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638 Series - HVS System

1. 15 1 3 DIMER ION RN 16 SS u NUM d MM MEINE 16 17 2 Connection Assignments and Functions 18 2 1 e Ia NR E E E 18 2 2 Overview of Compact Unit Connections aa 19 e 0 8 61615 05 un T 19 ee a ee ee ee eee eee 20 2 3 Assignments Power Connections ccccseeseccccceecceeeseceeeeeeeeeeeeeeeeeeeseaeeeseeeeeeessseeeaseeeeeessaaaeeeeeeeeees 21 e Power Ballast DC Bus Connection X60 enn eene nnne nnne nnne nnn nenas 21 e 24V Control Supply Voltage a a 21 e Gro aeo 8 NN TERRE RETO 21 e Brake Thermo Connection dd 22 2 4 Feedback SGNSOr X JO M 23 Feedback Module X93900 LLULLU UI aa 23 Feedback Connection X30 SUB D 09 Socket sss 24 e Feedback Module X300 with Memory 638A a a 25 2 5 Service Interface COM1 RS232 Uu LLL LR
2. Q 65 s unu eo uu mu au u 65 Power Board Layout Plan 638 66 Power Board Layout Plan GSS B G arabe 66 COmMMISSONINO eee R 67 Commissioning 67 Step 1 Wiring and COMMUNICATIONS Test a r 68 Step 2 Feedback Test and Motor Selection nennen 69 s p CON uyo o 70 Step 2 3 Motor with Resolver Feedback 71 Step 2 4 Motor with HIPERFACE Feedback nennen nnns 71 Step 2 5 Motor with SIN COS Feedback Linear Motor 71 Step Power Up and Drive Activation ccccccccccsccccceeceeeeeseecceeeeeeeeeeeeeeeeseeseeaeseeeeeeeessaeaeeeeeseeaaas 72 PONT m Vtt 72 er DINE PAC m 72 Step 4 Control Loop Optimization 7 Step 4 1 Control Loop Optimization with Rotary Motors
3. 57 Fi areata etree uuu 58 58 D S 58 Jo T 58 AS ROSIS OM uuu LT TOO 59 Selection of the Brake 0 59 Configuration of the Brake Resistor cccccccccceeeeceeeeseeeeeeeeeeeseeseeceeeeeeeseeueeeeeesseaeaaeeeeeeesssaeasansess 60 Wiring Instructions T T 62 General Wiring Instructions mM 62 General ieu u u u u u me 62 Seeker T 62 ODINO T 62 ANOO SUD QUIN EM E 62 yh ilk TE 62 Electromagnetic Compatibility EMC 63 UALS TON AIO 63 Example fOr MOUMUNG u uuu UT 64 07 02 12 02 EN V0608 doc Type 638 5 Table of Contents N O cO e 11 4 Hardware Configuration
4. 73 Step 4 2 Control Loop Optimization with Linear Motors 74 Step 5 Operation Mode 75 Step 6 Fieldbus Interface ccccccccssseeeccceecessseeeeeeesscceeseeneceeesceccseseseeeeesccccseneeeeeccsccessaeeeeesenseees 76 7 eee ee ee ee 77 Sale orque OIT STO 79 General Introduction a a aaa aaa rrraassssnnrrraassssssssssrrrrssssaa 79 Important Technical Terms and 79 Stop Category according to EN 60204 1 Chapter 9 2 2 80 Applications in Accordance with the Regulations 81 Trained Personnel a 81 Benefits with the Employment of the Safe Torque Off Function 81 Safety Instructions and Limitations nnn nennen nnn nnns 82 Safe Torque Off Function 5 nnns 83 Block Circuit DIT o iz 83 Status Diagram and Function of Terminals S
5. anis nnns asa anna nns 26 2 6 wcIIEEIeec19 27 Connection Safe Torque Off 1 1 as EE 27 Connection WITHOUT the utilization of the Safe Torque Off STO function 27 2 7 AONA COMIN 28 e Control Signal Plug X10 SUB 025 Socket nnns 28 2 8 Multi gels XAO uu 29 e COI ROTE 30 HAIG CTSA IDBDD U LU Lun 30 SEPPE MOO uu u umu 31 SPECO Er a 2142 amp 32 2 9 Fieldbus Intenace OON 33 PO c c 33 e P inning for gt E 33 Pinning tor CAN or DeviceNet sssini sssini aia aiai ni aiaa a niiae 34 PANDO WOR A OMI T uu u Su 34 FP WANTON ONS u u E Sau R 34 Pinning for 5 I O Interface Digital In and 35 2 10 F
6. 116 Pror OU O 117 Execute a BIAS 117 Execute a PLC progralrmi u uuu uyawaq 118 Execute a Mathematics program 118 BIAS Comifiands 119 PRD DOING detect X 120 STO Safety Parameter Report Proposal a nns 120 MERO oe eco ec 121 Modifican Record 122 07 02 12 02 EN V0608 doc 638 7 The Most Important Thing First Thank you for your confidence in choosing our products These operating instructions are intended to provide an overview of the technical data and features of our products Please read the operating instructions completely before operating the product Should you have any questions please contact your nearest service representative Improper application of this product in combination with dangerous high voltage can lead to serious injury or death Damage can also occur to motors or other products Therefore we request that you strictly observe our safety and installation instructions Safety Precaution
7. sVDC Figure Pulse Direction Puls Stepper Control Direction direction of rotation 2 direction of rotation 1 Preparatory time gt 2 5 us 2 Hold time 0 Fi a I t gt Puls Direction Control dc 5 Puls Direction Stepper 07 02 12 02 EN V0608 doc Type 638 31 2 Connection Assignments and Functions e SSI Encoder Interface EASYRIDER Windows Software e X40 Connection Modus SSI 13 Bit Singleturn Input X40 Connection Modus SSI 14 Bit Singleturn Input X40 Connection Modus SSI 25 Bit Multiturn Input 13 Bit Single 12 Bit Multiturn X40 Connection Modus SSI 26 Bit Multiturn Input 14 Bit Single 12 Bit Multiturn X40 Connection Modus SSI 18 Bit Multiturn Input 16 Bit Single 2 Bit Multiturn Incr I O X40 Serial Data from SSI Encoder DATA GRAY Code up to 26 Bit Inverted nul Serial Data from SSI Encoder DATA GRAY Code up to 26 Bit mm Shield Connector Clock Output Inverted TAKT Standard Frequenzy 179 kHz Clock Output TAKT Standard Frequenzy 179 kHz Supply Voltage Output Max 150 mA If other data required a Use of X300 Module b External Supply and TAKT twisted pairs DATA and DATA twisted pairs Cable Shielded shielding grounded at both ends Max Cable Length 200m Note For further information about SSI Synchronous Serial Interface please refer to the doc
8. Emission First Environment C2 Radiated Second Environment C3 EN 61 800 3 First Environment C1 First Environment C2 Second Environment C3 EMC Immunity EN 61800 3 Levels include EN 50081 2 E a and EN 50082 2 meet meet meet meet EMC Emission EN 61 800 3 Minimum standards for the Second Conducted First Environment C1 Environment are kept to First Environment C2 Second Environment C3 0 for max 100m motor cable length use the drive with Option A less leakage current and the external filter Type LNF RA 230 12 2 With external Filter of the Serie LNFB is a group RFI suppression for max 4 Device with a overall cable length of 60m possible 3 For the operation in the first environment with unlimited availability is a cabinet damping of at least 10 dB in the frequency range of 30 1000MHz necessary 106 07 02 12 02 EN V0608 doc Type 638 12 Technical Data 12 1 General Technical Data Power Circuit Circuit Overvoltage Monitoring max 400V DC 5V DC Clock Frequency Powerstage 638A 9 5 kHz 638B C 4 75kHz 9 5kHz Control Circuit See Insulation Concept Signal Inputs and Outputs Connection X10 ae ms Circuit Number of Outputs Signal Outputs via OPTO Coupler Umar 45V DC 0 60 mA short circuit proof resistive load 1UA 1 2A Number of Inputs Signal Outputs via OPTO Coupler 0 7 V DC or open 15 30 V DC lin 24VD
9. psr amp maeters Drava Lupe b2H8 7 Yas ds Guald of Tues E i Drive 670 04 4711 Serial Configuration yia Pi ragare TATAEE 618 WaB 33 Page Sen peratinT wode speed control EA Print preview In and Outputs d Pant Disa lal ainpukz Impar Start input Lateh input 1 Tapat 11 input ETAS Input 414 BiA2 input L4 Span Cater t EX EI Dasa arinrin Gia Spnichnm Dana 7 modd asd 6211 Aiei rr art L5 1 3 Bale c rzernkL i JU Aail 2 4 First system start procedure Steps D 3 6 7 successfully accomplished 78 07 02 12 02 EN V0608 doc Type 638 Safe Torque Off STO 9 1 General Introduction The following documentation is meant to provide the basic information concerning our drive controller and an understanding about the advanced safety oriented machine construction References to standards or other regulations are made in a general overview manner The specific standards or regulations for your installation will vary depending upon the equipment employed and the specifics of your application For more information we suggest referring to specific technical literature for example BIA Report 6 97 and BIA Report 5 2003 Information of the German Professional Trade Association These reports can be downloaded from http ww
10. 50 Groundmg Satety Grounding NE 50 Ground Connector a 50 Short Circuit Capacity and Discharge Currents cccccccccccssssseeceeeeeecaeeeeeceesesaeeeeeeeeeeessaaaseeeeeeess 50 P ower Mains HOM 51 Types ol p wer Mains RTT TT 51 Mains supply voltage range 638A 51 Mains supply voltage range 638B C a 51 Protective Ground Connection LLULLU 51 Cable 6 ee t 51 Dimensioning of power mains cable and the over current protection 51 Do Link Parallel COMME HOD LULU 54 SSI 54 Variation 1 Servo Drives without DC LINK protection 54 Variation 2 Servo Drives with DC LINK protection a 55 Fili HON 50 Lm 56 Installation Instructions and Warnings nnne nnns 56 Layout OF INE Ballast GAD
11. 43 Bacani Oper sting mote amp pedd Coni yurakli and Outputs Diqital inputs inputs Di Start input Input 0 Latch input 1 Input 1 Stark input BIAS I Hi amp s inpst 14 Input l Bil amp S5 input 15 Input 2 Reference mee sui Input 25 Latch input 2 Digital outputs Doti 77 Feti bigi Peach L1 nitis lisad Oukput 20 Trail xnnitortnu Duit put 262 4 4 OF Analog input Speed control Eel ing integrator 0 0 nds EHETE centre Des lija inalog Outputs Kia i Hele LU VY UUU rum Mode Current 10 V 10 Kotor i Kotor name ACH inf 4 Rated current j 30 dell In the Menu under commands select Save Data on the Drive 0 EASYRIDER File Commissioning Tuning Command Diagnosis Options Window F O mr 5 Deactivate Drive 10 J Activate Drive Shift F10 PC Login Fe PC Lagaut ShiFt F Reset Drive Fault Save Data on the Drive Select Axis Number Serial Single Commands 07 02 12 02 EN V0608 doc 638 8 Commissoning In the Menu under Data select Save As to save the drive parameters on the computer utilizing the file suffix wdd FE O E iniji Tuga Coupee agea Werke T AS Program IS Sara sb Em dE LL re Parameter E EI Ce EF COR gu Chose 1
12. Safety Gate resp Emergency Stop 1 Protected Area Control Cabinet IP54 Safety Relay Cat 4 e g Pilz PNOZ XV2 638 Servo Drive ACK acknowledg X Important The category 4 and PL e protection level can only be achieved with an active STO Power On Test Explanation The protection switch unit A1 must be set up with a fail safe time delay as determined and required by the specific category relating to the application environment The 638 Servo Drive must be properly configured for the operating environment See Chapter m Configuration and Parameter Settings Note The acknowledgement is only necessary when after the cancellation of the STO function by the automatic start up a potential danger for the people in the area or the equipment exists 92 07 02 12 02 EN V0608 doc Type 638 Safe Torque Off STO Application Example 3 Function Action Response Reaction Protection Level Stop Cat EN 954 1 150 13849 1 According to EN60204 Safety door monitoring or The STO is tripped when the safety Cat 3 PLd 0 emergency shut down WITHOUT door is opened or emergency shut protection monitoring switch down switch is activated op lt _ Safety Gate resp Emergency Stop Protected Area Control Cabinet IP54 Example Safety Gate closed Safety Switch closed Servo Drive activate control voltage 24V rem gt X10 22 Function Acknowledging acknowledgement Explanation The signal
13. With hardware monitoring of the contact difference between STO1 und STO2 Tolerance ca 20 Sec Active Time Delay tva gt 0 No additional special functions Active Delay Time va Active Hardware monitoring Inactive Active A Power Stage F 7 Segment Display P s Config Fiast 1 1 Reset Config This symbol will show if the STO Power on test is active Hardware Time Diagram Flow chart of the switching status from STO1 and STO2 Note for Standard Operation e The STO inputs should always be operated simultaneously If the safety parameter Active Time Delay is tya 0 s then both STO inputs will be turned on immediately after recognition 84 07 02 12 02 EN V0608 doc Type 638 9 Safe Torque Off STO 9 3 Configuration and Parameter Settings General Instructions for Parameter Settings The safe torque off STO basic function is a built in hardware oriented safety function which is not configurable Depending upon the specific application however it is possible to alter specific settings on the drive side which can increase the operational safety factor The configuration and programming of the safety parameters can be accomplished utilizing the Diagnosis and Parameter Setting screen in EASYRIDER for Windows This configuration process has been designed to assist the user in making the proper parameter settings in an attempt t
14. 1 According to the forward of the German edition of the standards EN 60204 1 11 98 electronic equipment for use with the emergency stop mechanism is acceptable as long as the requirements in the safety categories like those required in EN13849 1 are completely observed 07 02 12 02 EN V0608 doc Type 638 81 9 Safe Torque Off STO Safety Instructions and Limitations No Galvanic Separation of the Outputs The galavanic separation does not occur through the starting lockout function This therefore does not in any way provide protection against an electrical spike For operation interruptions maintenance service and cleaning of the equipment the entire system must be definitively and galvanically separated from the power supply at the main switch box and confirmation should be made that the system can not restart See EN 60204 1 5 3 Potential Sudden Jerking or Movement under Fault Condition In the event that two fault conditions appear at the same time in the power unit it is possible that unit may exhibit a sudden jerking or movement within a small angle of rotation This is dependent upon the number of pole pairs of the motor Rotary Type 2 pole 180 4 pole 90 6 pole 60 8 pole 45 Linear Motors 180 electric Malfunction during the Active Braking Phase with Stop Category 1 EN 60204 1 controlled stop with reliable monitored time delay If a fault in the drive system occurs during th
15. 638 Series Digital Servo Drive Product Manual 07 02 12 02 EN V0608 doc Additional Supporting Documentation UL CD lt EASYRIDER Windows Software UL 07 02 09 02 Feedback System UL 07 05 02 03 Product Manual Bus Interface SUCOnet K UL 07 05 03 02 L Product Manual Bus Interface CAN UL 07 05 04 02 Product Manual Bus Interface Profi Bus DP UL 07 05 05 02 L i Product Manual Bus Interface Interbus S UL 07 05 07 02 L Product Manual 1 0 Interface UL 07 05 08 02 Product Manual Bus Interface DeviceNet UL 07 09 04 02 Product Manual Suppression Aids EH UL 10 06 03 Product Manual Serial Tranfer Protocol EASY Serial 2 07 02 12 02 EN V0608 doc Type 638 Additional Supporting Documentation UL 10 06 05 Product Manual BIAS Commands 1L UL 12 01 Product Manual Plugs UL 12 02 Product Manual Cables UL 12 03 E Product Manual Ballast Resistors J Parker Hannifin GmbH Co KG All rights reserved No portion of this description may be produced or processed in any form without the consent of the company Changes are subject
16. Outputs Maton S30 Drive ES x44 0 Seed Current control switchable via Input X10 24 Drive name E38 H Operation mode 1 Speed control Speed 7 Curent control via 510 24 f Speed control 2 Current control Curent control 3 Speed Position control 3 Speed Position control via 10 24 switchable via Input X10 24 4 Position control without BIAS execution t 5 Pasition control with BIAS execution 4 Position control without 297 Default values BIAS execution 5 Position control with BIAS execution Abbrechen Operation Configuration There are opportunities ranging from simple current and speed control to programmable position control processes PLC supported by the 1500 BIAS command blocks BIAS User shell for intelligent drive controls See Chapters Operation Modes and m Software 07 02 12 02 EN V0608 doc Type 638 1 General Information 1 2 Model Code 638 X XX X F X STO XXX XXX 638 6th Generation Digital Servo Drive Size C Rated Current Rated Current 1 0 amps 2 0 amps 2 0 amps 5 0 amps 4 0 amps 7 5 amps 6 0 amps 10 0 amps 15 0 amps Intermediate Voltage 638A 638B 325 VDC 230 VAC 325 VDC 230 VAC 565 VDC 400 VAC 678 VDC 480 VAC With Integrated Filter Standard less leakage current AC side Y capacitators deactivated JP600 open Without EMC Clip Stan
17. 5 1 Installation General Safety The voltages carried by power supply cables motor cables connectors and certain parts of the drive can cause serious electric shock and even death e Danger of Electric Shock Caution Risk of electrical shock wait 3 minutes after switching off for discharging of the capacitors Disconnect the drive unit from the mains before working on it period of three minutes must pass after switching off so that the internal capacitors can discharge completely Until the discharge time is over there can be dangerous voltage stored in the module Persons who monitor or carry out electrical installation and maintenance must be adequately qualified and schooled in these activities Dangerous Areas The use of variable speed drives of all kinds can invalidate the certification for dangerous areas apparatus group and or temperature class of explosion protected motors Inspection and certification for the complete installation of servo motors and electronic components must be obtained Grounding Safety Grounding The grounding impedance must meet the requirements of local industrial safety regulations and should be inspected and checked at appropriate and regular intervals Ground Connections lt is recommended to attach a ground bus made of high conductivity copper as near as possible to the servo rack or regulator modules in order to minimize the length of the cable run connectio
18. Flexible with ferrule with 0 25 2 5 0 25 4 0 5 16 plastic sleeve Flexible with TWIN errule with plastic sleeve Approbation Data AWG UL C UL US 20 6 CSA X01 Solid Core and Control Multiple conductor line Flexible with ferrule without plastic sleeve Des te eas STO Active Flexible with ferrule with 0 25 0 5 0 25 0 5 0 25 0 5 X62 plastic sleeve Brake Flexible with TWIN Thermo ferrule with plastic sleeve 97 Approbation Data AWG AWG AWG UL C UL US 30 14 30 14 30 14 CSA 30 14 30 14 30 14 X61 Solid Core 0 2 2 5 0 2 10 0 2 10 Motor Multiple conductor line 0 2 2 5 0 2 6 0 2 6 Flexible with ferrule 0 25 2 5 0 25 6 0 25 6 without plastic sleeve Flexible with ferrule with 0 25 2 5 0 25 4 0 25 4 plastic sleeve Approbation Data AWG AWG AWG UL C UL US 30 12 28 8 28 8 CSA 28 12 28 8 28 8 X120 Solid Core and PC8 CC8 Approbation Data AWG AWG AWG UL C UL US 28 14 28 14 28 14 CSA 28 14 28 14 28 14 07 02 12 02 EN V0608 doc Type 638 3 Operating Mode 3 1 Operating Mode General The preselection of the device functions are carried out by choosing the operating modes 0 5 according to the following table see Operating modes and pin functions EASYRIDER Windows Software Each operating mode allows for the assignment of different in and output functions Operating Hints for Selecting the Operating Mode Mode Analog X10 5 18 Switching the o
