations can be interconnected using the system bus (SBus). The SBus supports transmission systems compliant with ISO The "Serial Communication" manual contains detailed information about the system bus. This manual can be obtained from SEW-EURODRIVE. Figure 14: System bus connection 6182AEN Cable specification Use a 2-core twisted and shielded copper cable (data transmission cable with braided copper shield). The cable must meet the following specifications: Conductor cross section.7 mm 2 (AWG 18) Line resistance 12 Ω at 1 MHz Capacitance per unit length 4 pf/m (12 pf/ft) at 1 khz Suitable cables include CAN bus or DeviceNet cables. Shielding Connect the shield at either end to the electronics shield clamp of the inverter or the master control and ensure the shield is connected over a large area. Also connect the ends of the shield to DGND. Line length The permitted total line length depends on the baud rate setting of the SBus (P816): 12 kbaud 32 m (16 ft) 2 kbaud 16 m (28 ft) kbaud 8 m (264 ft) 1 kbaud 4 m (132 ft) Terminating resistor Switch on the system bus terminating resistor (S12 = ON) at the start and end of the system bus connection. Disconnect the terminating resistor at the other devices (S12 = OFF). There must not be any difference of potential between the units connected with the SBus. Take suitable measures to avoid a difference of potential, such as connecting the unit ground connectors using a separate line. MOVIDRIVE Flying Saw 2

26 Installation 4 MOVIDRIVE compact MCH4_A 4.4 MOVIDRIVE compact MCH4_A Figure 1: MOVIDRIVE compact MCH4_A wiring diagram 863AEN 26 MOVIDRIVE Flying Saw

27 Installation MOVIDRIVE compact MCH4_A 4 PROFIBUS-DP (MCH41A) pin assignment Refer to the instructions in the MOVIDRIVE compact (MCV/MCS or MCH) operating instructions. (1) (2) RxD/TxD-P (B/ B) 3 RxD/TxD-N (A/ A) 8 CNTR-P 4 DGND (MV) VP (PV) 6 DGND (MV) 9 (3) 491AXX Figure 16: Assignment of 9-pin sub D plug to EN 17 V2 (1) X3: 9-pin sub D connector (2) Twist the signal wires together! (3) Conductive connection is necessary between the plug housing and the shield! INTERBUS FO (MCH42A) pin assignment Refer to the instructions in the MOVIDRIVE compact MCH operating instructions. OG BK BK OG X14 X1 L U CC BA RD TR FO1 FO2 X3 X31 X32 X33 X1 X11 X OG BK X14 X1 L U CC BA RD TR FO1 FO2 X3 X31 X32 X33 Figure 17: FO connection assignment 28AXX Connection Signal Direction Wire color of FO cable X3 FO remote IN Receive data Orange (OG) X31 (incoming remote bus) Send data Black (BK) X32 FO remote OUT Receive data Black (BK) X33 (outgoing remote bus) Send data Orange (OG) MOVIDRIVE Flying Saw 27

28 Installation 4 MOVIDRIVE compact MCH4_A System bus (SBus) MCH The "System bus (SBus)" manual contains detailed information. This manual can be ordered from SEW-EURODRIVE. Max. 64 CAN bus stations can be interconnected using the system bus (SBus). The SBus supports transmission systems compliant with ISO Only if P816 "SBus baud rate" = 1 kbaud: MOVIDRIVE compact MCH4_A units must not be combined with other MOVIDRIVE units in the same system bus combination. The units may be combined at baud rates 1 kbaud. Control unit Control unit Control unit X1: X1: X1: System bus high System bus low Reference potential System bus high System bus low SC11 SC12 DGND SC21 SC22 System bus high System bus low Reference potential System bus high System bus low SC11 SC12 DGND SC21 SC22 System bus high System bus low Reference potential System bus high System bus low SC11 7 SC12 8 DGND 9 SC21 1 SC22 11 System bus ON OFF System bus ON OFF System bus ON OFF Terminating resistor S 12 Terminating resistor S 12 Terminating resistor S 12 S 11 S 11 S 11 Figure 18: MOVIDRIVE compact MCH4_A system bus connection Cable specification Use a 2-core twisted and shielded copper cable (data transmission cable with braided copper shield). The cable must meet the following specifications: Conductor cross section.7 mm 2 (AWG 18) Line resistance 12 Ω at 1 MHz Capacitance per unit length 4 pf/m (12 pf/ft) at 1 khz Suitable cables include CAN bus or DeviceNet cables. Shielding Connect the shield at either end to the electronics shield clamp of the inverter or the master control and ensure the shield is connected over a large area. Also connect the ends of the shield to DGND. Line length The permitted total cable length depends on the baud rate setting of the SBus (P816): 12 kbaud 32 m (16 ft) 2 kbaud 16 m (28 ft) kbaud 8 m (264 ft) 1 kbaud 4 m (132 ft) Terminating resistor 21AEN Switch on the system bus terminating resistor (S12 = ON) at the start and end of the system bus connection. Disconnect the terminating resistor at the other devices (S12 = OFF). There must not be any difference of potential between the units connected with the SBus. Take suitable measures to avoid a difference of potential, such as connecting the unit ground connectors using a separate line. 28 MOVIDRIVE Flying Saw

29 Startup General information I Startup.1 General information Correct project planning and installation are the prerequisites for successful startup. Refer to the MOVIDRIVE MDX6/61B and MOVIDRIVE compact system manuals for detailed project planning instructions. Check the installation, including the encoder connection, by following the installation instructions in the MOVIDRIVE operating instructions and in this manual ( Sec. Installation)..2 Preliminary work Perform the following steps before startup: Connect the inverter to the PC using the serial port. With MDX61B: Xterminal via UWS21A option with PC-COM With MCH4_A: TERMINAL via USS21A option with PC-COM Install the SEW MOVITOOLS software (version 3. or higher). Start up the inverter with "MOVITOOLS/Shell." MDX61B or MCH4_A with asynchronous motor: CFC operating modes MDX61B or MCH4_A with synchronous motor: SERVO operating modes Select the "ISYNC" technology function from the "MOVITOOLS/Shell/Startup/Select Technology Function..." menu. Figure 19: Starting up the inverter 864AEN "" signal at terminal DIØØ "/CONTROLLER INHIBIT/." MOVIDRIVE Flying Saw 29

