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1. Wap or prr 029 a dui Figure 9 Attaching the ring screws contained in the delivery to ACOPOS 1640 128 drives ACOPOS User s Manual V1 69 Chapter 3 Installation Installation General Information ACOPOS servo drives can only be installed in an environment which corresponds to pollution degree II non conductive material When installing the device make sure that the maximum operating temperature 40 C is not exceeded and IP20 protection is provided as specified in the technical data For proper air circulation at least 80 mm has to be left free above and below the ACOPOS servo drive ACOPOS servo drives can be mounted directly next to each other the required distance between devices can be found in the respective dimensional diagram 70 ACOPOS User s Manual V1 Installation Dimensional Diagram and Installation Dimensions 2 Dimensional Diagram and Installation Dimensions 2 1 ACOPOS 1022 1045 1090 Distance to vA next device i Outgoing air 70 5 5 70 5 35 25 235 5 tol S CQM 361 320 3 71 5
2. e e E 27 Sy 02 i Of HO WS S 8 2 2 8 HO 9 8 o S S t HO 9 8 0000 OO 0 E O O O9 qui B e lt o d 5 e o e GIRI ogo 3 of See B 2g lt 9 85 55 ae 54 5 9 5 lt 9 c 8 E 7 27 Figure 12 Dimensional diagram and installation dimensions for ACOPOS 128M 1 For proper air circulation at least 80 mm has to be left free above and below the ACOPOS servo drive Approximately 160 mm free space is required under the ACOPOS servo drive to prevent cabling problems ACOPOS User s Manual V1 73 Chapter 3 Installation Installation Installation and Removal of Plug in Modules 3 Installation and Removal of Plug in Modules 3 1 General Information ACOPOS servo drives are equipped with four slots for plug in modules At present the following module arrangements must be used Plug in Module Operation Possible in this Slot 1 2 3 4 8AC110 60 2 x x x 8AC120 60 1 x x 8AC122 60 1 x x 8AC123 60 1 x x 8AC130 60 1 x x Table 36 Slot overview for ACOPOS plug in modules Caution e Keep the plug in modules in the original packaging and only take them out immediately before installation Avoid touching the plug in modules anywhere but on the front c
3. 277 2x fastening screws M5 280 Incoming air Chapter 3 Installation Figure 10 Dimensional diagram and installation dimensions for ACOPOS 1022 1045 1090 1 For proper air circulation at least 80 mm has to be left free above and below the ACOPOS servo drive ACOPOS User s Manual V1 Installation Dimensional Diagram and Installation Dimensions 2 2 ACOPOS 1640 0 sd D k 11 Fa Si 8 O Of _ 8 lt gt 5 5 8 i 8 8 8 Hg q5 08 lt E 0915 E Q 28 8 59 lt c aX oe 3 E o ecl o 5 1 S 22 2 Figure 11 Dimensional diagram and installation dimensions for ACOPOS 1640 1 For proper air circulation at least 80 mm has to be left free above and below the ACOPOS servo drive Approximately 160 mm free space is required under the ACOPOS servo drive to prevent cabling problems 72 ACOPOS User s Manual V1 Installation Dimensional Diagram and Installation Dimensions 2 3 ACOPOS 128M
4. Module Type ACOPOS plug in module 5101 Currently limited to slots 2 and 3 Power Consumption Max 1 2 W Resolver Input Resolver Type 2 Connection Module Side 9 pin DSUB socket Indications UP DN LEDs Electrical Isolation No Resolver ACOPOS Encoder Monitoring Yes Table 18 Technical Data AC122 42 ACOPOS User s Manual V1 Technical Data ACOPOS Plug in Modules Product ID 8 122 60 1 Resolution Depends on the maximum speed 14 bits rev for n 3900 12 bits rev for n 15600 min Bandwidth 1 7 kHz for n lt 3900 2 5 kHz for n 15600 min Precision x8 angular minutes Reference Output Signal Transfer Differential Voltage Output Current Frequency Differential Signals Typically 3 4 Veg Max 50 mAer 10 kHz Sine Cosine Inputs Signal Transfer Differential Voltage Possible Phase Shift to Ref Input Impedance at 10 kHz per pin Electrical Isolation Encoder ACOPOS Differential Signals Nom 1 7 Veg max 1 9 Varr x10 10 4 j 11 1 No common mode voltage on the sine cosine inputs max 20 V Operation Immunity 4 IEC 61000 4 2 ESD 15 kV IEC 61000 4 4 Burst 4kV Operational Conditions Environmental Temperature during 01050 Relative Humidity during Operation 5 to 95 non condensing Storage and Transport Conditions Storage Temperature 25 to 55 Relative Humidity for Storage
5. 122 Plug in Modules 116 165 Index Index Connector Encoder Connector hte 65 125 RESONO irinin aiaiai 65 127 General Information 61 Motor 62 123 Correctly installing cooling aggregates 78 Cross 107 D Danger Warmning eene 22 DG BUS der redde edes 89 Digital Mixed Module 130 47 120 Dimensioning Braking 94 Current Requirements of Plug in Modules 100 89 Formula Variables 101 Motor Connection 92 Power Mains Connection 81 Dimensions ec o 71 Drive 18 Drives See Servo Drives E Electromagnetic Compatibility of the Installati pM 103 Embedded Parameter Chip 13 Encoder Cables ice 57 125 Resolver in ree 59 127 Encoder Connector EnBD t i crie Een 65 125 Resolver oett 65 127 Encoder Resolution 150 Encoder Systems EnDat Encoder Interface 39 117 Incremental SSI Encoder IF
6. 2 2 59 8 007 12 1 seed 59 8CR010 12 1 59 8CR015 12 1 sss 59 8CR020 12 1 sees 59 8CR025 12 1 sss ees 59 8 001 00 1 65 8PM001 00 1 sss 62 ACOPOS User s Manual V1 8PMO002 00 1 esee 62 8PMO093 00 1 sees 62 8PR001 00 eee 65 8 1022 0041 oet 31 8V1045 00 1 eee 31 8V1090 00 1 31 8 2 33 8V10640 00 1 et 33 A ACTIO ene nece 36 116 AC 12015 56 o eene 38 117 AC122 ig ioni seien 41 118 AC 123 44 119 AC130 contem 47 120 ACOPOS 1022 nest pri RE 31 108 1045 31 108 1090 d 31 108 129 f enint 33 112 1640 gan 33 112 See Servo Drives B Braking 94 Cables Encoder Cables END ti iina 57 125 Resolver eet 59 127 General Information 51 Motor 52 122 Cam Editors ca ole mee 19 CAN Bus Interface AC110 36 116 163 Configurations GAN ken eee eene etes 20 Connections ACOPOS Servo Drives 108 Cable and
7. Switching cabinet Figure 15 Cooling aggregate on top of the switching cabinet ACOPOS User s Manual V1 79 Chapter 3 Installation Installation Using Cooling Aggregates in Switching Cabinets Cooling aggregate on the front of the switching cabinet o Ja Incoming air Outgoing air Cooling aggregate R R 959599999 Switching cabinet 5 s 6660666060006 Incoming air 4 2 Switching cabinet Air duct Cooling aggregate gt gt 99399 Outgoing air 80 Figure 16 Cooling aggregate on the front of the switching cabinet ACOPOS User s Manual V1 Dimensioning Power Mains Connection CHAPTER 4 DIMENSIONING 1 Power Mains Connection 1 1 General Information 1 1 1 System Configuration The power mains connection is made using terminals X3 L1 L2 L3 and PE The ACOPOS servo drives can be directly connected to TT and TN systems these are three phase systems with grounded neutral When using ungrounded IT systems three phase systems without grounded neutral isolation transformers must be used The secondary neutral must be grounded and connected to the ACOPOS protective ground conductor In this way it is possible to prevent overvoltages between external conductors and the ACOPOS housing Three p
8. Image Connection Pin Description Function in Function in SSI Incremental Mode Mode 1 A Channel A 2 A Channel A inverted 3 B Channel B 4 B Channel B inverted 5 RD Reference pulse Data input 6 RD Reference pulse Data input inverted inverted 15 a 7 T Clock output 8 Clock output inverted 9 1 9 5V out 0 35A Encoder supply 5 V 10 Sense 45V Sense 45 V 11 Sense COM Sense 0 V 12 COM 7 9 13 Encoder supply 0 V 13 15V 0 35 Encoder supply 15 V 14 A1 Activate encoder supply 1 15 2 Activate encoder supply 1 Table 64 Pin assignments AC123 incremental encoder SSI absolute encoder interface 1 To activate the encoder supply pins 14 and 15 must be connected in ACOPOS User s Manual V1 he encoder cable plug 119 Chapter 5 Wiring Wiring Plug in Module Connections 4 5 AC130 Digital Mixed Module 4 5 1 Pin Assignments Image Connection Pin Description Function 1 Dig 1 01 Digital input output 1 2 Dig I O 2 Digital input output 2 3 Dig 3 Digital input output 3 4 Dig I O 4 Digital input output 4 5 Dig I O 5 Digital input output 5 6 Dig 6 Digital input output 6 7 Dig I O 7 Digital input output 7 8 Dig 8 Digital input output 8 9 Dig 09 Digital output 9 10 Dig O 10 Digital output 10 11 24 Supply 24 V 12 COM 1 11 Supply 0 V Terminal Cr
9. Figure 4 Simple Function Test ACOPOS User s Manual V1 17 Chapter 1 General Information General Information ACOPOS Servo Family 1 9 Control Trigger The oscilloscope in the drive allows movements to be monitored in real time Many trigger possibilities allow data required for analysis to be easily obtained The graphic display of diagnosis data supports the user when making fine adjustments and when optimizing the movement Measurement cursor and reference points allow precision amp B amp R Automation Studio lala ax4 waf Zi File View Open Project Trace Object Tools Window 2 la A e 2 100 100 ax4 Lag error vine xpos 0 280400 0 01 deg y pos 0 054688 MUIeS 5 A LL 4 0 05 0 00 0 05 0 10 0 15 0 20 0 25 9 20 0 25 0 40 0 45 254 speed time s controller Set stator current quadravure component time s s 6 280400 pos 2 597068 1 776840 D s ESSA Ri ies a E 2 0 0 o 3 Druki b Ton motor i ATE For Help press F1 COM OFFLINE Figure 5 Control Trigger 18 ACOPOS User s Manual V1 General Information ACOPOS Servo Family 1 10 Cam Profiles for Everyone Modular technology plug ins allow homogenous integration of high performanc
10. Figure 67 Place mouse pointer on the action ncSTART Enter the value e g 5000 for s target position or relative traverse path in the parameter object value column Danger The traverse path must be adjusted for the conditions present installed mechanical parts etc Incorrect control of motors or mechanical parts connected to the motor shaft can cause unwanted and dangerous movements This could result in death severe injury or material damage e Acknowledge by pressing the ENTER key The new value is sent to the PLC ACOPOS User s Manual V1 153 ot sS 80 D Sc OF Getting Started Starting Up an ACOPOS Servo Drive Enabling the Trace Function Position the mouse pointer on the Trace enabled checkbox in the action window e Activate the checkbox by clicking on it with the left mouse button amp B amp R Automation Studio ax1_par waf View Inset Open Project Test Object Tools Window 2 la xl en By 100 100 HERE network 50 d Units encoder i pos 10000 Units s limit 10000 Units s F al pos 50000 Units s ncBASIS MOVE nclNIT HAG controller a2 pos 50000 Units ncCONTROL ncINIT 5 88 move 1 50000 Units s ncCONTROL neSWITCH DF 9 85 stop a2 neg 50000 Units ncCONTROL ncSWITCH ON 1 us h
11. by BER indusine E oktrahik www br autom tion com Automation Studio lej x Tools 7 a For Help press F1 I L Figure 33 B amp R Automation Studio Start up Screen 132 ACOPOS User s Manual V1 Getting Started Starting Up an ACOPOS Servo Drive Open the project recommended make a copy of sample project ACP10 GDM in the respective project path Click Open Project in the File menu B amp R Automation Studio Ee tiet 21 0 o ase Project Save Gaye All 1 CABR_AS_210 acp10 2C BR_AS_210 acp10 Exit Opens an existing project I Figure 34 Opening a project e Select ACP10 PGP ACP10 GDM e Load the project by clicking on the Open button Open zixl S0 A a E es ml meme Files of type Project Files adm Cancel 4 Figure 35 Selecting the project ACOPOS User s Manual V1 133 Getting Started Starting Up ACOPOS Servo Drive The selected project is then opened in the project window B amp R Automation Studio Eie Edit View Insert Open Project Object Tools Window 99 10 Project n Model no Slot Software Log book 1 0
12. 13 General Information 13 N NC Objects sse 16 P Plug in Modules ACTIO i ec eb 36 116 120 odes PR 38 117 AC 122 Me ance 41 118 44 119 i eee 47 120 Current Requirements 100 General Information 14 35 Installation and Removal 74 OVGIVIOW sende notte poe ceed 35 Power Mains Connection 81 Programming 15 Protective Ground Connection PE 82 111 R Resolver Cables Cable Schematic 128 Order Dala 59 Pin 127 Specifications 60 Str clure 127 Resolver Connector Order sees 65 Pin 127 Specifications 67 Resolver Interface 122 42 118 ACOPOS User s Manual V1 Index S Safety Guidelines 22 Sample 130 SOCUMILY setze cr ee 13 14 Servi CO ish cree tae te ee dide 15 Servo Drives ACOPOS 1022 1045 etc 31 108 Cables See Cable Gam Editor utet 19 CONCEP esie 27 Config
13. Permanent Description ACPID Module Name Version Transferto Size bytes Description 2003 cg CPU 4 cM 7CP474 60 1 0 227 Cyclic 1 10 ms 01 AE v0 00 User RAM 7676 y 02 fg ax iste 16265 03 acp10man h 22476 J 04 libacpl man a 2188 9 1 System Es 8v1045 001 fd sysconf v227 UserROM 752 8 110 6011 1 acpl cfg 0472 UserROM 212 20601 2 404 J 3 gcloader 1 31 UserROM 5816 4 4 ncolobal v017 UserROM 8020 y M 4 acpl man 0472 UserROM 66398 acpl par 0472 UserROM 15700 2 ACP10 Real Axis Tg n User 10 Text Module 8 acpi etx v0 00 UserROM 54696 Output Debus Find in Files Software module check Ok Line 16 of 18 COMI 62476 V224 RUN Figure 36 Project window with representation of the hardware and software configuration The left part of the window contains the hardware configuration for the project and the right part of the window contains the software configuration for the hardware component selected in the left part of the window Information When loading the project a connection is automatically established between the PC and the PLC If the connection is active the CPU type and RUN are shown to the right below the status bar see Figure 36 Project window with representation of the hardware and software configuration 134 ACOPOS User s Manual V1 Getting Started
14. nennen 99 5 Current Consumption of ACOPOS Plug in Modules 100 6 Formula Variables Used rece ree e d den 101 ACOPOS User s Manual V1 9 Table of Contents Chapter 5 Wiring ntn sre rna s de cnn iis 103 1 General Information rd e ee edd 103 1 1 Electromagnetic Compatibility of the Installation 103 1 GeneralInforriatior i tete te etd et edere etta dd d 103 1 1 2 Installation Notes 104 1 2 Overview of the Terminal Cross Sections 2 107 2 Connections ACOPOS 1022 1045 1090 108 2 1 Pin Assignments for Plug 109 2 2 Pin Assignments for Plug X2 tiet decet ce tee iei ter c een Ve prd 109 2 3 Pin Assignments for Plug 110 2 4 Pin Assignments for Plug X4 sssssssssseseeee enne enne nnne nennen 110 2 5 Pin Assignments for Plug X5 sssssssssseeeee eene nennen neret ens 110 2 6 Protective Ground Connection PE sss nenne 111 3 Connections ACOPOS 1640 128M emen 112 3 1 Pin Assignments for Plug XI sssri eniai nennen nnne 113 3 2 Pin Assignm nts X2 iii eet E HE 113 3 3 Pin Assignments for X3
15. Inputs Number of Inputs max 8 Wiring Sink Electrical Isolation Input ACOPOS Yes Input Input No Input Voltage Minimum 18 VDC Nominal 24 VDC Maximum 30 VDC Switching Threshold LOW 5V HIGH gt 15V Input Current at Nominal Voltage Inputs 1 4 Approx 10 mA Inputs 5 8 Approx 5 5 mA Switching Delay Inputs 1 4 Max 5 us Inputs 5 8 Max 35 us Event Counter Signal Form Square wave pulse Input Frequency Max 100 kHz 48 Table 22 Technical Data AC130 ACOPOS User s Manual V1 Technical Data ACOPOS Plug in Modules Product ID 8AC130 60 1 Counter Size 16 bit Inputs Input 1 Counter 1 Input 2 Counter 2 Incremental Encoder Signal Form Square wave pulse Evaluation 4 fold Encoder Monitoring No Input Frequency Max 62 5 kHz Count Frequency Max 250 kHz Reference Frequency Max 62 5 kHz Distance between Edges Min 2 5 us Counter Size 16 bit Inputs Input 1 Channel A Input 2 Channel B Input 3 Reference Pulse R Outputs Number of Outputs max 10 Type Transistor Outputs Outputs 1 4 push pull Outputs 5 10 high side Electrical Isolation Output ACOPOS Yes Output Output No Switching Voltage Minimum 18 VDC Nominal 24 VDC Maximum 30 VDC Continuous Current Outputs 1 4 Max 100 mA Outputs 5 8 Max 400 mA Outputs 9 10 2 Switching Delay Outputs 1 4 Max 5 u
16. 9 5 116 Table 61 Pin assignments for AC110 CAN Interface ACOPOS User s Manual V1 4 2 AC120 EnDat Encoder Interface 4 2 1 Pin Assignments Wiring Plug in Module Connections Image Connection Pin Description Function 1 A Channel A 2 COM 1 3 9 11 13 15 Encoder supply 0 V 3 B Channel B 4 5V out 0 25A Encoder supply 5 V 5 D Data input 6 15 7 R Reference pulse inverted 8 T Clock output 9 A Channel A inverted 1 10 Sense COM Sense input 0 V 11 B Channel B inverted 12 Sense 45V Sense input 5 V 13 D Data inverted 14 R Reference pulse 15 T Clock output inverted Table 62 Pin assignments for AC120 EnDat Encoder Interface ACOPOS User s Manual V1 117 Chapter 5 Wiring 4 3 AC122 Resolver Interface 4 3 1 Pin Assignments Wiring Plug in Module Connections Image Connection Pin Description Function 1 2 3 Cos Cosine input 4 Sin Sine input 5 Ref Reference Output 6 9 5 7 Cosine input inverted 8 Sin Sine input inverted 6 1 9 Ref V Reference output inverted Table 63 Pin assignments for AC122 Resolver Interface 118 ACOPOS User s Manual V1 Wiring Plug in Module Connections 4 4 AC123 Incremental Encoder and SSI Absolute Encoder Interface 4 4 1 Pin Assignments
17. USA 888 932 9183 CANADA 805 828 2505 Over 100 years cumulative experience 24 hour rush turnaround technical support service Established 1993 The leading independent repairer of servo motors and drives in North America Visit us on the web Www servo repair com www servorepair ca www ferrocontrol com www sandvikrepair com www accuelectric com Scroll down to view your document For 24 7 repair services USA 1 888 932 9183 Canada 1 905 829 2505 Emergency After hours 1 416 624 0386 Servicing USA and Canada Perfection in Automation ACOPOS User s Manual V1 ACOPOS USER S MANUAL V1 Version 1 0 February 2002 Mod MAACP1 E We reserve the right to change the contents of this manual without warning The information contained herein is believed to be accurate as of the date of publication however Bernecker Rainer Industrie Elektronik Ges m b H makes no warranty expressed or implied with regards to the products or the documentation contained within this book Bernecker Rainer Industrie Elektronik Ges m b H shall not be liable in the event of incidental or consequential damages in connection with or arising from the furnishing performance or use of these products The software names hardware names and trademarks used in this document are registered by the respective companies ACOPOS User s Manual V1 1 ACOPOS User s Manual V1 CHAPTER 1 GEN