19. Typ 10A 16A 10A 16A 10A 16A DC link resp AC supply gRL gRL gRL variant 1 638B Driver 638B03 638B05 638B08 638B10 638B15 mE Fl Switch Not recommended Input Supply Current 1 A 3 2 5 6 8 5 8 9 11 4 3 phase Fusible cut out VDE 6 16 gG 6 16 gG 10 16 16AgG 16A gG B6A 16A B6A 16A B10A 16A B16A B16A Automatic circuit breaker VDE Fusible cut out UL 2 6A 15A 6A 15A 10 15A 15A 15A Line contactor 3 DILM7 DILM7 DILM12 DILM15 DILM15 Fusible cut out 4 10A 30A 10A 30A 10A 30A 16 30A 16A 30A DC link resp AC supply gRL gRL gRL gRL gRL variant 1 Automatic circuit breaker VDE Typ lt lt lt lt D D lt O D Drive 638Cxx 638Cxx 1 2 ER _40AgG Line contactor S Typd DILM32 DILM40 Fusible cut out 4 32A 40A DC link resp AC supply variant 1 1 At maximum output voltage and rated current 2 UL listed JDDZ Fusible cut out Class K5 or H or rather UL listed JDRX Class H 3 Hecommended e g Kl ckner Moeller 4 Class gRL are fuese with combient protect for Cable and Semiconductor e g Fa SIBA Sicherungs Bau GmbH Serie 60 034 34 16 Fuseholder 5106304 x up to 30A Serie 50124 34 xx Fuseholder 5105804 3 up to 40A If these fuses are used the m
20. 6 Ground 485JCAN GND CAN H Bus Line dominant high Data OUT 9 j Data OUT inv with galvanic isolation e Pinning RP CC8 X120 with l O s 0 1 BIAS Input 122 BIAS Input 123 BIAS Output 125 6 BIAS Output 126 BIAS Output 127 8 BIAS Output 128 9 Ext 24 V Supply Ground Reference 0 V B The signal status of the l O s is shown with a 2mm LED LED on I O high LED off I O low min max cable cross section 0 08mm 1 5mm 07 02 12 02 EN V0608 doc Type 638 39 2 Connection Assignments and Functions DIP Switch Position for Option Module RP CCA and RP CC8 DIP Switch Position CAN 1 BUS termination 2 CAN2 BUS termination 3 RS485 RXD BUS termination 4 R5485 TXD BUS termination 5 Node number by Software closed 6 Reserve 7 Reserve 8 Module code open compatible to 2C8 2 Baud rate CAN1 M F 4 1 20 kBaud 50 kBaud 100 kBaud 125 kBaud 250 kBaud Example 500 kBaud Note number 5 1MBaud 800 kBaud 1000 kBaud 1MBaud gt Se 3 C3 0 C3 2 0 0 1 1 0 0 1 1 2 Node number 0 127 40 07 02 12 02 EN V0608 doc Type 638 2 Connection Assignments and Functions 2 13 Fieldbus Interface RP PCA PC8 Pinning Profibus DP and CAN2 BUS and RS485 Module RP PCA PC8 Pm uneton 3 B Request to Send PDP GND 6
21. Explanation Note Flow Chart Without Function No safety relevance Function X10 22 is freely programmable BIAS Initial Factory Settings default values Acknowledgement STO function activation See below Emergency Stop through additional low gt high edge of the X10 22 input acknowledgement and Emergency Stop before the STO shutdown through additional high gt low edge of the X10 22 input Acknowledgement STO function activation After the through additional recognition of the low gt high edge the active edge of the X10 22 input time delay will be acknowledgement started Emergency Stop Before the STO shutdown After the through additional recognition of the high gt low edge when the edge of the X10 22 input rotational speed 0 then the emergency stop ramp will be executed and when the rotational speed 0 the time delay for the brake will be started Value Range Explanation 4 Initial Factory Time delay for the activation of the final stage after Settings acknowledgement 24 V of both STO inputs for example of the Default Value acknowledgement inputs in the event that they have been Active Time Delay 4 500 10 ms configured in 10 ms increments Note If the STO inputs for example the acknowledgement inputs are removed OV before the expiration of the active time delay then the time will be reset and only reactivated with a new Function X10 22 edge 24 V Value Range Explanation Th
22. Profibus DP 1 Data INinv O dominant low 4 5 GND optional 6 Ground CAN2 BUS RS485 485 CAN GND 7 CAN Bus Line dominant high Data OUT Data OUT inv Pinning RP X120 with l O s 0 1 es BIAS Input 122 BIAS Input 123 ws 124 ios BIAS Output 125 6 BIAS Output 126 BIAS Output 127 8 BIAS Output 128 9 Ext 24 V Supply Ground Reference 0 V B The signal status of the l O s is shown with a 2mm LED LED on high LED off I O low min max cable cross section 0 08mm 1 5mm 07 02 12 02 EN V0608 doc Type 638 41 2 Connection Assignments and Functions DIP Switch Position for Option Module RP PCA PC8 DIP Switch Position CAN2 RS485 and Profibus DP 2 Note numbers 0 31 6 Bus termination CAN 7 8 Bus termination RS485 2 Note numbers 2 125 8 Reserve 9 10 Bus termination PDP Kl R K j K K RER ecaaat DIL CAN RS485 DIL Profibus DP Further information for the Profibus DP See Documentation 07 05 04 02 E Vxxxx 42 07 02 12 02 EN V0608 doc Type 638 2 Connection Assignments and Functions 2 14 Overview of the Terminal Cross Section Cross Section 638A 638B 638C mm X60 Solid Core 0 2 10 0 75 16 Line Multiple conductor line 0 2 6 0 75 16 Brak rakeresistor Flexible with ferrule 0 25 6 0 5 16 without plastic sleeve DC Link
23. Respective intermediate transformers must be used for higher supply voltages With grounded power mains autotransformers can also be used to adjust the voltage Neutral does not have to be connected for this type of transformer It is possible to use a lower supply voltage range Note In this case the internal DC BUS capacity may be not high enough specially in 1 phase mains supply and the user has to adjust the undervoltage monitoring parameter of the drive Mains supply voltage range 638B C The nominal supply voltage range is 3 400 480 AC 10 It is possible to use a lower supply voltage range Note In this case the internal DC BUS capacity may be not high enough and the user has to adjust the undervoltage monitoring parameter of the drive Protective Ground Connection PE The following information concerning the protective ground connection corresponds to EN 61800 5 1 Item 4 2 5 4 1and 4 2 5 4 2 Cable cross section The cross section for the protective ground conductor at X60 corresponds to the external conductor The 638 servo drive is a devices with increased leakage current larger than 3 5 mA AC or 10mA DC Therefore a second protective ground conductor must be connected at the case groundbolt with the same cross section as the first protective ground conductor on X60 Dimensioning of power mains cable and the over current protection The cross section from the power main cable and the rated current for the ove
24. X300 RM1 5 PTC INTC optional _ 8 sin X 9 carier o With parameter setting PTC can you temperature sensor Typ KTY note poling or thermo switch used EASYRIDER Menu Configuration Motor X30 Switch off at use resistor value in Ohm For thermo switch is the value 1000 Ohm in the EASYRIDER Menu Configuration Motor X30 Switch off at m m meee E e ie pe Configuration 630 X ACM D320 2 72 3 Rated current 64 M asinum current 285 A Hated torque 3 2 Mm afi s IT s Ma of pale pairs 3 77 sS Fhaseshiftirig Annn onset Inductance 24 mH i 4000 rm speed Resistance 09 Ohm 4 nterral counter kenzo I t monitoring 2 WENT ma kgernr pairs sensor Sensor offset Resolution 16 Bit gt Rotation direction negative Abbrechen 24 07 02 12 02 EN V0608 doc Type 638 Connection Assignments and Functions HIPERFACE Module X300 HF2 or X300_HM1 Module X300_HF2 X300_HM1 Function In Oo ref cos ref sin data MOVEass o o o gt lt C2 e e o O N gt lt C2 e
25. active overvoltage clamping 50V keyed Number of Inputs 4 Signal Outputs via OPTO Coupler L 0 7 V DC or open dd 15 30 V DC lin at 24VDC 8 mA Shortest Time for a Signal to All Inputs to Accept 1 ms the Signal in an Application Damping of the Transfer from default input Low to High 0 gt 24V 200yus Damping of the Transfer from default input High to Low 24 gt 0V 1000us 07 02 12 02 EN V0608 doc Type 638 12 Technical Data Digital Control data Current Limits Adjustment by speed control menu control menu Analog Input 0 10V 0 100 can be standardized 10Bit Speed Control Differential Setpoint Input Analog Resolution including sign Position Control Digital Communication RS232 Service Interface COM 19200 baud 8 data bits 1 start bit 1 stop bit parity even Optional RS232 RS422 RS 485 on SUB D Socket CAN1 Profibus DP SUCOnet K on SUB D Socket Interbus 5 on SUB D Socket OUT Interbus S Remote IN additional on SUB D socket Resolver Evaluation Transmitter Principles General The specified data refers to the combination of the standard resolver interface with Function Module X300_RD2 operated with the SSD Drives Resolver R 21 T05 R15 T05 Carrier Frequency ft 4 75 kHz Data was checked actual data results Quality improved 07 02 12 02 EN V0608 doc 638 109 12 Technical Data
26. e o Module X300_SC2 X300_SM1 Function ONG Z lt O COS sin zero pulse ref cos ref sin zero pulse Movaaaad Feedback Module X300 with Memory As of firmware version V8 35 the 638 Drive supports the X300 xM Modules This module has an additional memory chip Flash jn This flash stores the complete drive data firmware function code m o parameters application program When a drive is defect the X300 memory module can be replaced with the complete drive data in the new drive 4 u k LI You need no additional configuration work or software tools Requirement The drive type must be equal same current Attention during the 1 st switch on of the control voltage after the X300 module replacement After the replacement of the X300 module make sure that the 1st switch on of the 24V control voltage has no interruption during 60 seconds It is necessary that the copy program for Firmware and X300 Feedback function code are not interrupted Applications in Accordance with the Regulations When the 638A Drive supports the safety function Safe Torque Off in the sense of providing a definitive stopping of the equipment with protection against unanticipated start up in accordance with regulations EN954 1 Category 3 and EN after the X300 module change one must follow the instructions comp
27. ee o NN Table of Contents Page OC ANC AU em 107 EIER s 107 107 GOOL jj i u u gat E 107 Signal Inputs and Outputs Connection X10 a a 107 PUTO b 107 CONO Pic 108 108 Signal Inputs and Outputs Connection X120B resp 120C 108 UT d saio MERR RETRO I 109 T 109 Resolver Evaluation Transmitter Principles 109 Sesto dies Li MENTRE T Tm 110 FGA a E E R S 110 Keane M i um TL E E 111 O 111 DUUE FON OO S E A 112 Singlephase and Threephase SUPPLY cccccccccccccceeesseeceeeeeseeeeeeeeeeeeseueeeseeceeeeessueeseseeeeeeesssagaeses 112 O o S nn snn SS T SS EE EEE T s 113 5 m 114 cler 115 EASYRIDER Windows Software str etre snc 115
28. 07 02 12 02 EN V0608 doc 638 Remark Cause of Fault Condition 73 8 Commissoning Step 4 2 Control Loop Optimization with Linear Motors Remark Action Function Anticipated Result Cause of Fault Condition Prerequisite Step 0 0 90H Under Construction QwesemO a 74 07 02 12 02 EN V0608 doc Type 638 8 Commissoning 8 6 Step 5 Operation Mode Selection Remark Action Function Anticipated Result Cause of Fault Condition Prerequisite i In the EASYRIDER configuration menu select With the selection of the Additional information General and then select the appropriate operating mode one must also and assistance is operating mode select additional settings available through the EX Configuration 638 06 A 4711 utilization of the online For example help for Ba Genera nputs utputs otor rive General Inputs Outputs Motox30 Drive E 4 gt On Off Configuration EASYRIDER Software Drive name 8 06 Analog Setpoint Selection and Integrator Position Blocks Speed Current control 10 24 BIAS Program 1 Speed control Fieldbus Interface 2 Current control 3Speed 7 Position control via X10 24 4 Position control without BIAS execution Position control with BIAS execution OK Abbrechen 07 02 12 02 EN V0608 doc 638 75 8 Commissoning 8
29. 101 BIAS Input 102 3 BIAS Input 107 BIAS Input 108 BIAS Output 109 BIAS Output 110 24VSPS with galvanic separation Notice The inputs with the internal numbers 107 and 108 must be connected to pin numbers 3 and 4 The outputs with the internal numbers 109 and 110 must be connected to pin numbers 7 and 8 07 02 12 02 EN V0608 doc Type 638 35 2 Connection Assignments and Functions 2 10 Fieldbus Interface COM2 in Combination with COM3 OPTION SLOT A B Gss sss w w a e Pinning for Interbus S RP IBS Remote OUT Outgoing Interface SUB D09 Socket Module RP IBS Function Designation Data Line OUT Forward DO2 error voltage A a Data Line IN Backward DI2 2 error voltage A Reference Potential E VCCI Em Data Line OUT Forward error voltage B Le Data Line IN Backward error voltage B for additional Interbus S Interfaces Remote IN Incoming Interface SUB D09 Plug Module RP IBS Function Designation Data Line IN Forward error voltage A error voltage A E error voltage error voltage B pM Ee _ with galvanic isolation 36 07 02 12 02 EN V0608 doc Type 638 1 EX 9 2 Connection Assignments and Functions 2 11 Fieldbus Interface RP 2CA 2 8 e Pinning CAN1 BUS and CAN2 BUS Module RP 2 2C8 CREEK es 6 Optional Ground CAN GND CAN_H Bus Line
30. 7 76 Step 6 Fieldbus Interface Action Function Prerequisite Step 2 3 The overall system commissioning and the communications test of the fieldbus interface are dependent upon the interface configuration of the drive If there is not an options board connected then there are no more additional settings required and one can move on to Step 7 In the configurations menu under Fieldbus additional settings may be required depending upon the connection interface for the fieldbus board Remark Anticipated Result Cause of Fault Condition Additional information concerning start up procedure for the fieldbus interface connection can be found in the handbook about the Options Board 07 02 12 02 EN V0608 doc Type 638 8 Commissoning 8 8 Step 7 Data Save Remark Action Function Anticipated Result Cause of Fault Condition Prerequisite Step 5 6 Read the parameters shown in the EASYRIDER Data Menu under Drive Parameters FW EASYRIDER parameters Fe Commana Comrand Waxkiw ri nae k Fin Girhi s 5 UN Cose Parameter Gare re rw Par ameter ive ki POTERIT F aie Crs Filenase paraketer 1 a M Dir b386 Ub Yaf 39 61 at iurzxwimi Drive G39 UG 4711 Sea nui Pera Pres ilb eri Firsvare vers
31. 8 10 9 22 25 5 Rated power Pbnenn W 1100 Internal Brake Resistor Rbint Q 680 Pd W 15 670 849 1380 1750 guo tto tet 400 480V Loss 26 4 Fan Electronics Fan Control Power Loss a 11 5 400V 4 VUES 8 400V 9 5kHz Rating Class per A 11 8 480V 4 75kHz 16 8 480V 9 5kHz 7 Reference Output Power 638 2 Recommended Transformator power supply 07 02 12 02 EN V0608 doc 638 113 12 Technical Data Output Power 638B In the event of continuous operation in the full load range the limits as shown in the following diagram need to be respected Typical servo applications are not affected by this restriction S3 operation Start Stop At mains voltage 400V no restriction of the output power on the devices withstands 5 7 5 10 480V Netzspannung 5A 7 5 10A gt 5 sec x 45 lt 480V 4 75kHz 480V 9 5kHz 80 160 240 320 400 Output Voltage V 400 480V Netzspannung 15A 2 gt 5 1 8 1 6 gt 10 1 4 12 SA ll gt 20 a d E 22400 475kHz foo c sss UU U b ra 0 8 gt lt Z 400V _ _ gt j mM CC EC EL s 480V 4 75kHz 0 4 480V 9 5kHz 0 2 0 u 0 80 160 240 3
32. Channel Z zero impulse 9 Supply Voltage Output Max 150 mA 4 5 VDC Design Rule The input frequency range of the connected control must equal at least the value of the pulse output frequency on the X40 12 n x _ n max speed rpm ALT 60 Hz x increments e g 1024 l f output frequency at X40 1 2 4 5 Example n 4000 1 min 1 2 4000 1024 ne ee 1920 Hz 60 e Incremental Input EASYRIDER Windows Software X40 Connection Mode Incremental Input Parameter range of the input signals 10 1000000 increments Incremental Output eT Incremtal Input Note The operation of incremental encoders via long cables may cause a voltage drop of the encoder power supply We recommend the use of a separate voltage supply if necessary 30 07 02 12 02 EN V0608 doc Type 638 Connection Assignments and Functions Stepper Motor Input Two different modes are available EASYRIDER Windows Software X40 Connection Mode Stepper Motor Pulse Direction EASYRIDER Windows Software X40 Connection Mode Stepper Motor 2 Pulse INCR I O X40 Function Mode Pulse Direction Mode 2 Pulse READY 2 READY Designation 4 Pulse Inverted Pulse Inverted 5 Puse X JPuse _ J Reference Potential generally to connec GND _ L7 Diecioniweted Pulse invered _ 8 Direction Pus 9 _ Supply Voltage Output 150
33. Optimization Linear Motor when employing a motor with a Sin Cos Feedback system Terminals 1 and 4 on the X11 STO connection should be set at 24 V In the event that no fault condition arises On to Step 2 v With unanticipated operation or overheating of the motor turn off the drive and attempt to locate the cause of the problem Identify and rectify the fault condition Anticipated Result In order to eliminate the risk of a short circuit The drive remains in a non activated condition even after the power is connected The drive will show a DC link voltage Ucc of approx 325 V DC with an incoming supply of 230 V AC in a non activated condition Anticipated Result In the event that the Feedback System Sin Cos On to Step 4 2 Driver power stage is activated and the 7 segment display shows The drive is now set in the operations mode Delivery condition Speed control set to the analog setpoint gt M 07 02 12 02 EN V0608 doc Type 638 Remark Cause of Fault Condition X60 Connector Assignment X11 Connector Assignment STO Safe Torque Off 7 Segment Display H Remark Cause of Fault Condition X11 Connector Assignment The motor shaft can be set to turn slower through the 0 V offset setting of the analog setpoint input Diagnosis and Troubleshooting 8 8 5 Commissoning Step 4 Control Loop Optimizati
34. Output Power 638A In the event of continuous operation in the full load range the limits as shown in the following diagram need to be respected Typical servo applications are not affected by this restriction 53 operation Start Stop Puls duration by unloaded drive until supervising reaction Imaxr Inr gt 10 sec gt 20 sec Continous Operation 1 At servo drive 638A 06 Load limitations decreased to 66 with 1phase incoming supply and continuous operation and speed S1 Singlephase and Threephase supply Due to the line ripple of the DC Bus the rate of usable output voltage is reduced as follows This reduction affects the maximum attainable speed of the applied motor Three phase supply The unloaded output voltage will be reduced to approx 90 maximally 85 Single phase supply 50 60Hz see following Diagram Derating of Servo Drive output voltage in case of singel phase operation Output Current Aeff Se hae EM cuu pe ay 4 75 40 80 100 Output Voltage as of unloaded condition Hint for Parameterization To avoid the unexpected tripping of the under voltage threshold the parameter setting should be left on the default values EASYRIDER Windows Software Required motor terminal voltage for specified speed Approximation up to 3000RPM Ukl 1 2 EMF n 1000 I Rph RL V Required Motor Voltage V EMF B
