Operating Instructions

Transcription

1 Drive Technology \ Drive Automation \ System Integration \ Services * _0317* Operating Instructions ECDriveS Fieldbus Controller ECC-DFC, Roller Drive ECR, Gearmotor ECG Edition 03/ /EN

2 SEW-EURODRIVE Driving the world

3 Table of contents Table of contents 1 General information About this documentation Information about this documentation Structure of the safety notes Meaning of signal words Structure of section-related safety notes Structure of embedded safety notes Rights to claim under limited warranty Exclusion of liability Other applicable documentation Product names and trademarks Copyright notice Safety notes Preliminary information Operator's duties Target group Designated use Functional safety technology Transport Installation/assembly Restrictions of use Electrical connection Required preventive measure Stationary application Startup/operation Unit structure Type code Type code ECR roller drive Type code ECG gearmotor Type designation of the controls Type designation of the engineering software Overview of the roller drives ECR roller drive ECG gearmotor Overview of the hardware of the ECC-DFC fieldbus controller Definition of the motor direction of rotation Installation Mechanical installation Mounting the ECR roller drive Mounting the ECG gearmotor Mounting the modules of the ECC-DFC fieldbus controller Electrical installation ECR roller drive and ECG gearmotor Operating Instructions ECDriveS 3

4 Table of contents ECC-DFC fieldbus controller hardware Connections for linear conveyors Startup ECShell engineering software Configuration with the ECC-DFC fieldbus controller in linear conveyor operation Auto configuration of the linear conveyor system Operation Operating modes Status displays Jam states Network error Low voltage error Inspection/maintenance Removing a roller drive ECR roller drive ECG gearmotor Replacing a fieldbus module automatically Replacing a fieldbus module Storage Technical data Technical data of the ECR roller drive Electrical data Minimum roller length Minimum roller length for wet area design Wall thickness of the tubes Permitted load capacity of the tubes Dimensions Weight Technical data of the ECG gearmotor Electrical data Pulses per revolution Dimensions Weight Technical data of the ECC-DFC fieldbus controller Dimensions Operating Instructions ECDriveS

5 General information About this documentation 1 1 General information 1.1 About this documentation The current version of the documentation is the original. This documentation is an integral part of the product. The documentation is written for all employees who assemble, install, start up, and service this product. Make sure this documentation is accessible and legible. Ensure that persons responsible for the machinery and its operation as well as persons who work on the product independently have read through the documentation carefully and understood it. If you are unclear about any of the information in this documentation or require further information, contact SEW EURODRIVE. 1.2 Information about this documentation This documentation describes the ECDriveS roller drive system. These operating instructions include the installation and connection of the ECR roller drive / ECG roller gearmotor as well as the startup of the roller drive system with the ECC-DFC fieldbus control. 1.3 Structure of the safety notes Meaning of signal words The following table shows the grading and meaning of the signal words for safety notes. Signal word Meaning Consequences if disregarded DANGER Imminent hazard Severe or fatal injuries WARNING Possible dangerous situation Severe or fatal injuries CAUTION Possible dangerous situation Minor injuries NOTICE Possible damage to property Damage to the product or its environment INFORMATION Useful information or tip: Simplifies handling of the product Structure of section-related safety notes Section-related safety notes do not apply to a specific action but to several actions pertaining to one subject. The hazard symbols used either indicate a general hazard or a specific hazard. This is the formal structure of a safety note for a specific section: SIGNAL WORD Type and source of hazard. Possible consequence(s) if disregarded. Measure(s) to prevent the hazard. Operating Instructions ECDriveS 5

6 1 General information Structure of the safety notes Meaning of the hazard symbols The hazard symbols in the safety notes have the following meaning: Hazard symbol Meaning General hazard Warning of dangerous electrical voltage Warning of hot surfaces Warning of risk of crushing Warning of suspended load Warning of automatic restart Structure of embedded safety notes Embedded safety notes are directly integrated into the instructions just before the description of the dangerous action. This is the formal structure of an embedded safety note: SIGNAL WORD Type and source of hazard. Possible consequence(s) if disregarded. Measure(s) to prevent the hazard. 6 Operating Instructions ECDriveS

7 General information Rights to claim under limited warranty Rights to claim under limited warranty Read the information in this documentation. This is essential for fault-free operation and fulfillment of any rights to claim under limited warranty. Read the documentation before you start working with the product. 1.5 Exclusion of liability Read the information in this documentation, otherwise safe operation is impossible. You must comply with the information contained in this documentation to achieve the specified product characteristics and performance features. SEW EURODRIVE assumes no liability for injury to persons or damage to equipment or property resulting from non-observance of these operating instructions. In such cases, SEW EURODRIVE assumes no liability for defects. 1.6 Other applicable documentation Observe the corresponding documentation for all further components. 1.7 Product names and trademarks The brands and product names in this documentation are trademarks or registered trademarks of their respective titleholders. 1.8 Copyright notice 2017 SEW EURODRIVE. All rights reserved. Unauthorized reproduction, modification, distribution or any other use of the whole or any part of this documentation is strictly prohibited. Operating Instructions ECDriveS 7