18. Model Number Short Description Image Motor Cables 10 mm 8 005 12 5 Motor cable length 5m 4 x 10mm 2 2 1 5mm motor connector 8 pin Intercontec socket can be used in cable drag chains UL CSA listed 8 007 12 5 Motor cable length 7m 4 x 10mm 2 2 1 5 motor connector 8 Intercontec socket be used in cable drag chains UL CSA listed 8 010 12 5 Motor cable length 10m 4 x 10mm 2 x 2 x 1 5mm motor connector 8 pin Intercontec socket can be used in cable drag chains UL CSA listed 8 015 12 5 Motor cable length 15m 4 x 10mm 2 x 2 x 1 5mm motor connector 8 pin Intercontec socket can be used in cable drag chains UL CSA listed 8CM020 12 5 Motor cable length 20m 4 x 10mm 2 x 2 x 1 5mm motor connector 8 pin Intercontec socket can be used in cable drag chains UL CSA listed 8 025 12 5 Motor cable length 25m 4 x 10mm 2 x 2 x 1 5mm motor connector 8 pin Intercontec socket can be used in cable drag chains UL CSA listed Motor Cables 35 mm 8 005 12 8 Motor cable length 5m 4 x 35mm 2x2x1 5mn can be used in cable drag chains UL CSA listed 8 007 12 8 Motor cable length 7m 4 x 35mm can be used in cable drag chains U 2x2x1 5mm L CSA listed 8CM010 12 8 Motor cable length 10m 4 x 35mm 2 x 2 x 1 5mm can be used in cable
19. W Pencoder W 0 6 W The power consumed by the encoder Pengoder is calculated from the selected encoder supply voltage 5 V 15 V and the current required PEncoder W UEncoder Encoder The following values must be used for k 1 2 for 15 encoder supply 1 75 for 5 V encoder supply 3 A cable with at least 4 x 2 x 0 14 mm 2 x 0 5 mm is required for the maximum cable length The sense lines must be used 4 With shielded cable single shield and twisted pair signal lines e g 4 x2 x 0 14 mm 2 x 0 5 mm Both screws on the module must be tightened 5 Incremental encoders can be used as motor feedback only for asynchronous motors but can only provide limited control quality for this purpose An encoder with at least 1000 lines must be used for motor feedback 46 ACOPOS User s Manual V1 Technical Data ACOPOS Plug in Modules 2 7 AC130 Digital Mixed Module 2 7 1 General Description The 130 plug in module can be used in an ACOPOS slot A maximum of 8 digital inputs or 10 digital outputs are available points can be configured in pairs as inputs or outputs The first three inputs have incremental encoder functionality A B R The first two outputs can be operated in pulse width modulation PWM mode The inputs are divided into 4 standard max 10 kHz and 4 high speed max 100 kHz inputs The outputs include 4 high speed push pull outputs with a maximum curren
20. 130 60 1 42 0000000 47 101010 a 57 8 007 12 1 4100 57 8 010 12 1 4 4 11 57 8 015 12 1 4 0000 57 8 020 12 1 57 8 025 12 1 57 8CM005 12 1 esses 52 8CM005 12 3 ess ees 52 8 005 12 5 000000 53 8 005 12 8 0 0040 ees 53 8CM007 12 1 esses 52 8 007 12 3 2 0000 52 8 007 12 5 000000 53 8 007 12 8 0004 ees 53 8CM010 12 1 sess 52 8 10 12 3 52 8CM010 12 5 eeess ees 53 8 0 10 12 8 2 3 53 8CM015 12 1 esses 52 8CM015 12 3 esss ees 52 8 015 12 5 000000 53 8 15 12 8 53 8 20 12 1 3 52 8 20 12 3 52 8 20 12 5 53 8 20 12 8 53 8 25 12 1 3 52 8 25 12 3 3 52 8 025 12 5 200000 53 8 25 12 8 53 8 005 12 1
21. Ca Adit Be 114 3 4 Pin Assignments for Plug X4 2 2 4 2 101 00 114 3 5 5 lt ete aE e e ses 115 3 6 Pin Assignments for 5i eee ERE RE ERR Re tea eet 115 4 Plug in Module Connections nennen nennen enn 116 AC110 CAN Interface i idee eee eet e e ea reca dd did 116 4 1 1 PIDE ASSIgnrrients cae cene on etre ter ee pene 116 4 2 AC120 EnDat Encoder Interface nennen 117 42 1 PinAssignments 52 cre rrr ett ete i oe Fat int Pa e marine s 117 4 3 AC122 Resolver Interface sette na 118 4 3 1 Pim Assignments erm eee E OE UR USE PR Ro A ERA 118 4 4 AC123 Incremental Encoder and SSI Absolute Encoder Interface 119 4 4 1 Pin Assignments oot e ku t ER EL 119 4 5 AC130 Digital Mixed Module sese 120 4 5 1 Pin Assignments eene ceto vede e C GRE a Ue TER 120 4 6 Connecting Cables to Plug in Modules 2004224 10 121 5 Cables e 122 BL Motor Cable iode eri tt itte ette re prece pe ie ET Ere itr pee tsi et 122 5 1 1 Motor Cable Construction 2 122 5 1 2 Pin Assignments 8 12 1 8 12 3
22. Durability Oil resistant according to VDE 0472 part 803 as well as standard hydraulic oil Certification UL AWM Style 20669 90 600 V E63216 and CSA AWM 90 600 V FT1 1146064 Conductor Power Lines 10 mme tinned Cu wire 35 mm tinned Cu wire Wire Insulation Special thermoplastic material Wire Colors Black brown blue yellow green Signal Lines 1 5 mme tinned Cu wire Wire Insulation Special thermoplastic material Wire Colors White white red white blue white green Cable Construction Power Lines Stranding No Shield No Signal Lines Stranding White with white red and white blue with white green Shield Separate shielding for pairs tinned Cu mesh optical coverage gt 85 and foil banding Cable Stranding With filler elements and foil banding Cable Shielding Tinned Cu mesh optical coverage gt 85 and wrapped in isolating fabric Outer Sheathing Material PUR Color Orange similar to RAL 2003 flat Labeling BERNECKER RAINER 4x10 0 2x2x1 5 FLEX BERNECKER RAINER 4x35 0 2x2x1 5 FLEX Electrical Characteristics Conductor Resistance Power Lines lt 2 1 lt 0 6 O km Signal Lines lt 14 QO km lt 14 QO km Insulation Resistance gt 200 per km Isolation Voltage Wire wire 3kV Wire shield 1kV Operating Voltage Max 600 V Table 25 Cable specifications for 10 and 35 mm motor cables ACOPOS User s Manual V1 55 Chapter 2 Technical Data Technical Data Cabl
23. 81 1 1 2 Supply Voltage Range 81 1 1 3 Protective Ground Connection PE ssssseeeeeeneennee enne 82 fects Re FDA ne Pe unie dete re Pere 83 1 2 1 Individual ACOPOS Power Mains Connections 2 83 1 2 2 Implementing ACOPOS Power Mains Connections for Drive Groups 86 1 3 Current Protection 87 1 3 1 Rated Fault Current esee 87 1 3 2 Estimating the Discharge Current eene 88 1 3 3 Manufacturer Used 2 0404424 0 0 0 0 nennt 88 2 BUS n 89 2 1 General Information 89 2 2 WINING ete uns TS 90 2 3 Equal Distribution of the Applied Power via the Power Rectifiers 91 2 4 Equal Distribution of the Brake Power on the Braking Resistors 91 3 Motor Connection cree tee t d x eee eee eet 92 4 Braking ResISEOL iie Beni RR RU RR 94 4 4 General MfOnmation 4 52 bete teta tuae lel ed e de 94 4 2 Braking Resistor Connection nennen nene ene 95 4 3 Dimensioning the Brake Resistor 96 4 4 Setting Brake Resistor Parameters
24. Figure 66 Defining the software end switches Now the values can be adjusted to the mechanical parts used and acknowledged by pressing the ENTER key 152 ACOPOS User s Manual V1 Getting Started Starting Up an ACOPOS Servo Drive Entering the Traverse Path Position the mouse pointer on the action ncSTART for the subject ncREL_MOVE in the action window XU Automation Studio ax1_par waf Test Eile Edit View Insert Open Project Test Object Tools Window 7 1 x 10 99 D 1002 100 D FE network at par Value Unit 8 BS di U 95 dig in 8 4 Units T Trace enabled E pae encoder v pos 10000 Urits s Subject adm pw 5000 lr it ie 500 are EF al neg nits ONTROL reS Eee ncHOMING ncSTART BE homing ncLIMITS nclNIT CHB basis ncREL MOVE overide ncSERVICE ncREAD ncD parameter ncSERVICE ncSET ncDAT te oo neSIMHL ATINA neGWiTCH 9 ug stp xj New Chart 1 Univx ee al 3 Parameter Value Unit SH psrnetworki ncTRUE 5 aw par network MED par network 0 2 awl par network 0 ax1_par monitor s 0 Units axl par monitor v 0 Unis u i ES RESP PESE 0 0 20 0 30 6 50 0 50 0 100 0 Transferring ax tst ok 4 gt Find in Files atte ress 295224 AUN
25. 020 12 1 cable length 20m 10 x 0 EnDat connector 17 pin Intercon connector 15 pin DSUB plug can chains UL CSA listed ec 14mm 2 x 0 5mm Servo be used in cable drag 8 025 12 1 EnDat cable length 25m 10 x 0 EnDat connector 17 pin Intercon ec 14mm 2 x 0 5mm Servo connector 15 pin DSUB plug can be used in cable drag chains UL CSA listed Table 15 Order Data AC120 ACOPOS User s Manual V1 39 Chapter 2 Technical Data 2 4 3 Technical Data Technical Data ACOPOS Plug in Modules Product ID 8AC120 60 1 General Information C UL US Listed Yes Module Type ACOPOS plug in module 91011 Currently limited slots 2 and 3 Power Consumption EnDat single turn 512 lines E1 EnDat multi turn 512 lines E2 EnDat single turn 32 lines inductive EnDat multi turn 32 lines inductive 1 7 W 2 3 W In preparation In preparation Encoder Input Connection Module Side 15 pin DSUB socket Indications UP DN LEDs Electrical Isolation No EnDat Encoder ACOPOS Encoder Monitoring Yes Resolution 2 8000 number of encoder lines e g 4 million incr rev for 512 line encoders Precision 3 Sine Cosine Inputs Signal Transfer Differential Signals Signal Frequency DC 400 kHz Serial Interface
26. 145 ot sS 80 D Sc OF Getting Started Starting Up ACOPOS Servo Drive 2 2 4 Downloading the Project After making the preparations the project can now be transferred to the target system e Inthe Project menu click on Transfer To Target amp B amp R Automation Studio acp10 Project Eie View Insert Open Project Object Tools Window 2 De ng 5 Se 24 Description User RAM 9 8v1045 001 User ROM Z GACI20601 4 acpl0sys User ROM gcloader User ROM y 4 ncglobal User ROM 3 d acpl man User ROM 8AC110 60 1 1 42 x User ROM ij 10 User ROM 55 10 Real Axis z NE User RAM HE ACP10 Error Text Module LiB 1 vo User ROM Output Find in Files Transfers the entire project to the target Line 16 of 18 COMi 69475 V224 Figure 56 Click on the command to transfer the project to the target system 146 ACOPOS User s Manual V1 Getting Started Starting Up ACOPOS Servo Drive If an operating system has already been transferred to the PLC a version conflict could occur In this case the operating system on the PLC is to be applied to the operating system in the sample project e Select option Apply the current version perating System Mismatch x The OS version used in your project is not the same as on the target Mismatch detail Project Targ
27. 44 119 166 Resolver interface 42 118 EnDat Cables Cable 126 Order Data utc enu 57 Pin Assignments 125 57 Str cl re eerte Hed 125 EnDat Connector Order Dat a 65 Pin Assignments 125 Specifications 22 66 EnDat Encoder Interface AC120 39 117 F Formula Variables 101 Function Test 17 155 G Getting Started 129 Gudele S 159 l Incremental SSI Encoder IF AC123 44 119 Installation 23 69 103 Installation Dimensions 71 L Limit a 160 Modular Servo Drive Concept 27 Motor Cables Cable Schematic 123 124 Order 52 Pin Assignments 123 124 54 SUUCHUIE 122 ACOPOS User s Manual V1 Motor Connectors Order Data needs 62 Pin Assignments 123 124 Specifications 63 Motors Configurations 20 Embedded Parameter Chip
28. 5 e ig Trigger P H rigger2 L COM 1 2 X14 Ls 7 Shield 924 V End qd End LLL Ti ger X1 24 t MVis Enable MS n i ns 4 ecen c ove 88 j COM 5 8 ACOPOS x5 X6 2 1640 128M 8V1640 00 1 8V128M 00 1 1 1 1 24V out 0 5A COM 7 9 10 COM 7 9 10 COM 7 9 10 7 59 3 400 480 VAC 50 60 Hz 2 gt Figure 25 Connection overview 1640 128M 1 Connections X1 COM 5 8 and X4 COM 7 9 10 are internally connected in the device 112 ACOPOS User s Manual V1 Wiring Connections ACOPOS 1640 128M 3 1 Pin Assignments for Plug X1 xi Pin Description Function 1 Trigger Trigger 1 2 Quickstop Trigger2 Quickstop Trigger 2 3 COM 1 2 Trigger 1 Quickstop Trigger 2 0 V 4 Shield Shield Y e 5 End Positive HW limit x 6 End Negative HW limit 2 7 Ref Reference switch e 8 Enable Controller enable 9 10 11 12 5 8 Supply 0 V Terminal Cross Sections see Table 48 Terminal cross sections for ACOPOS servo drives on page 107 Table 55 Pin assignments for plug X1 ACOPOS 1640 128M 3 2 Pin Assignments for X2 X2 Pin Desc
29. The cross section of the DC bus wiring should then be selected as described in chapter 5 Wiring Table 48 Terminal cross sections for ACOPOS servo drives on page 107 so that the maximum current load of the cable cross section is greater than or equal to the thermal equivalent effective value of the compensation current gt Iq ACOPOS User s Manual V1 91 Chapter 4 Dimensioning Dimensioning Motor Connection 3 Motor Connection On B amp R motors the power connections the connections for the holding brake and the connections for the motor temperature sensor are all made using the same motor plug On the servo drive the motor connection is made using terminals X5 U V W and PE as well as terminals X4 B and T The motor connection must be shielded correctly see chapter 5 Wiring Section 1 1 Electromagnetic Compatibility of the Installation The structure of the motor connection can be seen in the following diagram i 12 EnDat 41 6 Resolver Figure 20 ACOPOS X4 X5 circuit diagram motor connection The cross section of the motor cable must be dimensioned for the thermal equivalent effective value of the motor current 1 If the motor is dimensioned correctly the nominal current for the motor can also be used here 1 If information concerning load torque inertia and friction are available the thermal equivalent effective value for the motor current of t
30. Starting Up ACOPOS Servo Drive 2 2 2 Preset Values for the Sample Project A few preset values must be defined on the target system before downloading the project CPU The sample project was originally created for a different PLC CPU 7CP474 60 1 This must be changed to the CPU used on the target system shown to the right under the status bar e In the left part of the window position the mouse pointer on the CPU 7CP474 60 1 B amp R Automation Studio File Edit View Insert Open Project Object Tools Window 2 D Sag 99 acp10 Project n Model no Software Log book CAN 1 0 Permanent Description Module Name Version Transferto Size bytes Description CPU SH Cyclic 1 10 ms S aw tst v0 00 User 7676 16265 acpl man h 22476 libacpl man a 2188 9 System 8v1045 0041 5 syscont 227 UserROM 752 8AC110 601 1 4 acpl c g 0472 UserROM 212 8AC120 60 1 2 M 4 3 gcloader via UserROM 5816 9 4 4 ncolobal V017 UserROM 8020 9 M M acpl man 0472 UserROM 66398 acpl par 047 2 UserROM 15700 55 ACP10 Real Axis Tg axl par v0 00 User 360 EE 10 Enor Text Module 8 acpi etx v0 00 UserROM 54696 1 Findin Fies COM CP476 V224 RUN Figure 37 Select the CPU in the left part of the window ACOPOS User s Manual V1 135 Chapter
31. The DC bus connections must be wired correctly no short circuits ground faults or reverse polarity A suitable measure to ensure that the wiring is secure against short circuits and ground faults 1 is the use of corresponding cabling Special rubber insulated wires with increased resistance to heat 90 of types e NSGAOU e NSGAFOU e NSGAFCMOU with a nominal voltage U U of at least 1 7 3 kV are considered to be secure against short circuits and ground faults in switchgear and distribution systems up to 1000 V 2 1 Cabling e g according to DIN VDE 0100 part 200 Electrical systems for buildings terms item A 7 6 2 See e g DIN VDE 0298 part 3 Use of cables and insulated wires for high voltage systems item 9 2 8 90 ACOPOS User s Manual V1 Dimensioning DC Bus 2 3 Equal Distribution of the Applied Power via the Power Rectifiers When creating a DC bus connection between several servo drives it is possible that the parallel connection of the power rectifiers causes incorrect distribution of the applied power To prevent this undesired effect appropriately dimensioned shunt resistors are integrated in the ACOPOS servo drives The following rules must be observed so that the effect of these shunt resistors is not cancelled out The length of the DC bus wiring is not allowed to exceed a total length of 3 m and must be within a single switching cabinet e Dimensioning the cross section of the ACOPOS servo d
32. 1 Unusual operating conditions must be arranged with B amp R 162 ACOPOS User s Manual V1 Standards and Certifications 6 International Certifications B amp R products and services comply with the applicable standards These are international standards from organizations such as ISO IEC and as well as national standards of organizations such as UL CSA FCC VDE VE etc We give special consideration to the reliability of our products in an industrial environment Certifications USA and Canada c UL us All important B amp R products are tested and listed by Underwriters Laboratories and are checked quarterly by a UL inspector This mark is valid for the USA and Canada and eases certification of your machines and Systems in these areas Listing is planned for ACOPOS servo drives Europe Ky All harmonized EN standards for the valid guidelines are met Russian Federation GOST R certification is planned for the export of ACOPOS servo drives in the Russian Federation ACOPOS User s Manual V1 Table 80 International Certifications 163 Chapter 7 Standards and Certifications Standards and Certifications 164 ACOPOS User s Manual V1 Numerics 8 110 60 2 36 8 120 60 1 39 INOLA 0 42 8 123 60 1 2 44
33. 107 17 155 Transport 2 nr eta 22 He 18 103 ACOPOS User s Manual V1 MAACP1 E
34. 35 16 35 lt 2 Table 38 Selection of the protective ground conductor cross section Increased Discharge Current ACOPOS servo drives are devices with increased discharge current larger than 3 5 mA AC or 10 mA DC Therefore a fixed immobile protective ground connection is required on the servo drives The following conditions must be met depending on the ACOPOS device being used ACOPOS Conditions Image 1022 In addition to the connection of the first protective ground 1045 conductor on terminal a second protective ground 1090 conductor with the same cross section must be connected on the designated terminal threaded bolt M4 1640 The cross section of the protective ground conductor 128M connected to terminal X3 PE must be at least 10 mm Cu 82 Table 39 Protective ground conditions according to ACOPOS device ACOPOS User s Manual V1 Dimensioning Power Mains Connection 1 2 Dimensioning In general dimensioning the power mains the overcurrent protection and the line contactors depend on the structure of the power mains connection The ACOPOS servo drives can be connected individually each drive has separate overcurrent protection and if necessary a separate line contactor or together in groups 1 2 1 Individual ACOPOS Power Mains Connections The structure of an individual power mains connection with line contactor and circuit breaker can be seen in the f
35. C to 125 C Housing Material Zinc casting nickel plated Gaskets Viton H NBR Crimp Range 12x0 06 1 mm Cable 5 5 10 5 mm Manufacturer Information Manufacturer INTERCONTEC Internet Address http www intercontec com Manufacturer s Product ID ASTA 021 FR 11 10 0005 000 Table 35 Specifications for Resolver Connector 8PRO01 00 1 ACOPOS User s Manual V1 67 Chapter 2 Technical Data 68 Technical Data Connectors ACOPOS User s Manual V1 Installation General Information CHAPTER 3 INSTALLATION 1 General Information Make sure that installation takes place on a flat surface which is correctly dimensioned The dimensional diagram lists the number and type of mounting screws to be used The ring screws contained in the delivery can be attached to the device to lift ACOPOS 1640 and ACOPOS 128M drives ACOPOS