35. Technical Unit Data Default setting Note The somewhat similar ratio of Pd continuous power rating to Pmax peak power rating is a prerequisite for the correct monitoring of the brake resistor employed in a parallel configuration This is guaranteed with the standard design configurations 60 07 02 12 02 EN V0608 doc Type 638 Electrical Installation Example for 638A EASYRIDER Motor 530 7 x41 rl Positian control Position control lintemal position with Pos reached window 400 INET Pos reached time 20 ms Trail window 1 6384 incr Trail Fault z r reactor HONE Brake circuit W Activate brake circuit Brake circuit setpoint 3r Resistance Ohm Rated power 120 Default values Determination of the resistance values through the employment of both internal and external resistors Internal Brake Resistor 170 Ohm External Brake Resistor 33 Ohm 1 1 Formula Rges Rint Rext 1 1 gt Rges 27 60 Rges 1700 330 Selected Resistance Value 27 6 Ohm Determination of the brake resistor rating through the employment of both the internal and external brake resistor ratings Internal Brake Resistor Rating 20 Watt External Brake Resistor Rating 100 Watt Formula Pges Pint Pext Pges 20W 100W gt Pges 120W Selected Power Rating 120 Watt CAUTION Installa
36. correct press the Acknowledge button twice to accept Safety Parameter no Value f 0 Function 410 22 Acknowledging Quick gt C 1 o iims L CORN Safety Password bs Change Password Protocol file Close 2 Access password enter BGSM Safety Please insert your password Cancel and verify with 4 Send the Parameter press Send one time Parameter no Value fe 0 Function 10 22 Acknowledging Guick gt 1 ms xx Acknowledging Correction Password s Change Password Protocol file Close 5 When the parameter display is green it confirms that the value is correct has been stored and power loss protected in the drive unit Once all of the relevant safety data parameters have been entered then it is possible to call up the protocol form of the actual safety parameter settings by pressing the Protocol file button ACROBAT Reader is required Note A copy of the Safety Parameter Protocol Form is available in the appendix of the Servo Drive Handbook and can be used for verification purposes 07 02 12 02 EN V0608 doc Type 638 9 Safe Torque Off STO Safety Parameter List The following safety functions are presently able to be configured e Parameter 0 Function Input X10 22 e Parameter 1 Active Time Delay e Parameter 2 STO Power On Test Parameter Value Range
37. dominant high NLIS Ege Lo Me with galvanic isolation Pinning RP 2C8 X120 with l O s 0 1 BIAS Input 122 BIAS Input 123 BIAS Output 125 6 BIAS Output 126 BIAS Output 127 8 BIAS Output 128 9 Ext 24 V Supply Ground Reference 0 V B The signal status of the l O s is shown with a 2mm LED LED on I O high LED off I O low min max cable cross section 0 08 1 5mm 07 02 12 02 EN V0608 doc 638 37 2 Connection Assignments and Functions DIP Switch Position for Option Module RP 2CA and RP 2C8 DIP Switch Position CAN zi Default alle off CTYITTTTT TT 2 Note numbers EERE 0 127 Bus termination 2 22 Baud rate CAN1 N 20 kbaud 50 kbaud 100 kbaud 125 kbaud 250 kbaud 500 kbaud 800 kbaud Example Note number 5 1Mbaud ses 1000 kbaud 1Mbaud OOOO NN DIP Switch Position BUS Termination Example 638A 38 07 02 12 02 EN V0608 doc Type 638 2 Connection Assignments and Functions 2 12 Fieldbus Interface RP CCA CC8 Pinning CAN1 BUS CAN2 BUS and RS485 Module 8 PIN Function Designation _ Alf LEA CAN L Bus Line CAN L dominant low CAN GND T ak RE _ 6 Optional Grund CANGND _ dominant high epe LE MI cM dominant low 4 _ 5 GND optional
38. factor of the three phase system When connecting to the power mains short term single or two phase operation because of contact chatter on the line contactor Estimation Single phase or two phase operation as Single phase operation with neutral line intermediate state when switching on the line contactor x 2x z x i A x 2x z x CaLF 3 LIA The discharge capacitance C the various 638 Servo Drives can be taken from the following table Servo Drives Filter 638A 01 06 638A 01 06 638A 01 06A LNF RA 230 12 1phase 3phase 1 3phase 1phasig JP 600 open Discharge 230nF 277nF 136nF capacitance Servo Drives 638B03 15 638B03 15 x A 3phasig 3phasig qw T capacitance Recommendation For less leakage current operation with 1phase supply it can be the following combination Use a Servo Drive with the optional Version 638Axx 3 A and a low leakage line filter Typ LNF 230 12 AC sided Y Capacitance deactive JP600 open see chapter Jumper When several 638A servo drives operates with 1phase supply and 3 phase are available in the machine the drives should be divided similar on the 3 phases so that the charging currents obliterate mutually when the system is powered up Note It only allowed to connect the DC Link Voltage between drives which are connected to the same phase or which have 3 phase supply 07 02 1
39. no set X variable X X variable Y Mode X const Teachvariable X variable Y Virtual program 07 02 12 02 EN V0608 doc Type 638 119 14 Appendix 14 4 STO Safety Parameter Report Proposal 1 General Information Checked according to STO inspection instruction Project Machine Drive name Inspector name 2 Safety Parameter Configuration Parameter description Acknowledgement Function X10 22 Quick Stop Acknowledgement Quick Stop STO Power On test 3 STO Function test according to manual Step 1 checked 638 Product Manual 07 02 12 02 E Chapter STO Step 2 checked step 3 checked I Step 4 checked 4 Acknowledgement according as configuration successful checked not used 5 Quick Stop according as configuration successful checked not used Quick stop integrator Commissioning Acceptance test date In service inspection date Signature inspector Signature inspector 120 Signature inspector 07 02 12 02 EN V0608 doc Type 638 15 07 02 12 02 EN V0608 doc Type 638 Memo 121 16 Modification Record V0106 preliminary version 07 04 2006 Dreilich V0206 preliminary version i ER TEE VO300 final version 21 08 2006 N Dreilich N Dreilich New Photos osos compete 6388 7072008 _ N Dreilich Phase 07 02 12 02 EN V0608 doc Type 638 Pa
40. overload of the drive 1 1 does the control loop oscillate P amplification too high mechanics stiff requirements too high is warning 8 evaluated lt overload of the motor 1 does the control loop oscillate P amplification too high mechanics stiff requirements too high is warning 8 evaluated Beh over temperature of the output stage gt 90 C adequate cooling of the regulator ambient temperature too high elf chassis shorting and short circuit due to hardware off motor cabling ok digital loops setup ok short circuit to chassis in the motor braking resistor ohm value too low try to start fresh send in for repair ballast module ok adequate ballast module NE Overload of the regulator 121 or motor 121 or temp output stage too high If no reaction within approx 3sec it switches off with signals 3 4 or 5 Signal 8 clears when there is no more danger or it Is switched off mechanics stiff defective bearings cold grease reduce requirements and creep to next possible STOP over temperature motor NTC PTC check overload of the motor cooling etc 2Eh motor temperature too high check overload of the motor cooling etc gt gt gt 80h ballast active off Brake energy is removed on 38h Warning 74 ballast too high ballast resistance usage gt 90 7Ch switch off ballast off off ballast r
41. ru axem cac erga a ode DRE km e ka d ev ee esca 41 Pinning Profibus DP and CAN2 BUS and RS485 41 Pinning AP XT20 IM iIc P 41 DIP Switch Position for Option Module RP PCA 8 42 Overview of the Terminal Cross Section sss nene 43 44 Mode Cc MERIT M 44 Operating Modes and Pin amp 45 Configurable Pin Functions Operating Mode Dependent 46 Functions Diagrams with Protection Mode Switch Off 47 Mechanical Installation 49 I su SS SS 49 Control Cabinet Mounting 2 0 49 49 El ecirieal uuu lll ll llu u ua 50 GCS uuu u uuu E unum usss aym 50 4 50 50 2 27 ATGAS
42. temperature sensor Typ KTY note poling or thermo switch used EASYRIDER Menu Configuration Motor X30 Switch off at use resistor value in Ohm For thermo switch is the value 1000 Ohm in the EASYRIDER Menu Configuration Motor X30 Switch off at ES Configuration 638 X LES Ba General E 24 Outputs Motor X30 Ez x4 4 HAETUEAP Rated curent Las en i 5 B4 current ARRI TER Hated torque 1 55 Nm T1 active at 1640 Ohm Ma of pole pairs 5 ps a P haseshiltirig 8 EMF at Ima VU TODO al hd asimum Annn Inductance mH speed 4000 Resistance 20 7 Ohm la 6 4 gs M Internal counter sersa 2t monitoring 2 Number of pole 1 Inertia 0 81 pairs sensor Resolution high 14 Bit Sensor offset Rotation direction negative a Motor library Abbrechen 22 07 02 12 02 EN V0608 doc 638 Connection Assignments and Functions Feedback Sensor X30 The feedback system creates a digital value from the feedback position sensor From this value the following is derived gt Commutation according to the pole division gt Actual rotational speed value gt Position value for the position controller Feedback Module X300 The X30 connection is directly connected to the F
43. the rectifier in the Device In order to protect the rectifier also in the circuit variant 1 mains fuses of the class gRL must be set in These are fuses with combined protection for wires and semiconductors gt With acommon DC link bus one should employ the 638A Series of Servo Drives exclusively gt Drives which are located immediately next to each other within the same control cabinet should be carefully arranged with the DC links being made employing a short wire connection Note Connect maximum 4 Servo drives together Note Units should be turned on together as shown Contactor K1 Switching delays can endanger the function of the rectifier and the soft power up circuitry wear effect Note The failure of individual AC fuses can go unnoticed as the power continues to be delivered through the DC bus of the units connected in parallel Regular checks of the fuses are therefore strongly recommended Note Careful planning and wiring are imperative A short circuit on DC bus link connections can cause serious damage to the rectifiers and drives Note With single phase power supply at 638A Devices it is recommended that only the same phase is used for all coupled drives The connection of different phases generates a DC Link voltage of 565V DC This can damage the devices 07 02 12 02 EN V0608 doc Type 638 Electrical Installation Layout of the Ballast Capacity Energy which is produced by the el
44. to the drive is definitively interrupted according to the requirements of EN1037 section 4 1 The drive unit is or alternatively not allowed to rotate and will therefore not be able to generate any dangerous Safe Torque Off rotational movements See EN 1037 section 5 3 1 3 The stopping position must not be monitored Should there be the potential of an outside energy source affecting the drive and STO function for example the dropping of a hanging load then additional action needs to or abbreviated as be taken to guarantee that no additional movement takes place i e installation of a STO mechanical brake The following measures are appropriate for incorporation with Safe Torque Off Protection between power connection and the drive system Line Fault Protection Protection between the power unit and the motor Motor Protection Protected lock of the control of the solid state power component Start up Lockout Start Up Lockout Protected lock of the control of the solid state power component With help of this function one can establish the activation of the Safe Torque Off 07 02 12 02 EN V0608 doc 638 79 9 Safe Torque Off STO Stop Category according to EN 60204 1 Chapter 9 2 2 Category Reaction Shutdown by immediate shut off Uncontrolled Uncontrolled shutdown is the stopping of the of power supply to the machines Shutdown machines movement by eliminating the po
45. 0 3 Pvmot Ib Rph RL W Pvmot 40 W Continuous Power 0 9 247 40 0 1 2 Pd 0 9 Pkin Pvmot tb1 T W 9 3 W Peak Power Pmax 1 8 247 40 1 8 Pkin Pvmot W Pmax 405 W Measurements Used Total Inertia kgm RPM at Start of Braking RPM Braking Time Sec Cycle Time Sec Motor Braking Current A Motor Resistance terminal terminal Q Cable Resistance of the Power Cable 07 02 12 02 EN V0608 doc 638 59 5 Electrical Installation Step 2 Example Drive Type Is internal and or external Brake Resistor required 638 Is the internal Brake Resistor sufficient or is no internal Overall Rating resistance available Should no resistance be available Internal Resistance then appropriately sized external Brake Resistor can be Continuous Power Pd 20W employed to meet system requirements according to the Peak Power Pmax 0 83kW table See below Requirement 9 3W Pmax 405W External and internal resistance can be employed Result The internal parallel configuration In this case the internal and external configuration is sufficient Capacities can be added together Selection Brake Resistor Only Parker or by our released ballast resistors used 638A01 638A02 638A04 638A06 33R 100W 638B033 638B053 100R 100W 56R 200W 638B036 638B056 100R 100W 638B037 638B057 100R 100W 638B083 100R 100W
46. 00 638 5 638xxxxFxS TORE XXX e E 638coxFxSTORBEAEex saacan STO xx 638 5 638xxxxFxST OPM O00xxx 638xxxxFxSTOWMMMEAExxx 638xxxxExSTO 000 1638 638 5 0 000 638xxxxFxSTORMIEAExxx 638xxxxFxST Os 00x 638xxxxFxSTOMAPIEAExxx 638xxxxFxST Ofte 000x xx 638 5 638 5 4 000 638 5 638xxxxFxSTORMe000xxx 638 5 1638 4000 DO
47. 2 02 EN V0608 doc Type 638 5 Electrical Installation 5 3 DC Link Parallel Connection With the operation of a group of drives it is possible to couple the DC link circuit of the 638 Drives Advantages gt Positive energy balancing utilization of braking energy with energy equalization achieved through the DC link Smaller load on the ballast resistors Increased DC link capacity through smaller residual rippling specifically with single phase applications Increase of the internal ballast peak performance Increase of the internal ballast continuous power rating Internal unit balancing resistance provides for a uniform rectifier load sharing with a parallel incoming power supply YYY NN Variation 1 Servo Drives without DC LINK protection Block Diaqram 1 Supply Connection for Servo Group 1 or 3 phase 230V AC Drive 1 Drive 2 Drive 3 T I1 T B8B i uu Fu m i Fs 4 I a Dhe m l la i w U 388 JJ Terry e H LLL JJ4 F back up fuse external ballast resistor if required Advantage no DC fuses necessary Disadvantage Sum of power limited by line fuse 54 07 02 12 02 EN V0608 doc Type 638 5 Electrical Installation Variation 2 Servo Drives with DC
48. 20 400 480 Output voltage V 114 07 02 12 02 EN V0608 doc Type 638 13 Software 13 1 EASYRIDER Windows Software EASYRIDER Windows software is a useful and convenient tool to use to control all drive functions Detailed online help information and instructions are available B LASYRIDEFI Exp O01 bed LT erie a M ci DIT TE mmarka Howe ram ig Quiend Looy ham Ir Variables from parmar Pragam wove oo Sed a a CT Lo mL andas gt co dinum Pat Acerleraline Variable 2 5uh Move innie Domy epus EC TE V arise deceleration Erde Wipo m V x grai Gr arm Pesan reached wares a conet marhad uintia 2 black rumi dump rrr Move eod ricordo wee Dh porhion 31 m PIE r Jump Moen Tum i parameter ACM Meee T 1 Attention T L 12 Ihe program Lead 453 Se CE See te dole bini Syelch oll ab 1630 lt LAU module 12906 El S E Starting poi ap 4 o ack ut iom 1 6039 I
49. 56R 200W 36R 300W 33R 300W 638B086 100R 100W 638B087 100R 100W 638B106 638B156 100R 100W 56R 200W 36R 300W 33R 300W beigprepged 638C being prepared Configuration of the Brake Resistor Brake Resistor Circuit Configurations 1 Activate Electronic Resistance The electronic resistance will be activated Activate Brake Resistor Y 2 Switching Threshold The switching threshold is to be selected Brake Resistor On 375V for 230V AC incoming power supply Default setting Brake Resistor On 375V for 400V AC incoming power supply Default setting Brake Resistor On 375V for 480V AC incoming power supply Default setting 3 Resistance Value The total resistance value is determined by the selection of both the internal and external brake resistor values which are combined to provide the overall parallel resistance When the brake resistors deviate from the table Selection Brake Resistor it should be noted that the minimal external resistance value of the controller is not undercut see m Technical Unit Data 4 Rated Power The brake resistor performance rating is determined by the sum of the selected internal and external brake resistor capacity values When the brake resistors deviate from the table Selection Brake Resistor it should be noted that the minimal external resistance value of the controller is not undercut see m
50. 90 3 4 check with 637f TerminalX11 1 4 check with 638 24h STO1 und STO Signale Difference gt 20 Seconds off off Switch On Control Voltage 638 only 100 off Module only L Tany 07 02 12 02 EN V0608 doc Type 638 10 Diagnosis and Trouble Shooting Display Explanation Output mmen Beady Wanin 635 637 637 6371 638 pup 5 um 26h 10 22 Quickstop Ramp active on off v 638 only X10 22 low high slope missing on off 638 2Ah Max speed overload off off check speed limits resp setpoint speed 4 CAN Open 402 Sync Message error in off Interpolated positioning mode 6 19 8 194 off 8 21 9Ch SSI Encoder Error off v1 8 33 8 36 9Ch CAN1 BUS Error Flashing display off V 8 31 off 8 34 Noise bus or lane missing off 638 only 638 SAFETY Parameter Ram Error off off 638 only 638 X300 xM Module Memory Error off off E 1Ah CAN2 Bus Error Flashing Display Control loop synchronization between drives Profibus Module Error gt gt gt gt gt IS ECh Warning setpoint current maximum limit reached and no actual current measurement check motor connection 2 2 638 Active Delay time runs Firmware Alteracode and Parameters missing 44h 638 X300 xM Module Memory Error off off 638 only
