MOVIDRIVE MD_60A Drive Inverters

Transcription

1 PROCESS FIELD BUS T MOVIDRIVE MD_60A Drive Inverters Addendum to System Manual Bus Positioning Edition 0/000 P R O F I B U S Device Net SBus 098 4X / 0000 C U L U L

2 Important Notes This additional information does not replace the detailed operating instructions! Installation should only be performed by electrical specialists observing applicable accident prevention regulations and the MOVIDRIVE operating instructions! Read through this manual carefully before you commence installation and startup of MOVI- DRIVE drive inverters with bus positioning. This manual assumes that the user has access to and is familiar with the documentation on the MOVIDRIVE system, in particular the MOVIDRIVE System Manual and the fieldbus documentation. Safety notes: Always follow the safety and warning instructions contained in this manual! Safety notes are marked as follows: Electrical hazard, e.g. during live working. Mechanical hazard, e.g. when working on hoists. Important instructions for safe and fault-free operation of the driven machine/system, e.g. pre-setting before startup. In this manual, cross references are signified by, e.g.:( 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 this information is observed. MOVIDRIVE Bus Positioning

3 Contents Page Project Planning...4. Application Fields...4. Hardware and Software Requirements PC and Software Inverters, Motors and Encoders...5. Functional Description Scaling of the Drive Limit Switches, Reference Cams and Machine Zero Point Process Data Assignment...8 Installation Software...0. MOVIDRIVE Basic Unit.... Bus Installation..... PROFIBUS..... INTERBUS CAN Bus DeviceNet System Bus (SBus) Connecting the Limit Switches...8 Startup General Information...9. Preliminary Work...9. Starting the Bus Positioning Program Setting the Fieldbus Parameters Setting the Scaling..... Setting Ramps and Limits....4 Parameters Starting the Drive Operating Modes Referencing Mode Jog Mode Automatic Mode Operation and Servicing Timing Diagrams Referencing Mode and Automatic Mode Jog Mode Moving Clear of Limit Switches Fault Information Fault Messages...5 MOVIDRIVE Bus Positioning

4 Project Planning Project Planning. Application Fields Bus positioning is particularly suited to the following sectors and applications: Materials handling technology Trolleys Hoists Rail vehicles Logistics Storage and retrieval units for high-bay warehouses Transverse carriages Palletizing/handling Multi-axis handling robots Gantries Bus positioning offers the following advantages in these applications: User-friendly user interface You only have to enter the parameters required for bus positioning (ratios, speeds, diameters) User-friendly application programs guide you through the process of setting parameters, so there is no need for complicated programming Monitor mode for optimum diagnosis You do not need any programming experience It doesn t take long to get to know the system 4 MOVIDRIVE Bus Positioning

5 Project Planning. Hardware and Software Requirements.. PC and Software Bus positioning is implemented as an IPOS plus program and forms part of the SEW MOVITOOLS software package. In order to use MOVITOOLS, you must have a PC with one of the following operating systems: Windows 95, Windows 98 or Windows NT version Inverters, Motors and Encoders Inverters Bus positioning can be performed using MOVIDRIVE MDV60A or MOVIDRIVE MDS60A. You need the MOVIDRIVE option (DFPA, DFIA, DFCA or DFDA) corresponding to the bus type you are going to be using. However, you do not need one of these options if you are going to use the system bus (SBus) which is provided as standard. An external encoder is required for positioning in applications with a non-positive connection between the motor shaft and the load. Absolute encoder interface type DIPA is required if an absolute encoder is being used as well. Bus positioning is not possible with MOVIDRIVE MDF60A because no encoder feedback is possible. Motors For operation on MOVIDRIVE MDV60A: Asynchronous servo motors CT/CV, encoder installed as standard. AC motors DT/DV/D with incremental encoder option or combination encoder AVY. For operation on MOVIDRIVE MDS60A: Synchronous servo motors DS/DY, resolver installed as standard. External encoders Interlocking connection between the motor shaft and the load: No external encoder is needed*. Non-positive connection between the motor shaft and the load: An external encoder is needed in addition to the motor encoder/resolver. Incremental encoder as external encoder Connection on the basic unit X4: Absolute encoder as external encoder Connection on the DIPA option X6: * If you also want to use an external encoder for positioning when there is an interlocking connection, you have to proceed in exactly the same way as with a non-positive connection. Possible combinations Motor shaft/load connection Interlocking, no external encoder needed. Non-positive, external encoder needed Encoder type, ext. encoder - Incremental encoder Absolute encoder Reference travel Yes Yes No Bus type Required option Other MOVIDRIVE option required No PROFIBUS DFPA INTERBUS DFIA CAN bus DFCA DeviceNet DFDA System bus (SBus) No option necessary Absolute encoder interface No Type DIPA MOVIDRIVE Bus Positioning 5