36. EnDat connector 17 pin In connector 15 pin DSUB plu chains UL CSA listed 0 0 14 2 x 0 5mm ercontec socket servo g can be used in cable drag 8CE025 12 1 EnDat cable length 25m 1 0x0 14mme 2 x 0 5mm EnDat connector 17 pin In connector 15 pin DSUB plu chains UL CSA listed ercontec socket servo g can be used in cable drag Table 26 3 3 2 Cable Specification Order Data EnDat Cables Product ID EnDat Cables General Information Cable Cross Section 10x0 14 mm 2 x 0 50 mm Durability Oil resistant according to VDE 0472 part 803 as well as standard hydraulic oil Certification UL AWM Style 20963 80 C 30 V E63216 and CSA AWM 90 30 V FT1 LL46064 Conductor Signal Lines 0 14 tinned Cu wire Wire Insulation Special thermoplastic material Wire Colors Blue brown yellow gray green pink red black violet white Supply Lines 0 5 mme tinned Cu wire Wire Insulation Special thermoplastic material Wire Colors White green white red Table 27 Cabl ACOPOS User s Manual V1 e specifications for EnDat cables 57 Chapter 2 Technical Data Technical Data Cables Product ID EnDat Cables Cable Construction Signal Lines Stranding No Shield No Supply Lines Stranding White red with white green and filler elements Shield No Cable Str
37. 15V 350 mA Short Circuit Overload Protection Yes Incremental Encoder 5 Signal Form Square wave pulse Evaluation 4 fold nput Frequency Max 200 kHz Count Frequency Max 800 kHz Reference Frequency Max 200 kHz Distance between Edges Min 0 6 us Counter Size 32 bit nputs Differential Voltage Inputs A B Minimum 25V Maximum 6v ACOPOS User s Manual V1 Table 20 Technical Data AC123 45 Chapter 2 Technical Data Technical Data ACOPOS Plug in Modules Operation Product ID 8AC123 60 1 SSI Absolute Encoder Baud Rate 200 kBaud Word Size Max 31 bit Differential Voltage Clock Output 120 Minimum 25V Maximum 5V Differential Voltage Data Input Minimum 25V Maximum 6v Operational Conditions Environmental Temperature during 0 to 50 C Relative Humidity during Operation 5 to 95 non condensing Storage and Transport Conditions Storage Temperature 25 to 55 C Relative Humidity for Storage 5 to 95 non condensing Transport Temperature 25 to 70 C Relative Humidity for Transport 95 at 40 C non condensing Table 20 Technical Data AC123 cont 1 Two modules can also be inserted In this case the module in slot 2 is automatically used for motor feedback 2 The power consumption of the plug in module can be approximated using the following formula
38. 4 ax par network 5 i ax1_par network 0 4 0 1 E al par network 0 ax1_par monitor s 0 Units EE EORR se sa asa se npe inii iM ax par monitor v 0 Unis 0 0 ED 9 0 20 0 40 0 50 0 80 0 100 0 x Transferring ax tst ok Output Find in Files For Help press F1 1 476 V2 24 RUN Figure 70 During the movement of the shaft the traverse path already completed is shown in the Watch window amp B amp R Automation Studio ax1_par waf 8 x CENTECUNI ON Tae coo ioe 1 9 9 P 100x 100 network E digin Units 9 88 encoder Units s dni Units s neBASIS_MOVE nclNIT 9 02 controller Units ncCONTROL nciNIT EM move Units s ncCONTROL ncSWITCH DF Be stop Units s ncCONTROL ncSWITCH ON ncHOMING ncSTART 9 98 homing ncLIMITS nclNIT Y 9 parameter ncREL MOVE 2 88 basis neSERVICE ncREAD 0 vanis neSERVICE ncSET ncDAl nc SIMI IL ne SWITCH zi New Chart 1 100 0 80 0 L 1 69 9 ax par network 5 ax par network 0 parnetwork 0 par monitor s 5000 Units 20 0 7 NP T par GES REY PI _pa mo
39. 6 Getting Started Getting Started Starting Up an ACOPOS Servo Drive e Open the shortcut menu with the right mouse button Position the mouse pointer on Replace with 7CP476 60 1 Select this menu item with the left mouse button B amp R Automation Studio Ele View Inset Open Project Object Tools Window 7 05 99 10 Project Software Log book CAN 1 0 Permanent Description Module Version Transerto Size bytes Description CPU m 10 ms v0 00 UserRAM 7676 16265 p10manh 22476 cpl man a 2188 8 1045 0041 227 UserROM 752 Dcto v0472 UserROM 212 8AC120 60 1 M 4 gcloader 1 31 UserROM _ 5816 4 4 ncolobal 017 UserROM 8020 9 M M acpi man v0472 UserROM 56388 i 1 0 47 2 UserROM 15700 55 2 ACP10 Real Axis par 0 00 User RAM 360 HE 10 Error Text Module 8 acpi etx v0 00 UserROM 54696 Debug Fies COMi 0 476 V224 RUN Figure 38 Select the command used to replace the CPU from the shortcut menu e Acknowledge the change of the CPU by clicking on the OK button Replace module x Replacing a module is potentially dangerous All data which cannot be adopted will be lost Figure 39 Acknowledge the change of the CPU 136 ACOPOS User s Manual V1 Getting Started Sta
40. All cables can be used for drag chain installations To prevent disturbances to encoder signals the holding brake and temperature sensor wires are in the motor cable and not in the EnDat or resolver cable 3 1 1 Manufactured Cables Using the B amp R cable guarantees that the EMC limits are not exceeded The cables are manufactured in the EU and are therefore subject to the strictest quality standards Information If other cables are used make sure that they have the same wave parameters If deviations exist additional measures are necessary to ensure that EMC guidelines are met ACOPOS User s Manual V1 51 Chapter 2 Technical Data Technical Data Cables 3 2 Motor Cables 3 2 1 Order Data Model Number Short Description Image Motor Cables 1 5 mm 8 005 12 1 Motor cable length 5m 4 x 1 5mm 2 x 2 x 0 75mm motor connector 8 pin Intercontec socket can be used in cable drag chains UL CSA listed 8 007 12 1 Motor cable length 7m 4 x 1 5mm 2 x 2 x 0 75mm motor connector 8 pin Intercontec socket can be used in cable drag chains UL CSA listed 8 010 12 1 Motor cable length 10m 4 x 1 5mm 2x 2 x 0 75mm motor connector 8 pin Intercontec socket can be used in cable drag chains UL CSA listed 8 015 12 1 Motor cable length 15m 4 x 1 5mm 2x 2 x 0 75mm motor connector 8 pin Intercontec socket can be used in cable drag chains UL CSA listed 8 020 12 1 Motor c
41. Baud Rate 500 kBit s Network Capable Yes Bus Termination Resistor Externally wired Operational Conditions Environmental Temperature during Operation 0 to 50 Relative Humidity during Operation 5 to 95 non condensing Storage and Transport Conditions Storage Temperature 25 to 55 Relative Humidity for Storage 5 to 95 non condensing Transport Temperature 25 to 70 Relative Humidity for Transport 95 at 40 non condensing Table 13 Technical Data AC110 cont 2 3 4 CAN Node Number Settings The CAN node number can be set using two HEX code switches 1 Code Switch CAN Node Number Top 16s position high Bottom 1s position low Table 14 Setting the CAN node number with the two HEX code switches Changing the node number becomes active the next time the ACOPOS servo drive is switched on There must be a terminating resistor 120 0 25 W between CAN H and CAN L at the beginning and end of the CAN bus 2 3 5 Indications The status LEDs show if data is being received RXD or sent TXD 1 Changing the node number using software is not possible Basis CAN ID can be changed The ACOPOS Manager only supports node numbers from 1 32 When using the NC157 positioning module only node numbers from 1 8 are possible ACOPOS User s Manual V1 37 Chapter 2 Technical Data Technical Data ACOPOS Plug
42. Pin Product ID Function Pin DSUB plug 1 2 3 Cos Cosine input 3 4 Sin Sine input 4 5 Ref Reference Output 5 7 Ia 3 7 Cosine input inverted 7 8 4 8 Sin Sine input inverted 8 5 9 Ref Reference output inverted 9 10 11 12 Table 72 Pin assignments for resolver cables ACOPOS User s Manual V1 127 Chapter 5 Wiring 5 3 3 Cable Schematic Wiring Cables Circular Plug DSUB ink AWG 24 os 9 e 9 1d AWG 24 M 2 gray E rer I AWG 24 na Cos 709 yellow AWG 24 o7 pd reen AWG 24 rg Cos 3 9 i 3 white AWG 24 Pg i b AWG 24 Sim 8 rown AWG 24 E i f 19 91 2o nc 2 nc nc 6 1 Oo 119 10 4 nc 12 04 nc Shield connected to plug housing 128 Figure 30 Cable schematic for resolver cables ACOPOS User s Manual V1 Getting Started Preparation CHAPTER 6 GETTING STARTED 1 Preparation 1 1 Unpacking the ACOPOS Servo Drive Remove the protective packaging from the ACOPOS servo drive Check the ACOPOS servo drive for obvious mechanical damage Danger Do not operate the ACOPOS servo drive if it is damaged This can cause severe personal injury or damage to property 1 2 Installing and Connecting the ACOPOS Servo Drive The guidelines and specifications for
43. Table 52 Pin assignments for plug X4 ACOPOS 1022 1045 1090 2 5 Pin Assignments for Plug X5 X5 Pin Description Function 1 PE Protective Ground Conductor 2 Ww Motor Connection W 3 V Motor Connection V 4 U Motor Connection U e n Terminal Cross Sections see Table 48 Terminal cross sections for ACOPOS servo drives on page 107 Table 53 Pin assignments for plug 5 ACOPOS 1022 1045 1090 110 ACOPOS User s Manual V1 Wiring Connections ACOPOS 1022 1045 1090 2 6 Protective Ground Connection PE The protective ground conductor is connected to the threaded bolt M4 provided using a cable lug For information concerning dimensioning see Chapter 4 Dimensioning Section 1 1 3 Protective Ground Connection PE Image Pin Description Function PE Protective Ground Conductor Terminal Cross Sections mm AWG Cable lug for threaded bolt M4 0 25 6 23 9 Table 54 Protective ground conductor PE ACOPOS 1022 1045 1090 Danger Before turning on the servo drive make sure that the housing is properly connected to ground PE rail The ground connection must be made even when testing the servo drive or when operating it for a short time ACOPOS User s Manual V1 111 Chapter 5 Wiring Wiring Connections ACOPOS 1640 128M 3 Connections ACOPOS 1640 128M
44. by clicking on e Position the mouse pointer on scaling e Expand the view by clicking on e Position the mouse pointer on load The parameters are now shown in the right part of the window par 3 B network HBa dig in HB encoder if 2 8 parameter 2 88 scaling 5 85 limit te controller 3 82 move 4 B message Units rev motor Figure 65 Setting the encoder resolution Now the values can be adjusted to the mechanical parts used and acknowledged by pressing the ENTER key ACOPOS User s Manual V1 151 Chapter 6 Getting Started Getting Started Starting Up an ACOPOS Servo Drive For additional safety the traverse path can be limited using software end switches pos sw end neg sw end The software end switches can be defined as follows e Position the mouse pointer on limit e Expand the view by clicking on e Position the mouse pointer on parameter The parameters are now shown in the right part of the window par exl par Value Unit Fia network V pos 50000 Units s B dig in 50000 Units s 182 encoder f al pos 500000 Units e a2 pos 500000 Units s _ 1 500000 Units 2 8 parameter a2 neg 500000 Units s HBE controller 0 sl 1 Ba move Lin pos 0 s EE message sw end MN neg sw end 2000000000 Units ds_waming 500 Units ds stop 1000 Units
45. cross section rated current for the overcurrent protection Ip mm A 1 5 13 5 13 12 2 10 15 2 13 16 1 16 2 5 18 3 16 16 5 16 21 20 22 20 4 25 25 23 16 28 25 30 25 6 32 32 29 25 36 32 37 32 10 44132 40 32 50 50 52 50 16 60 50 53 63 66 63 70 63 25 77 63 67 63 84 80 88 80 96 80 35 97 80 83 80 104 100 114 100 119 100 50 117 100 103 100 123 100 123 100 145 125 70 149 125 130 125 155 125 155 125 188 160 95 180 160 156 125 192 160 192 160 230 200 Table 41 Maximum current load for PVC insulated three phase cables or individual wires 1 The maximum current load value in 60204 1 is for an environmental temperature of 40 C In IEC60364 5 523 this reference temperature is 30 The values in Table 41 Maximum current load for PVC insulated three phase cables or individual wires on page 85 from IEC60364 5 523 are calculated with the factor 0 87 given in the standard and also at 40 ACOPOS User s Manual V1 85 Chapter 4 Dimensioning Dimensioning Power Mains Connection When determining the cross section for the power mains make sure that the cross section selected is within the range that can be used with power mains terminal X3 see Chapter 5 Wiring Table 48 Terminal cross sections for ACOPOS servo drives on page 107 Dimensioning the Line Contactor The rated current of the line contactor is oriented to the overcurrent protection for the power mains
46. drag chains U L CSA listed 8CM015 12 8 Motor cable length 15m 4 x 35mm 2 x 2 x 1 5mm can be used in cable drag chains U L CSA listed 8CM020 12 8 Motor cable length 20m 4 x 35mm 2 x 2 x 1 5mm can be used in cable drag chains U L CSA listed 8 025 12 8 Motor cable length 25m 4 x 35mm 2 x 2 x 1 5mm can be used in cable drag chains U L CSA listed Table 23 Order Data Motor Cables cont ACOPOS User s Manual V1 53 Chapter 2 Technical Data 3 2 2 Cable Specification Technical Data Cables Product ID Motor Cables 1 5 mm Motor Cables 4 mm General Information Cable Cross Section 4 1 5 mm 2x 2 x 0 75 mme 4 4 2 2 1 Wire Insulation Wire Colors Durability Oil resistant according to VDE 0472 part 803 as well as standard hydraulic oil Certification UL AWM Style 20669 90 C 600 V E63216 and CSA AWM I II 90 600 V FT1 1146064 Conductor Power Lines 1 5 tinned Cu wire 4 mme tinned Cu wire Special thermoplastic material Black brown bl ue yellow green Signal Lines Wire Insulation 0 75 mm tinned Cu wire Special thermo 1 mms tinned Cu wire plastic material Wire Colors White white red white blue white green Cable Construction Power Lines Stranding No Shield No Signal Lines Stranding White with white red a
47. encoder Accessories 7 911 9 Bus connector CAN 2 pcs 8CE005 12 1 EnDat cable length 5m 10 x 0 14mm 2 x 0 5mm EnDat connector 17 pin Intercontec socket servo connector 15 pin DSUB plug can be used in cable drag chains UL CSA listed 8 005 12 1 Motor cable length 5m 4 x 1 5mm 2 x 2 x 0 75mm motor connector 8 Intercontec socket can be used in cable drag chains UL CSA listed 0G0001 00 090 Cable PC lt gt PLC PW RS232 Online cable PLC CPU 7 476 60 1 2003 CPU 750 SRAM 1 5 MB FlashPROM 24 VDC 12 5 W supply 1 RS232 interface 1 CAN interface CAN electrically isolated network capable 4 slots for screw in modules system bus for expansion modules max 272 digital 80 analog I O points B amp R Automation Studio 1A4000 Lx B amp R AutomationSoftware CD full version Table 73 Configuration for the start up example 1 The procedure can change slightly depending on the hardware configuration 130 ACOPOS User s Manual V1 Getting Started Starting Up ACOPOS Servo Drive The hardware configuration will be called the target system in the following sections A PC with B amp R Automation Studio installed will also be needed 2 1 1 Sample Project Several sample projects are available in B amp R Automation Studio which can be used to test ACOPOS servo drives They are found in the directory BRAUTOMATION SAMPLES MOTION in the B amp R Automation Studio installati
48. equipment of machines Part 1 General requirements EN 1037 Safety of machinery prevention of unexpected start up EC 61508 Functional safety of electrical electronic programmable electronic safety related systems EC 954 1 Safety of machinery safety related parts of control systems Part 1 General principles of design TUV Sample test for secure restart prevention according to category 3 planned UL 508 C Power Control Equipment Table 76 Valid Standards for ACOPOS Servo Drives ACOPOS User s Manual V1 159 Chapter 7 Standards and Certifications Standards and Certifications 3 Electrical Limit Values for Immunity Tests according to IEC 61800 3 These immunity tests are valid for in dustry 2nd environment Tests according to IEC 61000 4 2 Electrostatic Discharge IEC 61800 3 Contact discharge to powder coated and bare metal housing parts 4 kV criteria Discharge through the air to plastic housing parts 8 kV criteria B Tests accord ing to IEC 61000 4 3 Electromagnetic Fields IEC 61800 3 Housing completely wired 80 MHz 1 GHz 10 V m 80 amplitude modulation with 1 kHz criteria A Tests according to IEC 61000 4 4 Burst IEC 61800 3 Power lines 2 kV 1 min criteria B direct coupling Lines for measurement and control functions in the process environment 2 kV 1 min criteria Signal interfaces other lines 1 kV 1 min crite
49. installing and wiring the respective ACOPOS servo drive can be found in chapters 3 Installation 4 Dimensioning and 5 Wiring 1 3 Connecting the ACOPOS Servo Drive with a B amp R PLC The ACOPOS servo drives are equipped with a CAN interface which can be used to connect to a B amp R PLC The connection is made using a a CAN cable pin assignments can be found in chapter 5 Wiring and in the User s Manual for the PLC ACOPOS User s Manual V1 129 Chapter 6 Getting Started Getting Started Starting Up an ACOPOS Servo Drive 2 Starting Up an ACOPOS Servo Drive The goal of the following example is move the shaft of a motor connected to an ACOPOS servo drive 5000 units In order to emphasize the important points of starting up the hardware this will be done using an sample project contained B amp R Automation Studio Danger Incorrect control of motors or mechanical parts connected to the motor shaft can cause unwanted and dangerous movements 2 1 General Information The start up procedure described here is based on the following configuration 1 Model Number Short Description Servo Drives 8V1045 00 1 Servo drive 3 x 400 480V 4 4A 2kW line filter and braking resistor integrated Plug in Modules 8AC110 60 1 ACOPOS plug in module CAN interface 8AC120 60 1 ACOPOS plug in module EnDat encoder interface Motor 8MSA4L E0 B4 Motor MSA4 series with EnDat
50. phase or two phase operation because of contact chatter on the line contactor Because of high frequency discharge currents occurring during operation when using long motor cables e Because of an extreme unbalance factor for the three phase system 1 The rated fault current listed by the manufacturer are maximum values which will definitely trip the protective device Normally the protective device is tripped at approximately 60 of the rated fault current ACOPOS User s Manual V1 87 Chapter 4 Dimensioning Dimensioning Power Mains Connection 1 3 2 Estimating the Discharge Current Depending on the connection of the ACOPOS servo drive different discharge currents flow to ground on the protective ground conductor PE Single phase or two phase operation as intermediate state when switching on the line contactor Umainsl V sesiis fmains HZ i CpIF Single phase operation with neutral lab or test operation Umainsl V 2 1 fmains HZ CpIF 2 48 ACOPOS nF 1022 1045 1090 660 1640 128M 241 Table 42 Discharge capacitance Cp 1 Integrated line filter in preparation 1 3 3 Manufacturer Used For example the AC DC sensitive 4 pin fault current protective device F 804 from ABB fault current 300 mA nominal current 63 A can be used Using this fault current protective device approximately 5 ACOPOS 1022 or 1045 1090 can be connected in par