51. C 8 s Accept the Signal in an Application gt 1 ms Damping of the Transfer from fast input default input Low to High zous xo 4 X10 of the Transfer from TR default input High to Low 24 gt 0V 250us X10 4 X10 25 e Thermo Control X30 No galvanic Separation to the Control Circuit Measurement Voltage at 100 1640 9999 Ohm 0 15V 1 7V 3 8V Measurement Range 100 99990hm short circuit proof Thermoswitch evaluable 07 02 12 02 EN V0608 doc Type 638 107 12 Technical Data 108 Thermo Control X62 Galvanic Separation to the Control Circuit Basic Isolated in acc with EN 61800 5 1 Galvanic Separation to the Power Circuit Double Isolation in acc with EN 61800 5 1 Measurement Voltage at 100 1640 6000 Ohm 0 15V 1 7V 3 2V Measurement Range 100 60000hm short circuit proof Thermoswitch evaluable Brake Control X62 Galvanic Separation to the Control Circuit Double Isolation in acc Nominal Voltage Supply 24V DC Max Brake Current Contact Protection for inductive Load Internal Varistor BR lt gt BR Signal Inputs and Outputs Connection X120B resp 120C Additional Galvanic Separation from Power and Control Circuit Nominal Voltage of the In and Outputs 24 V DC 20 10 4 Number of Outputs Signal Outputs via OPTO Coupler resistive load Imax 2A a7 Switching Frequency short circuit current limited by 5A over heating protection
52. Controller System System Start Up Time after Switching On max 6 seconds the Control Voltage Data Memory Organization Flash Eprom 256 KB RAM 64 KB EEPROM 96 kByte Mechanical Data Dimensions Dimensions see g Dimensions 638A 638B03 638B08 638 05 10 15 110 07 02 12 02 EN V0608 doc Type 638 12 Technical Data 12 2 Technical Unit Data 638 Servo Drive 638A01 638A02 638A04 638A06 Input Supply Voltage 50 60 Hz min grounded at the centre Un point TN networks max Phases Supply System Fuse Contactors Filter Inrush Current Limitation type Control Voltage US 21D a 24 29 Control Current Incl Fan Is DC Permanent nominal 0 4 maximum 0 8 Inrush peak nominal 3 maximum 6 0 8 2 5 25 220 Output Sine Voltage with Un jur __ 220 i Derating of Unr Rated Current Efficiency Inr Max Current Efficiency Imaxr Time for Imax n meu e terminal terminal Operating Point DO Ub Max Power Internal Brake Resistor Pd Min Ext Brake Resistor General Power Loss Fan Electronics Fan Control 2 stage control Power Loss Rating Class per A 7 4 75 2 9 9 5 2 33 use only our approved types Reference e Output Power Recommended Transformer power supply 07 02 12 02 EN V0608 doc Type 638 111 12 Technical Data e
53. FO F1 F3 F5 FO F1 F3 X10 12 F5 Output F2 F5 FO 2 5 F2 F5 FO F1 F3 F5 FO F1 F3 X10 13 F5 Output F2 F5 FO F2 F5 F2 F5 FO F1 F3 F5 FO F1 F3 X10 20 F5 F0 F2 F5 FO F2 F5 FO F2 F5 FO Ft F3 F5 FO F1 F3 FO 1 F2 F5 F4 F5 07 02 12 02 EN V0608 doc Type 638 45 3 Operating Mode 3 3 Configurable Pin Functions Operating Mode Dependent Input Functions Operating Mode Dependent Function Function Function Function Function Function Function FO F1 F2 F3 F4 Input 3 1 move manually ata Input move manually X10 15 X limit switch Set selection data 22 Input latch input 1 extended 1 X10 4 latch set selection data 20 Input latch input 2 1 X10 25 x set selection Input start slope 0 3 1 X10 11 gt 1 for BIAS regulator set move trouble reset data 2 commands Input operating mode 3 1 10 24 selection reference set selection Node no data 2 omax 0 1or 2 Sensor 3 lor 4 Input start slope 0 gt 1 strobe X10 2 ith position set slope 0 gt 1 selection in for BIAS set position control 4 selection Output position reference tracking synchron X10 12 reached output window format drive trouble exceded trigger Output temperature reference tracking start offset no X10 13 monitoring output window trigger regulator exceded trouble Output warning reference track
54. LC 90 07 02 12 02 EN V0608 doc Type 638 Safe Torque Off STO Application Example 1 Function Action Response Protection Level Stop Cat EN 954 1 150 13849 1 According to EN60204 Safety door monitoring or The STO is tripped when the safety Cat 4 PLe 0 emergency shut down with door is opened or emergency shut protection monitoring switch down switch is activated Example Safety Gate closed Safety Switch closed Servo Drive activate safety Gate resp Emergency Stop Protected Area Control Cabinet IP54 A1 Safety Relay Cat 4 e g Pilz PNOZ X2 638 Servo Drive ACK acknowledgement Important The category 4 and PL e protection level can only be achieved with an active STO Power On Test Note The acknowledgement is only necessary when after the cancellation of the STO function by the automatic start up a potential danger for the people in the area or the equipment exists 07 02 12 02 EN V0608 doc 638 91 9 Safe Torque Off STO Application Example 2 Function Action Response Reaction Protection Level Stop Cat EN 954 1 150 13849 1 According to EN60204 Safety door monitoring or Active braking occurs when the safety Cat 4 PLe 1 emergency shut down with door is opened the emergency shut protection monitoring switch and down switch is activated or tripping of time delay the STO occurs due to time delay Example Safety Gate closed Safety Switch closed Servo Drive activate
55. LINK protection Block Diaqram 2 Supply Connection for Servo Group 1 or 3 phase 230V AC F1 bis F3 back up fuse F1DC bis F2DC DC Bus fuse R external ballast resistor if required Advantage gt Sum of power not limited by line fuse Disadvantage gt DC fuses necessary 07 02 12 02 EN V0608 doc Type 638 55 5 56 Electrical Installation Function Softstart When switch on the supply voltage the DC link capacities become over a resistance loaded Attain the undervoltage threshold constant waiting period 2 4s that becomes charging resistor by a relay bridges The operating status undervoltage changes at the same time in ready When switching the supply voltage off the soft starting function becomes only after falling below undervoltage threshold again actively It is therefore particularly with intermediate circuit coupled Drives importantly before restarting the supply voltage to wait to those under voltage threshold is reached Up to standard undervoltage threshold of 160V the unchargeing time for the 6A Drives 5 approx 30 seconds Uncharging time to undervoltage threshold 160V see table 1638A401 06 638B03 05 638B08 15 638C being prepared Installation Instructions and Warnings gt DC Link connections of the Series 638 are not short circuit and earth fault proof and not protected against polarity reversal A short circuit on the DC Bus wires can be damage
56. NKA met oF the EHF 60 wired AE UN 28 ittis Activate bee veter ecu 2i Uetinition Fipsulance 2 weh on M leer 720 M o etd im E bi nee Speed IN Derinition p linen 52 Sanap 1 Acceleration Tue z Tated power x w mu 1 fe Definition rotten 2 Deceleration Mamim carn 1000 w bom d Derimition p Selita aa Ae He dal aid 3 PFosition 16 T Mie temperate BLAS Eeva cuend deve Dison N Start axis _ Liya CUM 2 CAN bus 1 Give start permission set start mark 3 CAN Bur MISE 5 Hove position n eon Start oF the ist absolute positioning add uae Arashin munde 6 Wait F r position reached Interrupt HIAS processing up to reaching the target pusitian i 7 Wait time 1000 5 Passi v waiting tine oF THUNM ms hi i gt i is Ha EE E i Ei ih Sa SE S 4 b 5 Auth 6350016 OMT EASYRIDER Instructions extract Auto pilo
57. RD2 638 6th Generation Digital Servo Drive A Size 04 4 Amps Rated Current 3 325 VDC 230 VAC F With Integrated Filter 0 Without EMC Clip STO Safe Torque Off 232 RS 232 Interface onslotA EAE I O Interface 14 10 on slot C RD2 Standard X30 Resolver on slot D Motor Feedback system 07 02 12 02 EN V0608 doc Type 638 Module Slots Layout Ts as Pi Diri ET PERTY General Information Module Slots 232 422 485 Motor Feedback System 527 Standard Resolver Option 5197 Option Sine Cosine with Memorychip as of FW V8 3 Resolver Memory HIPERFACE Memory Sine Cosine Memory Design B Design LE M ER AL H d CE D COCO heooc DoODoO I D D ii D hy LISTE LE LN Lh L mj PEJ iD D D hi ry a i 07 02 12 02 EN V0608 doc Type 638 5 15 1 General Information 1 3 Dimensions 638A Series 211 2x 5 mounting screw For sufficient air circulation you must a expansion space from 100mm u On the and outlet cooling Important gt Please note that on the front side of the unit approximately 70 mm of additional space is required for the signal mating
58. T Ps SUN Fe s gt ERES EXE Ls 638xxxxFxSTOMMMEAExxx 638xxxxFxSTO Bl 2CAxxx 638 5 2 8 638xxxxFxSTOLEE000xxx 638xxxxFxSTOPSEAExxx 638xxxxFxS TOES ES ma rss 638 5 2 638 5 000 638 5 638xxxxFxSTO 000xxx 638xxxxFxSTOMAIEAExxx 638 5 000 4 1 4 4 4 638xxxxFxSTOOOOEAExxx 000 No Option Possible Combination Only can be employed when utilizing the option module located at slot C internal BUS Example 638A043F0STO232EAE
59. TO1 und STO2 84 Configuration and Parameter Settings ccccccccccccssssseeeeceeeeeesseceeeeceeeeeesseceeeseessaeeeseeeeeeeeesaaensess 85 Application Example of STO Safe Torque nnns 90 Application Example 1 91 Application Example 2 nnne nnne nne nnn nine nnns 92 Application Example 3 o vk JUI wi bk kU Y si vid cv 93 Application Example 4 a nnn sena nnn nans 94 SEGA OMNE tmn 95 Signal Inputs Technical Data Terminal Connection 11 97 Diagnosis and Trouble Shooting s 98 7 esee eene nennen nnn nnn nnn nn nnn ener nennen enne nenne nnn nnn nnn nnn 98 neser ore TOUDI Os sss tentang 103 Trouble SHOO ENTER 104 Standards and Certifications T 105 Compliance with Regulations Limitations and Basic Conditions 105 07 02 12 02 EN V0608 doc Type 638 h
60. ack EMF of Motor V aus 1000 RPM Hph Resistance of Motor between terminals RL Line Resistance of Motor cable Motor Current 112 07 02 12 02 EN V0608 doc Type 638 12 Technical Data 638B Servo Drive 638B03 638B05 638B08 638B10 638B15 Input Supply Voltage 50 60 Hz jmn grounded at centre point Un 400 480 TN networks BLAN 25 10 Supply System m Power Mains Connection Inrush Current Limitation Softstart capacitor pre charging over 3409 Control Current nominal maximal lsDC A 06 10 07 11 811 Control Current Inrush peak lsDC A ms 3 maximal 6 0 8 2 5 25 Output Sine Voltage with Un Un Vef 388 465 Minderung von Unr o According to the load 1 Rated Current 400V AC 4 75kHz Ir TAL 25 5 75 10 15 Rated Current 400V AC 9 5kHz TAL 25 5 75 10 10 Rated Current 480V AC 4 75kHz TAL 25 5 75 10 145 Rated Current 480V AC 9 5kHz nr TAL 25 45 68 9 9 Max Current efficiency Imaxr A 5 10 15 20 30 BENE 4 400 480V AC yr All alll occae 9 5kHz 400 480V AC Brake Brake Circuit Operating Point DC M 675 760 Max Power 400 480V AC Pbmax kW 6 5 7 4 9
61. ains voltage may only be switched on when the Softstart function is active Device in Undervoltage operating state 58 07 02 12 02 EN V0608 doc Type 638 5 5 5 Electrical Installation Brake Resistor Selection of the Brake Resistor When employing a breaking mechanism with an operating motor driven system the contained energy flows back into the drive The capacitors within the motor can absorb a small portion of the excess energy The rest of the energy must be dissipated through a resistor in heat The activation of the Brake Resistor occurs depending upon the voltage threshold The resistance load is electronically simulated and monitored by our software EASYRIDER Windows Software Peak power Pmax and continuous power output Pd must be configured so that the specific requirements of the application are fulfilled The general rule for resistance measurements is as follows Pmax Pd lt 59 Movement Definition of Data Values for Example Speed at Brake Start n1 3000 RPM Braking Time 161 0 1 sec Cycle Time 2 0 sec Total Inertia J 0 0005 kgn Braking Current lb 3 2A Motor Resistance Roh 3 6 Ohm Cable Resistance RL 0 3 Ohm Step 1 Example Evaluation of the Brake Capacity Approximation without capacitor load friction and drive power loss Power of Motion Pkin 0 0055 0 0005 30002 0 1 Pkin 00055 J n12 tb1 W Pkin 247 W Motor Power Loss Pvmot 3 2 3 6
62. ake 8 1 i 1 i j i Active Power Stage I 1 I I Inactive a a 1 1 A Eum d 7 Segmenl rd H mae L Bi A 1 4 4 i FI d qa Display MI 6 4 i PM Contig i Config I Config Flow Chart Diagram Function X10 22 Acknowledgement 24V M STO1 STO2 ov 1 I I 24 x10 22 1 i 1 Acknowledging OV a t 1 1 i a 1 a Active i i P Delay Time 1 EO i i a a 1 t 1 1 i a 1 a Active Power Stage 1 1 I I 1 i Inactive a 1 i i 1 1 i i E zz J 1 F L1 1 f A c PN E ONG um Ed L E il Config 88 07 02 12 02 EN V0608 doc Type 638 9 Safe Torque Off STO Flow Chart Diagram Function X10 22 Emergency Stop 24V STO1 STOZ OV 24V X10 22 I Quick Stop QV L i i a 4 i i a Setpolnt i Speed a Active I Delay Time E va i i 1 I t Delay Time I 1 for brake a 1 F 1 I Activa I I Power Stage I Inactive 7 Segment A m Lf Display t Config Config Config Ue a 07 02 12 02 EN V0608 doc 638 89 9 Safe Torque Off STO 9 4 Application Example of STO Safe Torque Off Example Function Applic
63. and Drive Reset with constant repetition of the fieldbus command 0x16 will be works off only once For further processing it is necessary meanwhile to send another control word e g 0 status order 4 Viva 0 1 flank on input X10 11 Precondition The input X10 11 is with function 1 Reset drive fault configured EASYRIDER Windows Software There is no host login input Active X10 22 is inactive OV signal must be present min 250 ms 5 Viva 0 1 flank on input X120 1 Precondition The input X120 1 is with function 1 Reset drive fault configured EASYRIDER Windows Software There is no host login input Active X10 22 is inactive OV 1 signal must be present min 250 ms Notice t J After remove of the tracking error deactivation See the warning message E tracking error is active up to the next move command The error signal releasing before ready can be reset by deactivation the drive 07 02 12 02 EN V0608 doc Type 638 103 10 Diagnosis and Trouble Shooting 10 3 Trouble Shooting The following list refers to faults which can occur during operation Display Explanation and remedy no motor run despite current flow motor mechanically blocked 1 motor brake released motor runs unevently check setpoint wiring check grounding and shielding too high P amplification in the speed controller reduce value with EASYRIDER sett
64. ation Example 1 Safety door monitoring or emergency shut down with protection monitoring switch Application Example 2 Safety door monitoring or emergency shut down with protection monitoring switch and time delay Application Example 3 Safety door monitoring or emergency shut down WITHOUT protection monitoring switch Application Example 4 Safety door monitoring or emergency shut down with protection monitoring switch and time delay of several drives Minimal request of safety function from Cat 3 and PL d The safety function STO must activate for at least weekly This request is very important for application continuous operation and is satisfy by open the guard door and activate the emergency stop If the Safe torque off is activate very often additional measures are not necessary Only if the Guard door and or the emergency stop is connected directly or via safety unit at the 638 X11 Additional Minimal request of safety function by Cat 4 and PLe The category 4 and PL e can only be attained if the STO power on test is enabled The STO power on test needs low level at both STO inputs by switch on the 24V control voltage The drive can not activate if one or both STO inputs have high level The function must configure in the Safety Dialog parameter 2 default Active These minimal requests are necessary to detect a failure Failure detection is only possible if the safety function is activated Both measures could execute by a P
65. ation power suppl Impotant The insulation class for control electronics X40 is dequivalent to the insulation for power supply Required for protective separation PELV double insulation PE 18 07 02 12 02 EN V0608 doc Type 638 2 Connection Assignments and Functions 2 2 Overview of Compact Unit Connections e 638A01 to 638A06 24V DC X01 230V AC UCC X60 7 Segment Display Diagnosis DIAG Fieldbus 2 Option Possibilities used wihte Module 2C8 OPTION SLOT A B Multi Funktion INCR X40 Option Possibilities OPTION SLOT C Control Signal Plug CONTROL I O X10 s Safe Torque Off STO X11 Service Schnittstelle COM1 RS232 Motor Feedback M FEEDBACK X30 Brake Thermo BR TH X62 Motor MOTOR X61 AX300 Module 07 02 12 02 EN V0608 doc Type 638 19 2 Connection Assignments and Functions 638B03 to 638 15 24V DC X01 230 460 UCC X60 7 Segmen Display diagnosis DIAG Fieldbus COM2 Option possibilities OPTION SLOT A B Multi Function INCR X40 Control Signal Plug CONTROL I O X10 Safe Torque Off STO X11 Option possibilities OPTION SLOT C X300 Module Service Interface COM1 RS232 Braek Thermo BR TH X62 Motor MOTOR X61 Motor Feedback M Fedback X30 20 07 02 12 02 EN V0608 doc Type 638 2 Connection Assig
66. cks TE Fieldbus Optionally select temperature sensor Select the temperature sensor connection X30 or X62 in EASYRIDER Motor X30 Drive EI 4 gt Temp supervision 30 gt Sensor type Switch at Default X30 In the EASYRIDER configuration menu for Motor send the selected motor information on to the drive and save the selection 70 07 02 12 02 EN V0608 doc Type 638 Remark Cause of Fault Condition 638 X61 Connector Assignment When employing motors from other manufacturers itis possible to input and store the specific motor characteristics in the Customer Motor Library 638 X30 Connector Assignment or 638 X62 Connector Assignment 8 Commissoning Step 2 3 Motor with Resolver Feedback Remark Action Function Anticipated Result Cause of Fault Condition With standard motors equipped with Resolver Feedback when the unit is properly wired and the proper motor is selected no additional action is required For every360 motor shaft turn a position value of 2 65536 pulses is sensed Step 2 4 Motor with HIPERFACE Feedback Remark Action Function Anticipated Result Cause of Fault Condition The characteristics of the HIPERFACE Feedback System as the absolute measuring device multi turn provider allows for 2 additional parameter settings 1 Selection of the position location per rotation 16 or 20 bit 2 Selection
67. dard Safety Performance STO Safe Torque Off Standard Additional option module RP XXX on the drive for communication via COM2 No Option RS 232 interface RS 422 interface RS 485 interface CAN Bus 2 X CAN without I O s 2 x CAN 4 outputs and 4 inputs 2 x CAN RS 485 2 x 4 outputs and 4 inputs RS 485 CAN Bus DeviceNet SUCOnet K Profibus DP Interbus S Profibus DP CAN2 4 outputs and 4 inputs RS 485 Profibus DP cp RS 485 being prepared Additional Module on the mm via X200 No Option I O Interface 14 inputs 10 outputs X300 Functions Module Standard X30 Resolver Module 2nd Version Standard slot D HIPERFACE Module 2nd Version slot D Sine Cosine Module 2nd Version slot D with Memorychip as of firmware V 8 35 Resolver Memory Module 2nd Version z slot D HIPERFACE Memory Module 2nd Version slot D Sine Cosine Memory Module 2nd Version slot D Enter only when used Broad band contact X10 7 X10 8 Moisture Condensation Protection Only CAN2 can be employed when utilizing the option module located at slot C internal BUS B 07 02 12 02 EN V0608 doc Type 638 13 1 General Information Combination Possibilities for the Various Communication I O Modules Option Module gt Model Code 638oxxFXST OPEP 638 5 638xxxxFxSTOpZZ 638 0