6 Project Planning. Functional Description The bus positioning application offers the following functional characteristics: Any number of target positions can be defined and selected by means of a fieldbus/system bus. Important: The maximum possible travel distance depends on the travel unit which is set. Travel unit Max. possible travel distance /0 mm.7 m mm.7 m cm 7 m For positioning travel, the speed can be selected as required using the bus. Software limit switches can be defined and evaluated. Either incremental encoders or absolute encoders can be evaluated as external encoders. Straightforward connection to the machine control (PLC). The functions are implemented with three operating modes: Jog mode The drive is moved clockwise or counterclockwise using bits 9 and 0 in control word (PO). The speed in jog mode is variable and is specified by the PLC via the bus. Referencing mode Reference travel is started with bit 8 in control word (PO). Reference travel establishes the reference point (machine zero) for absolute positioning operations. Automatic mode Set speed and target position are specified using process output data (PO and PO). Cyclical checkback of actual speed and actual position in the user unit via process input data (PI and PI). Confirmation of the target position to which movement has taken place via virtual binary output target position reached. Control word Process output data (PO) Speed setpoint Target position Seed actual Status word value Actual position Process input data (PI) E Q Fig. : Data exchange via process data 0789AEN 6 MOVIDRIVE Bus Positioning

7 Project Planning.4 Scaling of the Drive The control needs to know the number of encoder pulses (increments) per travel unit so it can calculate the travel information and position the drive correctly. Furthermore, you can use the scaling function to tailor the unit of measurement suitable to your application. Drives without an external encoder (interlocking connection): In drives without an external encoder, you can have scaling performed automatically by the bus positioning startup procedure. To do this, you have to enter the following data: Diameter of the drive wheel or the spindle pitch Gear unit ratio (i gear unit, speed reduction) Additional gear ratio (i additional gear, speed reduction) The following scaling factors are then calculated.. Pulses/distance scaling factor [inc/mm] according to the formula: Pulses = 4096 i gear unit i additional gear Distance = π d drive wheel or s spindle pitch. Speed scaling factor (numerator value in rpm and denominator value in mm/s). You can also enter m/min or rpm as the unit for the denominator value. It is also possible to enter the pulses/distance and the scaling factor of the speed directly. If you enter a unit other than millimeter [mm] as the travel unit, then this user unit is also used for the position of the software limit switches, the reference offset and the bus positions. Drive with an external encoder (non-positive connection): In this case, you must have activated and scaled the external encoder before starting up the bus positioning. Make the following settings in Shell in order to do this: Set P94 Source actual position, EXT. ENCODER (X4) with incremental encoder or ABSOLUTE ENCODER (DIP). You can also make this setting during the startup of the bus positioning. Fig. : Setting the source actual position 0770AEN Set P94 P944 encoder factor numerator, encoder factor denominator and encoder scaling ext. encoder. This setting must be made in SHELL prior to the startup of bus positioning. Calculation of the scaling is now blocked during startup. For more information about scaling an external encoder, please refer to the IPOS plus Positioning and Sequence Control System manual (publication number 099 7). If you are using an absolute encoder, follow the startup instructions in the Positioning with Absolute Encoder and Absolute Encoder Interface DIPA manual (publication number ). MOVIDRIVE Bus Positioning 7

8 Project Planning.5 Limit Switches, Reference Cams and Machine Zero Point Note the following points during project planning: The software limit switches must be located within the travel range of the hardware limit switches. When defining the reference position (position of the reference cam) and the software limit switches, make sure they do not overlap. Fault message F78 IPOS SW limit switch is generated in the event of an overlap during referencing. You can enter a reference offset during startup of the bus positioning if you do not want the machine zero (= reference point for bus positioning) to be located on the reference point. The following formula applies: Machine zero = Reference position + Reference offset In this way, you can alter the machine zero without having to move the reference cam..6 Process Data Assignment The machine control (PLC) sends three process output data words (PO PO) to the inverter and receives three process input data words (PI PI) from the inverter. Process output data (PO) PO PO PO E Q PI PI PI Process input data (PI) Fig. : Process data channel 009BEN The assignment of the process output data words is as follows: PO control word Reserved Reserved Reserved Mode select Mode select Jog - Jog + Start Fig. 4: PO control word Controller inhibit/enable Enable/rapid stop Enable/stop /Hold control Ramp switchover Param. switchover Fault reset Reserved 079AEN PO setpoint speed Setpoint speed [user-defined unit] Fig. 5: PO setpoint speed 0794AEN PA target position Target position [user-defined unit] Fig. 6: PO setpoint position 0795AEN 8 MOVIDRIVE Bus Positioning

9 Project Planning The assignment of the process input data words is as follows: PI status word Fig. 7: PI status word Inverter status Motor running (n 0) Inverter ready IPOS reference (= drive referenced) In target position Brake released Fault / warning Limit switch CW Limit switch CCW 0796AEN PI actual speed Actual speed [user-defined unit] Fig. 8: PI actual speed 0797AEN PI actual position Actual position [user-defined unit] Fig. 9: PI actual position 0798AEN MOVIDRIVE Bus Positioning 9

10 Installation Installation. Software Bus positioning is a part of the SEW MOVITOOLS software package. 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. 4. The MOVITOOLS setup menu appears. Follow the instructions of the installation wizard. Now proceed as follows to install the bus positioning software:. Insert disk / with the fieldbus positioning into the disk drive of your PC.. Select Start/Run..... Type {Drive letter of your floppy disk drive}:setup and press the Enter key. 4. The bus positioning setup menu appears. Follow the instructions of the installation wizard. You can now use Program Manager to start MOVITOOLS. If a MOVIDRIVE unit is connected to your PC, select the correct port (PC COM port) and set point-to-point connection. Select <Update> to display the inverter in the "Connected Units" window. Fig. 0: MOVITOOLS window 0745AEN 0 MOVIDRIVE Bus Positioning