51. pre ler RAM 360 HE 10 Error Text Mod L acpi etx 54696 x Up Transfer to 3 os eal com 62476 V224 RUN Figure 44 Enable transferring the ACOPOS operating system ACOPOS User s Manual V1 139 ot sS 80 D Sc OF ACP10SYS is now enabled shown in black instead of gray and is also transferred the next time the project is downloaded Getting Started Starting Up an ACOPOS Servo Drive amp B amp R Automation Studio acp10 Project File Edt View Insert Open Project Object Tools Window ZG 3 t Big Model no Slot Software Log book Permanent Description E T a ons m Module Name Version Transferto Size bytes Description ni 3 cg CPU 762475501 0 EO Cyclic H 10 ms y 01 SE v0 00 UserRAM 7676 y 02 fg axtstc 16265 9 03 acp10man h 22476 y M libacpl man a 2188 ml System 8v1045001 syscont 227 UserROM 752 8AC110 601 1 acpl cfg 0472 UserROM 212 5 SACT20 60 1 2 User ROM 240416 3 gcloader 1 31 UserROM 5816 9 4 4 ncglobal v0 17 UserROM 8020 9 M 4 acp10man 0472 UserROM 66388 acpl par 0472 UserROM 15700 55 2 ACPIO Real Axis 1 par v0 00 User RAM 360 HE 10 Error Text Module L acpi etx v0 00 UserROM 54696 x Out
52. project was transferred successfully e Acknowledge the message by clicking the OK button 148 ACOPOS User s Manual V1 2 2 5 Test Function Getting Started Starting Up an ACOPOS Servo Drive Now control of the motor shaft can be taken over using the test function ACP10 real axis Position the cursor on the initial parameter module AX1 PAR amp B amp R Automation Studio acp10 Project 2003 752475501 10 B 01 3 02 9 03 04 1 ces 8v1045 001 8AC110 60 1 1 M 120 501 2 3 3 3 4 3 M El Output Find in Files Ele Edt View Insert Open Project Object Took Window 2 Ace oc Software Log book 1 0 Permanent Description 15 CPU 552 Cyclic 1 10 ms S ax tst fe 10 libacpl man 55 System 4 sysconf acpl cfg 4 acpl sys gcloader ncglobal 4 acpl man acpl par 55 ACP10 Real Axis Cum HE 10 Error Text Module 8 acpi etx v0 00 2 24 0472 0472 91 30 017 V0 47 2 V0 47 2 v0 00 x Transferring ax tst ok Description User RAM 7676 User ROM 752 User ROM 212 User ROM 240416 User ROM 5828 User ROM 8020 User ROM 66388 User ROM 15700 User RAM User ROM 54696 Line 16 of 18 COM CP476 V224 RUN Figure 62 Select initial parameter module AX1 PAR ACOPOS User s Manual V
53. quickstop When all changes are made the value list looks like this 1 par Value Unit reference ncACTIV HI pos hw end ncACTIV HI neg hw end ncACTIV HI ncACTIV HI trigger2 ncACTIV Figure 53 Levels after all changes are made 144 ACOPOS User s Manual V1 Getting Started Starting Up ACOPOS Servo Drive Now the object window can be closed Inthe File menu click on Close amp B amp R Automation Studio ax1_par waf Axis File View Open Project Object Tools Window 2 18 New Project UT 5 1 Open Project hit gt a voe reference ncACTIV 1 hw end ncACTIV HI neg hw end nc CTIV trigger ncACTIV_HI trigger2 Close Project Save 5 Save Project Esport Project Save All Page Setup Print Import 1 10 2 _ 5_210 10 Exit Output Find in Files Closes the active document 476 V224 RUN Figure 54 Closing the object window e Acknowledge the changes by clicking the Yes button B amp R Automation Studio Save changes to Ls C BR_AS_210 Samples Motion English C acp1 0 pgp pam ACP10 CPU ax1_par waf No J Cancel Figure 55 Acknowledge level changes The project window will be shown again ACOPOS User s Manual V1
54. used 1 Integrated line filter in preparation ACOPOS User s Manual V1 101 Chapter 4 Dimensioning Dimensioning Formula Variables Used 102 ACOPOS User s Manual V1 Wiring General Information CHAPTER 5 WIRING 1 General Information 1 1 Electromagnetic Compatibility of the Installation 1 1 1 General Information Servo drives are electrical equipment intended for use in industrial and commercial systems ACOPOS servo drives meet the requirements for adherence to the EMC guideline 89 336 EWG regarding electromagnetic compatibility of the installation Under the terms of the EMC guidelines such devices do not require certification because they are intended to be further processed by the competent machine and equipment manufacturer in compliance with the components and cannot be operated independently Evidence of compliance with the limit values required in the EMC guidelines must be provided by the manufacturer or the machine or system operator ACOPOS servo drives fulfill the requirements of IEC 61800 3 industry 2nd environment in regard to disturbance immunity and emitted disturbance When using the servo drives in living areas shops and small businesses additional filtering measures must be implemented by the user ACOPOS User s Manual V1 103 Chapter 5 Wiring Wiring General Information 1 1 2 Installation Notes 104 The switching cabinet or the system must be constructed appropri
55. 0 10 25 7 8 10 50 7 0 lines Flexible and fine wire lines X3 without Wire Tip Sleeves 0 2 4 24 10 4 16 11 5 10 35 7 2 Power Mains with Wire Tip Sleeves 0 25 4 23 10 4 16 11 5 10 35 7 2 Approbation Data UL C UL US E 30 10 12 4 10 2 CSA 28 10 14 4 52 9 Terminal tightening torque value Nm 0 5 0 6 254 9 25 3 Solid core and multiple conductor 014 15 28 16 0 14 1 5 28 16 014 15 28 16 4 lines Motor Flexible and fine wire lines holding without Wire Tip Sleeves 014 15 28 16 014 15 28 16 014 15 28 16 brake with Wire Tip Sleeves 025 05 23 20 0 25 0 5 23 20 025 05 23 20 temperature Approbation Data sensor ULIC UL US 30 14 30 16 30 16 28 16 28 16 28 16 Terminal tightening torque value Nm 0 22 0 25 0 22 0 25 0 22 0 25 Solid core and multiple conductor 02 4 24 10 10 25 7 3 10 50 7 0 lines X5 Flexible and fine wire lines Motor without Wire Tip Sleeves 02 4 24 10 4 16 11 5 10 35 7 2 with Wire Tip Sleeves 025 4 23 10 4 16 11 5 10 35 7 2 power Approbation Data UL C UL US 53 30 10 12 4 10 2 CSA 28 10 14 4 ad 12 2 Terminal tightening torque value Nm Solid core and multiple conductor 2 5 10 13 7 25 10 13 7 lines X6 Flexible and fine wire lines External without Wire Tip Sleeves 05 6 20 9 05 6 20 9 Braking with Wire Tip Sleeves 05 6 20 9 0 5 6 20 9 Approbation Data ULIC UL US 22 8 22 8 CSA 20 8 20 8 Terminal tightening torque value Nm 12 1 6 12 1
56. 1 149 ot sS 80 D Sc OF Getting Started Starting Up an ACOPOS Servo Drive Inthe Open menu click on Test B amp R Automation Studio File Edit View Insert Open Project Object Tools Window 2 Data Types Library Manager Object Declaration Watch Trace e 91399912 Size bytes ax tst v0 00 UserRAM 7676 bte 16265 acp10manh 22476 libacp10man a 2188 c System 8v1045001 fa sysconf 224 UserROM 752 8ACT10 60 1 S MERE i acpl0cfo v0472 UserROM 212 a 8AC120 60 acpl0sys 0472 UserROM 240416 gcloader v1 30 UserROM 5828 4 ncolobal 017 UserROM 8020 4 acpl man 0472 UserROM 66388 acpl par 0472 UserROM 15700 pia ACP10 Real Axis par HE 10 Error Text Module 18 acpi etx v0 00 UserROM 5469 Transferring ax tst ok Line 16 of 18 COM CP476 V224 RUN Figure 63 Command to open the test window The test window is shown amp B amp R Automation Studio ax1_par waf View Insert Open Project Test Object Tools Window 2 eee 100 100 que network BE D Units 2 2 encoder v pos 10000 Units s T p voneg 10000 Units s neBASIS_MOVE nciNIT 1 B amp controler ae au DcCONTROL nciNIT GB move al_neg 50000 Units e DeCONTROL n
57. 123 5 1 3 Cable Schematic for 8 12 1 BCMXXX 12 3 123 5 1 4 Pin Assignments for 8 12 5 124 5 1 5 Cable Schematic for 8 12 5 124 5 2 EnDat Encoder Cables nnne nnne nnns 125 5 2 1 EnDat Encoder Cable Construction sss 125 5 2 2 Pim Assignments eH de c REOR E XE RR ARE EHE ings HERR Ra A ERA 125 5 2 3 Cable Schlemalic eR ete 126 5 3 Resolver Cables E E E A nennen nennen nnn nn nennen nennen rennes 127 5 3 1 Resolver Cable Construction ssssssssssseeeeeeeeeeeenenenen nennen 127 5 3 2 PN Assigriirients rer ae e ee se rte eU 127 5 3 9 Gable Schematic dite 128 10 ACOPOS User s Manual V1 Table of Contents Chapter 6 Getting Started cereus 129 T Preparation mte p rera Me e a UNO Re 129 1 1 Unpacking the ACOPOS Servo Drive sse eene nenne 129 1 2 Installing and Connecting the ACOPOS Servo Drive 129 1 3 Connecting the ACOPOS Servo Drive with a B amp R 129 2 Starting Up an ACOPOS Servo 130 2 1 General 130 2 11 Sample Project
58. 2 1 8CMxxx 12 3 Circular connector Pin Product ID Function 1 U Motor Connection U 2 PE Protective Ground Conductor 3 Motor Connection W 4 V Motor Connection V A Temperature T Temperature C Brake D B Brake Table 67 Pin assignments for motor cable 8 12 1 8CMxxx 12 3 5 1 3 Cable Schematic for 8CMxxx 12 1 8CMxxx 12 3 Motor Plug Wire Tip Sleeves blue 1 5 4 mm EA o pod black 1 5 4 mm 1 4 brown 1 5 4 mm E Loy ellow green 1 5 4 mm bg whit 0 75 1 mm E T white red 0 75 1 mm OE white blue 0 75 1 mm EE T white green 0 75 1 mm o B y All shields connected to the plug Figure 27 Cable schematic for motor cable 8CMxxx 12 1 8CMxxx 12 3 ACOPOS User s Manual V1 123 Chapter 5 Wiring 5 1 4 Pin Assignments for 8CMxxx 12 5 Wiring Cables Circular connector Pin Product ID Function U U Motor Connection U Protective Ground Conductor Motor Connection W V V Motor Connection V 1 Temperature 2 Temperature Brake Brake Table 68 Pin assignments for motor cables 8CMxxx 12 5 5 1 5 Cable Schematic for 8CMxxx 12 5 shields connected to the plug Motor Plug Wire Tip Sleeves bl
59. 2 2A 1kW line filter and braking resistor integrated 8V1045 00 1 Servo drive 3 x 400 480V 4 4A 2kW line filter and braking resistor integrated 8V1090 00 1 Servo drive 3 x 400 480V 8 8A 4kW line filter and braking resistor integrated Accessories S 8 110 60 2 ACOPOS plug in module CAN interface 8 120 60 1 ACOPOS plug in module EnDat encoder interface 8 122 60 1 ACOPOS plug in module resolver interface 8AC123 60 1 ACOPOS plug in module incremental encoder and SSI absolute encoder interface 8AC130 60 1 ACOPOS plug in module 8 digital 1 0 configurable in pairs as 24V input or as output 400 100 2 digital outputs 2A Order TB712 terminal block separately 1 4 2 Technical Data Table 7 Order data ACOPOS 1022 1045 and 1090 Product ID 8V1022 00 1 8V1045 00 1 8V1090 00 1 General Information C UL US Listed Yes Power Mains Connection Mains Input Voltage 3 x 400 VAC to 480 10 Power filter according to IEC 61800 3 A11 second environment Limits from CISPR11 Group 2 Class A Frequency 48 Hz to 62 Hz Installed Load Max 3 kVA Max 5 kVA Max 10 kVA Starting Current 13A 13A 20A Switch on Interval 1 min Power Loss at Max Device Power 120W 180W 200W without Brake Resistor Table 8 Technical data ACOPOS 1022 1045 and 1090 ACOPOS User s Manual V1 31 Chapter 2 Technical Data Technical Data ACOPOS Servo Fami
60. 5 to 95 non condensing Transport Temperature 25 to 70 Relative Humidity for Transport 95 at 40 C non condensing Table 18 Technical Data AC122 cont 1 Two resolver modules can also be inserted In this case the module in slot 2 is automatically used for motor feedback 2 BRX resolvers have 1 primary winding and 2 secondary windings The primary winding is supplied with the reference output Sinusoidal voltages are induced into the secondary windings with amplitudes corresponding to the sine or cosine of the angle of rotation 3 In preparation 4 With B amp R resolver cable Both screws on the module must be tightened ACOPOS User s Manual V1 43 Chapter 2 Technical Data Technical Data ACOPOS Plug in Modules 2 6 AC123 Incremental Encoder and SSI Absolute Encoder Interface 2 6 1 General Description The ACOPOS plug in module AC123 is used to connect standard industrial incremental or absolute encoders with a synchronous serial interface SSI to ACOPOS servo drives For example this allows electronic gears to be configured which read master movements using external encoders If the encoder resolution is high enough motor feedback for asynchronous motors is also possible With incremental encoders the maximum counter frequency is 200 kHz Single and multi turn encoders with a maximum of 31 bits at 200 kBaud can be read as absolute SSI encoders The position is determined cyclica
61. 6 Table 48 Terminal cross sections for ACOPOS servo drives ACOPOS User s Manual V1 107 Chapter 5 Wiring Wiring Connections ACOPOS 1022 1045 1090 2 Connections ACOPOS 1022 1045 1090 3 400 480VAC L2 50 60 Hz 24V Q1 L1 L3 I pel oH 2i DC2 644 D gt lt N gt lt Hed Triggert 28 Quickstop Trigger2 1 2 24V 1 24V t Tits Shield 24V t X1 3 24 1 16 5 8 11 ACOPOS 8V1022 00 1 1022 1045 1090 8V1045 00 1 8V1090 00 1 CAN 111 12 EnDat 77 6 Resolver 108 Figure 24 Connection overview ACOPOS 1022 1045 1090 ACOPOS User s Manual V1 2 1 Pin Assignments for Plug X1 Wiring Connections ACOPOS 1022 1045 1090 xi Pin Description Function 1 Trigger Trigger 1 2 Quickstop Trigger2 Quickstop Trigger 2 3 COM 1 2 Trigger 1 Quickstop Trigger 2 0 V 4 Shield Shield Y e 5 End Positive HW limit x 6 End Negative HW limit 2 7 Ref Reference switch e 8 Enable Controller enable 9 10 11 24 Supply 24 V 12 COM 5 8 11 Supply 0 V Terminal Cross Sec
62. 72 The data recorded is shown in the Trace window The current position of the motor shaft is shown in the Watch window Display of the current position of the motor shaft Before the shaft movement During the shaft movement After the shaft movement a g ncTRUE ncTRUE wl parnetwokink ncTRUE ax par netwotk servi par network servi 0 ax1_par network servi 0 aw parmonitos 5000 Uni ax parmonitorv 0 ET xl par network init ax par netwotk servi par network servi 0 ax1_par network servi 0 axl_par monito s 0 Uni ax1_par monitory 0 ET ax1_par network init ax _par network servi ax1_par network servi 0 ax par network servi 0 axl_par monito s f par monitor v 1 ET nar mecsane nar massana nar mecsane cec Table 74 Display of the current position of the motor shaft in the Watch window ACOPOS User s Manual V1 157 Chapter 6 Getting Started Getting Started Starting Up an ACOPOS Servo Drive The following data concerning shaft movement is displayed in the Trace window Set Speed The acceleration phase the constant speed phase and the braking phase of the shaft movement can be evaluated here Lag Error Units 0 40 0 60 0 80 In the acceleration phase for the motor shaft increasing lag error Atconstant speed constant l
63. ACOPOS servo drives on page 107 86 ACOPOS User s Manual V1 Dimensioning Power Mains Connection Dimensioning the Line Contactor The rated current of a common line contactor is oriented to the overcurrent protection for the power mains connection The line contactor is selected so that the maximum current load is approximately 1 3 times the rated current of the overcurrent protection 1 3 Fault Current Protection Fault current protection RCD residual current operated protective device can be used with ACOPOS servo drives However the following points must be noted ACOPOS servo drives have a power rectifier If a short circuit to the frame occurs a flat DC fault current can be created which prevents an AC current or pulse current sensitive RCD Type A or AC from being activated therefore canceling the protective function for all connected devices Danger If used for protection during direct or indirect contact of the fault current protection RCD only a Type B RCD AC DC sensitive according to IEC 60755 can be used for the ACOPOS power mains connection Otherwise additional protective measures must be used such as neutralization or isolation from the power mains using an isolation transformer 1 3 1 Rated Fault Current On ACOPOS servo drives fault current protection with a rated fault current 1 of 2100 mA can be used However errors can occur e When connecting servo drives to the power mains short term single
64. Automation Studio Edit View Insert Open Project Object Tools Window 2 Deug 2 99 acp10 Project n Model no Slot Software Log book Permanent Description T d Bp Module Name Version Transferto Size bytes Description T cgi CPU Ef 7CP476 60 1 0 Cyclic 1 10 ms 7 01 SE v0 00 UserRAM 7676 y 02 axistc 16265 y 0 3 acpl manh 22476 9 04 libacpl man a 2188 9 1 c System 81045001 5 syscont 227 UserROM 752 8AC110 601 1 4 acpl c g 0472 UserROM 212 EN cS 2 4 acpl0sys v0472 UserROM 240416 3 gcloader UserROM 5816 4 4 ncolobal 017 UserROM _ 8020 Le acpl man v0472 UserROM 66388 acpl par 0472 UserROM 15700 55 ACP10 Real Axis User HE 10 Error Text Module 8 acpi etx v0 00 UserROM 54896 x Output Debug Findin Fies Line 16 of 18 COM 476 V224 Figure 46 Open initial parameter module AX1 PAR ACOPOS User s Manual V1 141 Chapter 6 Getting Started Getting Started Starting Up an ACOPOS Servo Drive e Position the mouse pointer on dig in amp B amp R Automation Studio ax1_par waf Axis View Open Project Object Tools Window 2 eT 02 gt 843 encoder i limit Be Be BE move
65. Be Find in Fies 1 CP476 V2 24 RUN Figure 47 Place the mouse pointer on dig in Expand the view by clicking on amp B amp R Automation Studio ax1_par waf Axis S9 Ele Edi View Open Project Object Tools Window 2 A 181 9 92 spa TUR 1 z Debug Fndin Fes COM CP476 V224 RUN Figure 48 Expand the view 142 ACOPOS User s Manual V1 Getting Started Starting Up an ACOPOS Servo Drive Position the mouse pointer on level The parameters are now shown in the right part of the window amp B amp R Automation Studio ax1_par waf Axis File View Open Project Object Tools Window 2 181 ugs 9154 9 9 B digin teference 58 r pos hw end 1 ne MW eni TES encoder i ide ncACTIV HI 95 limit trigger ncACTIV LO ncQUICKSTOP controller BG move 1 85 message x Output Debus Find in Files COM CP476 V224 RUN Figure 49 Displaying the level parameters To allow movement of the motor shaft the following parameters must be changed to the value ncACTIV pos hw end neg hw end e trigger2 quickstop ncACTIV_HI means that the inputs for both hardware end switches and the quick
66. Caution If a resistance less than the minimum resistance is used the brake chopper built into the ACOPOS device could be destroyed 1 Reliable braking resistors are available from Danotherm www danotherm com ACOPOS User s Manual V1 97 Chapter 4 Dimensioning Dimensioning Braking Resistor Then the following calculation Rg Q lg AI must be made to check if the average continuous power for the brake can be reached with the selected braking resistor on the ACOPOS servo drive The brake power which can be continually output by the ACOPOS device is limited by the built in fuse rated current of the built in fuse see Table 44 Braking resistors for ACOPOS servo drives on page 94 Power Data for the Braking Resistor The maximum power that the braking resistor must be able to dissipate is calculated as follows W gt Ppr W Brm The nominal power the power which can be continually dissipated for the braking resistor is calculated using the following formulas Pn W 2 aver Pa gt Po W The second condition depends on ACOPOS internal relationships 98 ACOPOS User s Manual V1 Dimensioning Braking Resistor 4 4 Setting Brake Resistor Parameters The braking resistors integrated in the ACOPOS servo drives as well as braking resistors which can be connected externally are controlled using a specially developed procedure This guarantees that the brake power is op