30 I Startup Starting the "flying saw" program.3 Starting the "flying saw" program General information Start "MOVITOOLS/Shell" Select "Startup/Flying saw" Figure 2: Starting the "Flying saw" program 866AEN Initial startup The startup windows will appear immediately if the "flying saw" is started for the first time. 3 MOVIDRIVE Flying Saw

31 Startup Starting the "flying saw" program I Control signal source, fieldbus parameters and process data description 867AEN Figure 21: Setting the control signal source, fieldbus parameters and process data description Control signal source: "FIELDBUS" or "SBUS" is set automatically with bus control. "TERMINALS" is set automatically with terminal control. Fieldbus parameters: Set the fieldbus parameters. Fixed parameters are blocked and cannot be changed. Process data description: Set the functions of process output data word PO2. You can set one of the following functions: No function: Setting for cut length control and for operation with one process data word (1 PD). The cut lengths are available as table values. Setpoint cut length: Setting for operation with three process data words (3 PD) and cut length control. The cut length is specified as variable via the bus. If "No function" is set, then process output data word PO3 also has no function. If "Setpoint cut length" is set, PO3 has the "Minimum reversing position" function. The minimum reversing position is the earliest possible position of the saw drive at which the drive can be decoupled and it is possible to move back to the home position. MOVIDRIVE Flying Saw 31

32 I Startup Starting the "flying saw" program Calculating the master scaling Figure 22: Setting parameters for calculating the master scaling 872AEN Diameter of driving wheel or spindle pitch: Select whether you have to enter "Diameter of driving wheel" or "Spindle pitch." Enter the value in [mm]. The value must not exceed three decimal positions. Gearing ratio (i gear unit): Enter the gear ratio of the gear unit. The value must not exceed three decimal positions. External ratio (i additional gear): Enter the gear ratio of the additional gear if you are using one. Enter the value 1 if you are not using an additional gear. The value must not exceed three decimal positions. Encoder resolution [Inc]: Enter the resolution of the motor encoder in increments according to the nameplate. Calculating the master scaling: Click the <Calculation> button. The program then calculates the pulses per distance in [increments/mm]. Stiffness synchronous drive control: You can set the stiffness of the control loop used for synchronous drive control. The default setting is 1. Set a value less than 1 if the slave drive is tending to oscillate. Set a value greater than 1 if the slave cannot follow the master (lag eror). Make changes in small steps, for example.1. The usual range of values is User travel unit [Inc/...]: The user unit "mm" is set by default. You must enter a larger user travel unit, for example "cm", for travel distances in excess of 6. m. You will then have to change the conversion factor manually, e.g. "6" instead of "6" for the user travel unit "cm" instead of "mm." 32 MOVIDRIVE Flying Saw

33 Startup Starting the "flying saw" program I Calculating the slave scaling Figure 23: Setting parameters for calculating the slave scaling 87AEN Diameter of driving wheel or spindle pitch: Select whether you have to enter "Diameter of driving wheel" or "Spindle pitch." Enter the value in [mm]. The value must not exceed three decimal positions. Gearing ratio (i gear unit): Enter the gear ratio of the gear unit. The value must not exceed three decimal positions. External ratio (i additional gear): Enter the gear ratio of the additional gear if you are using one. Enter the value 1 if you are not using an additional gear. The value must not exceed three decimal positions. Calculating the slave scaling: Click the <Calculation> button. The program then calculates the pulses per distance in [increments/mm]. Changing direction of rotation: Use this setting if the slave is running in opposite direction to the master. Do not use parameter P3 "Change direction of rotation." Diagonal cut: If you are using a diagonal saw, enter the required angle between the saw feed direction and the material feed direction. The correction value enables you to align the cut angle exactly. Enter a maximum of ±1 % as correction angle, the resolution is.1 %. If you are not using a diagonal saw, enter the value for both the angle and the correction. MOVIDRIVE Flying Saw 33

34 I Startup Starting the "flying saw" program Jog mode, reference travel and positioning Figure 24: Setting parameters for jog mode, reference travel and positioning 873AEN Jog mode: Set the "Rapid speed", "Slow speed" and "Ramp" parameters. Reference travel: Define the positions of the software limit switches, the reference offset and the reference travel type. The reference offset can be used for altering the machine zero point without having to adjust the reference point. You can set the following reference travel types: Type : Referencing to the next encoder zero pulse Type 3: Referencing to the CW limit switch (falling edge of the limit switch) Type 4: Referencing to the CCW limit switch (falling edge of the limit switch) Type : No reference travel, current position is machine zero point Positioning parameters: Set the "Positioning speed", "Positioning ramp", "Home position" and "Parking position" parameters. The home position is the rest position for the "flying saw." The sawing procedure starts from the home position. You can use the parking position to move the "flying saw" out of the working area for maintenance work. 34 MOVIDRIVE Flying Saw