11 Installation. MOVIDRIVE Basic Unit You must wire up the MOVIDRIVE basic unit as shown in the following wiring diagram, irrespective of the bus type you are using. DIØØ DIØ DIØ DIØ DIØ4 DIØ5 DCOM VO4 DGND ST ST X: X0: TF DGND DBØØ DOØ-C DOØ-NO DOØ-NC DOØ VO4 VI4 DGND X4: External encoder connection, Incremental encoder 5 V TTL (connection operating instructions MOVIDRIVE ) MOVIDRIVE /Controller inhibit Enable/rapid stop Reset Reference cam /Limit switch CW /Limit switch CCW Ref. X:DIØØ...DIØ5 +4V output Ref. potential for binary signals RS-485+ RS-485- X5: Motor encoder: Incremental encoder (MDV) or resolver (MDS) (connection operating instructionsmovidrive ) TF input Ref. potential for binary signals /Brake Relay contact /fault Normally open/fault Normally closed/fault Ready +4V output +4V input Ref. potential for binary signals S S MDV (MDS) X4 ENCODER IN/OUT X ma V R ON OFF X X X0 SUPPLY OUT 4V= X5 ENCODER IN (RESOLVER IN) Fig. : Wiring diagram for MOVIDRIVE basic unit 0799AEN MOVIDRIVE Bus Positioning

12 Installation. Bus Installation Please refer to the information in the relevant addendums to the operating instructions for information about bus installation. These addendums are included with the DFPA, DFIA, DFCA and DFDA fieldbus interfaces. Please refer to the operating instructions for information about installing the system bus (SBus). DFP PROFIBUS FMS / DP DFI INTERBUS-S Module Ident. 7 DFC CAN-Bus DFD DEVICE-NET 4 5 MDV (MDS) X S S ma V R ON OFF NA(5) NA(4) NA() NA() NA() NA(0) 0 DR() DR(0) 4 5 Mod/ Net PIO BIO BUS- OFF S S SBus X X X0 SUPPLY OUT 4V= X0 X4 ENCODER IN/OUT X5 ENCODER IN (RESOLVER IN) P R O F I PROCESS FIELD BUS B U S Device Net Fig. : Bus types 0800AXX MOVIDRIVE Bus Positioning

13 Installation.. PROFIBUS The PROFIBUS documentation package contains detailed information. This package can be obtained from SEW, publication number This documentation package contains the GSD files and type files for MOVIDRIVE to help with project planning and facilitate startup. Technical data: Option PROFIBUS fieldbus interface type DFPA Part number 8 74 Resources for startup/diagnosis Protocol types Supported baud rates Connection Bus termination Station address Default bus parameter GSD file DP identity number DBGA keypad MOVITOOLS or MX_SHELL PC program PROFIBUS-DP to EN 5070 V / DIN E 945 P PROFIBUS-FMS to EN 5070 V / DIN E 945 P Mixed mode PROFIBUS DP/FMS (combi-slave) Automatic detection of baud rate: 9.6 kbaud 9. kbaud 9.75 kbaud 87.5 kbaud 500 kbaud 500 kbaud 9-pin sub D socket Assignment to EN 5070 V / DIN 945 P Can be activated for cable type A (up to 500 kbaud) to EN 5070 V / DIN 945 P 0 5, can be set using DIP switch Min-T SDR for FMS/DP or DP mode can be selected via DIP switch SEW_6000.GSD 6000 hex = 4576 dec Fig. : Front view of DFPA 0009AEN Pin assignment: Fig. 4: Assignment of 9-pin sub D plug to DIN 945 0BEN MOVIDRIVE Bus Positioning

14 Installation.. INTERBUS The INTERBUS documentation package contains detailed information. This package can be obtained from SEW, publication number DFI INTERBUS-S Module Ident. 7 DIP switch to set the process data count 4 LED Green LED Red X0: Remote bus input Technical data: Option INTERBUS fieldbus interface type DFIA Part number 8 7 Resources for startup/diagnosis Connection Module ID DBGA keypad MOVITOOLS or MX_SHELL PC program Remote bus input: 9-pin sub D plug Remote bus output: 9-pin sub D socket RS-485 transmission technology, 6-core shielded and twisted-pair cable E hex = 7 dec X: Remote bus output Fig. 5: Front view of DFIA 0008AEN Pin assignment: Twisted-pair signal cables 9-pin type D connector Green Yellow Pink Grey Brown 6 7 /DO DO /DI DI COM E Q Conductive connection between t h i d Fig. 6: Assignment of 9-pin sub D socket of the incoming remote bus cable 0046AEN 9-pin sub D connector Twisted-pair signal cables E Q /DO DO /DI DI COM Bridged Fig. 7: Assignment of 9-pin sub D plug of the outgoing remote bus cable Green Yellow Pink Grey Brown Conductive connection between connector ho sing cable shield 0047AEN 4 MOVIDRIVE Bus Positioning