8 2 Safety notes Preliminary information 2 Safety notes 2.1 Preliminary information The following general safety notes have the purpose to avoid injury and damage to property. They primarily apply to the use of products described in this documentation. If you use additional components also observe the relevant warning and safety notes. 2.2 Operator's duties Make sure that the basic safety notes are read and observed. Make sure that persons responsible for the machinery and its operation as well as persons who work on the device independently have read through the documentation carefully and understood it. If you are unclear about any of the information in this documentation, or if you require further information, contact SEW EURODRIVE. The operator must ensure that the following works are only performed by qualified personnel: Transport Storage Setup and assembly Installation and connection Startup Maintenance and repair Shutdown Disassembly Waste disposal Make sure persons working on the product adhere to the following regulations, requirements, documents and information: National and regional safety and accident prevention regulations Warning and safety signs on the product All other relevant project planning documents, installation and startup instructions, wiring diagrams and schematics Do not assemble, install or operate damaged products All specific specifications and requirements for the system Make sure that systems with the product installed are equipped with additional monitoring and protection devices. Observe the applicable safety regulations and legislation governing technical equipment and accident prevention regulations. 2.3 Target group Specialist for mechanical work Any mechanical work may only be performed by adequately qualified personnel. Qualified personnel in the context of this documentation are persons familiar with the design, mechanical installation, troubleshooting and maintenance of the product, who possess the following qualifications: Qualification in the field of mechanics according to applicable national regulation. They are familiar with this documentation 8 Operating Instructions ECDriveS

9 Safety notes Designated use 2 Specialist for electrotechnical work Instructed persons Any electronic work may only be performed by adequately skilled persons (electrically). Qualified electricians in the context of this documentation are persons familiar with electrical installation, startup, troubleshooting and servicing of the product who possess the following qualifications: Qualification in the field of electrical engineering according to applicable national regulation. They are familiar with this documentation In addition to that, these persons must be familiar with the valid safety regulations and laws, as well as with the requirements of the standards, directives and laws specified in this documentation. The above mentioned persons must have the authorization expressly issued by the company to operate, program, configure, label and ground devices, systems and circuits in accordance with the standards of safety technology. All work in the areas of transportation, storage, operation and waste disposal must be carried out by persons who are trained appropriately. The purpose of the instruction is that the persons are capable of performing the required tasks and work steps in a safe and correct manner. 2.4 Designated use The product is intended for installation in electrical plants or machines. When installed in machines, startup (i.e. start of designated operation) is prohibited until it is determined that the machine complies with the local laws and directives. In the individual area of application, you must especially observe the Machinery Directive 2006/42/EC as well as the EMC Directive 2014/30/EC. The standards given in the declaration of conformity apply to the product. Using these products in potentially explosive atmospheres is prohibited, unless specifically designated otherwise. Air-cooled motors/gearmotors are designed for ambient temperatures of -10 C to +40 C and installation altitudes 1000 m above sea level. Observe any differing specifications on the nameplate. The ambient conditions must comply with all the specifications on the nameplate. 2.5 Functional safety technology The product must not perform any safety functions without a higher-level safety system, unless explicitly allowed by the documentation. Operating Instructions ECDriveS 9

10 2 Safety notes Transport 2.6 Transport Inspect the shipment for damage as soon as you receive the delivery. Inform the shipping company immediately about any damage. If the product is damaged, it must not be assembled, installed or started up. Observe the following notes when transporting the device: Ensure that the product is not subject to mechanical impact during transportation. Before transportation, cover the connections with the supplied protection caps. Only place the product on the cooling fins or on the side without connectors during transportation. Always use lifting eyes if available. If necessary, use suitable, sufficiently dimensioned handling equipment. Observe the information on climatic conditions in chapter "Technical data" of the documentation. 2.7 Installation/assembly Ensure that the product is installed and cooled according to the regulations in the documentation. Protect the product from excessive mechanical strain. The product and its mounted components must not protrude into the path of persons or vehicles. Ensure that components are not deformed and that insulation spaces are maintained, particularly during transportation. Electric components must not be mechanically damaged or destroyed. Observe the notes in the chapter "Mechanical installation" of the documentation Restrictions of use The following applications are prohibited unless explicitly permitted: Use in potentially explosive areas Use in areas exposed to harmful oils, acids, gases, vapors, dust, and radiation Operation in applications with impermissibly high mechanical vibration and shock loads in excess of the regulations stipulated in EN Operation at installation altitudes above 1000 m above sea level 2.8 Electrical connection Make yourself familiar with the applicable national accident prevention guidelines before you work on the product. Perform electrical installation according to the pertinent regulations (e.g. cable cross sections, fusing, protective conductor connection). The documentation at hand contains additional information. Make sure that all required covers are installed correctly after electrical installation. Make sure that preventive measures and protection devices comply with the applicable regulations (e.g. EN or EN ). 10 Operating Instructions ECDriveS

11 Safety notes Startup/operation Required preventive measure Ensure that the product is correctly attached to a SELV/PELV current supply Stationary application Necessary preventive measure for the product is: Type of energy transfer Preventive measure Direct power supply Ground connection 2.9 Startup/operation Observe the safety notes in the chapters "Startup" and "Operation" in the documentation. Make sure that the present transport protection is removed. Do not deactivate monitoring and protection devices of the machine or system even for a test run. Make sure the connection boxes are closed and screwed before connecting the supply voltage. Depending on the degree of protection, products may have live, uninsulated, and sometimes moving or rotating parts, as well as hot surfaces during operation. Additional preventive measures may be required for applications with increased hazard potential. You have to check the protection devices after each modification. When in doubt, switch off the product whenever changes occur in relation to normal operation. Possible changes are e.g. increased temperatures, noise, or oscillation. Determine the cause. Contact SEW EURODRIVE if necessary. Mechanical blocking or internal safety functions of the product can cause a motor standstill. Eliminating the cause of the problem or performing a reset may result in the drive re-starting automatically. If, for safety reasons, this is not permitted for the drivecontrolled machine, first disconnect the product from the supply system and then start troubleshooting. Risk of burns: The surface temperature of the product can exceed 60 C during operation. Do not touch the product during operation. Let the product cool down before touching it. Operating Instructions ECDriveS 11