35 Startup Starting the "flying saw" program I Parameters for the saw In this startup window, you define how the "flying saw" will be controlled. You can make the following settings: Cut length control without material sensor: You specify the cut length. The position of the material is measured either using an external encoder on the web or the motor encoder of the web drive. With control via terminals (MDX61B with DIO11B option) or via bus (fieldbus or system bus) with one process data word (1 PD), you can specify a maximum of eight cut lengths at startup. You must select the cut length for the particular sawing procedure in binary code using binary inputs DI1, DI16 and DI17 (terminal control) or the process output data PO1:13, PO1:14 and PO1:1 (bus control with 1 PD). In control via fieldbus with three process data words (3 PD), you can specify the variable cut length with the process output data word PO2 using the fieldbus. Figure 2: Cut length control without material sensor 73AXX Cut length control with material sensor: Specify the cut length in the same way as for cut length control. Control is effected by a sensor behind the saw drive. The sensor signal is sent to binary input DIØ2. The saw carriage is started depending on the set cut length when the material reaches this sensor. Note the following rule when specifying the cut length: Cut length sensor distance + engaging distance (Sensor distance = distance between home position of the saw and material sensor) MOVIDRIVE Flying Saw 3

36 I Startup Starting the "flying saw" program [2] [1] Figure 26: Cut length control with material sensor [1] = Sensor distance [2] = Engaging distance 368AXX Cut length control with label sensor: Labels must be attached to the material which is to be sawn. A sensor must detect the labels. The sensor signal is sent to binary input DIØ2 and triggers the sawing procedure. [1] [2] Figure 27: Cut length control with label sensor [1] = Sensor distance label [2] = Engaging distance 366AXX 36 MOVIDRIVE Flying Saw

37 Startup Starting the "flying saw" program I Cut length control without material sensor: 874AEN Figure 28: Parameters for the saw in cut length control without material sensor (terminal control or bus control with one process data word (1 PD)) Engaging distance: Enter the distance in [mm] for the startup cycle process. The slave drive (= saw carriage) is brought into synchronous operation with the master drive (= material feed) during the startup cycle process. Cut length [mm]: With control via terminals and bus (system bus or fieldbus) with one process data word (1PD), you have to enter the required cut lengths in this field. You can specify up to 8 different cut lengths. You select the required cut length using binary inputs DI1... DI17 (terminal control) or via the process output data PO1:13... PA1:1 (bus control with 1 PD). Binary input or process output data Cut length no. PO DI1 or PO1:13 "" "1" "" "1" "" "1" "" "1" DI16 or PO1:14 "" "" "1" "1" "" "" "1" "1" DI17 or PO1:1 "" "" "" "" "1" "1" "1" "1" This cut length table is not required for control via fieldbus with three process data words (3 PD). Specify the cut length with process output data word PO2 via the fieldbus. MOVIDRIVE Flying Saw 37

38 I Startup Starting the "flying saw" program Cut length control with material sensor: 87AEN Figure 29: Parameters for the saw in cut length control with material sensor (terminal control or bus control with one process data word (1 PD)). You must enter the following values in addition to cut length control: Sensor distance: Enter the distance between home position of the saw and material sensor in [mm]. Sensor delay time: Enter the delay of the material sensor in [ms]. This value effects the startup cycle mode control of the saw drive. 38 MOVIDRIVE Flying Saw

39 Startup Starting the "flying saw" program I Cut length control with label sensor: Figure 3: Parameters for the saw in cut length control with label sensor 88AEN Sensor distance: Enter the distance between home position of the saw and label sensor in [mm]. Sensor delay time: Enter the delay of the label sensor in [ms] ( data sheet of the sensor). This value effects the startup cycle mode control of the saw drive. MOVIDRIVE Flying Saw 39

40 I Startup Starting the "flying saw" program Repositioning and pulling a gap 881AEN Figure 31: Setting parameters for repositioning and "pulling a gap" (time-controlled) Parameters for repositioning: The saw drive must be moved back to the home position after the sawing procedure is complete. This process is called repositioning. You have to set various parameters for this step. Smooth repositioning: "YES" or "No". "YES"means that repositioning takes place with the lowest possible acceleration and as smoothly as possible. This setting reduces stress on the mechanism and cuts down the waiting time in the home position. Max. repositioning speed: Enter the value in [1/min] for the maximum motor speed at which repositioning should take place. Make sure that the maximum permitted speed ( P32) is not exceeded. Min. repositioning ramp: Enter the value in [s] of the minimum ramp time for accelerating the repositioning drive. Minimum reversing position: Enter the value in [mm] of the position from which the saw drive responds to the repositioning signal. Pulling a gap: The "pulling a gap" function pulls the saw blade away from the material after the sawing procedure is complete. In this way, you can implement what is referred to as "cut edge protection." Pulling back the saw blade prevents additional marks on the cut edge. In addition, you can use this function for separating the cut material so that it can be processed more easily subsequently. Pulling a gap: "time-controlled" or "position-dependent". "Time-controlled" means that the gap is established using the values for "Synchronization speed" and "Synchronization ramp". "Position-dependent" means that the gap is established 4 MOVIDRIVE Flying Saw

41 Startup Starting the "flying saw" program I using the "Master distance" value. Gap: Enter the size of the gap in [mm]. Synchronization speed ("time-controlled" only): Motor speed for time-controlled "pulling a gap." Note that the "Synchronization speed" must be faster than the web speed. Synchronization ramp ("time controlled" only): Acceleration ramp for timecontrolled "pulling a gap." Master distance ("position-dependent" only): The "pulling a gap" function is completed by the time the material has covered this distance. 881AEN Figure 32: Setting parameters for repositioning and "pulling a gap" (position-dependent) Saving changes The program prompts you to save your entries. The saved startup data are now available in your file system for further processing. Figure 33: Saving changes 4444AEN MOVIDRIVE Flying Saw 41

42 I Startup Starting the "flying saw" program Download Press "Download". All necessary settings are automatically made in the inverter and the "Flying saw" IPOS program is started. Figure 34: Download window 882AEN Starting the monitor After the download, the program asks you if you want to start the monitor. Figure 3: Monitor Yes/No 884AEN Select "Yes" to switch to the monitor where you can start in the required operating mode. Select "No" to switch to MOVITOOLS/Shell. 42 MOVIDRIVE Flying Saw