15 Installation.. CAN Bus The CAN bus documentation package contains detailed information. This package can be obtained from SEW, order number DFC CAN-Bus LED Green: TxD LED Red: RxD DIP switch to set process data length and baud rate DIP switch to set the base ID and to switch the termination resistor on/off Technical data: Option Part number Resources for startup/diagnosis Supported baud rates Connection Bus termination CAN fieldbus interface type DFCA 8 75 X DBGA keypad MOVITOOLS or MX_SHELL PC program can be selected via DIP switch: 5 kbaud 50 kbaud 500 kbaud 000 kbaud 9-pin sub D plug Assignment to CiA standard -core twisted cable to ISO 898 Can be switched on using DIP switch (0Ω) ID range 00 Base ID: 0 6, can be selected using DIP switch X0: Bus connection Fig. 8: Front view of DFCA 000AEN Pin assignment: Twisted-pair signal cables 9-pin sub D connector 6 7 DGND CAN High CAN Low DGND E Q Conductive line between Fig. 9: Assignment of 9-pin sub D connection 00AEN MOVIDRIVE Bus Positioning 5

16 Installation..4 DeviceNet The DeviceNet documentation package contains detailed information. This package can be obtained from SEW, order number DFD DEVICE-NET NA() NA(0) 0 NA(5) NA(4) NA() NA() DR() DR(0) 4 5 X0 Mod/ Net PIO BIO BUS- OFF S S LED display DIP switch for setting the node address (MAC-ID) and the baud rate X0: Bus connection Technical data: Option DeviceNet fieldbus interface type DFDA Part number Resources for startup/diagnosis Supported baud rates Connection Permitted line cross section Bus termination Address range which can be set (MAC-ID) DBGA keypad MOVITOOLS or MX_SHELL PC program can be selected via DIP switch: 5 kbaud 50 kbaud 500 kbaud 5-pin Phoenix terminal Assignment to DeviceNet specification (Volume I, Appendix B) According to DeviceNet specification Use of bus connectors with integrated bus terminating resistor (0 Ω) at the start and finish of the bus segment. 0 6 can be selected via DIP switch Fig. 0: Front view of DFDA 004AEN Terminal assignment: DFDA option card 4 5 The assignment of connecting terminals is described in the DeviceNet specification Volume I, Appendix A. Pin no. Meaning Meaning Color V- 0V4 Black CAN_L CAN_L Blue DRAIN DRAIN Bright 4 CAN_H CAN_H White 5 V+ 4 V Red 09AEN Fig. : DeviceNet terminal assignment 6 MOVIDRIVE Bus Positioning

17 Installation..5 System Bus (SBus) The System Bus manual contains detailed information about the system bus (SBus). This manual can be obtained from SEW, publication number Max. 64 CAN bus stations can be interconnected using the system bus (SBus). The SBus supports transmission systems compliant with ISO 898. Control unit Control unit Control unit X: X: X: REF AI AI AGND REF 4 5 REF AI AI AGND REF 4 5 REF AI AI AGND REF 4 5 system bus terminating resistor S S S system bus S system bus ON OFF terminating resistor ON OFF terminating resistor ON OFF X: Systembus X: Systembus X: DGND SC SC ref. potential DGND SC SC ref. potential DGND SC SC Systembus ref. potential system bus high system bus high system bus high system bus low system bus low system bus low S S Fig. : System bus connection 005AEN Special note: Use a -core twisted and shielded copper cable (data transmission cable with shield comprising copper braiding). Connect the shield at either end to the electronics shield clamp of MOVIDRIVE or the master control and ensure the shield is connected over a large area. Also connect the ends of the shield to DGND. The cable must meet the following specifications: - Conductor cross section 0.75 mm (AWG8) - Cable resistance 0 Ω at MHz - Capacitance per unit length 40 pf/m ( pf/ft) at khz Suitable cables are CAN bus or DeviceNet cables, for example. The permitted total cable length depends on the baud rate setting of the SBus: 50 kbaud 60 m (58 ft) 500 kbaud 80 m (64 ft) 000 kbaud 40 m ( ft) Switch on the system bus terminating resistor (S = ON) at the beginning and end of the system bus connection. Switch off the terminating resistor on the other units (S = OFF). There must not be any potential displacement between the units which are connected together using the SBus. Take suitable measures to avoid a potential displacement, e.g. by connecting the unit ground connectors using a separate lead. MOVIDRIVE Bus Positioning 7

18 Installation.4 Connecting the Limit Switches The cams of the limit switches must cover the travel range up to the stop. Only use limit switches with NC contacts (low-active)! CW drive inverter Distance of travel CCW limit switch CW limit switch Fig. : Connecting the limit switches 0746AEN 8 MOVIDRIVE Bus Positioning