68. e STO Power on Test does not allow by deactivated STO activate 0 default STO1 and STO2 High to activate the drive The 7 Segment Display shows The drive will able to activate deactivate 1 after the safety function STO was activated and is deactivate The safety function could activated by a safety gate or an emergency stop It is possible to use a PLC to automate this test STO Power On Test 07 02 12 02 EN V0608 doc Type 638 97 9 Safe Torque Off STO e Safety Password The safety password must be entered in the appropriate field every time that the Safety Parameter Configuration screen is selected The password is always comprised of 4 letters The difference between large and small case letters is recognized The drive side initial factory setting of the password is SAFE The responsibility to set the new safety password lies with the operator of the equipment The new safety password should only be shared with authorized personnel for example anyone who works on the STO and or has responsibilities in the areas of equipment operating guidelines or equipment safety and security Flow Chart Diagram Function X10 22 Acknowledgement Emergency Stop 24V STO12 STO28 OV 4 gt t A 10 22 24 Acknowledging I Quick Stop ov 1 setpoint ss i P B Active t a i a 1 i Delay Time va 1 1 I t Delay Time for br
69. e active braking phase the axel can coast to a stop uncontrolled or in the worst case continue to operate until the expiration of the predetermined shut off time Hanging Loads or Influencing External Forces In the event of a power failure the hanging loads can possibly fall in an uncontrolled manner endangering people or equipment The operation of hanging axes therefore requires special attention relating to risk analysis and mitigation with hanging loads Not for Use in Drive Applications in Field Weakening Operation Ranges With motors which are employed in field weakening operation ranges it is important to note that the operation of the STO function can be adversely affected specifically involving an uncontrolled increase in rotational speed life threatening over voltage and explosion of the drive unit Minimal request of safety function The safety function STO must activate for at least weekly Acknowledgement The configurable acknowledgement is only permissible with category B 82 07 02 12 02 EN V0608 doc Type 638 Safe Torque Off STO 9 2 Safe Torque Off Function STO General The electricity flow to the motor windings is controlled through a solid state power component bridge 6 times IGBT A microprocessor switch with PWM logic switches the IGTB s rotating field orientation Optical couplings are employed between the control logic and the power unit to provide for electrical isolation The X11 Co
70. ectrical brake motor will be fed into the DC link and then through the DC link coupling to serve other motors within the sequence Only a portion of the energy which is produced in this manner leads to an increase in the DC link voltage and will then at a specified voltage threshold be converted to heat and released through the units internal or external ballast Therefore an energy exchange occurs between the units creating a positive energy balancing and overall work load balance of the ballast switches A significant reduction factor in the load can be anticipated depending upon the specifics of the installation Layout Step by Step without reduction factors Remarks gt Addition of all internal unit ballast continuous ratings The load on the internal ballast will Addition of all internal unit ballast peak performance be evenly divided between all of the ratings units connected in parallel Forinformation concerning the required data and design layout of the ballast resistance See Chapter e Layout of the Ballast Resistance Arrange the external ballast resistance with regard for the braking power occurrence if possible 07 02 12 02 EN V0608 doc Type 638 57 5 Electrical Installation 5 4 Fuses Contactors 638A Servo Driver 638A01 638 02 638A04 638A06 M NENNEN NNNM 6 16A gG B6A 16A 2 6A 15A 3 Fusible cut out 4
71. ed Result Limitation of potential danger EASYRIDER for Windows The selected COM Port is shown on the lower right hand corner of the window of the EASYRIDER for Windows Software 6 55 v 8 32 CONI 7 Segment Display EASYRIDER Diagnosis Window J e 07 02 12 02 EN V0608 doc 638 Remark Cause of Fault Condition 638 Connector Assignment Electrical Installation Wiring Instructions Model Code EASYRIDER Software Cable Interface USB RS232 Adapter The available connections to the PC are shown in the Device Manager under System Control Ana m coa Q4 Brechin 6004 und LPT SER dered COR es P Orden LETT E Vocum pun Lor doce ura orani amem s a Bieter E u Commen ce Pin Assignments for the Power Supply Connection X01 7 Segment Display Symbol It is always the last window where settings j have been made which will be opened 8 Commissoning 8 3 Step 2 Feedback Test and Motor Selection Remark Action Function Anticipated Result Cause of Fault Condition Prerequisite T 638 X30 Step 4 ER Connector Assignment The feedback sensor is EJ connected to the 638 Drive through the X30 connection port Optionally Temperature sensor and or Brakre are connected to the X62 connector 638 X62 with X62 The
72. eedback Module X300 The mode of operation of the feedback system is specified by this plug in module see e Layout Module Slots The 638 Drive system therefore offers a built in flexibility and provides for the possibility of future modification 638B 638A i mM M aM cOM LOT E Mon SLOT D i 1 mm D K wm e Le _ k M e IJHKXHMODUCE SLOT D OF TION SLOT C _____________ x40 Code System Function Code external amp intern Servo Drive Exlernal Intern Model Type X300 Descripion gt gt o Resolver Memory Plug and Play The 638 Servo Drive is able to identify the type of X300 Module employed The EASYRIDER Windows Software loads the correct function code You follow the instructions in the EASYRIDER Windows Software For feedback module RD2 the function code is already pre set factory default Note When employing the Feedback Module X300 HF2 HIPERFACE please pay attention to documentation 07 02 09 02 E Vxx 07 02 12 02 EN V0608 doc Type 638 23 2 Connection Assignments and Functions Feedback Connection X30 SUB D 09 Socket Pinning for the Motor Feedback Socket X30 when employed with Resolver Module X300 RD2 or X300 RM1 Standard Module Module X300 RD2
73. eparated in accordance to regulation EN 1578 07 02 12 02 EN V0608 doc 638 27 2 2 7 28 Connection Assignments and Functions Signal Connection Control Signal Plug X10 SUB D25 Socket Inputs Outputs Control Signal Plug X10 Function Type Description 1 Shielding Connection Seen en 12VDC max 80 mA Auxiliary Supply Voltage 0 10V Ri 10 kOhm 6 Configurable n OufptAnadog Through JP100 soldered jumper C 7 assignable as a free and loopable potential for the READY Contacts ON Drive trouble free OFF Drive problem or Constant Ready power supply interruption E a rae Digital Inputs 10 Ground for Analog Signal Ground Er eo 12V DC max 80 mA Auxiliary Supply Voltage 17 Configurable Output Analog Rotational Speed Setpoint BN Input Analog 18 Scaleable differential with 0 10 Ri 10 kOhm respect to X10 5 u Specifications for the Power Limits Input Analog 19 can be activated and are scaleable 0 10 0 10 for 0 Imax Ri 10 kOhm 21 Nominal 24VDC Supply for Outputs ee j d Data for the digital in and outputs See Chapter m General Technical Data 07 02 12 02 EN V0608 doc Type 638 2 Connection Assignments and Functions 2 8 Multi Function X40 Description of the X40 Via a programmable processor the X40 connection can be configured different
74. esistance overloaded 6Ch X 300 Module not inserted off off or wrong inserted or defect X 300 testing 07 02 12 02 EN V0608 doc Type 638 99 10 Diagnosis and Trouble Shooting Display Explanation Servo drive ee X 300 setting wrong off off l j X 30 X40 Counter Configuration test in the EASYRIDER Windows Software 1Ch tracking window exceeded 3 on only in operation mode position control will be deleted with the next run command off 8 only in operation mode position control X10 8 10 14 X10 1 X10 14 off 20h limit switch 3 limit switch X10 xx on 0 Volt from Firmware 6 16 ogh limit switch 3 limit switch X10 xx 0 Volt from Firmware 6 16 3 gt 5 5 5 gt o gt e gt lt gt e off limit switch limit switch both limit switch X10 xx on 0 Volt X10 14 10 15 from Firmware 6 16 76h memory checksum error try new start store the value again 76h Different Drive type on X300 xM Module aus aus V 638 with X300 xM 62h DC Bus Unterspannung lt 100 V 4Eh 1 internal software error Watchdog off off H HM 2 blinking BIAS software error 1 Firmware version check 2 Bias program error fix EEh starting lockout RP SBT with 6371 O off starting lockout STO1 and STO2 with 638 Terminal X2
75. g fault display Assume Motor temp curve Time T Switch off 07 02 12 02 EN V0608 doc Type 638 A7 3 Operating Mode PTC Motor protection Output Temp FO X10 13 Output Ready X10 8 am l 7 Segment Display Warming fault time display Assume Motor temp curve T Switch off 48 07 02 12 02 EN V0608 doc Type 638 Mechanical Installation 4 1 4 2 4 3 Mounting In order to guarantee the best possible air circulation for the cooling unit the servo drive should only be installed in a vertical position The vertical installation above other systems or heat producing units can cause overheating Control Cabinet Mounting Installation should be carried out only in a control cabinet in which the inside is free from dust corrosive fumes gases and liquids Make absolutely sure that the condensing of evaporating liquids including atmospheric moisture is avoided Should the digital servo drive be installed in a place where condensation is likely a suitable anti condensation heater must be installed The heater must be SWITCHED OFF during normal operation Automatic switch off is recommended The servo drives should not be installed in areas which have been classified as dangerous unless they have been installed in an approved enclosure and in accordance with applicable regulations In such an application double check all aspects of the installation Please pay attention d
76. ieldbus Interface COM2 in Combination with COM3 OPTION SLOT 36 Pinning tor Interous SARE IBS 36 2 11 Fieldbus Interface RP 2CA 2C8 37 Pinning CAN1 BUS and 2 5 UU LLL 37 Pinning RP 208 X120 with VOS a 37 DIP Switch Position for Option Module RP 2CA and 2C8 38 2 12 Fieldbus Interface CCA CC8 39 Pinning CAN1 BUS CAN2 BUS and 5485 39 Pinning APC CS P a 39 DIP Switch Position for Option Module RP CCA and CO8 40 4 07 02 12 02 EN V0608 doc Type 638 Table of Contents C1 o C1 D 00 O Page Connection Assignments and Functions Fieldbus Interface RP PCA PB rea rr kde coke
77. iloring the installation to meet the specific application requirements provided that he she assumes all of the responsibility for any alterations or deviations from the prescribed installation instructions 07 02 12 02 EN V0608 doc Type 638 67 Commissoning step D Wiring and Communications Test Action Function Before Starting the Equipment Check the wiring in particular supply voltage incoming powerline motor wiring motor polarity feedback system Resolver HIPERFACE etc polarity Sine Cosine etc First uncouple the motor shaft before addressing critical mechanical problems Connection of the Diagnostic Interface Link for the Drive COM1 RS232 Connection to the PC and start EASYRIDER Windows Software Settings for the Connected COM Ports With the PC in Options Menu select Interface Selection Widow T mmudnte Comeuricatian La Spor chr al eee NUT ele aoe Lene Peay Pared Fran Damia cdd Supply Voltage US 24V DC through X01 Connection to the system Check the communications connections and functions by utilizing the Diagnosis window or by employing the F9 button on the keyboard Diagnosis Options Window me Diagnosis Fa i H Graphical Diagnosis p Fieldbusdiagnasis Graphical Memory Dump Ctrl F9 Force BIAS variables Anticipat
78. ing no X10 20 output window drive trouble exceded active ok reference tracking no motor brake output window drive trouble exceded BIAS function is freely programmable in operating mode 5 No function in operating modes 0 to 4 Fast input for optimal timing 1 With every row from the top to the bottom in which the function F2 is assigned to an input the binary value 2 increases by 1 See example Operating mode 4 Only numbers 0 9 are allowed to be set 2 Only possible with module RP CAN 3 Ifthe Option RP 2C8 PC8 See Fieldbus interface COM2 COMS is inserted the contact functions as described for the X10 plug are not valid The inputs are freely programmable utilizing the BIAS program AG 07 02 12 02 EN V0608 doc Type 638 3 Operating Mode Functions Diagrams with Protection Mode Switch Off 3 4 In accordance with EASYRIDER Windows Software Commissioning Motor Motor 30 Drive protection 121 Drive gt l t Norm Drive Output Warning FO X10 20 Output Ready X10 8 7 Segment Display Motor protection Output Warning FO X10 20 Output Ready X10 8 7 Segment Display fault display NT Output stage protection Output Warning FO X10 20 Output Ready X10 8 7 Segment Display 3 Warning fault 16 display 1 NTC Motor protection lt R_NTC1 lt R_NTC2 Output Temp FO X10 13 Output Ready X10 8 7 Segment Display Warnin
79. ing speed control too small l time in the speed controller reduce value with EASYRIDER setting speed control no reaction of setpoint progression despite Limit switch functions torque in standstill effective BIAS no current flow motor cables interrupted no torque despite activating the regulator Is input I extern X10 19 activated correctly config menu and not notched up limit switch input activated and not notched up Interference symptoms with power Ground loops in setpoint or actual value wiring frequency Shieldings laid on both sides Signal cables near high voltage cables Motor takes up preferred positions after Position encoder or motor cables with reversed 1 activation poles Resolver or Feedback encoder incorrectly adjusted Number of motor poles wrong matching config menu Motor runs up immediately after activation Motor cables or feedback cables reversed 1 although there is no setpoint Encoder incorrectly adjusted e g Resolver Motor reaches in idling cycle very different Feedback Encoder incorrectly adjusted speed when running to the right or to the left e g Resolver 1 Display or I mostly short after activating before warning 104 07 02 12 02 EN V0608 doc Type 638 11 Standards and Certufications 11 4 Compliance with Regulations Limitations and Basic Conditions European Directives EG Low Voltage Guidlines In accordance with EN61800 5 1 2006 95 EC Safe
80. ion of both the equipment and personnel tis recommended that one utilize the EASYRIDER Windows Software Program for the initial set up of the equipment This program communicates through the serial interface of the computer to the attached drive Information concerning the operation of the EASYRIDER software is discussed in this chapter We suggest that the software be first run the Simulation mode in order for the user to become familiar with and comfortable the system The EASYRIDER Windows Software also provides for additional interactive Help functions gt Due to security concerns some of the Menus are password protected The set up and start up of the equipment must be carried out by qualified personnel only gt The installation must be performed taking into consideration all of the specific safety regulations and security related functions concerning the equipment Double check all safety and security related items including the limit switch gt The conformity of the motor feedback system and the X300 feedback module built in to the drive must be checked by examining the name plates on the equipment gt For the initial equipment start up involving critical applications we recommend that a test be run without the mechanical connection being made If problems do arise then they can be solved without risk of damage to any other attached equipment gt An experienced installer does have the possibility of ta
81. iring 07 02 12 02 EN V0608 doc Type 638 eu 7 T FU Waman 7 7 1 Hardware Configuration Jumpers All jumpers are set to a standard preset JP100 Bridged Pad Bridged Pad 2 and 3 standard PME contact with reference to common output supply voltage on X10 21 READY contact can be freely wired JP101 Bridged Pad Analog input X10 19 with internal pull up to 12 V JP1 JP2 Bridged Pad Adjust identically 2 and 3 standard X10 15 high active X10 15 low active JP3 JP4 Bridged Pad Adjust identically 2 and 3 standard X10 14 high active X10 14 low active JP2 8 JP2 3 JP2 7 JP2 2 Open Default RP CAN DEV 2CA 2C8 CC8 CCA PDP PC8 PCA RP 232 422 485 IBS EA5 SUC JP600 d Close Minimal current leakage with external filter operation 07 02 12 02 EN V0608 doc 638 65 7 Hardware Configuration 66 Power Board Layout Plan 638A JP23 JP2 8 JP22 JPA JP2 JP JP4 View solder side solder jumper JP2 3 JP2 8 JP2 2 JP2 JP1 JP4 07 02 12 02 EN V0608 doc Type 638 8 Commissoning 8 1 Commissioning Preparation Caution Improper installation conditions and or wiring can cause uncontrolled movement and operation of the equipment Please carefully observe all safety instructions and regulations for the protect
82. l plug in receptacles it is possible to increase the potential connections to the field bus system and or the input output terminals e Various motor feedback loop systems can be supported by employing the flexible feedback module X300 e Through the employment of additional 638 drives it is optionally possible to couple the DC link e Minimal Housing Dimension is provided through the intelligent compact design of the unit e Overview of Standard Digital Communication Power Canmnactian Conta Voltage RSAZZ Cana Profits DP amp ta Ap ication poh ArT at j Encodar 1 Cuiput h Opnon 510 mol used Digital Output for PLC Safely paerfnrmanos EASYRIDER Garvice imbertaca Windews Satwnara 9 ie Disgnesis 1 LX Programming 07 02 12 02 EN V0608 doc 638 1 12 General Information Determining Criteria for the Utilization of the 638 Drive Decisions relating to the appropriate selection of the motor type feedback system and drive type as well as the system layout and option modules required are dependant upon the specific application and the anticipated operating mode of the system There are 6 operating modes to choose from ua r gt 5 BA General E l rputs