43 Startup Starting the "flying saw" program I Monitor The monitor with the status display appears immediately if the "flying saw" is restarted after initial startup has already been performed. Operation without bus: You can select between "Status" and "State." Operation with fieldbus/system bus: In addition to "Status" and "State," you can also display "Fieldbus process data 1" and "Fieldbus process data 2." Status Figure 36: "Flying saw" monitor, status display 913AEN Repeated startup Press "Startup" if you want to repeat the startup. The startup windows will appear ( Initial startup). MOVIDRIVE Flying Saw 43

44 I Startup Starting the "flying saw" program State The "State" tab shows a condition chart with the possible conditions of the "flying saw." The chart shows the current condition and in what direction a change of condition is possible. Figure 37: "Flying saw" monitor, condition display 914AEN 44 MOVIDRIVE Flying Saw

45 Startup Starting the "flying saw" program I Operation with fieldbus/system bus If operating with the fieldbus/system bus, you can also have the fieldbus process data displayed. Fieldbus process data 1 Only for operation with fieldbus/system bus: Figure 38: "Flying saw" monitor, fieldbus process data 1 91AEN MOVIDRIVE Flying Saw 4

46 I Startup Starting the "flying saw" program Fieldbus process data 2 Only for operation with fieldbus/system bus: Figure 39: "Flying saw" monitor, fieldbus process data 2 917AEN 46 MOVIDRIVE Flying Saw

47 Startup Starting the "flying saw" program I Control in the monitor In addition to monitor operation, you can also simulate a control in the "Fieldbus process data 2" display. "" signal at terminal DIØØ "/CONTROLLER INHIBIT/." For this purpose, activate the "control" radio button above "PO1". You can now activate and deactivate the individual bits of the control word (PO1) and specify values for the process output data words PO2 and PO3. Press "Send PO" to send these control words to the inverter. Figure 4: Control simulation 917AEN The inverter now performs the travel command in accordance with these specifications. DIØØ "/CONTROLLER INHIBIT" = "" must be set to switch from "Control" to "Monitor." "Monitor" must be active to exit the "flying saw" program. MOVIDRIVE Flying Saw 47

48 I Startup Parameters and IPOS variables.4 Parameters and IPOS variables Startup automatically sets the following parameters and IPOS variables, which are loaded into the inverter during the download: Parameter number P... Index Description Setpoint source Control signal source Feedforward filter (DRS) Synchronous speed Synchronous ramp Binary input DI Binary input DI Binary input DI Binary input DI Binary input DI Binary input DI6 (MDX61B only) Binary input DI7 (MDX61B only) Binary input DI Binary input DI Binary input DI Binary input DI Binary input DI Binary input DI Binary input DI Binary input DI Binary output D Binary output D Binary output D3 (MDX61B only) Binary output D4 (MDX61B only) Binary output D (MDX61B only) Binary output D Binary output D Binary output D Binary output D Binary output D Binary output D Binary output D Binary output D Operating mode Parameter lock SBus address SBus timeout delay SBus baud rate 48 MOVIDRIVE Flying Saw

49 Startup Parameters and IPOS variables I Parameter number P... Index Description Fieldbus timeout delay Response fieldbus timeout Response SBus timeout Setpoint description PO Setpoint description PO Setpoint description PO Actual value description PI Actual value description PI Actual value description PI PO data enable Reference offset Reference travel type SW limit switch CW SW limit switch CCW Modulo function IPOS variable Description H Control signal source for IPOS program H1 PO2 description H2 Slave type H3 Slave value H4 i gear unit slave H i additional gear slave H6 Slave pulses H7 Slave distance H8 Diagonal angle H9 Master type H1 Master value H11 i gear unit master H12 i additional gear master H13 Master pulses H14 Master travel H1 Stiffness H16 MFilterTime H17 GFMaster H18 GFSlave H19 Unit slave 1 H2 Unit slave 2 H21 Unit master 1 H22 Unit master 2 H26 H27 H28 H29 Rapid speed Creep speed Jog ramp Software limit switch CW user MOVIDRIVE Flying Saw 49

50 I Startup Parameters and IPOS variables IPOS variable H3 H31 H32 H33 H34 H3 H36 H37 H38 H39 Description Software limit switch CCW user Use hardware limit switch Reference offset user Reference travel type - user Travel speed Ramp Home position - user Home position Parking position user Parking position H41 Automatic mode for IPOS program H42 Engaging distance user H43 Engaging distance H44 Label sensor distance user H4 Label sensor distance H46 Sensor delay time user H47 Sensor delay time H48 Number of cut lengths for IPOS program H49 Cut length 1 - user H Cut length 1 H1 Cut length 2 user H2 Cut length 2 H3 Cut length 3 user H4 Cut length 3 H Cut length 4 user H6 Cut length 4 H7 Cut length - user H8 Cut length H9 Cut length 6 user H6 Cut length 6 H61 Cut length 7 user H62 Cut length 7 H63 Cut length 8 user H64 Cut length 8 H6 Number of actual cut lengths H66 Automatic mode user H7 H71 H72 H73 H74 H7 H76 H77 H78 Smooth repositioning Travel speed Ramp Minimum reversing position user Minimum reversing position Maximum reversing position user Maximum reversing position Minimum cut length user Minimum cut length MOVIDRIVE Flying Saw

51 Startup Parameters and IPOS variables I IPOS variable H79 H8 H81 H82 H83 H84 H8 H86 Description Maximum master speed - user Maximum master speed Speed unit Pulling a gap Gap user Gap Gap master distance user Gap master distance H9 H91 H92 H93 H94 Bus type for GetSys command Master encoder resolution Diagonal cut correction Material sensor distance user Material sensor distance Do not alter these parameters and IPOS variables after startup! MOVIDRIVE Flying Saw 1