67. ERAL INFORMATION CHAPTER 2 TECHNICAL DATA CHAPTER 3 INSTALLATION CHAPTER 4 DIMENSIONING CHAPTER 5 WIRING CHAPTER 6 GETTING STARTED ACOPOS User s Manual V1 ACOPOS User s Manual V1 CHAPTER 7 STANDARDS AND CERTIFICATIONS INDEX ACOPOS User s Manual V1 5 ACOPOS User s Manual V1 Table of Contents Chapter 1 General Information sess 13 1 ACOPOS Servo Family Eee eir 13 1 1 5 Operation tip p RR ERR 13 1 2 Taking ito the Emmitt i eiie cr eet tI de tide nen 14 1 3 Individual Configurations 14 1 4 Configuring Instead of Programming ssseeeneeeeeenneneneenee nennen 15 1 5 EASY ELEME 15 1 6 Software and Hardware as a Unit sss 16 1 7 Plain Text for Functions crie ecu eee she fees elven Puce ATL det 16 1 8 Simple Function TeSt n ti dee Oc e tera 17 1 9 Control Trigger p edicere e re de 18 1 10 Cam Profiles for Everyone sse nennen nennen nennen 19 2 ACOPOS Config ratiohs nene rre nuca rasis deve cba 20 ze 20 21 AW Configuration 20 2 1 2 ConfigutratiOn 21 3 Safety Guidelities ucro 22 3 1 General Information entere entrent in
68. Module Name Version Transfer to Descriptio 4 EH aG CPU L7CP474 60 1 Q Cyclic Ht 10 ms HSE ax tst User ROM 9160 ax_tst2 UserROM 9160 F r i 133 1 138 User ROM 9160 system acpl cfg UserROM 32968 syscont User ROM 752 sys lib UserROM 23684 burtrap UserROM 12164 ncglobal User ROM 8020 gcloader User ROM 5828 acpl par UserROM 15500 10 User ROM 66116 G Data modules 9 paral User ROM 224 para2 UseROM 224 9 5 8v1090 00 1 9ac110 60 41 8C120 601 rJ MSA3L E0 30 gt 98V1090 00 1 8AC110 60 1 8AC120 60 1 8AC123 601 SMSA3LEO 30 5 81030 00 94c110 60 1 84C120 60 1 UserROM 224 acpl sys 240512 2 ACP10 Real Axis ad User ROM 350 d ac 380 Li SMSA3LEO 32 5 05 8v1990 00 1 User ROM 350 Line 55 of 58 COM OFFLINE Figure 3 Software and Hardware as a Unit 1 7 Plain Text for Functions NC Objects that can be accessed by the application program are also stored on the CPU like the application program Creating NC Objects for axes a CNC system or a cam profile takes place using dialog boxes and special data module editors The individual hardware and software channels are assigned symbolic names This eases use and increases clarity The initial parameters are set in a separate editor in plain text 16 ACOPOS User s Man
69. Signal Transfer RS485 Baud Rate 625 kBaud Electrical Isolation Encoder ACOPOS Sense Lines No common mode voltage max 7 V 2 compensation of max 1 V Immunity 4 IEC 61000 4 2 ESD 15 kV IEC 61000 4 4 Burst 4kV Operational Conditions Environmental Temperature during Operation 0 to 50 Relative Humidity during Operation 5 to 95 non condensing Storage and Transport Conditions Storage Temperature 25 to 55 C Relative Humidity for Storage 5 to 95 non condensing Transport Temperature 25 to 70 C Relative Humidity for Transport 95 at 40 C non condensing Two EnDat modules can also be inserted 1 2 3 4 40 Table 16 Technical Data AC120 n this case the module in slot 2 is automatically used for motor feedback Noise on the encoder signal reduces the resolution that can be used by approx 3 bits factor of 8 The precision is actually limited by the encoder With B amp R EnDat cable Both screws on the module must be tightened ACOPOS User s Manual V1 Technical Data ACOPOS Plug in Modules 2 5 AC122 Resolver Interface 2 5 1 General Description The AC122 plug in module can be used in an ACOPOS slot The module is equipped with a resolver interface The plug in module handles the output from resolvers which are built into B amp R servo motors or used as an encoder for external axes This resolver delivers the absolute positio
70. able length 20m 4 x 1 5mm 2x 2 x 0 75mm motor connector 8 pin Intercon Socket can be used in cable drag chains UL CS listed o es amp 8 025 12 1 Motor cable length 25m 4 x 1 5mm 2x 2x0 75mm motor connector 8 pin Intercontec socket can be used in cable drag chains UL CSA listed Motor Cables 4 mm 8 005 12 3 Motor cable length 5m 4 x 4mm 2x 2 x 1mm motor connector 8 pin Intercontec socket can be used in cable drag chains UL CSA listed 8 007 12 3 Motor cable length 7m 4 x 4mm 2 x 2 1mm motor connector 8 pin Intercontec socket can be used in cable drag chains UL CSA listed 8 010 12 3 Motor cable length 10m 4 x 4mm 2 x 2 1mm motor connector 8 pin Intercontec socket can be used in cable drag chains UL CSA listed 8 015 12 3 Motor cable length 15m 4 x 4mm 2 x 2 x 1mm motor connector 8 pin Intercontec socket can be used in cable drag chains UL CSA listed 8 020 12 3 Motor cable length 20m 4 x 4mm 2 x 2 x 1mm motor connector 8 pin Intercontec socket can be used in cable drag chains UL CSA listed 8 025 12 3 Motor cable length 25m 4 x 4mm 2 x 2 x 1mm motor connector 8 pin Intercontec socket can be used in cable drag chains UL CSA listed Table 23 Order Data Motor Cables 52 ACOPOS User s Manual V1 Technical Data Cables
71. able 48 Terminal cross sections for ACOPOS servo drives on page 107 1 The cross section of the braking resistor cable must be dimensioned for the thermal equivalent effective value of the respective brake current If information concerning the flow of the brake current is available calculate the thermal equivalent effective value of the brake current using 1 AM t Iram DLP M The cross section of the braking resistor connection should then be selected as described in Table 41 Maximum current load for PVC insulated three phase cables or individual wires on page 85 so that the maximum current load of the cable cross section is greater than or equal to the thermal equivalent effective value of the brake current Iz gt Iq ACOPOS User s Manual V1 95 Chapter 4 Dimensioning Dimensioning Braking Resistor 4 3 Dimensioning the Brake Resistor Like other drive components the externally connected braking resistors must be dimensioned according to the requirements of the application To determine the required braking power max and aver the mechanical values M t a t Tcyge must be known The following formulas are used to determine the drive power curve P t W M t Nm 5 1 n t mmin t rad s1 2 ONU RUNE d B 60 s 1 o M t fi P Br aver 7 M t 0 Pa t Figu
72. ag error In the braking phase decreasing lag error Actual stator current quadrature component Rxl par Current controller Actual stator current quadrature component 01 02 02 19 15 06 0 80 PI HEETE ooh ee eee The various movement phases are represented here Acceleration of the motor shaft current increases Constant speed current decreases Braking phase current becomes negative Table 75 Output of the recorded data in the Trace window 158 ACOPOS User s Manual V1 Standards and Certifications CHAPTER 7 STANDARDS AND CERTIFICATIONS 1 Valid European Guidelines for ACOPOS Servo Drives e guidelines 89 336 EWG e Low voltage guidelines 73 23 EWG Machine guidelines 98 37 EG 2 Valid Standards for ACOPOS Servo Drives Standard Description EC EN 61800 2 Adjustable speed electrical power drive systems Part 2 General requirements Rating specifications for low voltage adjustable frequency a c power drive Systems EC EN 61800 3 Adjustable speed electrical power drive systems Part 3 EMC product standard including specific test methods EC 61800 5 draft Adjustable speed electrical power drive systems Part 5 Safety requirements Electrical and thermal 61131 2 Programmable controllers Part 2 Equipment requirements and tests EC 60204 1 Safety of machinery Electrical
73. allel 88 ACOPOS User s Manual V1 Dimensioning DC Bus 2 DC Bus 2 1 General Information With ACOPOS servo drives itis possible to connect several servo drives via the DC bus 1 This connection allows compensation of brake and drive energy of several axes or the distribution of brake energy to several braking resistors The connection is made using terminals X2 DC and DC The structure of the DC bus connections can be seen in the following diagram UHHE Ba x2 i ores ta oF Figure 19 ACOPOS X2 circuit diagram DC bus connections Caution To prevent excessively high discharge currents from flowing over the individual servo drives make sure that smaller servo drives are not connected between two larger servo drives Chapter 4 Dimensioning 1 The connection of the DC bus for several ACOPOS 1022 1045 or 1090 modules is only possible within combined groups also see Section 1 2 2 Implementing ACOPOS Power Mains Connections for Drive Groups With ACOPOS 1640 and 128M modules it is also possible to connect individual ACOPOS servo drives because of built in phase and power mains monitoring ACOPOS User s Manual V1 89 Dimensioning DC Bus 2 2 Wiring The DC bus connections on the ACOPOS servo drives do not have short circuit and ground fault protection and are not protected against reverse polarity Therefore the DC bus connections must be wired correctly Caution
74. anding with foil banding Cable Shielding Cu mesh optical coverage gt 85 and wrapped in isolating fabric Outer Sheathing Material PUR Color Orange similar to RAL 2003 flat Labeling BERNECKER RAINER 10x0 14 2x0 50 FLEX Electrical Characteristics Conductor Resistance Signal Lines lt 140 O km Supply Lines lt 40 Q km Insulation Resistance gt 200 per km Isolation Voltage Wire wire 15kV Wire shield 0 8 kV Operating Voltage Max 30 V Mechanical Characteristics Temperature Range Moving 10 C to 70 Still 20 C to 90 C Outer Diameter 7 3 mm 0 25 mm Flex Radius gt 55 mm Speed lt 4ms Acceleration lt 60 m s Flex Cycles 23 000 000 Weight 0 08 kg m Table 27 Cable specifications for EnDat cables cont 58 ACOPOS User s Manual V1 3 4 Resolver Cables 3 4 1 Order Data Technical Data Cables Model Number Short Description Image 8CR005 12 1 Resolver cable length 5m 3 x 2 x 24 AWG 19 resolver connector 12 pin Intercontec socket servo connector 9 pin DSUB plug can be used in cable drag chains UL CSA listed 8CR007 12 1 Resolver cable length 7m 3 x 2 x 24 AWG 19 resolver connector 1 connector 9 pin DSUB plug can be used in cable drag chains UL CSA listed 2 pin Intercontec socket servo 8CR010 12 1 Resolver resolver connector connector 9 pin DSUB plug can be used in cable drag chains UL CSA listed cabl
75. ange MHz Quasi peak Value 30 lt f lt 230 40 dB V m measured at distance of 30 m 230 lt f lt 1000 50 dB V m measured at distance of 30 m Table 78 Electrical limit values for emission tests according to IEC 61800 3 ACOPOS User s Manual V1 161 Chapter 7 Standards and Certifications Standards and Certifications 5 Environmental Limit Values according to IEC 61800 2 Operational Conditions IEC 61800 2 Environmental Temperature during Operation 5 to 40 Relative Humidity during Operation 5 85 non condensing Power Reduction in Relation to Installation Altitude 1 10 per 1000 m installation altitude Max 2 000 m above sea level Degree of Pollution according to IEC 60664 1 2 non conductive material Overvoltage Category according to EC 60364 4 443 1999 Protection according to IEC 60529 IP20 Vibration 2 lt f lt 9Hz 0 3 mm amplitude 9 lt f lt 200 Hz 1 m s acceleration Storage and Transport Conditions Storage Temperature 25 to 55 C Relative Humidity for Storage 5 95 non condensing Transport Temperature 25 to 70 Relative Humidity for Transport 95 at 40 C non condensing Vibration during Transport 2 lt f lt 8Hz 8 lt f lt 200 Hz 200 lt f lt 500 Hz 3 5 mm amplitude 10 m s acceleration 15 m s acceleration Table 79 Environmental Limit Values according to IEC 61800 2
76. as 24V input or as output 400 100mA 2 digital outputs 2A Order TB712 terminal block separately ACOPOS User s Manual V1 35 Table 11 Module overview for plug in modules Chapter 2 Technical Data 2 3 AC110 CAN Interface 2 3 1 General Description Technical Data ACOPOS Plug in Modules The AC110 plug in module can be used in an ACOPOS slot The module is equipped with a CAN interface This fieldbus interface is used for communication and setting parameters on the ACOPOS servo drive for standard applications 2 3 2 Order Data Model Number Short Description Image Plug in Module 8AC110 60 2 ACOPOS plug in module CAN interface Accessories 7AC911 9 Bus Connector CAN 0 912 9 Bus Adapter CAN 1 CAN interface 0AC913 92 Bus Adapter CAN 2 CAN interfaces including 30 cm A connection cable 2 2 25 if 2 3 3 Technical Data Table 12 Order Data AC110 Product ID 8AC110 60 2 General Information C UL US Listed Yes Module Type ACOPOS plug in module Slot Currently limited to slot 1 Power Consumption 0 7 W CAN Interface Connection Module Side 9 pin DSUB plug Indications RXD TXD LEDs Electrical Isolation Yes CAN ACOPOS Table 13 Technical Data AC110 36 ACOPOS User s Manual V1 Technical Data ACOPOS Plug in Modules Product ID 8AC110 60 2 Maximum Distance 60m
77. ated brass Protective Ground Connection on Housing According to VDE 0627 Protection according to DIN 40050 IP67 when connected Certifications UL CSA Electrical Characteristics Signal Contacts Nominal Current 9A Nominal Voltage 32V Isolation Voltage L L 1500 V Contact Resistance 5 Mechanical Characteristics Temperature Range 40 C to 125 Housing Material Zinc casting nickel plated Gaskets Viton H NBR Crimp Range 17x0 06 1 mm Cable 9 12mm Manufacturer Information Manufacturer INTERCONTEC Internet Address http www intercontec com Manufacturer s Product ID ASTA 035 FR 11 12 0005 000 Table 34 Specifications for EnDat Connector 8 001 00 1 66 ACOPOS User s Manual V1 Technical Data Connectors 4 3 3 Specifications for Resolver Connector 8PR001 00 1 Product ID 8 001 00 1 General Information Contacts 12 signal contacts Degree of Pollution 3 Installation Altitude up to 2 000 m Insulator PBT UL94 VO listed Contacts Gold plated brass Protective Ground Connection on Housing According to VDE 0627 Protection according to DIN 40050 IP67 when connected Certifications UL CSA Electrical Characteristics Signal Contacts Nominal Current 9A Nominal Voltage 160 V Isolation Voltage L L 2500 V Contact Resistance 5 Mechanical Characteristics Temperature Range 40
78. ately In order to avoid disturbances motor cables encoder cables control cables data cables are to be properly shielded Inductive switching elements such as contactors or relays are to be equipped with corresponding suppressor elements such as varistors RC elements or damping diodes All electrical connections are to be kept as short as possible Cable shields are to be attached to the designated shield terminals and the plug housing Shielded cables with copper mesh or tinned copper mesh are to be used Twisting or extending the protective mesh using single conductors is not allowed Unused cable conductors are to be grounded on both sides if possible ACOPOS User s Manual V1 Wiring General Information The ground connections and shield connections have to be made as illustrated in the following diagram L1 3 400 480VAC L2 50 60 Hz L3 PE 24 to l Hed Trigger1 H HH og Quickstop Trigger2 1 2 Q ot shield 24 V te p 29 End To i SG End lt Ref x1 avt 2 Enable 24 t 24 OVI 19 5 8 11 8V1022 00 1 1022 1045 1090 8V1045 00 1 8V1090 00 1 CAN m oid 3 447 x3 ne x2 j X1 3 12 EnDat Resolver Figure 23 Connection diagram for ground and shie
79. ates may cause condensation which can damage the ACOPOS servo drives installed there Condensation can enter the ACOPOS servo drives with the cooled air stream Make sure that only well sealed switching cabinets are used condensation caused by outside air entering the switching cabinet During operation with the switching cabinet doors open e g service the ACOPOS servo drives are not allowed to be cooler than the air in the switching cabinet at any time after the doors are closed To keep the temperature of the ACOPOS servo drives and the switching cabinet at the same level the cooling aggregate must remain in operation even when the system is switched off Cooling aggregates must be installed in a way that prevents condensation from dripping into the ACOPOS servo drives This should be considered when selecting the switching cabinet special construction for use of cooling aggregates on top of the switching cabinet Also make sure that condensed water which forms in the cooling aggregate fan when it is switched off cannot sprinkle into the ACOPOS servo drives Make sure the temperature setting of the cooling aggregates is correct 78 ACOPOS User s Manual V1 Installation Using Cooling Aggregates in Switching Cabinets Cooling aggregate on top of the switching cabinet Cooling aggregate Ta o gt oo D908 Switching cabinet Cooling aggregate
80. connection The line contactor is selected so that the maximum current load is approximately 1 3 times the rated current of the overcurrent protection 1 2 2 Implementing ACOPOS Power Mains Connections for Drive Groups The structure of the power mains connection for a drive group with line contactor and circuit breaker can be seen in the following diagram L1 3 400 480VAC L2 50 60 Hz L3 Figure 18 Circuit diagram for ACOPOS X3 power mains connection for a drive group Dimensioning the Power Mains and Overcurrent Protection The cross section of the distribution point and all power mains connections are chosen according to Table 41 Maximum current load for PVC insulated three phase cables or individual wires on page 85 so that the maximum current load for the cable cross section selected 1 is greater than or equal to the sum of the calculated mains current lz 2 Imains The rated current of the overcurrent protection must be less than or equal to the maximum current load for the cable cross section selected see Table 41 Maximum current load for PVC insulated three phase cables or individual wires on page 85 ls 1 1 When determining a common cross section for several drives especially with different sized ACOPOS modules make sure that the cross section selected is within the range that can be used with the power mains terminals see Chapter 5 Wiring Table 48 Terminal cross sections for
81. d connection ACOPOS User s Manual V1 61 Chapter 2 Technical Data 4 2 Motor Connectors 4 2 1 Order Data Technical Data Connectors Model Number Short Description Cable Diameter 9 17 mm 8 001 00 1 Motor connector 8 pin Intercontec socket crimp range 4 x 0 5 2 5mm 4 x 0 06 1 0 for cable 0 9 14mm IP67 UL CSA listed 8 002 00 1 Motor connector 8 Intercontec socket crimp range 4 x 0 5 4 0mm 4 x 0 06 1 0mm for cable 0 14 17mm IP67 UL CSA listed Cable Diameter 17 26 mm 8 003 00 1 Motor connector 8 pin Intercontec socket crimp range 4x 1 5 10mm 4 x 0 5 2 5mm for cable 17 26mm IP67 UL CSA listed 62 Table 30 Order data for motor connectors ACOPOS User s Manual V1 Technical Data Connectors 4 2 2 Specifications for 8 001 00 1 and 8 002 00 1 Product ID 8 001 00 1 8 002 00 1 General Information Contacts 8 4 power and 4 signal contacts Degree of Pollution 3 Installation Altitude up to 4 000 m Insulator PA UL94 V0 listed Contacts Gold plated brass Protective Ground Connection on Housing According to VDE 0627 Protection according to DIN 40050 IP67 when connected Certifications UL CSA Electrical Characteristics Overvoltage Category 3 Power Contacts Nominal Current 25A Nominal Voltage 800 VAC VDC Isolation Vo