12 3 Unit structure Type code 3 Unit structure 3.1 Type code Type code ECR roller drive Example: ECR-A2M Z-B-V0 Product family EC EC = ECDriveS device family Product type R R = Roller Design A A = IP54 degree of protection standard W = IP66 degree of protection wet area application Z = Operation to -30 C deep-freezing application Voltage 2 2 = 24 V Motor connection M Motor cable M8, 1000 mm Roller diameter mm Roller length 450 Roller length according to table "Minimum roller length" ( 2 54). 045 Speed in m/min Speed class Tube options Z Z = Steel, galvanized standard J = Stainless design U = PUR coating 3 mm P = PVC hose 2 mm K = Cone 3.6 on galvanized steel C = Cone 3.6 on steel in stainless steel design D = PVC hose on steel in stainless steel design E = PUR coating on steel in stainless steel design X = Special design 12 Operating Instructions ECDriveS

13 Unit structure Type code 3 Example: ECR-A2M Z-B-V0 B A = Cable side: M on 11 mm hexagon Opposite side: M8 female thread B = Axis design Cable side: M on 11 mm hexagon Opposite side: Smooth 11 mm spring-loaded hexagon axis C = Cable side: 11 mm hexagon Opposite side: M8 female thread X = Special design V0 A0 = Smooth tube without groove or drive head V0 = Drive head for V-belt Transmission head V1 = Micro drive head for Poly-V-belt in shape PJ according to DIN 7867 G0 = Tube with groove head G1 = Grooved tube with groove position 50/80 XX = Special design Operating Instructions ECDriveS 13

14 3 Unit structure Type code Type code ECG gearmotor Example: ECG-A2M-67-A-K0 Product family EC EC = ECDriveS device family Product type G G = Gearmotor Design A A = IP54 degree of protection Voltage 2 2 = 24 V Motor options M M8 plug connector 67 Reduction ratio i = Gear unit reduction ratio Version A A = Standard Output shaft K0 K = Key X Special design Type designation of the controls ECC-DBC = Binary control ECC-DFC = Fieldbus control ECC-DFC = EtherCAT -compatible control ECIO = IO module PROFINET, Ethernet/IP TM, Modbus/TCP ECIO = IO module EtherCAT Type designation of the engineering software ECShell 14 Operating Instructions ECDriveS

15 XX- Unit structure Overview of the roller drives Overview of the roller drives ECR roller drive [1] [2] [3] [2] [1] Electrical connection [2] Axis journal [3] Motor roller Nameplate [1] XX-XXX- XX- XXXXX X XXX A01001 [3] 3 1 DC24V [2] [1] Type designation, e.g.: ECR-A2M Z-B-V0 [2] Voltage [3] Serial number Operating Instructions ECDriveS 15

16 3 Unit structure Overview of the roller drives ECG gearmotor [1] [2] [3] [1] Electrical connection [2] Gearmotor [3] Motor shaft Nameplate Operating Instructions ECDriveS

17 Unit structure Overview of the hardware of the ECC-DFC fieldbus controller Overview of the hardware of the ECC-DFC fieldbus controller ECC-DFC modules are designed such that they can be installed and integrated in the side frame of the conveyor belt. ECC-DFC modules can be used to control up to 2 motor roller zones of the conveyor belt. Each ECC-DFC has interfaces for 2 motor roller zones with the associated 2 photo sensors and an upstream and downstream network. There are also discrete connecting locations for setting up a complete control system for the motor roller conveyor systems, which are divided up into zones. [7] [1] [2] [3] [4] [5] [6] [8] [9] [10] [11] [1] ECC-DFC [12] [17] [16] [15] [14] [13] [12] [12] [1] Removable IP54 cover for Ethernet connections [2] Left motor connection, 4-pin M8 connector for motor roller connection [3] "Left motor" LED motor status indicator [4] Button for module exchange [5] Left connection RJ45 Ethernet network connection between modules [6] Power LED indicator of the module [7] Removable IP54 cover for the power wiring compartment [8] Status LED indicator of the module [9] Right connection RJ45 Ethernet network connection between modules [10] "Right motor" LED motor status indicator [11] Right motor connection, 4-pin M8 connector for motor roller connection [12] 1 x power wiring cable gland for degree of protection IP54, 2 x RJ45 protective casing for degree of protection IP54 [13] Right sensor connection, M8 connection for zone photo sensor [14] Right sensor status LED indicator [15] DC 24 V power connections with LED indicator [16] Left sensor status LED indicator [17] Left sensor connection, M8 connection for zone photo sensor INFORMATION The designations "left" and "right" for the module connections are based on the shown view of the module and must not be confused with the product flow direction on the conveyor belt. The direction of the product flow is designated using "upstream" or "downstream". Operating Instructions ECDriveS 17

18 3 Unit structure Definition of the motor direction of rotation 3.4 Definition of the motor direction of rotation The definition of the motor direction of rotation is based on the view of the motor roller from the cable output side of the roller, as shown in the following figure. Clockwise (CW) Counterclockwise (CCW) 18 Operating Instructions ECDriveS

19 Installation Mechanical installation 4 4 Installation 4.1 Mechanical installation Mounting the ECR roller drive CAUTION Improper fixation of the axis can destroy the motor roller. Possible damage to property. Make sure not to damage the cable during assembly. Ensure the correct torque for the screw connections. Do not use an impact screwdriver to tighten the screws and nuts. INFORMATION The procedure for the mechanical installation depends on the design of the motor roller. Operating Instructions ECDriveS 19

20 4 Installation Mechanical installation Design A Cable side: M on 11 mm hexagon Opposite side: M8 female thread Mounting hole position: M12 nut/m8 screw Proceed as follows: Start at the cable side: 1. Guide the connector and the cable through the profile hole on the cable side. 2. Insert the axis into the profile hole on the cable side. Continue with opposite side: [2] [1] [1] M8 screw with spur-cut teeth [2] Axis journal Press axis journal [2] inwards on the opposite side. 4. Secure axis journal through profile hole with a M8 screw with spur-cut teeth. Continue with cable side: [2] [1] [1] M12 flange nut [2] Axis Operating Instructions ECDriveS