52 I Startup Starting the drive. Starting the drive Operating modes Following the download, switch to the "flying saw" monitor by selecting "Yes." You can set the operating mode using terminals DI1Ø and DI11 in terminal control or bits 8 and 9 of "PO1: control word" in bus control. Note the following points to start the drive. This procedure applies to all operating modes: Binary inputs DIØØ "//CONTROLLER INHIBIT//" and DIØ3 "ENABLE/RAPID STOP/ must get a "1" signal. Only for operation with fieldbus/system bus: Set the control bit PO1: "CONTROLLER INHIBIT/ENABLE" = "" and the control bits PO1:1 "ENABLE/RAPID STOP" and PO1:2 "ENABLE/STOP" = "1." Terminal (in bus mode, virtual terminal in control word PO1) Operating mode DI1Ø (PO1:8) DI11 (PO1:9) Jog mode "" "" Reference travel "1" "" Positioning "" "1" Automatic mode "1" "1" Jog mode (DI1Ø = "", DI11 = ""): Direction of rotation as seen onto the drive side of the motor. DI13 = "1": Motor is turning clockwise. DI14 = "1": Motor is turning counterclockwise. DI1 = ""/"1": Jog mode at slow speed/rapid speed With regard to the direction of rotation, bear in mind whether you are using a 2 or 3-stage gear unit. Reference travel (DI1Ø = "1", DI11 = ""): Reference travel is started by DI12 = "1." The reference position is defined by reference travel to one of the two limit switches. The reference offset is set during startup and you can use it to alter the machine zero without having to move the limit switch. The following formula applies: Machine zero = reference position + reference offset Positioning (DI1Ø = "", DI11 = "1"): Positioning is started by DI12 = "1." DI13 = ""/"1": Movement to home position/parking position. Positioning is used for moving between the home and parking position under position control. Automatic mode (DI1Ø = "1", DI11 = "1") Automatic mode is started by DI12 = "1." The drive is moved to the home position by DI14 = "1." Terminal control or fieldbus with one process data word (1 PD): During startup of the "flying saw", you define whether cut length control or cut length control with label sensor is active in automatic mode. 2 MOVIDRIVE Flying Saw

53 Startup Jog mode I.6 Jog mode DI1Ø (PO1:8) = "" and DI11 (PO1:9) = "" Specify the direction of rotation as seen onto the drive side of the motor. With regard to the direction of rotation, bear in mind whether you are using a 2 or 3-stage gear unit. DI13 = "1" = Motor is turning clockwise (CW) DI14 = "1" = Motor is turning counterclockwise (CCW) DI1 = "" = Jog mode in slow speed DI1 = "1" = Jog mode in rapid speed The speeds for slow speed and rapid speed and the ramp are set during startup of the "flying saw." Figure 41: Jog mode 626AEN MOVIDRIVE Flying Saw 3

54 I Startup Reference travel.7 Reference travel DI1Ø (PO1:8) = "1" and DI11 (PO1:9) = "" DI12 = "1" starts reference travel The reference position is defined by reference travel to one of the two limit switches. The reference offset is set during startup and you can use it to alter the machine zero without having to move the limit switch. The following formula applies: Machine zero = reference position + reference offset Figure 42: Reference travel 628AEN 4 MOVIDRIVE Flying Saw

55 Startup Positioning I.8 Positioning DI1Ø (PO1:8) = "" and DI11 (PO1:9) = "1" DI12 = "1" = Starts positioning DI13 = "" = Positioning to home position DI13 = "1" = Positioning to parking position Positioning is used for moving between the home and parking position under position control. Figure 43: Positioning 629AEN MOVIDRIVE Flying Saw

56 I Startup Automatic mode.9 Automatic mode DI1Ø (PO1:8) = "1" and DI11 (PO1:9) = "1" DI12 = "1" = Starts automatic mode DI14 = "1" = Starts repositioning Terminal control or fieldbus with one process data word (1 PD): During startup of the flying saw, you define whether cut length control or cut length control with label sensor is active in automatic mode. Cut length control The setpoint cut length is specified in two ways when cut length control is active: 1. In terminal control, using binary code via binary inputs DI1... DI17. A maximum of eight different cut lengths are possible. 2. In control via fieldbus or system bus, the cut length is specified using process output data PO1:13, PO1:14 and PO1:1. Figure 44: Automatic mode with cut length control 626AEN 6 MOVIDRIVE Flying Saw

57 Startup Automatic mode I Sequence of cut length control Note the following sequence for cut length control: Apply "1" signals to binary inputs DIØØ "/Controller inhibit" and DIØ1 "Enable/rapid stop." Only for operation with fieldbus/system bus: Set the following control bits: PO1: "Controller inhibit/enable" = "" PO1:1 "Enable/rapid stop" = "1" PO1:2 "Enable/Stop" = "1" Terminal control or fieldbus with one process data word (1 PD): Select the required cut length via DI1... DI17 or PO1:13... PO1:1. Fieldbus with three process data words (3 PD): Specify the cut length with process output data word PO2. Start automatic mode with DI12 (PO1:1) "Start" = "1." The "1" signal must be active for the entire duration of positioning. Apply a "1" signal to binary input DI14 (PO1:12) "Repositioning." The signal must be present at least until the home position is reached. The drive now moves to the home position and waits there until the set material length is reached. With cut length control without material sensor, the material length is counted starting from the ""-"1" edge at DI12 "Start." With cut length control with material sensor, the material length is counted starting from the ""-"1" edge at DIØ2 "Sensor." When the material length has been reached, the drive automatically engages and synchronizes itself with the master position. Binary output DO12 (PI1:1) "Drive synchronous" is set to "1" during synchronous operation. Once the drive reaches the set reversing position, movement back can be triggered by a "1" signal at binary input DI14 (PO1:12) "Repositioning." The drive disengages and moves back to the home position under position control. When the drive reaches the home position, binary output DO17 (PI1:1) "Home position reached" is set to "1." The drive stops with position control. Note the following points: The "1" signal can be permanently present at binary input DI14 (PO1:12) "Repositioning." The drive disengages when reaching the minimum reversing position and moves back to the home position. The drive remains in synchronous operation if DI14 (PO1:12) "Repositioning" remains set to = "." Use the "pulling a gap" function if you want to separate the material following the cut. Proceed as follows: Apply a "1" signal to binary input DI14 (PO1:11) "Gap." Once the minimum reversing position is reached, an offset corresponding to the value entered during startup is established. The "1" signal can be permanently present. Once the drive has reached the offset value, binary output DO13 (PI1:11) "Gap finished" is set to "1." The drive remains in synchronous operation. Fault F42 "Lag fault" is signaled if the cut length is set so small that the material feed has already exceeded the cut length by the time the home position is reached. Remedy: Less feed. MOVIDRIVE Flying Saw 7