19 Startup Startup. General Information Correct project planning and installation are the pre-requisites for successful startup. Refer to the MOVIDRIVE system manual for detailed project planning instructions. The system manual forms part of the MOVIDRIVE documentation package (publication number 099 9). Check the installation, including the encoder connection and the fieldbus interface installation, by following the installation instructions in the MOVIDRIVE MD_60A operating instructions, the fieldbus documentation packages and in this manual (Sec., page 0). If you are using an absolute encoder as the external encoder (connection on DIPA X6:), please also refer to the installation and startup instructions in the Positioning with Absolute Encoder and Absolute Encoder Interface DIPA manual (publication number ).. Preliminary Work Perform the following steps before the startup of bus positioning: Connect the inverter to the PC using the serial port (RS-, USSA on PC-COM). Install MOVITOOLS on the PC (Sec.., page 0) and start the program. Start up the inverter using <Shell>. With MOVIDRIVE MDV60A and DT/DV/D motors, in VFC-n-CONTROL operating mode. With MOVIDRIVE MDV60A and CT/CV motors, in CFC operating mode. With MOVIDRIVE MDS60A and DS/DY motors, in SERVO operating mode. Only for operation with an external encoder (absolute or incremental encoder). Absolute encoder: Start up the DIPA absolute encoder interface; this sets parameters P94 P944 ( Positioning with Absolute Encoder and Absolute Encoder Interface DIPA manual, publication number ). Incremental encoder: Set P94 P944 encoder factor numerator/denominator and encoder scaling ext. encoder in Shell. Refer to the IPOS plus Positioning and Sequence Control System manual, number 099 7, for a detailed description of the parameters. 0 signal at terminal X: (DIØØ, /Controller inhibit).. Starting the Bus Positioning Program Start <Shell>. In Shell, start Startup/bus positioning. Fig. 4: Starting the Bus positioning program 0989AEN MOVIDRIVE Bus Positioning 9

20 Startup.. Setting the Fieldbus Parameters Initial startup: The window for setting the fieldbus parameters appears straight away if the bus positioning program has been started for the first time. Fig. 5: Fieldbus parameters of bus positioning 0804AEN You have to make the following settings in this window: Set the fieldbus type The system bus (SBus) can always be set; no option is required for this. You can also select PROFIBUS, INTERBUS, CAN or DEVICENET if there is a fieldbus interface (DFPA, DFIA, DFCA or DFDA) connected to the OPTION slot. Set the address Set the timeout time Set the timeout response Set the baud rate A few of these settings must be made using DIP switches on the fieldbus interface. The corresponding boxes have a gray background and nothing can be entered in them. 0 MOVIDRIVE Bus Positioning

21 Startup.. Setting the Scaling Fig. 6: Setting the scaling 0806AEN You have to make the following settings in this window: Set the source actual position; this selects which encoder is used for position measurement in positioning: Motor encoder (X5) for operation without an external encoder. EXT. ENCODER (X4) with an incremental encoder as the external encoder. ABSOLUTE ENCODER (DIP) with an absolute encoder as the external encoder. If you are not using an external encoder: Calculate the pulses/distance scaling factor. Select the Drive Wheel Diameter or Spindle Pitch box and enter the value in millimeters [mm] or /0 millimeter [/0 mm]. Enter the ratio (i) values for the gear unit and additional gear. Press <Calculate> to calculate the scaling factor. The pulses/distance are entered in the unit inc/mm. You can also enter the scaling factor directly. In this case, you can enter a unit of your choice for the distance. It is not possible to calculate the scaling for drives with an external encoder. MOVIDRIVE Bus Positioning

22 Startup Distance scaling factor The distance scaling factor is calculated and entered automatically if you have the scaling calculated by the program. You have to calculate and enter the distance scaling factor yourself if you do not have it calculated by the program, for example if you are using an external encoder. This is explained with two examples in the online help for the bus positioning. Speed scaling factor The speed scaling factor is calculated and entered automatically if you have the scaling calculated by the program. You have to calculate and enter the speed scaling factor yourself if you do not have it calculated by the program, for example if you are using an external encoder... Setting Ramps and Limits Fig. 7: Setting ramps and limits 0807AEN MOVIDRIVE Bus Positioning

23 Startup You have to make the following settings in this window: Enter software limit switches and the reference offset. The entries are made in the user units of the scaling. Enter the position of the software limit switches. A line of numbers appears in the bottom half of the screen. This represents the travel distance delimited by the software limit switches. Make sure the positions of the software limit switches are within the travel distance of the hardware limit switches and that they do not overlap the reference position. Entering zero for both software limit switches causes them to be deactivated. Enter the reference offset. The reference offset corrects the machine zero. The following formula applies: Machine zero = Reference position + Reference offset. Select the correct type of reference travel (0 7). ] [ ZP ] [ CAM ] [ CAM ] [ ] [ ] [ ] [ CAM ] [ CAM Type 0: No reference travel. The reference position is the zero pulse left of the current position. Machine zero = Zero pulse left of the current position + Reference offset Type : The reference position is the left end of the reference cam. Machine zero = Reference point + Reference offset Type : The reference position is the right end of the reference cam. Machine zero = Reference point + Reference offset Type : The reference position is the right-end limit switch. No reference cam is required for this. Machine zero = Reference point + Reference offset Type 4: The reference position is the left-hand limit switch. No reference cam is required for this. Machine zero = Reference point + Reference offset Type 5: No reference travel. The reference position is the current position without reference to a zero pulse. Machine zero = Current position + Reference offset Type 6: The reference position is the left-hand end of the reference cam. Machine zero = Reference point + Reference offset Type 7: The reference position is the right-hand end of the reference cam. Machine zero = Reference point + Reference offset 079AXX Enter ramp times for jog mode and automatic mode. You must enter the ramp times in the unit [s]. They are used for calculating the speed values in the unit [mm/s] on the basis of the scaling factor. Enter speed limits. Enter the maximum speeds for automatic mode, jog mode and the closed-loop speed controller. The speed values for automatic mode and jog mode must be at least 0 % less than for the closed-loop speed controller (P0 Maximum speed ). MOVIDRIVE Bus Positioning