21 Installation Mechanical installation 4 5. Screw the flange nut from outside onto the axis [2] on the cable side. 6. Grip axis [2] from inside with a suitable tool and tighten the nut with a tightening torque of 50 Nm. Continue with the opposite side: 7. Grip axis journal from inside with a suitable tool on the opposite side and tighten the screw from outside with a tightening torque of Nm. Operating Instructions ECDriveS 21

22 4 Installation Mechanical installation Design B Cable side: M on 11 mm hexagon On the opposite side: Smooth 11 mm spring-loaded hexagon axis Mounting hole position: M12 nut Proceed as follows: Start at the cable side: 1. Guide the connector and the cable through the profile hole on the cable side. 2. Insert the axis into the profile hole on the cable side. Continue with opposite side: [1] [2] [1] Profile hole [2] Spring axis Press spring axis [2] inwards on the opposite side and insert the motor roller into the conveyor. 4. When the motor roller reaches its proper position on the profile hole [1], release spring axis. Continue with cable side: [2] [1] [1] M12 flange nut [2] Axis Operating Instructions ECDriveS

23 Installation Mechanical installation 4 5. Screw the flange nut from outside onto the axis [2] on the cable side. 6. Grip axis [2] from inside with a suitable tool and tighten the nut with a tightening torque of 50 Nm. Operating Instructions ECDriveS 23

24 4 Installation Mechanical installation Design C Cable side: 11 mm hexagon Opposite side: M8 female thread Mounting hole position: Retaining plate on cable side Proceed as follows: Start at the cable side: 1. Guide the connector and the cable through the profile hole on the cable side. 2. Insert the axis into the profile hole on the cable side. Continue with opposite side: [2] [1] [1] M8 screw with spur-cut teeth [2] Axis journal Press axis journal [2] inwards on the opposite side. 4. Secure axis journal through profile hole with a M8 screw with spur-cut teeth. 24 Operating Instructions ECDriveS

25 Installation Mechanical installation 4 Continue with cable side [1] [2] [3] [4] [1] M6 flange nuts [2] Part A [3] Part B [4] Stud bolt [5] M5 screw [6] Base plate [6] [5] Screw base plate [6] with 2 M5 screws from outside onto the side profile and tighten the screws with a tightening torque of Nm. 6. Thread part A [2] over the cable. [4] [2] [3] [1] [1] [1] M6 flange nuts [2] Part A [3] Part B [4] Locating edge of the axis The locating edge of the axis [4] must be in direct contact with the profile from the inside. Operating Instructions ECDriveS 25

26 4 Installation Mechanical installation 8. Place part B [3] from outside onto part A [2] so that they are parallel. 9. Tighten part B [3] with a M6 nut [1] with a tightening torque of 8 10 Nm. 10. Tighten part A [2] with a M6 nut [1] with a tightening torque of 8 10 Nm Continue with the opposite side: 11. Grip axis journal from inside with a suitable tool on the opposite side and tighten the screw from outside with a tightening torque of Nm. 26 Operating Instructions ECDriveS

27 Installation Mechanical installation Mounting the ECG gearmotor CAUTION Sharp edges due to open keyway. Cuts. Insert the key into the keyway. Pull a protective tubing over the shaft. 4 x M Proceed as follows: 1. Place the motor onto the carrier plate. 2. Secure motor with 4 M5 screws with spring washers as threadlocker. 3. Tighten the screws with a tightening torque of Nm Mounting the modules of the ECC-DFC fieldbus controller Each module of the fieldbus controller has 2 holes [1] for mounting purposes. The holes have a diameter of 6 mm. [1] [1] [1] Mounting holes Ø 6 mm ECC-DFC Operating Instructions ECDriveS 27

28 4 Installation Electrical installation 4.2 Electrical installation CAUTION Risk of crushing if the drive starts up unintentionally. Before you start working on the unit, disconnect the motor and all connected options from the power supply. Secure the motor against unintended power-up ECR roller drive and ECG gearmotor The roller drives come equipped with a cable outlet on the connection side. The cable outlet has a coded M8 socket, see chapter "Overview of the roller drives" ( 2 15). The roller drive is connected to the module of the ECC-DFC fieldbus controller. [2] [2] [1] [1] [3] ECC-DFC [1] Photo sensors [2] Motor rollers [3] ECC-DFC fieldbus controller Operating Instructions ECDriveS

29 Installation Electrical installation ECC-DFC fieldbus controller hardware Left and right motor and sensor ports Both motor and sensor ports use a 4-pin M8 connector. Each connector is mechanically coded to ensure that alignment is correct when the connector is plugged in. [1] [1] ECC-DFC [2] [2] [1] Motor port [2] Sensor port Operating Instructions ECDriveS 29

30 4 Installation Electrical installation Left and right Ethernet ports NOTICE Using unshielded cables can result in loss of data and unexpected results. Make sure that all Ethernet cables used to connect modules are shielded. Use protective sleeves to achieve IP54 degree of protection. Both ports are standard RJ45 sockets that correspond to the standard pin assignment of the Ethernet connection. In order to comply with degree of protection IP54, Ethernet cables must be equipped with protective sleeves. The following figure shows the Ethernet cables used with sleeves to protect the RJ45 connector at the Ethernet cables. The scope of delivery of each module includes 2 sleeves. ECC-DFC [1] IP54 protective sleeve [1] [1] In order to correctly fit the IP54 protective sleeve to the RJ45 connector, a special tool is required, such as a Phoenix Contact FL IP54 assembly tool. The special tool is not included in the delivery. 30 Operating Instructions ECDriveS