82. de 35 2 9 ACTTO SGAN Interlace minnin ihe teer 36 2 3 1 General Description 20000 36 2 3 2 Order Data zx asc fecti 36 ACOPOS User s Manual V1 7 Table of Contents 2 33 Technical ie one T date 36 2 3 4 CAN Node Number Settings 0 2224 00 nennen nenne 37 2 93 5 IndIGaltiOris EM E D cx se ar Par RES RITE BEI 37 2 4 AC120 EnDat Encoder Interface 38 2 4 1 General Description essen enne enne nnne 38 2 4 2 Order Dalai tec ee ese 39 2 4 3 Technical Data ive det donee Suave seuss eor ven er Ue e bad 40 2 5 AC 122 Resolver Interface x t tette be tetendit es 41 2 5 1 General Description ie ied eed de e eda 41 2 5 2 Order Dalla pone eee tete Ee ted 42 2 5 9 Technical Data 42 2 6 AC123 Incremental Encoder SSI Absolute Encoder Interface 44 2 6 1 General Description einer 44 2 6 2 Order Data 44 2 6 3 Technical Date cte err orte bed app oct 45 2 7 AC130 Digital Mixed Module essen nennen nennen enn 47 2 7 1 Gene
83. duct line consisting of servo drive and motor components B amp R has provided the basis for complete and uniform automation solutions Branch specific functions and intuitive tools allow for short development times and create more room for innovation 1 1 Secure Operation The embedded parameter chip on the motor is one factor used to guarantee maximum security It contains all mechanical and electronic data relevant to the functionality of the motor Parameters no longer have to be set manually and start up times are substantially reduced Secure operation also means that relevant data can be requested during service and the cause of the problem can be determined EMC was given special attention in order to guarantee proper operation in an industrial environment Field tests have been carried out under difficult conditions in addition to the tests defined in the standard The results confirm the excellent values measured by the testing laboratory and during operation The filter required to meet the CE guidelines is also integrated in the device This simplifies installation considerably ACOPOS User s Manual V1 13 Chapter 1 General Information General Information ACOPOS Servo Family Figure 1 Secure Operation 1 2 Taking it to the Limit Operational security is also improved by monitoring high temperature components IGBT modules brake resistor motor windings Models with computer support allow component tempera
84. e 25 to 70 C Relative Humidity for Transport 95 at 40 C non condensing Mechanical Characteristics Dimensions Width 70 5 mm Height 375 mm Depth 235 5 mm Weight 4 0 kg 4 1 kg 4 4 kg Table 8 Technical data ACOPOS 1022 1045 and 1090 cont 32 ACOPOS User s Manual V1 Technical Data ACOPOS Servo Family 1 5 ACOPOS 1640 128M 1 5 1 Order Data pairs as 24V input or as output 400 100 2 digital outputs 2A Order TB712 terminal block separately Model Number Short Description Image Servo Drives 8V1640 00 1 Servo drive 3 x 400 480V 64A 32kW line filter and braking resistor integrated 8V128M 00 1 Servo drive 3 x 400 480V 128A 64kW line filter and z braking resistor integrated Accessories 8AC110 60 2 ACOPOS plug in module CAN interface 8AC120 60 1 ACOPOS plug in module EnDat encoder interface 4 8AC122 60 1 ACOPOS plug in module resolver interface f 8AC123 60 1 ACOPOS plug in module incremental encoder and 55 absolute encoder interface 8AC130 60 1 ACOPOS plug in module 8 digital 1 0 configurable in Table 9 Order data ACOPOS 1640 128M 1 Integrated line filter in preparation 1 5 2 Technical Data Product ID 8V1640 00 1 8V128M 00 1 General Information C UL US Listed Yes Power Mains Connection Mains Input Voltage 3 x 400 VAC to 480 VAC 10 96 Power filter according to IEC 61800 3 A11 second envir
85. e length 10m 3 x 2 x 24 AWG 19 12 pin Intercontec socket servo 8CR015 12 1 Resolver resolver connector connecto chains U cable length 15m 3 x 2 x 24 AWG 19 12 pin Intercontec socket servo r 9 pin DSUB plug can be used in cable drag L CSA listed 8CR020 12 1 Resolver resolver connector connecto chains U cable length 20m 3 x 2 x 24 AWG 19 12 pin Intercontec socket servo r 9 pin DSUB plug can be used in cable drag L CSA listed 8CR025 12 1 Resolver resolver connector 12 pin Intercontec socket servo connectoi cable length 25m 3 x 2 x 24 AWG 19 r 9 pin DSUB plug can be used in cable drag chains U L CSA listed Table 28 Order Data Resolver Cables ACOPOS User s Manual V1 59 Chapter 2 Technical Data 3 4 2 Cable Specification Technical Data Cables Product ID Resolver Cables General Information Cable Cross Section 3x 2x24 AWG 19 Durability Oil resistant according to VDE 0472 part 803 as well as standard hydraulic oil Certification UL AWM Style 20671 90 30 V E63216 and CSA AWM 90 C 30 V I II 1146064 Conductor Signal Lines 24 AWG 19 tinned Cu wire Wire Insulation Special thermoplastic material Wire Colors White brown green yellow gray pink Cable Construction Signal Lines Stranding White with brown gr
86. e Permanent memory OK IN Figure 41 Selecting the user memory on the PLC ACOPOS User s Manual V1 137 ot sS 80 D Sc OF Getting Started Starting Up an ACOPOS Servo Drive e user memory is erased Clear Memory x Erasing memory Please wait Figure 42 Erasing the user memory After clearing the user memory the project window will be shown again Operating System Download The first time an ACOPOS servo drive is started up the ACOPOS operating system ACP10SYS must also be transferred to the target system In the sample project transferring ACP10SYS is deactivated shown in gray in the right part of the window Transferring ACP10SYS must be activated separately in the sample project Position the mouse pointer on ACP10SYS in the right part of the window B amp R Automation Studio Dec ICON C NUM D Sag trenc acp10 Project ol Software Log book CAN 1 0 TPU Permanent Description 55 0 Module Name Version Transferto Size bytes Description Ea 2003 Sy CPU 10 EQ Cycle H 10m j 01 2 v0 00 User RAM 7676 y 02 9 16265 03 acpl manh 22476 J 4 libacpl man a 2188 c System 8v1045 001 fd sysconf v2 27 UserROM 752 8 110 6011 1 4 acpl c g 0472 UserROM 212 20601 2 ju
87. e selected motor can also be used here 84 ACOPOS User s Manual V1 Dimensioning Power Mains Connection The cross section of the power mains and the rated current of the overcurrent protection used are chosen according to Table 41 Maximum current load for PVC insulated three phase cables or individual wires on page 85 so that the maximum current load for the cable cross section selected is greater than or equal to the calculated mains current gt 152 Imains The rated current of the overcurrent protection must be less than or equal to the maximum current load for the cable cross section selected see Table 41 Maximum current load for PVC insulated three phase cables or individual wires on page 85 The following table shows the maximum current load of PVC insulated three phase cables three current carrying wires according to IEC60204 1 at 40 C environmental temperature 1 and 70 maximum conductor temperature maximum current load for installation type F and cross sections greater than 35 mm IEC60364 5 523 is used for installation types B1 and B2 Installation Types Wire Cross Section Three individual Three phase cable Three phase cable Three phase cable Three individual wires in insulating in insulating on walls in a cable tray wires in a cable tray conduit or cable conduit or cable duct duct B1 B2 Maximum current load for the cable
88. e tools such as the Cam Editor The mouse is used to define fixed points synchronous sections or interpolations Effects of positioning behavior on speed acceleration and jolt for the slaves axes connected can be monitored directly Chapter 1 General Information B amp R Automation Studio cam_vor2 waf Cam lej x Inset Open Project Object Tools Window 2 0 571489 0 705021 bccaist 0 571439 aiff 0 709021 0 571489 21 204399 0 571489 sma2 ss2 Gradient T 0221050 0078433 147973 185115 T 0000000 0000000 0172037 0 000000 T 2 0658950 0821567 147973 185115 2 0490064 0470596 0509935 0529404 3599337125000 3 0827963 1 000000 1 000000 1 000000 0 For Help press F1 COM CP476 V224 RUN Figure 6 Cam Profiles for Everyone ACOPOS User s Manual V1 19 General Information ACOPOS Configurations 2 ACOPOS Configurations 2 1 CAN 2 1 1 Configuration 1 Functionality The following ACOPOS functions are possible with this configuration e Point to Point Electronic Gears Electronic Compensation Gears Cross Cutter e Electronic Cam Profiles Flying Saw Line Shaft B amp R SYSTEM 2003 All CPUs for B amp R SYSTEMS 2003 2005 2010 and LS251 with CAN Bus CAN Bus B amp R SYSTEM 2003 max 8 nodes nodes possible in the network with
89. eSwITCH OF HBe stop a2 neg 50000 Units s ncCONTROL ncSWITCH ON Yes n ncHOMING ncSTART TSE homing ncLIMITS nclNIT 8 parameter ncREL MOVE ELBE basis ncSERVICE ncREAD e neSERVICE ncSET ncDAl nc SIMI IL ATINA ne SWITCH x Chart 1 Wniex 80 0 n 60 0 1 par netwo 5 parnetwork ax1_par network 0 ax par network 0 ax parmonitor s 0 Units par monito 0 Unis 9 0 eem 0 0 20 0 40 0 50 0 30 0 100 0 COMi CP476 V224 RUN Figure 64 Test window for ACOPOS servo drives 150 ACOPOS User s Manual V1 Getting Started Starting Up an ACOPOS Servo Drive 2 2 6 Starting the Motor Movement Danger The traverse path must be adjusted for the conditions present installed mechanical parts etc Incorrect control of motors or mechanical parts connected to the motor shaft can cause unwanted and dangerous movements This can cause severe personal injury or damage to property If mechanical parts are mounted on the motor the number of encoder units per motor revolution must be adjusted to the mechanical characteristics possible traverse path etc The number of encoder units per motor revolution units rev motor can be set as follows e Position the mouse pointer on encoder if e Expand the view by clicking on e Position the mouse pointer on parameter e Expand the view
90. een with yellow gray with pink Shield No Cable Stranding The 3 pairs together covered by foil banding Cable Shielding Cu mesh optical coverage 290 and wrapped in isolating fabric Outer Sheathing Material PUR Color Orange similar to RAL 2003 flat Labeling BERNECKER RAINER 3x2x24 AWG FLEX Electrical Characteristics Conductor Resistance 24 AWG lt 86 Insulation Resistance gt 200 per km Isolation Voltage Wire wire 15kV Wire shield 0 8 kV Operating Voltage Max 30 V Mechanical Characteristics Temperature Range Moving 10 C to 80 C Still 40 C to 90 Outer Diameter 6 5 mm 0 2 mm Flex Radius 250mm Speed lt 4m s Acceleration 60 m s Flex Cycles 23 000 000 Weight 0 07 kg m Table 29 Cable specifications for resolver cables 60 ACOPOS User s Manual V1 Technical Data Connectors 4 Connectors 4 1 General Information B amp R offers five different motor encoder connectors for AC servo motors All connectors have IP67 protection The metallic housing provides a protective ground connection on the housing according to VDE 0627 All plastic used in the connector is UL94 VO listed High quality gold plated cage connector contacts guarantee a high level of contact security even when reinserted many times Using the B amp R connector guarantees that the EMC limits for the connection are not exceeded Make sure that connectors are put together correctly including a proper shiel
91. er switching off the device wait until the DC bus discharge time of at least five minutes has passed The voltage currently on the DC bus must be measured with a suitable measuring device before beginning work This voltage must be less than 42 VDC to rule out danger The Run LED going out does not indicate that voltage is not present on the device Signal LED Description Ready green Lit when the ACOPOS servo drive is ready for operation and the power level can be enabled operating System present and booted no permanent or temporary errors Run orange Lit as soon as the power level is enabled for the ACOPOS servo drive Error red Lit when an error occurs on the ACOPOS servo drive After correcting the error the LED is automatically switched off Examples of permanent errors Motor feedback not connected or defective Low level on the enable input Motor temperature sensor not connected or defective nternal error on the device e g IGBT heat sink temperature sensor defective Examples of temporary errors 24 VDC supply voltage exceeds the tolerance range DC bus voltage exceeds the tolerance range nternal 15 VDC control voltage exceeds the tolerance range GBT current limit reached Over temperature on the motor temperature sensor Over temperature on the servo drive IGBT junction heat sink conductive tracks Over temperature on the braking resistor CAN network faulty Table 4 LED Status ACOPOS U
92. es Product ID Motor Cables 10 mm Motor Cables 35 mm Mechanical Characteristics Temperature Range Moving 10 C to 70 Still 20 to 90 C Outer Diameter 20 1 mm 0 7 mm 32 5 mm x1 mm Flex Radius 150 8 mm 243 8 mm Speed lt 4 Acceleration 60 m s Flex Cycles 23 000 000 Weight 0 77 kg m 2 2 kg m Table 25 Cable specifications for 10 and 35 mm motor cables cont 56 ACOPOS User s Manual V1 3 3 EnDat Cables 3 3 1 Order Data Technical Data Cables Model Number Short Description Image 8CE005 12 1 EnDat cable EnDat connector 17 pin In connector 15 pin DSUB plu chains UL CSA listed length 5m 10 x 0 14mm 2 x 0 5mm ercontec socket servo g can be used in cable drag 8CE007 12 1 EnDat cable EnDat connector 17 pin In connector 15 pin DSUB plu chains UL CSA listed length 7m 10 x 0 14mm 2 x 0 5mm ercontec socket servo g can be used in cable drag 8CE010 12 1 EnDat cable length 10m 1 EnDat connector 17 pin In connector 15 pin DSUB plu chains UL CSA listed 5 0 0 14 2 x 0 5mm ercontec socket servo g can be used in cable drag 8CE015 12 1 EnDat cable length 15m 1 EnDat connector 17 pin In connector 15 pin DSUB plu chains UL CSA listed 0 0 14 2 x 0 5mm ercontec socket servo g can be used in cable drag 8CE020 12 1 EnDat cable length 20m 1
93. et Version V227 V224 Mismatch handling Replace the 05 on the target Figure 57 Operating system version conflict e Acknowledge by clicking the Continue button Operating System Mismatch 2 x The OS version used in your project is not the same as on the target Mismatch detail Project Target Version V227 V224 Mismatch handling C Replace the OS on the target c lgnore the mismatch between project and Emme oe Figure 58 Acknowledge selection of conflict resolution ACOPOS User s Manual V1 147 Chapter 6 Getting Started Getting Started Starting Up an ACOPOS Servo Drive Amessage will be displayed by B amp R Automation Studio Acknowledge this message by clicking Yes B amp R Automation Studio transfer of the application to the target 2 cold restart s zu 1 warm restart s will be LI ed resulting in possible data loss Do you want to continue Figure 59 Acknowledge message from B amp R Automation Studio with Yes The project is transferred Project Transfer 2 x Object neglobal gt Processor CPU ay Size 8020 Figure 60 project is transferred The following message is given after the project has been successfully transferred Transfer Project 2 x q The entire project on the target is now up to date Figure 61 The
94. hase isolation transformers with the corresponding input and output voltages and a vector group with secondary neutral can be used e g 3 x 400 V 3 x 400 V Dyn3 Danger The ACOPOS servo drives are only allowed to be operated directly on grounded three phase industrial mains TN TT systems When using the servo drives in living areas shops and small businesses additional filtering measures must be implemented by the user 1 1 2 Supply Voltage Range The permissible supply voltage range for ACOPOS servo drives is 3 x 400 VAC to 3 x 480 x10 Respective intermediate transformers must be used for other 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 ACOPOS User s Manual V1 81 Chapter 4 Dimensioning Dimensioning Power Mains Connection 1 1 3 Protective Ground Connection PE The following information concerning the protective ground connection corresponds to IEC 61800 5 draft Item 3 2 5 3 Connection elements for the protective ground conductor and must be followed Wire Cross Section The wire cross section for the protective ground conductor is oriented to the external conductors and must be selected according to the following table Wire Cross Section for External Line A Minimum Wire Cross Section for Protective Ground Connection mm lt 16 16 lt lt
95. he motor used is calculated as follows 1 Al t WIA gi 92 ACOPOS User s Manual V1 Dimensioning Motor Connection The cross section of the motor cable is chosen for B amp R motor cables according to the following table so that the maximum current load for the cable cross section selected is greater than or equal to the thermal equivalent effective value of the motor current The following table shows the maximum current load for special insulated three phase cables according to IEC60364 5 523 at 40 environmental temperature 1 and 90 C maximum cable temperature Installation Types Wire Cross Section Three phase cable in insulating Three phase cable on walls Three phase cable in a cable conduit or cable duct tray B2 C E Maximum current load of the cable 17 mm A 15 17 8 20 20 9 4 31 9 36 4 38 2 10 54 6 64 6 68 3 35 116 5 138 8 143 8 Table 43 Maximum current load for special insulated three phase cables When determining the cross section for the motor cable make sure that the cross section selected is within the range that can be used with motor connection terminal X5 see Chapter 5 Wiring Table 48 Terminal cross sections for ACOPOS servo drives on page 107 1 The entry for the maximum current load in 60364 5 523 is for an environmental temperature of 30 The values in Table 43 Maximum current load for special insulated three phase cable
96. i eue deberi te cad 131 2 1 2 Preparing the Hardware for Sample Project acp10 gdm 131 PAPA M PEE 131 2 2 1 Load Sample Project 2 2 diet 131 2 2 2 Preset Values for the Sample 134 2 2 3 Preset Values Concerning Wiring esee 140 2 2 4 Downloading the 146 2 2 5 PESE FUNCION sien aei ete die bere 148 2 2 6 Starting the Motor Movement 2 44 222242 150 Chapter 7 Standards and Certifications 159 1 Valid European Guidelines for ACOPOS Servo Drives 159 2 Valid Standards for ACOPOS Servo Drives 159 3 Electrical Limit Values for Immunity Tests according to IEC 61800 3 160 4 Electrical Limit Values for Emission Tests according to IEC 61800 3 161 5 Environmental Limit Values according to IEC 61800 2 162 6 International Certifications nennen nnne nennen enn 163 ACOPOS User s Manual V1 11 Table of Contents 12 ACOPOS User s Manual V1 General Information ACOPOS Servo Family CHAPTER 1 GENERAL INFORMATION 1 ACOPOS Servo Family With the introduction of the ACOPOS pro