24 Startup AUTO Press Next>> when you have entered the values you want. The program prompts you to save the values you have set. The download window appears after the settings have been saved. Press <Download>. All necessary settings are automatically made in the inverter and the Bus positioning IPOS program is started. Fig. 8: Download window 0809AEN After the download, the program asks you if you want to switch to the monitor. In the monitor, you can run a diagnostic of your application and check the control signals. Fig. 9: Monitor Yes/No 080AEN Select Yes to switch to the bus positioning monitor ( Fig. 0, page 5). You can start in the operating mode you want there. Select No and you switch to the Shell window. 4 MOVIDRIVE Bus Positioning

25 Startup Repeat startup: The bus positioning monitor appears if bus positioning is started after the startup procedure has already been performed Process data traffic in hexadecimal notation PO control word, decoded into individual bits. PI status word, decoded into individual bits. 4 Process data in decimal notation and with user units. 5 Status of the binary inputs of the basic unit. 6 Position of the software limit switches and current position of the drive. Fig. 0: Bus positioning monitor 08AEN Pressing <Startup> calls up the window for setting the fieldbus parameters. You can then perform the startup. MOVIDRIVE Bus Positioning 5

26 Startup.4 Parameters The bus positioning startup automatically sets the following parameters: Parameter number Parameter Setting 00 Setpoint source SBus or FIELDBUS 0 Control signal source SBus or FIELDBUS 0 Maximum speed rpm 600 Binary input DIØ Enable/rapid stop 60 Binary input DIØ Reset 60 Binary input DIØ Reference cam 60 Binary input DIØ4 /CW limit switch 604 Binary input DIØ5 /CCW limit switch Binary inputs DIØ DI7 IPOS input Binary outputs DOØ DO7 IPOS output 8 SBus address SBus timeout delay s 86 SBus baud rate 5/50/500/000 kbaud 89 Fieldbus timeout delay s 8 Response fieldbus timeout No response Display fault Immediate switch-off/fault Emergency stop/fault Rapid stop/fault Immediate switch-off/warning Emergency stop/warning Rapid stop/warning 86 Response SBus timeout 870 Setpoint description PO IPOS PO data 87 Setpoint description PO IPOS PO data 87 Setpoint description PO IPOS PO data 87 Actual value description PI IPOS PI data 874 Actual value description PI IPOS PI data 875 Actual value description PI IPOS PI data 876 PO data enable On These parameters must not be altered after startup! 6 MOVIDRIVE Bus Positioning

27 Startup.5 Starting the Drive After downloading the startup data, select Yes to switch to the bus positioning monitor. The operating mode is set using control word..5. Operating Modes The operating modes are selected with bits and (mode select) of PO control word. Operating mode Invalid mode Jog mode Referencing mode Automatic mode PO: Bit 0 0 PO: Bit 0 0 PO control word : Reserved Reserved Reserved Mode select Mode select Jog - Jog + Start Fig. : PO control word Controller inhibit/enable Enable/rapid stop Enable/stop /Hold control Ramp switchover Param. switchover Fault reset Reserved 079AEN Jog mode The drive is moved clockwise or counterclockwise using bits 9 and 0 in the control word (PO). The speed is specified in PO set speed. Referencing mode Reference travel is started with bit 8 in the control word (PO). Reference travel establishes the reference point (machine zero) for absolute positioning operations. Automatic mode Positioning is started in automatic mode with bit 8 in the control word (PO). The control specifies PO set speed and PO set position. The inverter signals PI actual speed and PI actual position back to the control. You have to select Referencing mode operating mode with the control word (PO) if the drive has not yet been referenced or if you want to reference it again. It is impossible to select automatic mode unless reference travel has been performed successfully. MOVIDRIVE Bus Positioning 7

28 Startup.5. Referencing Mode PO: bit = 0 and bit = The reference position is defined by reference travel to the reference cam. The reference offset is set during startup and you can use it to alter the machine zero without having to move the reference cam. The following formula applies: Machine zero = Reference point + Reference offset Fig. : Referencing mode 08AEN The correct type of reference travel must be set. If it is not, repeat the bus positioning startup and set the type of reference travel you want. Apply signals to DIØØ /Controller inhibit and DIØ Enable/rapid stop and set the control bits PO: Enable/rapid stop and PO: Enable/stop =. Start reference travel with control bit PO: 8 Start =. The signal must be present for the entire duration of the reference travel. If the drive reaches the reference position (DIØ Reference cam = ), the drive continues moving at reference speed and stops with position control when it leaves the reference position (DIØ 0 ). Status bit PI: IPOS reference is set (= signal). The signal at PO: 8 can now be revoked. The drive has now been referenced. Now set the operating mode you require. 8 MOVIDRIVE Bus Positioning

29 Startup.5. Jog Mode PO: bit = and bit = 0 In jog mode, you can set the control bits PO: 9 Jog + and PO: 0 Jog - to move the drive clockwise or counterclockwise. The speed is specified by PO set speed. Jog mode is required for service purposes when the drive should be moved independently of the automatic function of the machine. Fig. : Jog mode 084AEN MOVIDRIVE Bus Positioning 9