58 I Startup Automatic mode Cut length control with label sensor The setpoint cut length is determined by labels when cut length control with label sensor is active. The labels must be located on the material to be cut and are detected by a sensor. Figure 4: Automatic mode with cut length control with label sensor 6262AEN 8 MOVIDRIVE Flying Saw

59 Startup Automatic mode I Sequence of cut length control with label sensor Note the following sequence for cut length control with label sensor: Apply "1" signals to binary inputs DIØØ "/Controller inhibit" and DIØ1 "Enable/Rapid stop." Only for operation with fieldbus/system bus: Set the following control bits: PO1: "Controller inhibit/enable" = "" PO1:1 "Enable/rapid stop" = "1" PO1:2 "Enable/Stop" = "1" Start automatic mode with DI12 (PO1:1) "Start" = "1." The "1" signal must be active for the entire duration of positioning. Apply a "1" signal to binary input DI14 (PO1:12) "Repositioning." The signal must be present at least until the home position is reached. The drive now moves to the home position until a ""-"1" signal edge on binary input DIØ2 "Sensor" starts the sawing procedure. The drive automatically engages and synchronizes itself with the material to be cut. Binary output DO12 (PI1:1) "Drive synchronous" is set to "1" during synchronous operation. Once the drive reaches the set reversing position, movement back can be triggered by a "1" signal at binary input DI14 (PO1:12) "Repositioning." The drive disengages and moves back to the home position under position control. When the drive reaches the home position, binary output DO17 (PI1:1) "Home position reached" is set to "1." The drive stops with position control. Note the following points: The "1" signal can be permanently present at binary input DI14 (PO1:12) "Repositioning." The drive disengages when reaching the minimum reversing position and moves back to the home position. The drive remains in synchronous operation if DI14 (PO1:12) "Repositioning" remains set to "." Use the "pulling a gap" function if you want to separate the material following the cut. Proceed as follows: Apply a "1" signal to binary input DI14 (PO1:11) "Gap." Once the minimum reversing position is reached, an offset corresponding to the value entered during startup is established. The "1" signal can be permanently present. Once the drive has reached the offset value, binary output DO13 (PI1:11) "Gap finished" is set to "1." The drive remains in synchronous operation. MOVIDRIVE Flying Saw 9

60 Operation and Service 6 Timing diagrams 6 Operation and Service 6.1 Timing diagrams The following prerequisites apply to the timing diagrams: Startup performed correctly DIØØ "/CONTROLLER INHIBIT" = "1" (no inhibit) DIØ1 "ENABLE/RAPID STOP" = "1" With control via fieldbus/system bus, you must set the following bits in control word PO1: PO1: = "" (CONTROLLER INHIBIT/ENABLE) PO1:1 = "1" (ENABLE/RAPID STOP) PO1:2 = "1" (ENABLE/STOP) Jog mode DI1Ø DI11 DI13 DI14 DI1 n [1/min] n2 n1 -n1 -n2 (1) (2) (3) (4) Figure 46: Timing diagram of jog mode 62AXX DI1Ø = Mode selection (1) = Start jog mode, clockwise DI11 = Mode selection (2) = Switch mode slow speed rapid speed DI13 = Clockwise (3) = Switch mode rapid speed slow speed DI14 = Counterclockwise (4) = Start jog mode, counterclockwise DI1 = Slow speed/rapid speed n1 = Slow speed for jog mode DBØØ = /Brake Set during commissioning n2 = Rapid speed for jog mode Set during commissioning 6 MOVIDRIVE Flying Saw

61 Operation and Service Timing diagrams 6 Reference travel DIØ4 DIØ DI1Ø DI11 DI12 n [1/min] n1 DOØ2 (1) (2) (3) Figure 47: Reference travel timing diagram 6439AXX DIØ4 = /Right limit switch (1) = Start reference travel DIØ = /Left limit switch (2) = CCW limit switch reached DI1Ø = Mode selection (3) = Reference position reached DI11 = Mode selection DI12 = Start reference travel DOØ2 = Axis referenced MOVIDRIVE Flying Saw 61

62 Operation and Service 6 Timing diagrams Positioning DI1Ø DI11 DI12 DI13 n [1/min] n1 -n1 DO17 (1) (2) (3) (4) Figure 48: Positioning timing diagram 644AXX DI1Ø = Mode selection (1) = Start positioning DI11 = Mode selection (2) = Target = Home position reached DI12 = Start positioning (3) = Parking position is selected as target DI13 = Select target for positioning (4) = Target = Parking position reached "" = Home position, "1" = Parking position DO17 = Target position reached 62 MOVIDRIVE Flying Saw