31 Installation Electrical installation 4 Power connections IP54 installation Proceed as follows to create a power wiring installation that is compliant with IP54: 1. Route the power cables through the cable gland [2]. 2. Secure the cable ends using the cable terminal. 3. Push the fuse terminal over the cables until it snaps into the terminal socket. The terminal socket is integrated in the module cover. 4. Close the power wiring compartment securely with the cover [1]. [1] ECC-DFC [2] ECC-DFC [1] Removable IP54 cover for the power wiring compartment [2] Cable gland of the power wiring Operating Instructions ECDriveS 31

32 4 Installation Electrical installation Power supply of the logic and the motor rollers Each module of the fieldbus controller has separate power connections for the logic and the motor. This means separate current supply systems can be used for the logic and the motor. For example, the motor current supply can be switched off using an emergency stop system. If the motor current supply operates separately, the logic current supply can remain switched on. Module communication is then still active and can transmit status messages to monitoring systems. Note that the supply to the motor rollers simultaneously also supplies the logic with power. The following figure shows a shared current supply for motor rollers and logic. LOGIC + GND MDR + [1] - + [1] 24 V current supply The following figure shows a separate current supply for motor rollers and logic LOGIC + GND MDR + [1] - + [1] - + [2] [1] 24 V current supply [2] OFF switch Operating Instructions ECDriveS

33 Installation Electrical installation 4 Grounding of the current supply CAUTION Hazard due to incorrect dimensioning of the current supply and/or incorrect grounding. Before starting installation work, familiarize yourself with the power requirements of the motor rollers. Make sure that the DC 24 V current supplies and the wiring are correctly dimensioned on the basis of the applicable directives and standards. Make sure that the devices are correctly grounded during installation. The DC current supply ground or - must always be grounded at all current supply units. Regardless of whether the logic and the motor rollers have a shared or a separate current supply, the DC supply mass connections must be connected. One of the two current supplies must have a grounded DC connection. Avoid direct ground connection of more than one current supply DC connection since this can lead to unintentional ground loops. The following figures show a shared and a separate current supply connection and their DC supply ground and grounding connections. The following figure shows a shared current supply with combined DC supply ground and grounding connections. [1] - + [1] [1] 24 V current supply Operating Instructions ECDriveS 33

34 4 Installation Electrical installation The following figure shows a double current supply with combined DC supply ground and grounding connections. [1] - + [1] - + [1] [1] 24 V current supply 34 Operating Instructions ECDriveS

35 Installation Electrical installation Connections for linear conveyors The fieldbus controller is designed for linear conveyor operation in such a way that an auto configuration process runs, which is carried out by the ECShell engineering software. Before the auto configuration process can be carried out, each individual module of the fieldbus controller must be correctly connected to the assigned motor rollers and photo sensors in order to achieve the required operating results. In general, each module detects the sensor connection to which a device is connected and determines its specific configuration as soon as the auto configuration process has triggered auto configuration. Before the system is configured for operation, each motor roller and each photo sensor must be correctly connected to the modules of the fieldbus controller. The fieldbus control modules then determine the operating mode on the basis of the way in which the photo sensors and motor rollers are connected. A fieldbus module can be operated as: 2-zone controller with 2 motor rollers and 2 photo sensors 1-zone controller with 1 motor roller and 1 photo sensor 1-zone controller with 2 motor rollers and 1 photo sensor Example 1 2-zone control In this example, a motor roller and a photo sensor are connected to both the left and right interface area. The fieldbus controller will control the 2 motor rollers as independent logical conveyor belt zones. [2] [2] [1] [1] [3] ECC-DFC [1] Photo sensors [2] Motor rollers [3] ECC-DFC fieldbus controller Operating Instructions ECDriveS 35

36 4 Installation Electrical installation Example 2 Single-zone control In this example, a single motor roller and a single photo sensor are connected to either the left or right interface area. The fieldbus controller controls the motor roller as an individual, independent logical conveyor belt zone. or ECC-DFC ECC-DFC Example 3 Single-zone control with 2 motor rollers In this case, a module of the fieldbus controller will control 2 motor rollers together and operate them as a single zone with a single photo sensor, which is connected to either the left or right port. This configuration is typical especially for inclined conveyor belt zones, since inclined conveyors need the additional torque of a second motor roller to transport loads. or ECC-DFC ECC-DFC Operating Instructions ECDriveS

37 Installation Electrical installation 4 Examples of invalid configurations INFORMATION Auto configuration is not aborted by an invalid configuration. However, an invalid configuration will result in faulty operation and lead to unexpected results. Auto configuration of the fieldbus controller is determined by the way in which the photo sensors are arranged. Inconsistently connected photo sensors and motor rollers can result in unexpected and wrong results. or ECC-DFC ECC-DFC In this example, the fieldbus controller will attempt to act as a single-zone controller. This installation is faulty because the motor rollers are not connected to the same interface area as the photo sensors. or ECC-DFC ECC-DFC In this example, the fieldbus controller will attempt to act as a 2-zone controller although only one motor roller is connected. Operating Instructions ECDriveS 37

38 5 Startup ECShell engineering software 5 Startup CAUTION Risk of crushing if the drive starts up unintentionally. Before you start working on the unit, disconnect the motor and all connected options from the power supply. Secure the motor against unintended power-up. CAUTION Risk of crushing if the drive starts up unintentionally Make sure that the drive is in idle state before you start working on the unit. CAUTION The surfaces of the drive can be very hot during operation. Risk of burns. Let the motor cool down sufficiently before you start working on it. 5.1 ECShell engineering software For information on the ECShell engineering software, refer to the "ECDriveS Fieldbus Controller ECC-DFC" manual. 38 Operating Instructions ECDriveS