83. le circuitry certified application Two safety oriented performance protections in Switching Effort examples The grouping of multiple series connections required drives together on a main contactor is possible Application in Extremely high switching frequency This performance feature is not achievable through Production Processes through the use of almost wear free the employment of conventional technology technology Low voltage relays and an electronic switch The condition High Switching Safe Torque Off is achieved through Frequency the use of a wear free electronic High Reliability switches IGBT S Less Wear Application in The drive remains power and control With the utilization of power contactors on the Production Processes elated in a connected condition No incoming power line a long wait time is required for significant wait time with re start the energy discharge from the DC link Faster Reaction Time With the use of two motor side power contactors it Faster Re Start is possible to increase the reaction time however one must recognize the potential disadvantages a Make certain that switching occurs only in a power free condition DC Power Prevent arcing b Increased cost for EMC conforming cabling Emergency Stop According to the German Edition of Shutdown employing a mechanical switching Function the Standards Permissible without element is required mechanical power switch element activation 1
84. letely as stated in the validation report 07 02 12 02 EN V0608 doc Type 638 25 2 Connection Assignments and Functions 2 5 Service Interface COM1 RS232 Functions gt Supports all diagnostic and parameter configuration activities gt connection utilizing our communications cable KnPC D gt Communication utilizing our operational program software EASYRIDER Windows Software Com 1 RS232 Function Drive Side RS232 on PC PIN z E B 4 Pin Modular Plug Length KnPC637 631 03 0 PC Side Sub D 09 Plug KnPC637 631 05 0 Drive Side 4 Pin RJ 10 Plug Note The service interface port is not galvanically separated and should therefore not be used as the operations interface port fixed wiring The network connection with the PC must be located near the Drive in order to receive the reference potentials of the units together 26 07 02 12 02 EN V0608 doc 638 2 2 6 Connection Assignments and Functions Safe Torque Off Connection Safe Torque Off X11 Plug X11 STO1 Channel 1 ACTIVE STO1 Channel 1 ACTIVE_STO1 Parallel to PIN 1 Ready potential free contact assembly Ready potential free contact assembly Further description of this function can be found in Chapter Safe Torque STO Connection WITHOUT the utilization of the Safe Torque Off STO function Input AC 24V The control supply voltage must be definitively s
85. ly EASYRIDER Windows Software Standard functions Incremental output Incremental input Stepper motor pulse inputs SSI interface The unobstructed configurability provides ideal conditions for synchronous applications General Data XO Maximum Cable Length connected to 25 m galvanically insulated terminals Encoder For extended distances please contact our engineer controls 2m Maximum Cable Length connected to ground Pay attention to provide for good common grounding related terminals other drives controls Maximum Number of Signal Inputs to one as 8 incremental output configured device Output Signals Driver Model MAX483 or compatible RS422 Differential Logic Level Nominal Range Input Signals Differential Input Level Nominal Signal Difference Current Consumption Notice Master Slave Operation 1 Master Maximum 8 Slaves Condition Devices must be located directly side by side 07 02 12 02 EN V0608 doc 638 29 2 Connection Assignments and Functions e Incremental Output EASYRIDER Windows X40 Connection Mode Incremental Output Incremental encoder simulation for processing in positioning modules Standard 1024 increments with Pulse Duty Cycle Additional selectable pulse settings 16384 8192 4096 2048 512 256 128 64 Inc I O X40 1 Channel B B o Channel Inverted B 1 E 6 Petree Channel Z Inverted Zero Impulse 8
86. nments and Functions 2 3 Assignments Power Connections Power Ballast DC Bus Connection X60 638A Plug X60 m Designation Funston 0 Volt DC Bus External Ballast Resistor DC Bus 3 RB2 External Ballast Resistor Power Connection 1 230V AC Power Connection 2 230V AC 6 L3 N Power Connection 3 230V AC Ground Protective Ground 638B Plug X60 m Designation Fanci 0 Volt DC Bus External Ballast Resistor DC Bus External Ballast Resistor Power Connection 1 400V AC Power Connection 2 400V AC 13 Power Connection 3 400 AC Ground Protective Ground e 24V Control Supply Voltage X01 Plug X01 Pin Designation Functor 24V Supply Us Input 1 Supply Us Output with PIN 1 jumpered setup wiring Reference Potential OV setup and Wirin Reference Potential OV example Motor Connection X61 Plug X61 Pin Destanation M1 U Motor Supply M2 V Motor Supply M3 W Motor Supply Protective Ground 07 02 12 02 EN V0608 doc Type 638 21 2 Connection Assignments and Functions e Brake Thermo Connection X62 Stecker X62 ine ml w 2 Supply Voltage Mechanical Brake Input Refer Potential Supply Voltage Mechanical Brake a Control Mechanical Brake riu sms Control Mechanical Brake T Thermo NTC Setup and Wiring Thermo PTC NTC example 0 with parameter setting PTC can you
87. nnector Plug STO is located on the front of the drive unit This connector plug is controlled utilizing two optical couplings which communicate over two channels through terminals STO1 and STO2 and which in a controlled condition supplies the PWM optical coupler with control of the solid state power component A test takes place to determine the condition of the input channels Within the given window of time the condition of both channels must be identical In the event that a fault condition exists different signals from STO1 and STO2 then the coupling power supply is shut off and a signal is sent to the 7 segment display The re activation of the power supply to the coupling is then only possible by performing a hardware reset by turning the equipment off and then back on again In addition to the description of the hardware based shut off through the two channel communication the internal unit processor provides for a software based shutdown of the PWM circuit The PWM circuit can be set for time delayed activation after the recognition of the activation of both STO inputs through the programming of the safety parameters for the active time delay Block Circuit Diagram urge Controller suppressor Software Hardware Logic 1STO1 x inverted acting signal 07 02 12 02 EN V0608 doc Type 638 83 9 Safe Torque Off STO Status Diagram and Function of Terminals STO1 und STO2
88. ns The recommended dimensions are Thickness d z 5 to 6 mm Due to increased discharge currents gt DC 10mA resp gt AC 3 5mA the grounding connection of the drive has to be connected 2 times At power supply connector X60 7 and at the housing grounding screw Short Circuit Capacity and Discharge Currents Due to the working principles of servo drives there may discharge currents to the ground exceeding DC 10mA resp AC 3 5mA Suitable for use in a system capable of delivering not more than 5000 RMS symmetrical amperes 240V 638A 480V 638B C maximum Note according to UL508C 50 07 02 12 02 EN V0608 doc Type 638 5 2 Electrical Installation Power Mains Connection Types of power mains The 638 servo drives can be directly connected to TT and TN Systems TT and TN Systems are three phase systems with grounded neutral When using the servo drive in IT mains three phase systems without grounded neutral isolation transformers must be used The secondary neutral must be grounded and connected to the 638 protective ground conductor General is valid that with a phase earth voltage rated isolation voltage gt 300V AC the isolation requirements necessary clearance and creapage distance Test voltage etc Concerning the EC Low Voltage Guideline is not filled anymore and so that the CE conformity is not given Mains supply voltage range 638A The nominal supply voltage range is 1 3 230 AC 10
89. o eliminate the potential for systematic programming errors and or improper parameter settings The relevant safety secondary function parameters Acknowledgement and Active Time Delay can only be set within the Configuration Safety dialog box The data are saved under Parameter Data utilizing the suffix WDD But the safety relevant data will not transmit by Transmit Parameters Safety parameter MOTE The safety parameter will not be transmit safety reasons Editing this parameter is possible via the safety dialog only CONTINUE In the Configuration Safety dialog box the relevant safety parameters will shown by an open parameter file The user has to transmit the parameter safely to the drive 07 02 12 02 EN V0608 doc Type 638 85 9 Safe Torque Off STO 86 EASYRIDER Safety Parameter Data Entry Dialog Boxes 1 Commissioning menu select Safety EASYRIDER File Commissioning Tuning Command Ba General ie In Outputs mE EB Motor Drive 2 x40 Supervision Jf Safety Positionblocks T Fieldbus 3 Enter Safety Password select Parameter Nr and enter the appropriate Value 77 Safety Parameter na Value fe Function 210 22 Acknowledging Quick functian 1 Acknowledging Quick Stop Acknowledging 2 Quick Stop Send Correction Safety Password Change Password Protocol file 4 When the yellow display is
90. of the absolute position value according to the connection between the motor and the mechanical component Note It is necessary to initially provide the angular commutation parameter value as the absolute value for the HIPERFACE provider when employing a motor from another manufacturer with HIPERFACE Feedback onto Step 2 5 Motor with SIN COS Feedback Linear Motor Remark Action Function Anticipated Result Cause of Fault Condition Additional settings are required with the employment of this variation which are described in the following section Step 4 2 Optimization Linear Motors Onto Step gt 07 02 12 02 EN V0608 doc Type 638 71 8 Commissoning 8 4 Step 3 Power Up and Drive Activation Step 3 1 Power Up Action Function Prerequisite Step D The power supply is connected to the X60 connection of the 638 Drive Establish the X60 connection when lacking only when the drive system is not connected to the power supply Terminals 1 and 4 on the X11 STO connection should be set at 0 V Turn on the power and check the voltage in the Drive Diagnostic Menu Diagnosis 638 06 4711 act position 1 0 INKA act position 2 0 Motor Drive actual speed 0 rpm effective current et value Step 3 2 Drive Activation Action Function It is necessary to make additional settings as described in Step 4 2
91. on Step 4 1 Control Loop Optimization with Rotary Motors Action Function Prerequisite Step In the EASYRIDER Commissioning Menu select Speed Controller PY nan Bt D DFPE K eT Er eim E iuum oum D amam th i s L imm larf km ama cd i ansa sasi NES amp and with F8 Start the Test Generator Attach the mechanical component with the motor shaft Perform step 4 1 2 again Within the EASYRIDER Commissioning Menu select Position Control when employing the position control settings Mim mee 4i hese IR suc m mmm i gies ee mim als mm T Pah Set the position and speed with F8 Start the Test Generator On to Step 5 gt Anticipated Result gt M Check the speed and power variation characteristics utilizing an oscilloscope and through the adjustment of the P and sections set the parameters for the control rigidity Pay attention with linear motion The speed generator is controlled by time and recognizes no parameters unless the limit switch is configured Check the speed power variation and control deviation characteristics utilizing an oscilloscope and through the adjustment of the P and V sections set the parameters for the power control rigidity gt M
92. ource One must pay specific attention to the vertical axes without a mechanical self inhibitor or balanced weight According to Machine Regulations 89 392 EWG i e EN 292 EN 954 und EN 1050 when considering the safety and risk analysis the machine constructor is responsible to make certain that the overall safety system for the whole machine takes all of the integrated components into consideration Note that the electrical drives must also be included in this consideration One must pay attention to and follow the instructions completely as stated in the validation report with regard to the initial start up service intervals troubleshooting and repair of the equipment The STO conformance protocol outlines a suggestion for the documentation of the relevant safety parameters in the validation report Trained Personnel Planning installation and initial system commissioning require a detailed understanding of this information Protective safety standards and risk mitigation issues which are connected to the specifics of the installation must be recognized and taken into consideration as well as appropriate actions to be taken in the event of an emergency Benefits with the Employment of the Safe Torque Off Function Safety Category 4 performance Level e according to EN 13849 1 Performance Application of the Safe Conventional Solution Utilization of Feature Torque Off Function External Switching Components Requirement Reduced Simp
93. over current protection 52 07 02 12 02 EN V0608 doc Type 638 Electrical Installation Fault Current Protection Servo Drive of the 638series can cause a DC current in protective grounding Where for the protection in case of a direct or indirect contact residual current device RCD is used only a RCD of the type B AC DC sensitive is permissible on the current supply side If is permissible for application should types with increased trip current 300 and or short time delayed to be used A another preventive measure must be used e g separation from the environment by double or reinforced insulation or separation from the public supply system by a transformer Rated Fault Current Line filters have high discharge currents due to intern capacities In the servo drive of the series 638 an intern line filter is integrated Additional discharge currents are caused by the capacities of the Motor cable and the motor winding Through the PWM frequency of the Inverter the leakage current have high frequently rates The suitability of the RCD is to test for the respective application Generally we do not recommend the operation with RCD s The value of the leakage current depends on the following points gt Lenght and characteristic of the motorcable PWM Frequency gt Operation with or without shielding How and where is the motor housing grounded Comment High fault currents can occur Extreme unbalance
94. perating modes 1 and 2 through input X10 24 Speed control analog Torque controller analog Analog X10 5 18 Simple applications with the requirement of switching between Digital position and speed control position controller input 10 24 Handling like operating mode 4 Digital or Analog in acc General position controlled systems Up to 10 positions can be to parameter setttings stored under identifier numbers and activated as shown pos selection Nr 0 9 function F2 data 2 2 ZN input start function F2 X10 2 axis move to selected position number output position reached function FO X10 12 t1 2ms minimum t2 2ms minimum Digital or Analog in acc Simple to complex systems using BIAS instructions to programming or via up to 1500 command blocks digital communication PLC Functions e g fieldbus 44 07 02 12 02 EN V0608 doc Type 638 3 Operating Mode 3 2 Operating Modes and Pin Functions Operating Modes 0 1 2 3 4 5 Available Torque Speed Torque Position Position Position Control Contact Control Control Control Speed Control BIAS Numbers Control Functions Input FO F1 FO F1 FO F1 FO F1 F2 FO F1 F2 X10 14 F3 F3 F6 FO F1 F2 FO F1 F2 FO F1 F2 F6 F3 F3 F6 Input FOF Input FOF Input 1 1 F1 F1 F1 F2 F FO FO F1 F2 F6 L torque L torque H speed H speed control control Output F2 F5 FO F2 F5 F2 F5
95. permitted This command is only permitted This command is only This command is only permitted in the in the BIAS task in the PLC and MATH Task permitted in the MATH Task BIAS and MATH Task Move position Move position Position const Position parameter variable X Move Speed ae p UU SL i 5 incremental position Speed const variable X position parameter Acceleration Move datum Move datum es parameter Move infinite Move infinite Deceleration positive Deceleration const positive Se variable X Move infinite negative Gear factor FLU program parameter Variable X Move Move synchron Position reached Position reached synchron parameter window const window variable X Move analogue ane u Remaining position Remaining position const variable X Synchronous Move speed Ramp filter const BIAS Execution Save table settings 1 integrator variable X pointer const synchronous Move speed Actual_position X Actual position X Wait for settings 2 variable const variable Y position reached Move nine Gear factor const Move PID speed Wait time const Move PID torque Wait time variable X Cycle lenath const Set point BIAS execution pointer variable X Cycle lenath variable X axis const Set Pod Load parameter axis
96. plugs gt When installing multiple servo drives there is minimum space on the side gt The unit should only be mounted vertically as shown 16 07 02 12 02 EN V0608 doc Type 638 1 General Information 638B Series 4 x 5 mounting screw 5 For sufficient air circulation you must a expansion space from 100mm minimum on the inlet and outlet cooling 66mm for 638B03 and 638B05 86mm for 638B10 and 638B15 44mm for 638B03 and 638B05 64mm for 638B08 638B10 and 638B15 Important Please note that on the front side of the unit approximately 70 mm of additional space is required for the signal mating plugs gt When installing multiple servo drives there is minimum space on the side gt The unit should only be mounted vertically as shown 07 02 12 02 EN V0608 doc Type 638 17 Connection Assignments and Functions 2 1 Insulation Concept The insulation of the 638 units is achieved in various insulation classes or groups Power Connections Customer part X60 11 12 13 DC BUS resistance X61 1 2 COM1 COM2 Common option modules Remote IN SS X10 X62 Brake X10 digital sss X62 Thermo T _ lt Yj X01 Us DC 24V ND U double insulation VDE 0160 NW basic insulation supplementary insulation via opto coupler or relay no total insulation k WS Insul