30 Startup.5.4 Automatic Mode PO: bit = and bit = In automatic mode, you use the controller to specify the set speed and set position by means of process output data words (PO and PO). The inverter signals the actual speed and actual position back to the control in process input data words (PI and PI). Fig. 4: Automatic mode 085AEN Apply signals to DIØØ /Controller inhibit and DIØ Enable/rapid stop and set the control bits PO: Enable/rapid stop and PO: Enable/stop =. Start positioning with control bit PO: 8 Start =. The signal must be present for the entire duration of positioning. Bit Set position = is set in status word PI when the drive has reached the required position. The drive stops with position control. The drive immediately moves to the new position if control bit PO: 8 Start continues to be = and a new position is specified with PO set position. 0 MOVIDRIVE Bus Positioning

31 Operation and Servicing 4 4 Operation and Servicing 4. Timing Diagrams The following preconditions apply to timing diagrams: DIØØ /Controller inhibit = and DIØ Enable/rapid stop = signals. Binary output DBØØ /Brake is set. The brake is released and the drive stops with position control. 4.. Referencing Mode and Automatic Mode DIØØ /Controller inhibit DIØ Enable/stop DIØ Reference cam PA: Mode select PA: Mode select PA: 8 Start PA Setpoint speed PA Target position PE: IPOS Reference PE: In position n [/min] DBØØ /Brake Start reference Reference mode activated 0E8 hex 00FC hex In reference position Start positioning travel Automatic mode activated 0BB8 hex 0E8 hex 000 hex 005F hex In position 5 In position 5 In position 95 Fig. 5: Timing diagram of referencing mode and automatic mode 086AEN MOVIDRIVE Bus Positioning

32 4 Operation and Servicing 4.. Jog Mode DIØØ /Controller inhibit DIØ Enable/stop PA: Mode select PA: Mode select PA: 9 Jog + PA: 0 Jog - PA Setpoint speed 0E8 hex 0BB8 hex 0E8 hex n [/min] Start jog mode DBØØ /Brake Fig. 6: Timing diagram of jog mode 089AEN MOVIDRIVE Bus Positioning

33 Operation and Servicing Moving Clear of Limit Switches When the drive moves onto a limit switch (DIØ4 or DIØ5 = 0 ), bit PI: 5 (fault) is set to and the drive is stopped with an emergency stop ( Sec. 4., page 4). Proceed as follows to move the drive clear again:. Set jog mode as the operating mode (PO: = and PO: = 0 ).. Set bit PO: 6 (fault reset) to ; bit PI: 5 (fault) is set to 0.. Leave bit PO: 6 set to. This means the drive is automatically moved clear at a motor speed of n = 00 rpm. 4. Once the drive has moved clear, DIØ4 or DIØ5 is set from 0. Now set PO: 6 to 0 and set the required operating mode, for example automatic mode (PO: = and PO: = ). DIØØ /Controller inhibit DIØ Enable/stop DIØ4 /Limit switch right PA: Mode select Automatic mode Jog mode Automatic mode PA: Mode select PE: 5 Fault PA: 6 Fault reset ➀ Movement onto limit switch ➁ Movement clear of limit switch Fig. 7: Moving clear of limit switches 0990AEN MOVIDRIVE Bus Positioning

34 4 Operation and Servicing 4. Fault Information The fault memory (P080) stores the last five fault messages (faults t-0 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 fault occurs: Fault which occurred Status of the binary inputs/outputs Operating status of the inverter Inverter status Heat sink temperature Speed Output current Active current Unit utilization DC link circuit voltage ON hours Enable hours Parameter set Motor utilization. There are three shut-off responses depending on the fault; the inverter is inhibited when in fault status. Instant disconnection: 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 = 0 ). Rapid stop: The drive is braked with the stop ramp t/t. Once the stop speed is reached, the brake is applied (DBØØ /Brake = 0 ). The output stage goes to high-resistance after the brake reaction time has elapsed (P7 / P75). Emergency stop: The drive is braked with the stop ramp t4/t4. Once the stop speed is reached, the brake is applied (DBØØ /Brake = 0 ). The output stage goes to high-resistance after the brake reaction time has elapsed (P7 / P75). RESET: A fault message can be acknowledged by: Switching the mains power off and on again. Recommendation: Observe a minimum switch-off time of 0 s for the main contactor K. Reset by binary input DI0. Startup of the bus positioning causes this binary input to be assigned the Reset function. Press the reset button in the MOVITOOLS manager. Fig. 8: Reset with MOVITOOLS 077AEN Manual reset in Shell (P840 = YES or [Parameter] / [Manual reset]) Manual reset using the DBGA (pressing the <E> key in the event of a fault gives direct access to parameter P840) Timeout active: If the inverter is controlled via a communications interface (fieldbus, RS-485 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. 4 MOVIDRIVE Bus Positioning