63 Operation and Service Timing diagrams 6 Automatic mode Cut length control without material sensor DI1Ø DI11 DI12 DI13 DI14 DI1 DI16 DI17 n [1/min] n2 n1 -n1 DO12 DO13 DO17 (1)(2) (3) (4) () (6) (7) (8) (9) 6441AXX Figure 49: Timing diagram for automatic cut length control mode without material sensor DI1Ø = Mode selection (1) = Start material detection, length is DI11 = Mode selection adopted, length measured from this point DI12 = Start automatic mode (2) = Start repositioning DI13 = Pulling a gap (3) = Home position reached DI14 = Repositioning (4) = Cut length reached, start sawing procedure DI1 = Cut length binary coded 2^ () = Synchronous speed reached, cut length for DI16 = Cut length binary coded 2^1 the next sawing procedure is adopted DI17 = Cut length binary coded 2^2 (6) = Minimum reversing position reached, start DO12 = Drive in synchronous operation pulling a gap DO13 = Pulling a gap finished (7) = Pulling a gap finished DO17 = Home position reached (8) = Sawing procedure finished because DI14 = "1" immediately start repositioning (9) = Home position reached MOVIDRIVE Flying Saw 63

64 Operation and Service 6 Timing diagrams Cut length control with material sensor DIØ2 DI1Ø DI11 DI12 DI13 DI14 DI1 DI16 DI17 n [1/min] n2 n1 -n1 DO12 DO13 DO17 (1)(2) (3) (4) () (6) (7) (8) (9) 647AXX Figure : Timing diagram for automatic cut length control mode with material sensor DIØ2 = Material sensor signal (1) = Start material detection, cut length is DI1Ø = Mode selection adopted, length measured from this point DI11 = Mode selection (2) = Start repositioning DI12 = Start automatic mode (3) = Home position reached DI13 = Pulling a gap (4) = Cut length reached, start sawing procedure DI14 = Repositioning () = Synchronous speed reached, cut length for DI1 = Cut length binary coded 2^ the next sawing procedure is adopted DI16 = Cut length binary coded 2^1 (6) = Minimum reversing position reached, start DI17 = Cut length binary coded 2^2 pulling a gap DO12 = Drive in synchronous operation (7) = Pulling a gap finished DO13 = Pulling a gap finished (8) = Sawing procedure finished because DI14 = "1" immediately DO17 = Home position reached start repositioning (9) = Home position reached 64 MOVIDRIVE Flying Saw

65 Operation and Service Timing diagrams 6 Cut length control with label sensor DIØ2 DI1Ø DI11 DI12 DI13 DI14 n [1/min] n2 n1 -n1 DO12 DO13 DO17 (1) (2) (3) (4) () (6) (7) Figure 1: Timing diagram for automatic cutting mark control 6442AXX DIØ2 = Sensor signal cutting mark (1) = Start repositioning DI1Ø = Mode selection (2) = Home position reached DI11 = Mode selection (3) = Start sawing procedure DI12 = Start automatic mode (4) = Minimum reversing position reached, start DI13 = Pulling a gap pulling a gap DI14 = Repositioning () = Pulling a gap finished DO12 = Drive in synchronous operation (6) = Sawing procedure finished because DI14 = "1" immediately DO13 = Pulling a gap finished start repositioning DO17 = Home position reached (7) = Home position reached MOVIDRIVE Flying Saw 6

66 Operation and Service 6 Fault information 6.2 Fault information The fault memory (P8) stores the last five fault messages (faults t- to t-4). The fault message of longest standing is deleted whenever more than five fault messages have occurred. The following information is stored when a malfunction occurs: Fault that occurred Status of binary inputs/outputs Operating status of the inverter Inverter status Heat sink temperature Speed Output current Active current Unit utilization DC link voltage ON hours Enable hours Parameter set Motor utilization. There are three switch-off responses depending on the fault; the inverter remains blocked in fault status: Immediate switch-off: The unit can no longer brake the drive; the output stage goes to high resistance in the event of a fault and the brake is applied immediately (DBØØ "/Brake" = ""). Rapid stop: The drive is braked with the stop ramp t13/t23. The brake is applied once the stop speed is reached (DBØØ "/Brake" = ""). The output stage goes to high resistance after the brake reaction time has elapsed (P732 / P73). Emergency stop: The drive is braked with the emergency ramp t14/t24. The brake is applied once the stop speed is reached (DBØØ "/Brake" = ""). The output stage goes to high resistance after the brake reaction time has elapsed (P732 / P73). Reset A fault can be acknowledged by: Switching the power supply off and on again. Recommendation: Observe a minimum switch-off time of 1 s for the input contactor K11. Reset by binary input DIØ3. Startup of the "Flying saw" causes this binary input to be assigned with the "Reset" function. Only for operation with fieldbus/system bus: "" "1" "" signal at bit PO1:6 in control word PO1. Press the reset button in the MOVITOOLS Manager. Figure 2: Reset with MOVITOOLS 2771AEN Manual reset in MOVITOOLS/Shell (P84 = "YES" or [Parameter] / [Manual reset]). Manual reset with DBG6B (MDX61B) or DBG11A (MCH4_A). Timeout active If the inverter is controlled via a communication interface (fieldbus, RS-48 or SBus) and the power was switched off and back on again or a fault reset was performed, then the enable remains ineffective until the inverter once again receives valid data via the interface, which is monitored with a timeout. 66 MOVIDRIVE Flying Saw