97. ications for EnDat Connector 8 01 00 1 66 4 3 3 Specifications for Resolver Connector 8 1 00 1 67 8 ACOPOS User s Manual V1 Table of Contents Chapter 3 Installation 2 coiere rn rna ruo rario nus 69 1 General Informatiori ted ede eet ede ge dr ee Ee 69 2 Dimensional Diagram and Installation Dimensions 71 2 1 ACOPOS 1022 1045 1090 71 2 2 ACOPOS 1640 iode EE RI ee Id oiv iet Or rode 72 2 9 ACOPOSA298M ta iu ele edet ex UO Dope ede 73 3 Installation and Removal of Plug in Modules eeeemm eme 74 3d Generalnformiation one es 74 ee eee eee e tt eo dette ede ee des 74 CRpPMICIICUMI T 75 4 Installing Various ACOPOS Series Devices Directly Next to Each Other 76 5 Using Cooling Aggregates in Switching Cabinets sse 78 Chapter 4 Dimensioning 1 81 1 Power Mains Connection eec ede e dan d ve e 81 1 1 General Information nennen enne 81 1 1 1 System Configuration
98. ies 1 Integrated line filter in preparation 2 The braking resistor integrated in the ACOPOS servo drives 1640 and 128M is dimensioned so that it is possible to brake to a stop in a typical drive situation The integrated power supply concept starting with the ACOPOS 1640 allows the 24 VDC voltage supply on the servo drive and the connected encoders and sensors which can also be supplied via the 24 VDC output to remain for the entire stopping procedure if there is a power failure In may cases it is not necessary to use a 24 VDC UPS which is otherwise needed In addition to connection possibilities for all standard encoder systems the ACOPOS servo drives also provide a modular fieldbus interface ACOPOS servo drives are suitable for both synchronous and asynchronous servo motors and have a built in line filter which meets the limit values for CISPR11 Group 2 Class A Caution ACOPOS servo drives are suitable for use on a circuit capable of delivering not more than 10000 RMS Symmetrical Amperes 528 Volts maximum 28 ACOPOS User s Manual V1 1 3 Status LEDs Technical Data ACOPOS Servo Family The ACOPOS servo drives are equipped with three LEDs for direct diagnosis LED Designation Color 1 Ready green 2 Run orange 3 Error red Table 3 Status LEDs ACOPOS servo drives If no LEDs are lit the ACOPOS servo drive is not being supplied with 24 VDC Danger Aft
99. in Modules 2 4 AC120 EnDat Encoder Interface 2 4 4 General Description The AC120 plug in module can be used in an ACOPOS slot The module is equipped with an EnDat encoder interface The module handles the output from EnDat encoders which are built into B amp R servo motors or used as an encoder for external axes The encoder input signals are monitored In this way broken connections shorted lines and encoder supply failure can be recognized EnDat is a standard developed by Johanes Heidenhain GmbH www heidenhain de incorporating the advantages of absolute and incremental position measurement and also offers a read write parameter memory in the encoder With absolute position measurement absolute position is read in serially the search home procedure is usually not required Where necessary a multi turn encoder 4096 revolutions should be installed To save costs a single turn encoder anda reference switch can also be used In this case a search home procedure must be carried out The incremental process allows the short delay times necessary for position measurement on drives with exceptional dynamic properties With the sinusoidal incremental signal and the fine resolution in the EnDat module a very high positioning resolution is achieved in spite of the moderate signal frequencies used The parameter memory in the encoder is used by B amp R to store motor data among other things In this way the ACOPOS servo drives are alway
100. ion Image 8AC122 60 1 ACOPOS plug in module resolver interface Accessories 8CR005 12 1 Resolver cable length 5m 3 x 2 x 24 AWG 19 resolver connector 12 pin Intercontec socket servo connector 9 pin DSUB plug can be used in cable drag chains UL CSA listed 8CR007 12 1 Resolver cable length 7m 3 x 2 x 24 AWG 19 resolver connector 12 pin Intercontec socket servo connector 9 pin DSUB plug can be used in cable drag chains UL CSA listed 8CR010 12 1 Resolver cable len resolver connector h 10m 3x 2x 24 AWG 19 2 pin Intercontec socket servo connector 9 pin DSUB plug can be used in cable drag chains UL CSA listed 8CR015 12 1 Resolver cable length 15m 3 x 2 x 24 AWG 19 resolver connector 12 pin Intercontec socket servo connector 9 pin DSUB plug can be used in cable drag chains UL CSA listed 8CR020 12 1 Resolver cable length 20m 3 x 2 x 24 AWG 19 resolver connector 12 pin Intercontec socket servo connector 9 pin DSUB plug can be used in cable drag chains UL CSA listed 8CR025 12 1 Resolver cable length 25m 3 x 2 x 24 AWG 19 resolver connector 12 pin Intercontec socket servo connector 9 pin DSUB plug can be used in cable drag chains UL CSA listed 2 5 3 Technical Data Table 17 Order Data AC122 Product ID 8 122 60 1 General Information C UL US Listed Yes
101. ioned so that it is possible to brake to a stop in a typical drive situation 2 The ACOPOS servo drives are designed so that either the integrated braking resistor or the external braking resistor can be activated Braking with both braking resistors atthe same time is not possible Switching takes place using the software and is only possible during the servo drive initialization phase 398 Switching to internal external braking resistor 1 external 0 internal default 3 The fuses used must be fast acting fuses 210 x 38 mm for 600 V AC DC For example type KLKDOxx xx is the rated current of the fuse in amperes e g KLKD030 from Littelfuse www littelfuse com can be used 4 The braking resistors integrated in ACOPOS servo drives 1022 1045 and 1090 are optimally dimensioned for the respective sizes 94 ACOPOS User s Manual V1 Dimensioning Braking Resistor 4 2 Braking Resistor Connection The external braking resistors are connected using terminals X6 RB RB and PE The structure of the braking resistor connection can be seen in the following diagram Figure 21 Circuit diagram for ACOPOS X6 external braking resistor on ACOPOS 1640 and 128M When determining the cross section 1 for the braking resistor connection make sure that the cross section selected is within the range that can be used with braking resistor connection terminal X6 see Chapter 5 Wiring T
102. irectly Next to Each Other When installing various ACOPOS series devices directly next to each other we recommend aligning the vertical position so that the LED displays of the respective devices are lined up ACOPOS ACOPOS ACOPOS 1022 1640 128M 1045 1090 49998 coco e CA N n A N A N Vertical displacement of the position of the upper mounting holes Figure 14 Installing various ACOPOS series devices directly next to each other You can see from the image above that the vertical offset of the upper mounting holes is 10 mm The distances for the lower mounting holes and the number and size of the screws required can be taken from the dimensional diagrams for the respective ACOPOS servo drives 76 ACOPOS User s Manual V1 Overview of the vertical offsets No offset 10 No offset Table 37 Overview of the vertical offsets ACOPOS ACOPOS ACOPOS User s Manual V1 7T Installation Using Cooling Aggregates in Switching Cabinets 5 Using Cooling Aggregates in Switching Cabinets To prevent exceeding the required environmental temperatures it may be necessary to cool the air inside of a switching cabinet Caution Incorrect installation of cooling aggreg
103. itude Max 2 000 m above sea level Degree of Pollution according to IEC 60664 1 2 non conductive material Overvoltage Category according to EC 60364 4 443 1999 Protection according to IEC 60529 20 Storage and Transport Conditions Storage Temperature 25 to 55 Relative Humidity for Storage 5 to 95 non condensing Transport Temperature 25 to 70 Relative Humidity for Transport 95 at 40 C non condensing Mechanical Characteristics Dimensions Width Height Depth 276 mm 460 mm 295 mm 402 mm 460 mm 295 mm Weight 24 1 kg 33 8 kg Table 10 Technical data ACOPOS 1640 128M cont 1 Integrated line filter in preparation 34 ACOPOS User s Manual V1 Technical Data ACOPOS Plug in Modules 2 ACOPOS Plug in Modules 2 1 General Information The ACOPOS drives are equipped with four plug in module slots You can select the plug in modules required for your application and insert them into the ACOPOS servo drive 2 2 Module Overview Model Number Short Description 8AC110 60 2 ACOPOS plug in module CAN interface 8AC120 60 1 ACOPOS plug in module EnDat encoder interface 8AC122 60 1 ACOPOS plug in module resolver interface 8AC123 60 1 ACOPOS plug in module incremental encoder and SSI absolute encoder interface 8AC130 60 1 ACOPOS plug in module 8 digital I O configurable in pairs
104. k 0 ax1_par monitor s 0 Units Units 0 Units s xz x Transferring ax tst ok Findin Fies For Help press F1 COMi CP476 V224 RUN Figure 69 Place mouse pointer on the action ncSTART e Click on the j button on the toolbar The motor shaft now moves according to the traverse path s defined and the Trace function starts ACOPOS User s Manual V1 155 Ke ot 55 80 D Sc OF Getting Started Starting Up an ACOPOS Servo Drive Display and Evaluation of the Trace Function amp B amp R Automation Studio ax1_par waf 8 x Gh View Inset Open Project Test Object Tool Window 2 la x Deng i Belo amp HILL PRECES 75 gt Il 100x 100 qua network dig in Units TB encoder v pos 10000 Units s HBe limi 10000 Units s ncBASIS MOVE ncINIT controler pee 3090 ncCONTROL nclNIT BE move 50000 Units 2 ncCONTROL ncSWITCH OF EBE stop EX 2000 ncCONTROL ncSWITCH ON ncHOMING ncSTART homing ncLIMITS nclNIT ncREL MOVE ncSERVICE ncREAD 0 M ncSERVICE ncSET ncDAT neSIMITL neSWiTCH s 9 ug stop zl New Chart 1 100 0 80 0 1 i 50 0
105. l V1 125 Chapter 5 Wiring Wiring Cables 5 2 3 Cable Schematic Circular Plug DSUB E hite 0 5 mm COM 1 3 9 11 13 15 10 e c 2 white red 0 5 mm a 45V out 0 25A 7o o4 von green 0 14 mm b 150 o 1 Ld 0 14 mm rd 12 gray mm by th M white 0 14 mm bg 140 o5 a black 0 14 mm Fg T i ac mm 8 brown 0 14 mm Bg A 16 99 ink 0 14 mm Sense COM 4o ER i 10 yellow 0 14 mm bg B 13 4 11 Fg blue 0 14 mm N Sense 5 1o I o 12 D 17 violet 0 14 mm 53 1 red 0 14 mm 90 2 E o 15 1 1 2o nc 1 ro 6 nc ne 7 5 nc no 14 nc PES EIS Shield connected to ne plug housing MES SE Figure 29 Cable schematic for EnDat encoder cables 126 ACOPOS User s Manual V1 5 3 Resolver Cables 5 3 1 Resolver Cable Construction Wiring Cables D Amount Product ID Remark 1 1 Encoder cable 3x2x24 AWG 19 2 1 Circular connector 12 pin socket ASTA 021 FR 11 10 0005 000 3 1 DSUB housing 45 metal plated 9 pin plug 4 1 Kink protection 5 3 2 Pin Assignments Table 71 Resolver cable construction Circular connector
106. ld connections ACOPOS User s Manual V1 105 Chapter 5 Wiring Wiring General Information The protective ground conductor for the power mains PE and the protective ground conductor for the motor lines are internally connected with the housing of the ACOPOS servo drive The second protective ground conductor connection is required because of the increased discharge current 23 5 mA on the ACOPOS servo drives 1022 1045 and 1090 The same cross section as the protective ground conductor for the power mains must be used The two trigger inputs only internally filter disturbances up to approx 50 us therefore proper grounding of the cable shields is important The cable shield must be connected to the designated terminal On all plug in modules the two screws used to fasten the module must be tightened so that the mounting bracket is connected to ground Cable connection via DSUB plug The cable shield must be connected using the designated clamp in the metallic or metal plated plug housing The plug housing must be fastened to the designated device connector using safety screws Cable connection via terminals The cable shield must be connected to the designated terminal The cable shield for the motor line is connected with the ACOPOS housing via the grounding plate using the grounding clamp provided Shield connection for the motor cable using grounding clamps 1022 1045 1090 1640 128M E E C
107. lly initiated by the module and is exactly synchronized with the ACOPOS controller clock The input signals are monitored for both encoder types In this way broken connections shorted lines and encoder supply failure can be recognized With incremental encoders the count frequency and distance between edges is also monitored With absolute encoders the parity bit is evaluated and a plausibility check carried out 2 6 2 Order Data Model Number Short Description Image 8AC123 60 1 ACOPOS plug in module incremental encoder and SSI absolute encoder interface Table 19 Order Data AC123 44 ACOPOS User s Manual V1 2 6 3 Technical Data Technical Data ACOPOS Plug in Modules Product ID 8 123 60 1 General Information C UL US Listed Yes Module Type ACOPOS plug in module 91011 Currently limited to slots 2 and 3 Power Consumption 7 5 W Depends on the current requirements for the encoder connected 2 Encoder Input Connection Module Side 15 pin DSUB socket Indications UP DN LEDs Electrical Isolation Yes Encoder ACOPOS Encoder Monitoring Yes Signal Transfer Differential signal transfer Cable Length 3 Max 50m Immunity 4 IEC 61000 4 2 ESD 15kV IEC 61000 4 4 Burst 4kV Encoder Supply Supply Voltages Internal select between 5 V 15 V Sense Lines for5 V Yes 2 compensation of max 2 V for15 V No Load 5V 350 mA
108. ltage L L 6000 V Contact Resistance lt 3 MQ Signal Contacts Nominal Current 9A Nominal Voltage 250 VAC VDC Isolation Voltage L L 2500 V Contact Resistance 5 MQ Mechanical Characteristics Temperature Range 40 C to 125 Housing Material Zinc casting nickel plated Gaskets Viton H NBR Crimp Range 4x0 5 2 5 mm 4x0 06 1 mm 4x0 5 4mm 4x 0 06 1 mm Cable o 9 14 mm 14 17 Manufacturer Information Manufacturer Internet Address INTERCONTEC http www intercontec com Manufacturer s Product ID BSTA 108 FR 19 08 0006 000 BSTA 108 FR 35 16 0006 000 Table 31 Specifications for motor connectors 8 001 00 1 and 8 002 00 1 ACOPOS User s Manual V1 63 Chapter 2 Technical Data 4 2 3 Specifications for 8 003 00 1 Technical Data Connectors Product ID 8 003 00 1 General Information Contacts 8 4 power and 4 signal contacts Degree of Pollution 3 Installation Altitude up to 4 000 m Insulator PA UL94 VO listed Contacts Gold plated brass Protective Ground Connection on Housing According to VDE 0627 Protection according to DIN 40050 IP67 when connected Certifications UL CSA Electrical Characteristics Overvoltage Category 3 Power Contacts Nominal Current 75A Nominal Voltage 630 VAC VDC Isolation Voltage L L 6000 V Contact Resistance 1 mo Signal Contac
109. ly Product ID 8V1022 00 1 8V1045 00 1 8V1090 00 1 24 VDC Supply Input Voltage with motor holding brake 24 VDC 6 2 without motor holding brake 24 VDC 30 20 Current Requirements Max 2 5 A current for motor holding brake Motor Connection Maximum Switching Frequency 20 kHz 20 kHz 10 kHz Continuous Current at 400 V 2 2 Aeff 44 Aat 8 8 Aeff Continuous Current at 480 V 1 7 Aeff 3 3 Aeff 6 6 Aeff Peak Current 14 Agr 24 Aeff 24 Aeff Maximum Motor Line Length 25m Protective Measures Short circuit and ground fault protection Motor Holding Brake Connection Maximum Output Current 1A Protective Measures Short circuit and ground fault protection Braking Resistance Peak Power Output 3 5 kW 7 kW 7 kW Continuous Power Output 130W 200W 200W Operational Conditions Environmental Temperature during 0 to 45 C Operation Relative Humidity during Operation 5 to 95 non condensing Power Reduction in Relation to 10 per 1000 m installation altitude nstallation Altitude Max 2 000 m above sea level Degree of Pollution according to 2 non conductive material EC 60664 1 Overvoltage Category according to ll EC 60364 4 443 1999 Protection according to IEC 60529 IP20 Storage and Transport Conditions Storage Temperature 25 to 55 Relative Humidity for Storage 5 to 95 non condensing Transport Temperatur
110. ly implemented in an application program 1 5 Easy Service All necessary data is placed in application memory on the controller so that service is limited to simply exchanging the device The program does not have to be changed After the system is started again the controller automatically or when requested by the user installs the operating system used on the system After this procedure is complete the parameters are sent to the servo drive again Problems resulting from different software versions or parameters can be ruled out ACOPOS User s Manual V1 15 Chapter 1 General Information General Information ACOPOS Servo Family 1 6 Software and Hardware as a Unit B amp R integrates all relevant technologies in one tool B amp R Automation Studio Adding a B amp R ACOPOS servo drive is done in a Windows Look amp Feel environment which becomes routine after using the program a few times Wizards and selection boxes ease configuration of servo axis parameters The target system is shown in a clear tree structure Detailed information concerning the target system with integrated hardware documentation ranging from software to terminal assignments reduces project development times considerably B amp R Automation Studio lala Project View Inset Open Project Object Tools Window 2 Os gl Belo 4 2 2 Model no Software Logbook CAN 1 0 TPU Permanent Description 5 E
111. n over one revolution Normally the movement path is longer than one revolution In this case a reference Switch must be used and a search home procedure carried out The encoder input signals are monitored In this way broken connections shorted lines and encoder supply failure can be recognized 1 The module is designed for the evaluation of BRX resolvers These resolvers are fed with a single sinusoidal signal reference signal and deliver two sinusoidal signals as the result The amplitude of these signals change with the angular position sine or cosine form Unlike BRX resolvers BRT resolvers can be fed with two sine signals which are offset by 90 A single sine signal with constant amplitude is returned The phase position of this signal depends on the angular position During start up the AC122 module is automatically identified by the ACOPOS operating system Making automatic adjustments to the motor resolution parameter and reading the motor parameters and limit values is not possible because the resolver does not have parameter memory like the EnDat encoder If the precision resolution bandwidth or ease of setting parameters is not sufficient with the resolver the EnDat system should be used see Section 2 4 AC120 EnDat Encoder Interface 1 In preparation ACOPOS User s Manual V1 41 Chapter 2 Technical Data 2 5 2 Order Data Technical Data ACOPOS Plug in Modules Model Number Short Descript