35 Operation and Servicing 4 4. Fault Messages The fault or warning code is displayed in BCD format. The following display sequence is adhered to: Flashes, approx. s Display off, approx. 0. s Tens digit, approx. s Display off, approx. 0. s Ones digit, approx. s Display off, approx. 0. s Fig. 9: Fault message 008AXX The display switches over to the operation display following a reset or if the fault or warning code once more resumes the value 0. List of faults: The following table shows a selection from the complete list of faults ( MOVIDRIVE MD_60A operating instructions). It only lists those faults which can occur specifically in table positioning. A dot in the P column means that the response is programmable (P8_ Fault response). The factory set fault response is listed in the Response column. Fault Name Response P Possible cause Action code 00 No fault - 07 DC link overvoltage Immediate switch-off DC link voltage too high - Extend deceleration ramps - Check feeder cable to braking resistor - Check technical data of braking resistor MOVIDRIVE Bus Positioning 5

36 4 Operation and Servicing Fault code Name Response P Possible cause Action 08 n-monitoring Immediate switch-off 4 Encoder Immediate switch-off 6 External terminal 7 Limit switches missing 8 Fieldbus timeout 9 Limit switch reached Emergency stop Emergency stop Rapid stop Emergency stop TF sensor No response 6 No option Immediate switch-off 9 Reference travel Immediate switch-off - Speed controller or current controller (in VFC operating mode without encoder) operating at setting limit due to mechanical overload or phase fault in the power system or motor - Encoder not connected correctly or incorrect direction of rotation -n max is exceeded during torque control - Encoder cable or shield not connected correctly - Short circuit/open circuit in encoder cable - Encoder defective External fault signal read in via programmable input - Open circuit/both limit switches missing - Limit switches swapped over in relation to motor sense of rotation No master-slave communication took place within the configured response monitoring period In IPOS mode, a limit switch was reached - Motor too hot, TF has tripped - Motor TF not connected or connected incorrectly - Connection of MOVIDRIVE and TF interrupted on motor - Jumper missing between X0: & X0:. With MDS: X5:9 X5:5 connection missing. - Type of option pcb not allowed - Setpoint source, control signal source or operating mode not allowed for this option pcb - Incorrect encoder type set for DIPA - No reference cams - Limit switches not connected correctly - Type of reference travel was altered during reference travel - Reduce load - Increase deceleration time setting (P50 or P50) - Check encoder connection, possibly swap over A/A and B/B in pairs - Check encoder voltage supply - Check current limitation - Increase length of ramps, if appropriate - Check motor cable and motor - Check mains phases Check encoder cable and shield for correct connection, short circuit and open circuit Eliminate specific cause of fault; reprogram terminal if appropriate - Check wiring of limit switches - Swap over limit switch connections - Reprogram terminals - Check master communication routine - If appropriate, extend fieldbus timeout time (P89) or switch off monitoring - Check travel range - Correct user program - Let motor cool down and reset fault - Check connections/link between MOVIDRIVE and TF - If no TF is connected: Jumper X0: to X0:. With MDS: Jumper X5:9 to X5:5. - Set P84 to No response - Use correct option pcb - Set correct setpoint source (P00) - Set correct control signal source (P00) - Set correct operating mode (P700 or P70) - Set correct encoder type Check type of reference travel which is set and conditions required for it 6 MOVIDRIVE Bus Positioning

37 Operation and Servicing 4 Fault code Name Response P Possible cause Action 4 Lag error Immediate switch-off 47 System bus timeout 78 IPOS SW limit switches Rapid stop No response 9 DIP work area Emergency stop 9 DIP encoder fault 94 EEPROM checksum 95 DIP plausibility error Emergency stop Immediate switch-off Emergency stop - Incremental encoder connected incorrectly - Acceleration ramps too short - P-component of positioning controller too small - Speed controller parameters incorrect - Value for lag error tolerance too small Fault during communication via system bus Only in IPOS operating mode: Programmed target position is outside travel range delimited by software limit switches Only with DIPA option: Drive has moved beyond the permitted work area of the absolute encoder. Setting of encoder type/work area DIP parameters may be incorrect. Only with DIPA option: The encoder signals a fault, e.g. power failure - Connection cable between the encoder and DIP does not meet the requirements (twisted pair, shielded) - Cycle frequency too high for cable length - Permitted max. speed/acceleration of encoder exceeded - Encoder defective Inverter electronics disrupted. Possibly due to EM interference or defect. Only with DIPA option: Unable to determine a plausible position - Incorrect encoder type set - IPOS travel parameter set incorrectly - Numerator/denominator factor set incorrectly - Zero adjustment performed - Encoder defective - Check incremental encoder connection - Increase length of 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 Check system bus connection - Check user program - Check position of software limit switches Check position offset and zero offset parameters - Check absolute encoder connection - Check connection cable - Set correct cycle frequency - Reduce max. traveling velocity or ramp - Fit new absolute encoder Send the unit in for repair - Set correct encoder type - Check IPOS travel parameter - Check traveling velocity - Correct numerator/denominator factor - Reset after zero adjustment - Fit new absolute encoder MOVIDRIVE Bus Positioning 7

38 We are available, wherever you need us. Worldwide. SEW-EURODRIVE right around the globe is your competent partner in matters of power transmission with manufacturing and assembly plants in most major industrial countries. SEW-EURODRIVE GmbH & Co P.O.Box 0 D-7664 Bruchsal/Germany Tel Fax Telex sew@sew-eurodrive.com