97. protection In addition all digital signal inputs and outputs are provided with a galvanic separation utilizing either a relay or an optical coupler In this way an increased level of protection against potential interference and a limitation of potential damage due to incorrect connections are provided The voltage level must not exceed the designated low safety voltage of 60V DC or 25V AC respectively in accordance with EN 61800 5 1 VDE 0160 The operator must make sure that these regulations are strictly followed High Voltage Danger of Electrocution Life Threatening Danger Certain parts of the servo drive are supplied with dangerous electrical current Physical contact with these components can cause death life threatening injuries and or serious damage to Danger equipment and property Due to safety considerations and product guarantees the operator is prohibited from opening the servo drive case Service maintenance and repair of our products should only be carried out by specified representatives of the company Expert configuration and professional installation as described by this document are the best way to insure problem free operation of our servo drives Caution 07 02 12 02 EN V0608 doc 638 9 Safety Precautions Please Observe 10 Pay Special Attention to the Following Permissible Protection Class Protective Grounding operation is only permitted when the protecti
98. r current protection should be dimensioned for the average current load to be expected In the supply line a protection about a protective circuit breaker or fuse shall be provided Circuit breakers with tripping characteristic C or fuses with tripping characteristic gM are to be used One determines the load to be expected on the average as follows S VA 1 phase supply mains 3 phase supply I mains VA Netz x5 x Uwe The apparent power S can be calculated to that as follows 2X I X Naverage min 1 60 The constant k for the different servo drives can be taken from the following table S VA Mer Nm x k x 07 02 12 02 EN V0608 doc Type 638 51 5 Electrical Installation 638 1 638 2 638A 4A 638A 6A 638B 03 638B 05 638 08 638 10 638B 15 When information about load torque Inertia and the friction situation be there the effective momentum is calculated with following formula in case of correct motor dimensioning also the rated torque of the employed motor can be used 1 Me i i Nm NE na tai aa 5 For the determination Of Naverage there must be corresponding information about the positioning cycle Naverage min 1 mn x gt ni min 1 x tils cycle The cross section of the power main cable and the rated current of the used fuse are chosen in accordance with table Current carrying capacity of PVC isolated three pha
99. r damage which may occur when the product instructions and or the applicable regulations are not explicitly observed 07 02 12 02 EN V0608 doc Type 638 1 General Information 1 1 System Description Special Features of the 638 Servo Drive e The digital 638 servo drive provides for the electrical connection rotational speed and position control of the AC servo motor e All of the functions and system controls are digitally regulated employing a sampling rate of 105ps e The 638 servo drive supports the safety function Safe Torque Off STO providing for a definitive system shut down for protection against an unanticipated start up in accordance with the requirements as stated in EN 13489 1 Category 4 Performance Level e and EN1037 e he feedback generated from the braking energy is dissipated through the employment of internal ballast resistance and when required through the employment of additional external ballast resistance e he AC supply voltage can be directly connected or it can be connected through a transformer as required Important only operated on networks which are grounded at the centre point TN networks e The servo drive additionally requires a 24 V DC control supply voltage connection e The built in internal EMC filter corresponds to the requirements regarding susceptibility to interference for industrial systems as described in EN50081 1 e By employing various option modules through 2 additiona
100. requisite Safety 1 1 1 Safety Parameter Parameter Nr STO Power On Test is Active 1 1 2 Supply Voltage US 0 V off 24V DC Voltage to Terminal X11 1 and Terminal X11 4 Terminal X11 1 Test Switch off 24 V DC Voltage at terminal X1 1 1 Wait approx 20 seconds 7 Segment Display After approx 20 seconds Software STO 7 Segment control mechanism Display successful Switch on 24 V DC Hardware STO control mechanism successful 07 02 12 02 EN V0608 doc Type 638 Ej Aktiv v If the safety parameter Start up Test is deactivated then the drive will be activated immediately after the switch is turned on Test steps 2 4 can then be performed anyway 9 Safe Torque Off STO Terminal X11 4 Test Switch the 24V Rebuild Supply Voltage STO Test Step 1 Off gt On Switch off 24 V DC Voltage at Terminal X11 4 Wait approx 20 seconds Check 7 Segment Display After approx 20 seconds Check Software STO 7 Segment control mechanism Display successful Switch on 24 V DC Hardware STO Voltage at control mechanism Terminal X11 4 successful Terminal X11 1 and Switch the 24V Terminal X11 4 Test Supply Voltage Rebuild Off gt On STO Test Step 1 Switch Off 24 V DC Voltage at Terminal X11 1 and Terminal X11 4 Wait approx 20 seconds Check 7 Segment Display After approx 20 seconds If the drive has no Switch on 24 V DC fault and no other Voltage at swi
101. rker Hannifin GmbH amp KG Electromechanical amp Drives Automation Group Im Sand 14 D 76669 Bad Sch nborn Tel 49 0 7253 9404 0 Fax 49 0 7253 9404 99 sales automation parker com www parker automation com Parker Hannifin GmbH amp Co KG Electromechanical amp Drives Automation Group Robert Bosch StraBe 22 D 77656 Offenburg Tel 49 0 781 509 0 Fax 49 0 781 509 98176 sales automation parker com Parker Hannifin GmbH amp Co KG Electromechanical amp Drives Automation Group Von Humboldt StraBe 10 D 64646 Heppenheim Tel 49 0 6252 7982 0 Fax 49 0 6252 7982 05 sales automation parker com We reserve the right to make technical changes The data correspond to the current status at the time of printing
102. rmo notice Step Connector Assignment 2 2 3 only when the power supply is Make the X30 connection to the drive Eliminate the risk of a short circuit disconnected Check the counter function by looking at the When employing a motor Actual Position Locator Display 1 under the with a brake make Drive Diagnosis window of the EASYRIDER certain that the brake is Software and the movement of the opened motor shaft OO with linear motors the actual speed rpm movement of the rotor effective current Rotor position Status DiveDffCOM 1 2 Motor feedback 07 02 12 02 EN V0608 doc Type 638 69 8 Commissoning Step 2 2 Motor Selection Anticipated Result Action Function Prerequisite Step The motor cable is connected to the 638 Drive through the X61 connection port 2 2 2 Inthe EASYRIDER configuration menu for Motor select Motor Library and then scroll down to the appropriate motor utilizing the motor type information as listed on the name plate Fi E EASYRIDER LLL UE amp File Commissioning Tuning Comme RE 13 GA Aran SY E ACM 2000124713 1 General amp ACMA UAE A Kasa EA In j Outputs ACH RONE DA ArH mr ADM TT Drive 2n D L1 3 52 40 ADHA SHI E ADM Supervision BM anna SM DELIA Safety Positionbla
103. s Parameter into variables commands BIAS Command overview Control commands Flag commands In output commands Variable commands Mathematics commands 1 0 Mathematics commands 2 1 Floating point commands coc de ce DD Drac o e With these commands you will be able to program the required machine process in chains of steps The size of a program is limited to a maximum of 1500 BIAS commands The design of the programs occurs with EASYRIDER software at the PC and can be transmitted into the servo drive via serial communication If you create the BIAS program with the EASYRIDER shell jump labels comments and a unit for the position presettings are provided A further possibility is programming or transmitting and controlling the BIAS program via a field bus respectively The necessary command coding is listed in the command instruction During the calculation of a BIAS program is is possible to start parallel a PLC SPS Task and or a Mathematics Task The PLC Task is calculated parallel to the BIAS Task and has a subset of the commands Save Table The command is allowed in the PLC Task only The Mathematik Task is calculated in the interruptfree processing time of the drive and has also subset of the commands 07 02 12 02 EN V0608 doc Type 638 13 Software Program layout A BIAS program consists of 3 basic memory areas 1 The program definition contains all definitions for starting and proce
104. s We assume that as an expert you are familiar with and will observe all of the relevant safety regulations especially in accordance with VDE 0100 VDE 0113 VDE 0160 EN 50178 the accident prevention regulations of the employer s liability insurance company and the DIN regulations Additionally it is imperative that all relevant European Union Safety Directives be observed Depending on the type and location of the installation additional regulations e g UL DIN must also be fully observed If our products are operated in connection with components from other manufacturers their operating instructions are also subject to be strictly observed 07 02 12 02 EN V0608 doc Type 638 Safety Precautions Digital servo drives corresponding to EN 61800 5 1 VDE 0160 are electronic power components utilized for the regulation of the flow of energy in high voltage electrical power installations They are exclusively designed configured and approved to supply our servo motors Handling installation operation and maintenance are only permitted under the conditions of and in keeping with the effective and or legal regulations regulation publications and this technical document Attention The operator must make sure that these regulations are strictly followed The Concept of Galvanic Separation and Insulation Galvanic separation and insulation corresponding to EN 61800 5 1 VDE 0160 provides for additional insulation
105. s for STO1 and STO2 are delivered utilizing two separate channels The wiring layout plan must allow for the physical separation of the wiring channels or incorporate adequate insulation protection and separation Note The acknowledgement is only permissible with category B The acknowledgement is not permissible for use if the dangerous area is accessible In this case employment of an external acknowledgement unit is necessary The acknowledgement is only necessary when after the cancellation of the STO function by the automatic start up a potential danger for the people in the area or the equipment exists 07 02 12 02 EN V0608 doc Type 638 93 9 Safe Torque Off STO Application Example 4 Function Action Response Reaction Protection Level Stop Cat EN 954 1 150 13849 1 According to EN60204 Safety door monitoring or Active braking occurs when the safety Cat 4 PLe 1 emergency shut down with door is opened the emergency shut protection monitoring switch and down switch is activated or tripping of time delay of several drives the STO occurs due to time delay Example Safety Gate closed Safety Switch closed serval Servo Drive activate w HCH open L 1 Protected Area Control Cabinet IP54 Safety Relay Cat 4 e g Pilz PNOZ XV2 Time Delay tvs 638 Servo Drive 1 a ACK acknowledglement Safety Gate resp Emergency Stop Plant Important The category 4 and PL e protec
106. se cable or single conductors so that the permissible current carrying capacity of the chosen cross section larger or alike to the calculated main current With drive groups this is the sum of the main currents Icurrent carrying capacity 2 Imain Icurrent carrying capacity 2 2 The rated current of the fuse must be equal to or less than the permissible current carrying capacity of the chosen cross sectional cable lt lcurrent carrying Capacity lt gt current carrying capacity IR The following table show the maximum current load of PVC insulated three phase cables or conducting wires according to IEC60204 1 at 40 C environmental temperature and 70 C maximum conductor temperature Line cross section Individual wires Cable in Cable on walls Cable ina in insulating insulating cable tray conduit or conduit or cable duct cable duct B1 B2 C E Aeff Aeff Aeff 07 76 When determinating the cross section for he power mains make sure that the cross section selected is within the range that can be used with power mains terminal X60 See Assignments Power Connections Dimensioning the Line Contactor The rated current of the line conductor is oriented to the over current for the power mains connection The line contactor is set up so that nominal operating current specified by the manufacturer of the line contactor for catergory AC 1 is approximately 1 3 times the rated current of the
107. ssing a BIAS program the entries for defining a unit for position presetting and the necessary configurations of the inputs and outputs 2 The command memory contains up to 1500 BIAS commands 3 The synchronous parameters contain the definitions for the 16 synchronous profile blocks and the 2048 supporting points zynchron parameter program definitions jump program start igna program reactions units jump extended configuration 1499 end of program The basic memory areas are part of the BIAS program In the EASYRIDER for Windows Software the extension is WBD Execute a BIAS program The BIAS processing is started in operating mode 5 position control with BIAS processing after activating the output stage of the regulator The first BIAS block to be executed is determined in the BIAS program definition Parameter program start After that the regulator processes one BIAS command sequentially every trajectory cycle If the BIAS processing encounters a move command it can be started with the Low High slope of the start input Serie Input Configuration 635 637 6374 6371 688 X10 11 Start input BIAS Function 0 631 X10 9 Start input Function 3 Alternatively move commands are started when the start identifier is set before the move command via the BIAS command Start axis The following blocks will be processed after a successful start If the command Wait for position reached follo
108. t function as an interactive tutorial System identification BIAS instruction set editor Oszilloscope function Start up and commissioning tools Setting of parameters and setting of configurations Servo diagnostics interface diagnostics and fieldbus diagnostics Motor library Save system data in file and load system data from file Send system data to servo drive and save system data in servo drive Load system data from servo drive O O O O O QO Q Q QO QOQ Important Edited data in EASYRIDER is transmitted to the RAM of the servo drive and becomes active only after executing the SEND command Only the instruction SAVE in EEPROM writes data into a non volatile memory Data is stored there in the event of power failure 07 02 12 02 EN V0608 doc Type 638 115 1 13 2 Software Introduction The selection of the Operating Mode 5 with the Drives 630 Serie activates the complete functionality of all control loops and the BIAS program processing The EASYRIDER Software is the programming tool to create load and save the BIAS Programs The programming language Bedienersprache fur intelligente Antriebs Steuerungen was developed to allow the programming of complex and yet clear programs Therefore the BIAS commands were divided according to their function into the 12 following command groups Move command Move command parameters Parameter commands Parameter from variables command
109. tage within the limits power stage active fault free 12h internal STOP with serial deactivating off activate drive via serial interface 82h drive of serial interface bus interface deactivated only if bus interface is integrated deactivated with delay time for the brake deactivated via serial command 92h Active input is activated with switching on of of 24 V control voltage switch enable X10 xx switch on 0 V and 10 7 10 22 4 after that 24 V Under voltage of control voltage off Power supply switched on Power supply o k internal fuse o k control voltage lt 17 V Under voltage in DC bus lt Ua low threshold off cO eo 2 deactivated via input O gt check power supply power supply unit wiring fuse check under voltage parameter DAh feedback system error e g resolver off off wiring to encoder system ok encoder system supply ok Dah flashing v ooh Resolver Feedbacksystem Error 8 36 wiring to resolver system ok DAh flashing off off HIPERFACE Feedbacksystem Error 8 36 6Eh wiring to HIPERFACE system ok Check serial HIPERFACE channel 98 07 02 12 02 EN V0608 doc Type 638 10 Diagnosis and Trouble Shooting Display Explanation Output Servo drive mmen Beady Wanin 635 637 637 6371 638 pape 5 Fon
110. tch off condition Terminal X11 1 and is set then the drive Terminal X11 4 5 activated Once all of the relevant safety test steps have been accomplished the actions taken must be documented The protocol form can be found in the Appendix STO Safety Parameter Report Proposal 96 07 02 12 02 EN V0608 doc Type 638 9 Safe Torque Off STO 9 6 Signal Inputs Technical Data Terminal Connection X11 General The technical data provided in the section General Technical Data is valid with the exception of the data listed below Nominal Voltage from the Inputs 24 V DC Required Insulation from the protective extra low voltage PELV Control Voltage 24V STO Control Voltage Protection Number of Inputs 2 Signal Inputs via Opto Coupler L 0 7 V DC or open H 15 30 V DC lin at 2AVDC 8 mA STO1 L STO activate OOOO STO2 L STO activate use Break Time at Unequal Input Conditions approx 20 seconds Function see Status Diagram 07 02 12 02 EN V0608 doc Type 638 97 10 Diagnosis and Trouble Shooting 10 1 7 Segment Display Many sources of faults can be narrowed down with the diagnosis display Display Explanation mmen Bendy vara 635 637 637 6371 638 ce UE oon no display off off any control voltage external fuses ok 03h on off system ready for operate drive ready not active oth drive active and ready for operate on of v v DC link vol