39 Startup Configuration with the ECC-DFC fieldbus controller in linear conveyor operation Configuration with the ECC-DFC fieldbus controller in linear conveyor operation Auto configuration of the linear conveyor system The goal of auto configuration of ECC-DFC networked fieldbus controllers is to provide a simple and fast way of starting up a linear conveyor system. Auto configuration requires the use of the ECShell engineering software on a PC. This PC must be connected to the network module that is the furthest upstream. Defining a linear conveyor system Auto configuration can be used in only a linear conveyor system. A linear conveyor system is defined as a single uninterrupted conveyor line without mixing or diversion mechanisms. A linear conveyor can contain curve sections, but the flow of the transported material takes place continuously from the infeed zone to the unloading area A networked ECC-DFC solution is capable of controlling complex conveyor lines that also contain diversion or mixing equipment. However, configuration with a PC and software is required for this. Information about PC-based configuration can be found in the self-help dialog of the ECShell engineering software. Auto configuration procedure The flow direction of the conveyor system determines how the auto configuration procedure is started. The fieldbus controller module that is the furthest upstream is defined as the auto configuration master. The auto configuration procedure is initiated by the auto configuration master. Because of its physical location on the conveyor belt and in the Ethernet connection chain, the auto configuration master automatically connects to all downstream modules and configures their IP addresses for communication. The program then automatically configures the flow direction. Do the following to start auto configuration: 1. Start the ECShell engineering software and press F2. Choose "Network Services" in the dialog window and click [Discover]. 2. When the modules of the fieldbus controller appear in the table, choose the modules you want to configure and click [AutoConfig], as shown in figure When the topology has been set up, select the module from which you wish to configure the line and click [AutoConfig From the Selected Node], as shown in figure This triggers the auto configuration process, which will propagate itself on all following fieldbus controller modules and configure the entire line. Operating Instructions ECDriveS 39

40 5 Startup Configuration with the ECC-DFC fieldbus controller in linear conveyor operation INFORMATION In order for the auto configuration process to work properly, the transported material must be removed from the entire conveyor line. INFORMATION Note that the number of modules per subnetwork is limited to 220. Figure Operating Instructions ECDriveS

41 Startup Configuration with the ECC-DFC fieldbus controller in linear conveyor operation 5 Figure Note that in the topology view, the detailed information for each module is shown in red if the module has not been configured. You can also select the module graphic from the topology view, right-click to display the context menu and initiate the auto configuration from there, see figure 3. Figure The node selected for auto configuration does not have to be the first module that is directly connected to the PC. The module at the other end of the line can also be selected as the auto configuration master, as shown in figure 4. Operating Instructions ECDriveS 41

42 ECC-DFC ECC-DFC ECC-DFC Startup Configuration with the ECC-DFC fieldbus controller in linear conveyor operation Figure Automatic detection of the position of the module at the opposite side The cable connections between the left and right Ethernet port can be used if the module of the fieldbus controller is going to be installed at the opposite side frame of the conveyor system. When it is correctly connected, it is detected by the auto configuration program, and the flow rate is configured accordingly. The following figure shows an example of how the opposite position can be detected. [2] [1] [1] [2] [1] [2] [1] Left [2] Right 42 Operating Instructions ECDriveS

43 Startup Configuration with the ECC-DFC fieldbus controller in linear conveyor operation 5 Results of auto configuration Normal results Figure 5 When the auto configuration procedure is complete, each module of the fieldbus controller is automatically restarted. If a module has been successfully configured and has been restarted, the status LED of the module flashes in green. The topology view shows the detailed information of the module in black text (no longer red) when the auto configuration has been successfully completed; see figure If all status LEDs of the module flash in green, a load is placed in the zone that is furthest upstream in order for complete verification of the configuration. If the auto configuration was successful, the load is transported to the discharge zone. If this does not occur, you can look up possible errors and how to remedy them in chapter "Problem solution for failed auto configuration". INFORMATION Bear in mind that an auto configuration of an already configured network can only be started by the auto configuration master (of the module that is the furthest upstream). When auto configuring another module of the fieldbus controller again, only a local restart is performed. The process lasts a few seconds. Operating Instructions ECDriveS 43

44 5 Startup Configuration with the ECC-DFC fieldbus controller in linear conveyor operation Problem solution for failed auto configuration The following table contains some typical indicators of error statuses and the relevant measures to be taken as the solution. Fault status Status LEDs OK with unexpected result The status LED is flashing or illuminated in red at one or more modules Measure Check: All photo sensors for proper functioning Whether all zones are free All networks All motor rollers All sensors All power connections All connections whether they are valid, see examples of invalid configurations (page 37). Correct invalid connections. Repeat auto configuration. Ensure that no Ethernet switches or PCs are connected between the modules of the fieldbus controller. The auto configuration procedure is aborted if a device that is not part of the fieldbus controller module is detected along the path to the final node. Modules up to this point are configured, but the others are not. If a fieldbus controller module is removed from an existing network that is already operational, wait for at least 2 minutes before a new auto configuration procedure is started. This time is needed so that the Ethernet switches at the remaining modules can reset. 44 Operating Instructions ECDriveS

45 Operation Operating modes 6 6 Operation 6.1 Operating modes The ECC-DFC fieldbus controller offers 2 operating modes for the roller drives: ECO mode BOOST mode ECO mode offers the optimum performance characteristics for normal operation. BOOST mode allows an increased torque for short periods. This operating mode provides a power reserve, for example for travel along curves with high throughput, for containers that rub against the railing, or for conveyor drives. Operating Instructions ECDriveS 45

46 6 Operation Status displays 6.2 Status displays The status of the fieldbus module is indicated using several LEDs. All LEDs have several colors and are context sensitive. An exception are the LEDs "Ethernet link" and "Activity". The different meanings of all LEDs of the fieldbus controller are explained in the following table. The numbers relate to the positions on the module, see the following figure. [7] [1] [2] [3] [4] [5] [6] [8] [9] [10] [11] [1] ECC-DFC [12] [17] [16] [15] [14] [13] [12] [12] [3] "Left motor" LED motor status indicator [6] Power LED indicator of the module [8] Status LED indicator of the module [10] "Right motor" LED motor status indicator [14] Right sensor status LED indicator [15] DC 24 V power connections with LED indicator [16] Left sensor status LED indicator An ON/OFF cycle lasting for about ½ a second is regarded as "slow flashing", whereas an ON/OFF cycle lasting for about ¼ of a second is regarded as "fast flashing". Network and module function Display Position LED status Description Module status [8] Slowly flashing red Module starts work processes Slowly flashing green Quickly flashing green and slowly flashing red Quickly flashing red Slowly flashing yellow Lights up yellow Module is ready Fail-safe mode Auto configuration mode active Connection to peer lost or searching for firmware updates Firmware update in progress 46 Operating Instructions ECDriveS