67 Operation and Service Fault messages Fault messages Display The fault or warning code is displayed in BCD format. The following display sequence is adhered to: Flashes, ca. 1 s Display off, ca..2 s Tens, ca. 1 s Display off, ca..2 s Ones, ca. 1 s Display off, ca..2 s 138AXX Following a reset or if the fault or warning code resumes the value, the display switches to the operating display again. Fault list The following table shows a selection from the complete list of faults ( MOVIDRIVE operating instructions). Only those faults are listed that can occur specifically with this application. A dot in the "P" column indicates that the response is programmable (P83_ Fault response). The factory set fault response appears in the "Response" column. Fault Designation Response P Possible cause Remedy code No fault - 7 V Z overvoltage 8 n-monitoring Immediate switch-off Immediate switch-off DC link voltage too high Extend deceleration ramps Check connection leads to the braking resistor Check technical data of braking resistor Reduce load Speed controller or current controller Increase deceleration time setting (P1 or (in VFC operating mode without P3). encoder) operating at setting limit due Check encoder connection, swap A/A and B/B to mechanical overload or phase failure pairs if necessary in the power supply or motor. Check encoder voltage supply Encoder not connected correctly or Check current limitation incorrect direction of rotation. Extend ramps if necessary n max is exceeded during torque control. Check motor cable and motor Check mains phases MOVIDRIVE Flying Saw 67

68 Operation and Service 6 Fault messages Fault Designation Response P Possible cause Remedy code 1 IPOS-ILLOP Emergency stop 14 Encoder Immediate switch-off 2 EEPROM Rapid stop Fieldbus Timeout Limit switch reached 31 TF sensor 36 No option 42 Lag error 94 EEPROM checksum Rapid stop Emergency stop None Response Immediate switch-off Immediate switch-off Immediate switch-off Incorrect command detected during running of IPOS plus program. Incorrect conditions during command execution. Encoder cable or shield not connected correctly Short circuit/broken encoder wire Encoder defective Access to the EEPROM of the memory card has failed No communication between master and slave within the projected response monitoring. A limit switch was reached in IPOS plus operating mode. Motor too hot, TF sensor has tripped TF sensor of motor not connected or not connected properly Connection of MOVIDRIVE and TF on motor interrupted No jumper between X1:1 and X1:2. Type of option card not allowed. Setpoint source, control signal source or operating mode not permitted for this option card. Incorrect encoder type set for DIP11A. Incremental encoder connected incorrectly Accelerating ramps too short P component of positioning controller too small Speed controller parameters set incorrectly Value of lag error tolerance too small Inverter electronics faulty. Possibly due to EM interference or defect. Check program memory content and correct if necessary. Load correct program into program memory. Check program sequence ( IPOS plus manual) Check encoder cable and shield for correct connection, short circuit and broken wire. Call up default setting, perform reset and set parameters again. Contact SEW service if the error occurs again. Replace memory card. Check communications routine of the master Extend fieldbus timeout time (P819)/deactivate monitoring Check travel range. Correct user program. Let motor cool off and reset fault Check connections/link between MOVIDRIVE and TF. If no TF is connected: Jumper X1:1 with X1:2. Set P83 to "NO RESPONSE" Use correct option card. Set correct setpoint source (P1). Set correct control signal source (P11). Set correct operating mode (P7 or P71). Set the correct encoder type. Check rotary encoder connection Extend ramps Set P component to higher value Set speed controller parameters again Increase lag error tolerance Check encoder, motor and mains phase wiring Check mechanical components can move freely, possibly blocked up Send the unit in for repair. 68 MOVIDRIVE Flying Saw

69 7 7 Index A Application examples 3 Application fields 2 Automatic mode 3 Cut length control 3 Cut length control with label sensor Automatic mode, with label sensor 62 Automatic mode, with material sensor 61 Automatic mode, without material sensor 6 B Bus control 16 C Connection System bus (SBus) 22 D Description of flying saw 2 E Error messages Error list 64 F Fault information 63 Functional characteristics 6 Functional description 6 I Identification 4 Installation 13 Application version 13 CANopen 2 DeviceNet 21 INTERBUS 19 INTERBUS with FO 18 MCH4_A 23 MDX61B with bus control 16 MDX61B with terminal control 14 MOVITOOLS 13 PROFIBUS 17 Software 13 System bus 22 J Jog mode, 7 M Monitor 4 Operation with fieldbus/system bus 42 P Positioning 2, 9 Process data assignment 11 Process input data 12 Process output data 11 Program identification 4 Project planning Automatic mode 8 Inverter, motor and gear unit Jog mode 7 Material travel and web speed 1 MDX61B with bus control Operating modes, 7 PC and software Positioning 8 Process data assignment 11 Process input data 12 Process output data 11 Reference travel 7 R Reference travel 1, 8 Reset 63 S Safety instructions 1 Starting the drive 49 Startup 26 Control signal source 28 Cut length control with label sensor 33, 36 Cut length control with material sensor 32, 3 Cut length control without material sensor 32, 34 Download of startup data 39 General information 26 Initial startup 27 Jog mode, reference travel, positioning 31 Master scaling 29 Parameters and IPOS variables 4 Parameters for the saw 32 Preliminary work 26 Repositioning, pulling a gap 37 Slave scaling 3 Starting the program 27 System bus (SBus) Connection 22 System description 2 T Terminal control 14 Timeout 63 Timing diagram Automatic mode, with label sensor 62 Automatic mode, with material sensor 61 Automatic mode, without material sensor 6 Jog mode 7 Positioning 9 Reference travel 8 Timing diagrams 7 W Warning instructions 1 MOVIDRIVE Flying Saw 69

70

71

72 Gearmotors \ Industrial Gear Units \ Drive Electronics \ Drive Automation \ Services How to drive the world With people who think fast and develop the future with you. With a service network that is always close at hand around the world. With drives and controls that automatically improve your work performance. With a comprehensive knowledge in the most important branches of industry today. With uncompromising quality whose high standards will simplify daily operations. SEW-EURODRIVE Driving the world With a global presence for quick and convincing solutions. Anywhere. With innovative ideas that offer a solution for future problems today. With an Internet presence that is available around the clock and offers information as well as software updates. SEW-EURODRIVE GmbH & Co KG P.O. Box 323 D Bruchsal / Germany Phone Fax sew@sew-eurodrive.com