111. te must be bare metal and not reduced by varnish All screws must be properly tightened resolver connections Place all wires and cables as close as possible to grounded metal parts Separate power and control cables Minimum distance 0 3 Cross Points 90 Avoid cable loops The run between the line filter and drive has to be as close and short as possible drilled Maintain the shielding as close as possible to the cable end max distance 8 cm 8 cm max Connect shielded connections according to general view of connections See chapter 2 1 Ground shielding on both sides with the shortest possible cable run For long cables Connect additional shielded areas along the way Connect the shielded area to well grounded points Connect unused wires in cables to the ground ww w L Install control cables close to grounded metal parts or shielding when leaving the control cubicle Pay close attention to the grounding of control transformer DC 24V Use a transformer with a metal socket and pay attention to provide for good conductive contact on mounting plate Pay close attention to the overall grounding of the complete system Interconnect several mounting plates using copper rails or copper band Pay attention to the ground connection between the control cabinet and the equipment 07 02 12 02 EN V0608 doc Type 638 63 6 64 Wiring Instructions Example for Mounting X61 Motor Connector W
112. thematics program A task as math program for supervisory calculation can be started parallel to the sequential processing of a BIAS program and or PLC program The mathematics program is started by processing the BIAS command Mathematics program After the mathematics program is activated the programmed mathematics commands are processed as of the specified block number The command end of program mode 0 within a mathematic program causes a jump back to the start of the mathematics program The command end of program mode z3 cancels the mathematics program The reaction of the mathematics program to the deactivation of the output stage can be adjusted in the BIAS program definition parameter program reaction mathematics program Thus it is possible to allow the mathematics program to continue to process also during the deactivation of the regulator In this mode the command Mathematic program is executed at the first or second line if the PLC program is on line 1 of the BIAS progam or at line O if the drive is not enabled The calculation of the mathematics commands is done in the interruptfree calculation time of the drive In a standard application approx 10 commands are processed every 2ms 07 02 12 02 EN V0608 doc Type 638 13 Software 13 3 BIAS Commands _Position const AEM AES WI sed uno _ Profile value variable X Save table PLC program This command is only
113. tion level can only be achieved with an active STO Power On Test Explanation The protection switch unit A1 must be set up with a fail safe time delay as determined and required by the specific category relating to the application environment The 638 Servo Drive must be properly configured for the operating environment See Chapter m Configuration and Parameter Settings Only 16 drives could plug together in a group Note The acknowledgement is only necessary when after the cancellation of the STO function by the automatic start up a potential danger for the people in the area or the equipment exists 94 07 02 12 02 EN V0608 doc Type 638 Safe Torque Off STO 9 5 STO Function Test The STO function must be tested when e The system is set up for the first time See Commissioning e Any component of the system is replaced e Any activity involving the wiring takes place After all modifications to the drive system For example parameter modifications software updates etc e Established maintenance schedules dictate or after the machine has been inactive for a long period of time The STO functions test must be carried out by qualified personnel with consideration for the required safety provisions Depending upon the system configuration and application additional or other tests may be required Test Steps STO Test Step 1 STO Test Step 2 STO Test Step 3 STO Test Step 4 STO Test Step 5 Pre
114. tion of External Brake Resistors Brake resistors create heat The Brake Resistor must therefore be installed in a manner which provides safeguards against the potential danger of inadvertent touching or the danger of fire during both normal operations and under fault conditions 07 02 12 02 EN V0608 doc Type 638 61 6 6 1 62 Wiring Instructions General Wiring Instructions General Information Digital servo drives are designed for operation in metallic grounded enclosures For problem free operation as well as for the observance of all regulations the drive unit back must be connected with the cabinet mounting plate electrically and fixed Control Cabling Recommended cross section 0 25 mm The control signal lines must be laid seperately from the power signal lines See e Hints for Mounting The resolver cable must contain three shielded pairs and must be shielded as a whole The shielding should be connected to the ground spread out on the drive side We recommend using the resolver cable KIR Cables utilized for transmitting data must always be shielded Power Cabling Recommended selection according to rated current Use only 75 Cu cables Analog Setpoint The setpoint input is a differential input Therefore the poling can be configured depending upon the application requirements Important the setpoint voltage must be galvanically connected to the reference potential of the control connections pl
115. to change without notice Parker Hannifin has registered in part trademark protection and legal protection of designs The handing over of the descriptions may not be construed as the transfer of any rights Made in Germany 2008 07 02 12 02 EN V0608 doc Type 638 3 Table of Contents Page The Most Important Thing First 8 Sally UC CAUUIOINS 9 1 General Information U J Q J J 11 1 1 SY tem ESS ClO UO MA sue ULLA ut 11 Special Features of the 638 Servo Drive ccccccccccsssseseeeeeeeeeeeeeceeeeeeeeueeseeeeeeseessaaaseeeeeessaaaaaseeess 11 Overview of Standard Digital COMMUNICATION 11 Determining Criteria for the Utilization of the 638 Drive 12 e Operation Configuratio LLL a ua tret Op Decor 12 1 2 VS E MERE T 13 Combination Possibilities for the Various Communication I O 14 Module Slots LL Sau 15 Module DO uu
116. ty requirements Electrical thermal and energy EG EMC Directive EN 61 800 3 Emissions and immunity levels for 2004 108 EC Power drive systems Power Conversion Equipment Industrial Control Equipment Insulation Requirement Protection Class EN 50 178 Overvoltage Category IEC 60364 4 443 1999 ll Pollution Degree EN 61800 2 4 1 2 1 2 Environmental Conditions General Environmental EN 61800 2 D Ambient Temperature Rating Operations IEC 60721 3 3 5 bis 40 C 3K3 Storage IEC 60721 3 3 25 bis 55 C 1K4 Transport IEC 60721 3 2 25 bis 70 C 2K3 Allowable Humidity Operations IEC 60721 3 3 lt 85 non condensing 3K3 Storage IEC 60721 3 3 lt 95 1K4 Transport IEC 60721 3 2 lt 95 at 40 C 2K3 Vibration EN60068 2 6 10Hz lt f lt 57Hz sinusoidal Test FC 0 075mm amplitude 57Hz lt fs150Hz sinusoidal 19 10 sweep cycles per axis 1 Oktave Minute Air Pressure 86 106 kPa EN 60529 IP20 Under lt 1000m above sea level with 100 power rating Over gt 1000m lt 2000m above sea level decrease the power rating by 1 per 100m All 638A Forced ventilation internal fan 638B 08 10 15 All 638C 07 02 12 02 EN V0608 doc Type 638 105 11 Standards and Certfications EMC Requirement x 638 638B 638C EMC Emission EN 61 800 3 max ____max Motorcable length cable max Motor cable length Conducted First Environment
117. ug X10 It is possible to connect one pole directly to the ground GND Safety Rules Caution Plug Unplug all mating connector is only allowed e Power Supply off e Control Voltage off e DC Link discharge discharge time gt 3 minutes e The user must ensure protection against accidental touching 07 02 12 02 EN V0608 doc Type 638 Wiring Instructions 6 1 Electromagnetic Compatibility EMC Conformity in accordance with the EEC Directive 89 336 has been evaluated using a reference system consisting of a compact type drive and a line filter on mounting plate connected to an AC synchronous motor The motor cable is mainly responsible for EMC emissions The motor cable must be installed therefore employing exceptional care The layout of grounding is very important Grounding has to be low impedance for high frequencies That means all ground connecting parts have to be connected over a large surface contact area The measurements provided are valid only with the use of our cables suppression aids and line filters and by application of the following wiring instructions Hints for Mounting All components are mounted inside of a steel control cubicle on a mounting plate min thickness 3mm Recommended Galvanized 77 YY 77 YY YY YY 77 YY 77 YY 77 YY 77 YY 77 YY 77 YY YY 77 YY YY YY YY YY Z 77 The connection between the drive housing the filter housing and the mounting pla
118. umentation of the appropriate suppliers e g Comp Sick or Hengstler 32 07 02 12 02 EN V0608 doc 638 2 2 9 Connection Assignments and Functions Fieldbus Interface COM2 Additional functions can be realized through the optional employment of the Options Modules RS232 RS422 RS485 CAN1 DeviceNet Profibus DP SUCOnet Input Output 5 2 Pee j 6 Data in ven 8 DataOut Lege Options module RP 422 without galvanic separation Options module RP 485 with galvanic separation Parallel wiring for up to 16 units Full Duplex 4 Wire 07 02 12 02 EN V0608 doc Type 638 33 34 Connection Assignments and Functions Pinning for CAN or DeviceNet Module CAN CAN 1 RP DEV Function Designation L Bus Line CAN L dominant low CAN GND d qe co 4 6 Optional Ground CAN GND 7 CAN H Bus Line CAN H dominant high with galvanic separation Pinning for Profibus DP Module RP DP with galvanic separation Pinning for SUCOnet K Module RP SUC Pin Function 4 4 Signal Ground SGND TE RB with galvanic separation 07 02 12 02 EN V0608 doc Type 638 Connection Assignments and Functions Pinning for 5 l O Interface Digital In and Outputs Module RP EA5 BIAS Input
119. uring installation of the unit to provide for adequate space and ventilation See a Dimensions General Rule It is better to place heat producing devices low in an enclosure to support internal convection and to spread out the heat If placing such devices up high is unavoidable enlarging the upper dimensions at the expense of height or the installation of fans should be considered Cooling and Ventilation The digital servo drives are inherently designed to protect against damage which may be caused due to overheating A temperature sensor is mounted on the heat sink When the temperature reaches a level above gt 95 C the unit will be automatically shut down This setting can not be altered The cooling of the power module will be assisted as much as possible with an internal fan Depending upon the temperature the fan unit will operate at one of two levels in order to limit unnecessary wear and potential pollution Make sure a cabinet of proper size is selected for adequate air circulation If the device is placed and operated in a non ventilated environment the case volume of the specified control cabinet must be calculated in accordance with the following table Unit Volume Cabinet 638A01 638A06 638B03 638805 638B08 638815 For more specific information please refer to the information provided by the manufacturer of the cabinet 07 02 12 02 EN V0608 doc Type 638 49 5 Electrical Installation
120. ve conductor is connected according to regulations Operation of the servo drive when employing a residual current operated protective device as the sole protection against indirect touching is not permissible The servo drive may only be used in conjunction with machines or electrical systems when placed in control cabinets which comply with EEC Directive98 37EEC Machine Directive and EEC Directive 89 336 EEC EMC Directive Work on or with the servo drive may only be carried out with insulated tools Installation work may only be done in a de energized state When working on the drive one should not only block the active input but also separate the drive completely from the main power connection CAUTION Risk of Electrical Shock Wait 3 minutes after switching the component off to allow the capacitors to discharge Screws sealed with varnish fulfill an important protection function and may not be tampered with or removed It is prohibited to penetrate the inside of the unit with objects of any kind Protect the unit from falling parts pieces of wire metal parts etc during installation or other work in the control cabinet Metal parts can lead to a short circuit in the servo drive Before putting the unit back into operation remove any additional covers so that the unit does not overheat When conducting measurements on the servo drive it is imperative to pay attention to the electrical isolation We are not liable fo
121. w hvbg de d bia pub rep index html Important Technical Terms and Explanations Safety Category 3 Definition according to the regulation Performance Level d Circuit with built in protective functions for individual fault conditions according to EN 13849 1 Some but not all faults will be recognized The frequent occurrence of fault conditions can lead to a loss of the safety functions The remainder of the risk must be understood and accepted The determination for the application of the appropriate safety category requirements risk analysis lies with the installer and operator of the equipment You can reference the method described in EN13849 1 1996 Appendix B as an example Safety Category 4 Definition according to the regulation Performance Level e The safety related parts must be designed in a way that a single fault condition in according to EN 13849 1 each safety related part will not guide to loss of the safety function and the single fault will be detected before or on next demand of the safety function If this is not possible ab accumulation of faults should not a lead to the loss of the safety function The determination for the application of the appropriate safety category requirements risk analysis lies with the installer and operator of the equipment You can reference the method described in EN13849 1 1996 Appendix B as an example Safe Stop With the activation of Safe Torque the energy supply
122. wer supply driving components to the power components of the machine Available brakes and or other mechanical braking systems should be employed Shutdown by a means which Controlled Controlled shutdown is the stopping of the machines maintains the power supply Shutdown movement by for example the setback of the connection to the machine drive electronic command signals to zero as soon as the component to bring movement stop signal is recognized by the controller while the to a standstill The power power supply to the machine drive components connection will be broken only remains intact until a standstill condition is achieved after standstill has been achieved Shutdown by a means which Controlled This category will not be covered in the functions maintains the power supply Shutdown description of the manual connection to the machine drive component 80 07 02 12 02 EN V0608 doc Type 638 Safe Torque Off STO Applications in Accordance with the Regulations The 638 Drive supports the safety function Safe Torque Off in the sense of providing a definitive stopping of the equipment with protection against unanticipated start up in accordance with regulations EN ISO 13849 1 Category 4 Performance Level e and EN 1037 The motor must stopped controlled through the machine controller However it does not provide for any verification of cessation of movement which may have been produced from some external s
123. with Alteracode and Parameter and BIAS Data missing X300 xM Module 07 02 12 02 EN V0608 doc Type 638 10 Diagnosis and Trouble Shooting Servo drive Code Comment 04 638 X300 xM Module Memory Error Alteracode missing 40h 638 X300 xM Module Memory Error Parameter and BIAS Data missing 1 Reaction to these errors chapter Function diagrams from inputs and outputs 2 With configuration corresponding chapter a Operating modes and pin functions 3 Operating mode Position Control only 4 The display code you can get with the serial command internal diagnosis 2 0x26 in byte 16 The error signals are shown as long as there is control voltage Us also when the power DC Bus is switched off for safety reasons 102 07 02 12 02 EN V0608 doc Type 638 10 Diagnosis and Trouble Shooting 10 2 Reset of a Drive Trouble A general precondition for correct execution of the Reset is the elimination blinking BIAS Possible error signals at 120 The error signals of the drive can be reset via 1 Control voltage OFF ON 2 the serial command Drive Reset 0x02 The host login must be occurred The drive must be deactivated via the serial command deactivate Drive 0x00 3 the fieldbus command Drive Reset 0x16 22 decimal The host login must be occurred via the BUS command 0x01 The drive must be deactivated via the BUS command deactivate Drive 0x14 The fieldbus comm
124. ws a move command block processing will only be continued after the target position is reached 631 635 637 1 899ms 637 6371 638 0 844ms 07 02 12 02 EN V0608 doc Type 638 13 Software Execute PLC program A cyclic PLC program for supervisory monitoring tasks can be started parallel to the sequential processing of a BIAS program The PLC program is started by processing the BIAS command PLC program After the PLC program is activated the programmed PLC commands are processed as of the specified block number The command of program mode 0 within a PLC program causes a jump back to the start of the PLC program The regulator processes one PLC command sequentially every trajectory cycle The reaction of the PLC program to the deactivation of the output stage can be adjusted in the BIAS program definition parameter program reaction PLC program Thus it is possible to allow the PLC program to continue to process also during the deactivation of the regulator Is in this mode the first command of the BIAS execution the command PLC program the PLC task starts automatically independently of the state deactive active of the drive In the plc loop not all of the BIAS commands are allowed In the 3 command overview the allowed commands are listed The check of allowed commands is done by the drive during run time Drive type Trajectory cycle 631 635 637 1 899ms 637 6371 638 0 844ms e Execute a Ma

638 Series - HVS System

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