47 Operation Status displays 6 Motors Display Position LED status Description Left motor and right motor [3] + [10] OFF Motor not running and no error found Lights up green Connection established Lights up red Motor running: Indicates current limiting Motor not running: Motor not correctly connected or is running hot Supply voltage is less than 18 V or above 30 V Slowly flashing red Quickly flashing red Motor is overloaded and the controller is limiting the current in order to lower the temperature Motor short circuit detected between at least two of the phase windings Sensors Display Position LED status Description Sensors [14] + [16] Lights up yellow Module starts up Lights up green Lights up red Slowly flashing red Quickly flashing red Sensor input activated Sensor status signal Zone congested or sensor missing Network stop status Current Display Position LED status Description Current [6] Lights up blue Current supply for logic and motor is connected Slowly flashing blue Supply voltage for the motors under 18 V Operating Instructions ECDriveS 47

48 6 Operation Jam states 6.3 Jam states The fieldbus controller detects 2 types of jam states: Sensor jam No arrival jam Sensor jam If a load blocks the photo sensor in an upstream zone, the controller detects a sensor jam, see also "Sensors" status displays in chapter "Status displays" (page 46). Once the load has been removed from the vicinity of the photo sensor, the sensor jam is automatically canceled as soon as the standard 5 seconds of the reset timer have elapsed. If a sensor jam occurs, the controller will attempt to remedy this condition. First the motor of the affected zone runs slowly backwards for 1 second in order to clear the blocked sensor. If the sensor is still blocked after this first attempt, then this movement will be repeated twice. If the sensor is clear after one of these three attempts, the zone returns to normal function, and the controller will attempt to continue transporting the load under normal ZPA control (singulation mode). If the sensor is still blocked after these three attempts, the zone will remain in "sensor jam" condition. The load has to be removed manually and the zone to be restarted. No arrival jam If a load leaves an upstream zone and is transported to the next downstream zone, the upstream zone expects a confirmation of receipt from the downstream zone. This communication takes place automatically within the fieldbus network. If a new load arrives in the upstream zone while this is still waiting for a confirmation of receipt from the downstream zone, the new load will jam in this upstream zone. If the upstream zone does not receive the confirmation within the jam timer time interval, the controller will generate a No Arrival Jam error message. As soon as a No Arrival Jam error occurs, the controller automatically stops all new loads in the upstream zone for a preset time and then continues with the normal ZPA function (singulation mode). The time settings of the jam timer and the reset timer are the same, i.e. 5 seconds by default. This means the maximum time for which a new load would jam in the upstream zone would be 10 seconds. INFORMATION The time interval of 5 seconds for the jam timer is a preset value. Instructions for modifying this value can be found in the help function integrated in the ECShell engineering software. 6.4 Network error If the Ethernet network connection between the fieldbus modules is interrupted during operation, loads continue to be transported and jam in the zone where the network has been interrupted. As soon as network communication is restored, the zone returns to normal operation and the load is continued to be transported. 48 Operating Instructions ECDriveS

49 Operation Low voltage error Low voltage error If the supply voltage of a fieldbus module drops below DC 18 V, the affected zone will enter jam mode. This condition remains until the supply voltage of the module reaches at least DC 21 V. INFORMATION Repeated stopping or delaying of normal zone-to-zone movement may be an indication of low voltage. If this behavior is observed continuously, measure the voltage at the point that is furthest from the current supply unit and check the dimensions of the current supply and the wiring techniques in order to ensure that the correct voltage is provided at all modules. INFORMATION The ECShell engineering software has several diagnosis functions. These can be used to determine how often the current supply has dropped below DC 18 V. This option can assist with finding electrical problems in the system. Operating Instructions ECDriveS 49

50 7 Inspection/maintenance 7 Inspection/maintenance CAUTION Risk of crushing if the drive starts up unintentionally. Before you start working on the unit, disconnect the motor and all connected options from the power supply. Secure the motor against unintended power-up. CAUTION Risk of crushing if the drive starts up unintentionally. Make sure that the drive is in idle state before you start working on the unit. CAUTION The surfaces of the drive can be very hot during operation. Risk of burns. Let the motor cool down sufficiently before you start working on it. If necessary, all components of the ECDriveS system are replaced. It is not planned to have the components repaired. 50 Operating Instructions ECDriveS

51 Inspection/maintenance Removing a roller drive Removing a roller drive ECR roller drive To remove a roller, follow the instructions in reverse order of installation described in chapter "Mounting the ECR roller drive" ( 2 19) ECG gearmotor To remove the gearmotor, follow the instructions in reverse order of installation described in chapter "Mounting the ECG gearmotor" ( 2 27). 7.2 Replacing a fieldbus module automatically If a conveyor system with auto configuration has been started up, the fieldbus modules store the configuration data of their neighboring modules. This configuration data is updated automatically when the parameters of the conveyor are modified by the ECShell engineering software. The fieldbus firmware uses this function for easy module replacement, so that the entire conveyor system does not have to be reconfigured if a single module is replaced. INFORMATION Automatic module replacement can also be used in systems with several subnetworks. It is not necessary to temporarily interrupt network connections or isolate the subnetwork in which the replacement is going to take place Replacing a fieldbus module To replace a fieldbus module, do the following: 1. Disconnect all module connections: Motor(s), sensor(s), hardware, network, and power. The order does not matter. 2. Connect the new module to the motor(s), sensor(s), hardware, network, and power. 3. Start the ECShell engineering software. 4. Press F2 and click [Discover] in the "Network Services" tab. ð All modules in the network are now displayed. Operating Instructions ECDriveS 51

52 7 Inspection/maintenance Replacing a fieldbus module automatically 5. Click the [AutoConfig] button. ð The topology view opens Choose the fieldbus module to be replaced from the list on the left side, and click [Replace Selected Node]. The text information for this module is indicated in red in the topology view Operating Instructions ECDriveS

53 Inspection/maintenance Storage 7 7. Click [Replace Selected Node]. 8. Wait until the fieldbus module has completed its internal boot-up procedures, which is indicated by the module status LED flashing in green. You can also replace a module by selecting the module graphic in the topology view, right-clicking it to display the context menu, and selecting [Replace this Node] Storage Never store the roller motor / gearmotor and the modules of the control in the open. Store the roller motor / gearmotor and the modules of the control in a temperature range of -30 C to +70 C and a relative humidity of 10% to 90% (non-condensing). Operating Instructions ECDriveS 53

54 8 Technical data Technical data of the ECR roller drive 8 Technical data 8.1 Technical data of the ECR roller drive Electrical data ECO mode BOOST mode Voltage Nominal mechanical output power at 25 C Nominal current DC 24 V 40 W 2.5 A Starting current 3 A 5 or 8 A Ambient temperatures -10 C to +40 C Humidity 10 90%, non-condensing Minimum roller length Tube diameter Speed class Transmission head options Smooth tube A0 Poly-V-belt V1 Grooved tube 1) G1 Minimum roller length in mm 15, 20, mm 353 mm 365 mm 50 mm 35, 45, 60, mm 325 mm 338 mm 1) position of the grooves at 50 mm and 80 mm 95, 125, 175, mm 302 mm 314 mm Minimum roller length for wet area design Tube diameter Speed class Transmission head options Smooth tube A0 Poly-V-belt V1 Grooved tube 1) G1 Minimum roller length in mm 15, 20, mm 35, 45, 60, ) position of the grooves at 50 mm and 80 mm 95, 125, 175, Wall thickness of the tubes The wall thickness of the tubes is 1.5 mm. 54 Operating Instructions ECDriveS

55 Technical data Technical data of the ECR roller drive Permitted load capacity of the tubes Roller length Diameter Load capacity in kg 50 mm Dimensions Design A Cable side: M on 11 mm hexagon Opposite side: M8 female thread Mounting hole position: M12 nut/m8 screw L=RL RL [2] 1 Ø D Ø17 [1] M8x15 M12 x BF=RL [1] Motor connection, cable length 1000 mm [2] Connector plug Operating Instructions ECDriveS 55

56 8 Technical data Technical data of the ECR roller drive Design B Cable side: M on 11 mm hexagon Opposite side: 11 mm spring-loaded hexagon axis Mounting hole position: Nut M12 L=RL RL [2] Ø D Ø18 Ø12 [1] M12 x BF=RL [1] Motor connection, cable length 1000 mm [2] Connector plug Design C Cable side: Smooth 11 mm hexagon Opposite side: M8 female thread Mounting hole position: Retaining plate on cable side L=RL RL [2] Ø Ø12 D Ø17 [1] BF=RL+9 M8x [1] Motor connection, cable length 1000 mm [2] Connector plug 56 Operating Instructions ECDriveS

57 Technical data Technical data of the ECR roller drive 8 Dimensions retaining plate PR-D-30H-FU-N [1] [2] 9 [3] [4] 2 x Ø [1] Part A [2] M6 flange nut [3] Part B [4] Base plate PR-D-30H-FU-N-ST [1] [2] 9 [3] [4] 2 x Ø [1] Part A [2] M6 flange nut [3] Part B [4] Base plate Operating Instructions ECDriveS 57

58 8 Technical data Technical data of the ECR roller drive PR-D-30H-PU-N [1] [2] 9 [3] [4] 2 x Ø [1] Part A [2] M6 flange nut [3] Part B [4] Base plate PR-D-30H-PU-N-ST [1] [2] 9 [3] [4] 2 x Ø [1] Part A [2] M6 flange nut [3] Part B [4] Base plate 58 Operating Instructions ECDriveS

59 Technical data Technical data of the ECR roller drive Weight Tube diameter Speed class Roller length Weight in kg 15, 20, mm 35, 45, 60, , 125, 175, Operating Instructions ECDriveS 59

60 8 Technical data Technical data of the ECG gearmotor 8.2 Technical data of the ECG gearmotor Electrical data ECO mode BOOST mode Voltage Nominal mechanical output power at 25 C Nominal current DC 24 V 40 W 2.5 A Starting current 3 A 5 or 8 A Ambient temperatures -10 C to +40 C Humidity 10 90%, non-condensing Pulses per revolution Nominal gear ratio Real gear ratio Pulses per revolution Gear unit backlash in degrees Operating Instructions ECDriveS

61 Technical data Technical data of the ECG gearmotor Dimensions [3] L L [1] 0.5 L 2 26 ø42 ø44 27 ø16 ø20 [2] 25 4 M5x M6x ø [1] Nameplate [2] Motor connection, cable length = 1000 mm [3] Connector plug Gear unit stages Length L in mm 2 stages stages Weight Gear unit Reduction ratio Weight in kg 3 stages 67, 45, 33, stages 18, 15, 11, Operating Instructions ECDriveS 61

62 8 Technical data Technical data of the ECC-DFC fieldbus controller 8.3 Technical data of the ECC-DFC fieldbus controller Dimensions x Ø ECC-DFC Operating Instructions ECDriveS

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