112. na M 4 J 3 Qeloader UserROM 5816 9 4 4 ncolobal v0 17 UserROM 8020 J M M acpl man 0472 UserROM 66388 acpl par 0472 UserROM 15700 CHE ACPIO Real Axis 0 00 User RAM 360 10 Enor Text Module L acpi etx v0 00 UserROM 54696 x Debug Frain Fies Line 10 of 18 COMI CP476 V224 RUN Figure 43 Place mouse pointer on ACOPOS operating system ACP10SYS 138 ACOPOS User s Manual V1 Getting Started Starting Up an ACOPOS Servo Drive e Open the shortcut menu with the right mouse button Position the mouse pointer on Disable Click on Disable with the left mouse button to cancel deactivation amp B amp R Automation Studio File View Inset Open Project Object Tools Window 2 acp10 Project n Software Log book 1 0 Permanent Description Ew 10 Module Name Version Transferto Size bytes Description SP 2008 _ BP cg cM 10 EO Cyclic H 10m J 01 6 ax tst v0 00 UserRAM 7676 9 02 ax iste 16265 03 acpl manh 22476 J 04 libacpl man a 2188 9 1 cl System 81045001 syscont UseROM 752 BACTIDLDA 1 10 UserROM 212 j oce acpi s 7 M 4 J 3 gcloader 5816 4 ncglobal 8020 M acpl man erROM 66388 10 __ 15700 552 ACP10 Real Axis T par
113. nd white blue with white green Shield Separate shielding for pairs tinned Cu mesh optical coverage gt 85 and foil banding Cable Stranding With filler elements and foil banding Cable Shielding Tinned Cu mesh optical coverage gt 85 and wrapped in isolating fabric Outer Sheathing Material PUR Color Orange similar to RAL 2003 flat Labeling BERNECKER RAINER 4x1 5 2x2x0 75 FLEX BERNECKER RAINER 4x4 0 2x2x1 5 FLEX Electrical Characteristics Conductor Resistance Power Lines lt 14 QO km lt 5 2 O km Signal Lines lt 29 lt 14 QO km Insulation Resistance gt 200 per km Isolation Voltage Wire wire 3kV Wire shield 1kV Operating Voltage Max 600 V Mechanical Characteristics Temperature Range Moving 10 C to 70 Still 20 C to 90 C Outer Diameter 12 8 mm 0 4 mm 15 8 mm 0 5 mm Flex Radius 96 mm 118 5 mm Speed lt 4 Acceleration 60 m s Table 24 Cable specifications for 1 5 and 4 mm motor cables 54 ACOPOS User s Manual V1 Technical Data Cables Product ID Motor Cables 1 5 mm Motor Cables 4 mm Flex Cycles 23 000 000 Weight 0 26 kg m 0 45 kg m Table 24 Cable specifications for 1 5 and 4 mm motor cables cont Product ID Motor Cables 10 mm Motor Cables 35 mm General Information Cable Cross Section 4 10 2 2 1 5 mm 4 35 2 x 2 x 1 5 mm
114. neren entr 22 3 2 Intended Use Leer nett He een dee diate hp 22 3 3 Transport and Storage a a aE aa nnne ener nnne nennen 22 3 4 Installation ee Rhet ode eb E e eerie 23 3 5 Operating teu ie er dea Oat a ee EORR PEDE SE Red 23 3 5 1 Protection against Touching Electrical Parts see 23 3 5 2 Protection from Dangerous Movements 24 3 6 Safety Notices E tre ue CONI t rti bt ere dtp nat 25 Chapter 2 Technical Data 121 1 2 27 1 ACOPOS Servo Family 5 3 2 eror tede n et dived eoo cabe opo ena 27 1 1 Modular Servo Drive Concept 27 1 2 General Description iiie e eias Lue pee e de 28 BEDS cas cate hilo eben eie tiec 29 1 3 1LED Status Mm 30 1 4 ACOPOS 1022 1045 and 1090 nennen nennen 31 144 71Order Bata cut el AE a eden igi pta ec uu SE ce bo 31 1 4 2 Technical Data 31 15 ACOPOS 1640 128M oet eoe Bethe reel ear 33 i wuso doce ES 33 1 5 2 Technical D ta ure eee e leere dere eae 33 2 ACOPOS plug in modules ta edet ette eit et te ei 35 2 1 General Information e t ete he e ER EE E 35 2 2 Module Overview eiit eoe de e eee tek dde ecd dev da
115. nitory 0 Unis 0 0 i PLT SLI 0 0 20 0 40 0 60 0 0 0 100 0 x Transferring ax tst ok For Help press F1 COM CP476 V224 RUN Figure 71 The defined traverse path was completed and the Trace data is loaded 156 ACOPOS User s Manual V1 Getting Started Starting Up ACOPOS Servo Drive B amp R Automation Studio ax1_par waf Test BEE View Insert Open Project Test Object Tools Window 2 18 xl JD Hg Beloa xa F asalto EIL RR ES 100 100 i s Ta Peek H lig in i SAC 188 encoder i limit Units s 4 Units s 515 MOVE nclNIT PBE controller Units s ncCONTROL nclNIT 2 85 move Units s ncCONTROL ncSWITCH DF Bt stop Units ncCONTROL ncSWITCH_ON Lgs n ncHOMING ncSTART FT ncLIMITS nclNIT 9 parameter rcREL MOVE ncSERVICE ncREAD 0 ncSERVICE ncSET ncDAT noSIMLIIL ATINA neSWITCH 9 20 9 40 axl par Position loop controller S aw par network axl par network 0 par network 0 Current controller Actual stator current quadrature component 01 02 02 12 15 06 ax1_par monitor s 5000 Units 0 80 ax1_par monitor v 0 1_ 0 m we y tmt ettet A x Transferring ax tst ok 18000 0 COM CP476 V224 RUN Figure
116. o ncHOMING ncSTART PBS homing ncLIMITS nelNIT __ EBE basis ncREL MOVE neSTART over ncSERVICE ncREAD ncb Be pas ncSERVICE _ ncSET ncDAT ncSIMI II ATINA ne WITH x 9 ug stop x ad e Bl pannetwork i aw par network ax par network 0 ax par network 0 ax1_par monitor s 0 Units ax1_par monitor v 0 Unis Transferring tst ok 11 Eum Finda Fies For Help press F1 COM CP476 V224 RUN Figure 68 Enable trace function 154 ACOPOS User s Manual V1 Getting Started Starting Up an ACOPOS Servo Drive Start the Motor Movement e Position the mouse pointer on the action ncSTART for the subject ncREL_MOVE in the action window B amp R Automation Studio ax1_par waf Test View Insert Open Project Test Object Tools Window 2 laj 9 9 2 c9 2 2 100 Trace enabled T RD v pos Units s 10000 Units s al pos 50000 Units s a2 pos 50000 Units s al neg 50000 Units s a2 neg 50000 Units s neBASIS_MOVE ncINIT neCONTROL nclNIT ncCONTROL ncSWITCH OF ncCONTROL ncSWITCH ON ncHOMING ncSTART ncLIMITS nclNIT ncREL MOVE mun 5 ncSERVICE ncREAD ncD ncSERVICE ncSET ncDAT nc SIMI IL ne SWITCH aw par network ax1_par network 0 ax1_par networ
117. oa 106 Table 47 Grounding the motor cable On the motor side the cable shield is connected to the motor housing using the motor plug and connected to ground via the machine On the motor side the encoder cable shield is connected to the motor housing using the encoder plug and connected to ground via the machine ACOPOS User s Manual V1 Wiring General Information 1 2 Overview of the Terminal Cross Sections Terminal Cross Sections 8V1022 00 1 8V1640 00 1 8V128M 00 1 8V1045 00 1 8V1090 00 1 2 AWG mm AWG mm AWG Solid core and multiple conductor 014 15 28 16 0 14 1 5 28 16 014 15 28 16 lines Flexible and fine wire lines 1 without Wire Tip Sleeves 0 14 15 28 16 0 14 1 5 28 16 014 15 28 16 with Wire Tip Sleeves 025 05 23 20 0 25 0 5 23 20 0 25 0 5 23 20 Approbation Data UL C UL US E 30 16 p 30 16 30 16 CSA 28 16 28 16 28 16 Terminal tightening torque value Nm 0 22 0 25 0 22 0 25 0 22 0 25 Solid core and multiple conductor 02 4 24 10 10 25 7 3 10 50 7 0 lines Flexible and fine wire lines x2 without Wire Tip Sleeves 02 4 24 10 4 16 11 5 10 35 7 2 DC Bus with Wire Tip Sleeves 025 4 23 10 4 16 11 5 10 35 7 2 Approbation Data UL C UL US 30 10 gt 12 4 10 2 CSA 28 10 14 4 A 12 2 Terminal tightening torque value Nm 0 5 0 6 25 3 25 3 Solid core and multiple conductor 02 4 24 1
118. ollowing diagram L1 3 400 480VAC L2 50 60 Hz L3 Figure 17 Circuit diagram for ACOPOS X3 individual power mains connection ACOPOS User s Manual V1 83 Chapter 4 Dimensioning Dimensioning Power Mains Connection Dimensioning the Power Mains and Overcurrent Protection The cross section of the power mains and the rated current for overcurrent protection should be dimensioned for the average current load to be expected The power mains are to be equipped with overcurrent protection in the form of a circuit breaker or a fuse Circuit breakers time lag with type C tripping characteristics according to IEC 60898 or fuses time lag with type gM tripping characteristics according to IEC60269 1 are to be used The average current load to be expected can be calculated as follows S VA 18 Umainsl V The apparent power S can be calculated as follows ImainsLA 2 1 2 SIVA MINM k 60 ACOPOS k 1022 2 8 1045 2 4 1090 2 4 1640 17 128M 15 Table 40 Constant 1 Circuit breakers are available on the market with rated currents from 6 A to 63 A Outside of this range fuses must be used 2 If information concerning load torque inertia and friction are available the effective torque is calculated as follows Meg Nm Im 2 2 t s cycle If the motor is dimensioned correctly the nominal torque for th
119. on directory This start up example is based on the sample project BRAUTOMATION SAMPLES MOTION DEUTSCH C ACP10 PGP ACP10 GDM starting with ACOPOS operating system version V 0 47 2 Look in 9 10 File name Jacpi0 Open Files of type Project Files gdm z Cancel Figure 31 Open sample project Information During start up changes will be made to the sample project We recommend that you make a copy of the sample project entire ACP10 PGP directory see Figure 31 Open sample project in a different project directory and use it for the start up 2 1 2 Preparing the Hardware for Sample Project acp10 gdm Check the wiring of the ACOPOS servo drive connections also see chapter 5 Wiring e Set node number 1 on the AC110 plug in module see chapter 2 Technical Data e Connect the PC with the PLC using the online cable see user s manual for the PLC for information concerning the online cable connection to the PLC e Apply power to the PLC and the ACOPOS servo drive 24 VDC 400 VAC You make sure the ACOPOS servo drive boots correctly by watching the blink code see chapter 2 Technical Data ACOPOS User s Manual V1 131 Chapter 6 Getting Started Getting Started Starting Up an ACOPOS Servo Drive 2 2 Start up 2 2 1 Load Sample Project Start B amp R Automation Studio BER AutomationStudio Version V 2 1 D
120. onment Limits fromCISPR11 Group 2 Class A Brake Resistor Frequency 48 Hz to 62 Hz Installed Load Max 54 kVA Max 98 kVA Starting Current 26 A at 400 VAC Switch on Interval Anywhere Power Loss at Max Device Power without 1600 W 3200 W 24 VDC Supply Input Voltage 24 VDC 25 25 Current Requirements Max 6 A 1 4 x current for motor holding brake Table 10 Technical data ACOPOS 1640 128M ACOPOS User s Manual V1 33 Chapter 2 Technical Data Technical Data ACOPOS Servo Family Product ID 8V1640 00 1 8V128M 00 1 Motor Connection Maximum Switching Frequency 10 kHz 5kHz Continuous Current at 400 V 64 Aer 128 Aeff Continuous Current at 480 V 48 96 Aat Peak Current 200 Ag 283 300 Agr 425 Maximum Motor Line Length 25m Protective Measures Short circuit and ground fault protection Motor Holding Brake Connection Maximum Output Current 3A Protective Measures Short circuit and ground fault protection Braking Resistance Peak Power Int Ext 7 250 kW 8 5 250 kW Continuous Power Int Ext 0 2 24 kW 0 24 24 kW Operational Conditions Environmental Temperature during Operation 0 to 40 Relative Humidity during Operation 5 to 95 non condensing Power Reduction in Relation to nstallation Altitude 10 per 1000 m installation alt
121. oss Sections mm AWG Solid core and multiple conductor lines 0 5 1 5 20 14 Flexible multiple wire line without Wire Tip Sleeves 0 5 1 5 20 14 with Wire Tip Sleeves 0 5 1 5 20 14 Approbation Data UL C UL US and CSA UL C UL US 26 14 CSA 26 14 Table 65 Pin assignments AC130 digital mixed module 120 ACOPOS User s Manual V1 Wiring Plug in Module Connections 4 6 Connecting Cables to Plug in Modules Figure 26 Connecting Cables to Plug in Modules Stress relief for the cable is implemented using a cable tie The cable tie is to be run through the eye on the bottom of the plug in module Make sure that the ventilation slots on the bottom of the ACOPOS drive are not blocked ACOPOS User s Manual V1 121 Chapter 5 Wiring 5 Cables 5 1 Motor Cables Wiring Cables 5 1 1 Motor Cable Construction white blue white green white red white blue black yellow green Pos Amount Product ID Remark 1 1 Motor lines 4 1 5 mm 2 x 2 x 0 75 mm 4x4mm 2x2x1 mm 4 10 mm 2x2 x 1 5 mm 4x 35 mm 2 x 2 x 1 5 mm not prefabricated 2 1 Circular connector BSTA 108 FR 19 08 0006 000 for 8 12 1 and 8 12 3 BSTA 108 FR 35 16 0006 000 for 8CMxxx 12 5 3 1 Shrink wrap 4 8 Wire tip sleeve Table 66 Motor cable construction 122 ACOPOS User s Manual V1 Wiring Cables 5 1 2 Pin Assignments 8CMxxx 1
122. over Take the necessary steps to protect against electrostatic discharges 3 1 1 Installation 1 Disconnect the ACOPOS servo drive from the power mains and prevent reconnection 2 Switch off 24 VDC supply voltage 3 Remove screw from the bottom of the slot cover 4 Loosen screw on the front don t remove it completely the screw could fall into the ACOPOS servo drive 74 ACOPOS User s Manual V1 Installation Installation and Removal of Plug in Modules 5 Remove slot cover Figure 13 Installing ACOPOS plug in modules 6 Insert plug in module in the free slot see diagram shown above 7 Fasten the plug in module with the two screws 8 Switch on 24 VDC supply voltage 9 Connect ACOPOS servo drive to the power mains 3 1 2 Removal 1 Disconnect the ACOPOS servo drive from the power mains and prevent reconnection 2 Switch off 24 VDC supply voltage 3 Remove screw from the bottom of the plug in module 4 Loosen screw on the front don t remove it completely the screw could fall into the ACOPOS servo drive 5 Remove plug in module 6 Insert slot cover in free slot 7 Fasten the slot cover with the two screws 8 Switch on 24 VDC supply voltage 9 Connect ACOPOS servo drive to the power mains ACOPOS User s Manual V1 75 Chapter 3 Installation Installation Installing Various ACOPOS Series Devices Directly Next to Each Other 4 Installing Various ACOPOS Series Devices D
123. put Debug Findin Fies Line 10 of 18 COM 476 V224 RUN Figure 45 The operating system is also transferred the next time the project is downloaded Information After successfully downloading the operating system the first time Disable can be set again which shortens the download time for projects 2 2 3 Preset Values Concerning Wiring The further procedure depends on the wiring of the digital servo drive control inputs End Switch and Quickstop are Wired If the hardware end switches normally closed are wired to X1 End and X1 End and a quickstop switch normally closed is wired to X1 Quickstop Trigger2 according to chapter 5 Wiring Section 2 Connections ACOPOS 1022 1045 1090 then start up can be continued with Section 2 2 4 Downloading the Project 140 ACOPOS User s Manual V1 Getting Started Starting Up ACOPOS Servo Drive End Switch and Quickstop are not Wired If the hardware end switches and quickstop are not wired it is possible to change the parameters so that the motor shaft can still be moved Danger When moving the motor shaft without the hardware end switches connected movements of mechanical parts mounted on the motor shaft must be considered Otherwise severe personal injury or damage to property can occur Position the cursor on the initial parameter module AX1 PAR e Open the object by double clicking with the left mouse button B amp R
124. rail The ground connection must be made even when testing the servo drive or when operating it for a short time Before turning the device on make sure that all voltage carrying parts are securely covered During operation all covers and switching cabinet doors must remain closed Control and high power contacts can have voltage applied even when the motor is not turning Touching the contacts when the device is switched on is not permitted ACOPOS User s Manual V1 23 Chapter 1 General Information General Information Safety Guidelines Before working on servo drives they must be disconnected from the power mains and prevented from being switched on again Danger After switching off the device wait until the DC bus discharge time of at least five minutes has passed The voltage currently on the DC bus must be measured with a suitable measuring device before beginning work This voltage must be less than 42 V DC to rule out danger The Run LED going out does not indicate that voltage is not present on the device The connections for the signal voltages 5 to 30 V found on the servo drives are isolated circuits Therefore the signal voltage connections and interfaces are only allowed to be connected to devices or electrical components with sufficient isolation according to IEC 60364 4 41 or EN 50178 Never remove the electrical connections from the servo drive with voltage applied In unfavorable conditions arcs can occ
125. ral Description 2 47 2 7 2 Order Data 47 22753 rechnical Data ort egi ede ei vete vet eere aeter erre 47 3 Cables eo ente irre etate e dederit eeu Dod e Eee rues 51 3 1 General Information hdi eet eit ee teg 51 3 11 Mani factured Cable 2 eet 51 3 2 Motor Cables ee oet teret eite tens 52 3 2 J Order Data E etiem LLL IDA ADI al 52 3 2 2 Cable Specification e eoe cete pex RED CERE 54 3 3 EnDat Cable mem mee eR 57 3 3 A Order Data 55 uere Rei Ett 57 3 3 2 Cable Specification rtr 57 9 4 Resolver eite ei iecit a re e E 59 3 4 Order Data naL Loren alain 59 3 4 2 Cable Specification idee enden te ene 60 4 CONNECTS rtr ret ett e id 61 4 1 Gerieral Information ee sete nen a ive eee dee ee 61 4 2 Motor GonneclorS sucio eee tte et ee ede t 62 42 1 Order Data 62 4 2 2 Specifications for 8 001 00 1 and 8PMO002 00 1 63 4 2 3 Specifications for 8 003 00 1 64 4 3 Encoder Connector e nene nennt 65 a Ordf gt ETE 65 4 3 2 Specif
126. ransport mounting installation commissioning and operation of the product and have the respective qualifications e g IEC 60364 Be sure to follow national accident prevention guidelines The safety guidelines connection descriptions type plate and documentation and limit values listed in the technical data are to be read carefully before installation and commissioning and must be observed Danger Handling servo drives incorrectly can cause severe personal injury or damage to property 3 2 Intended Use Servo drives are components designed to be installed in electrical systems or machines They are not being used as intended unless the machine meets EG regulation 98 37 EG machine regulation as well as regulation 89 336 EWG EMC regulation The servo drives are only allowed to be operated directly on grounded three phase industrial mains TN TT power mains When using the servo drives in living areas shops and small businesses additional filtering measures must be implemented by the user The technical data as well as the values for connection and environmental guidelines can be found on the type plate and in the documentation The connection and environmental guidelines must be met Electronic devices are generally not fail safe If the servo drive fails the user is responsible for making sure that the motor is placed in a secure state 22 ACOPOS User s Manual V1 General Information Safety Guidelines 3 3 Tran
127. re 22 Diagram of a typical movement with the brake power curve Pp t 1 1 If as shown a typical triangular brake power curve occurs then the average brake power can be calculated directly with the following formula 1 P W L BRaverl TeycielS 2 96 ACOPOS User s Manual V1 Dimensioning Braking Resistor The calculation is continued by deriving the brake power curve Pp t from the drive power curve The power must be set to zero in areas where it is positive P t gt 0 This results in the following maximum brake power WI abs max P t W Then the average brake power is calculated over the given cycle e nerd i Pe t S In order to use an external braking resistor 1 the following parameters must be calculated e resistance e the maximum power Pp max e the nominal power Pg N Resistance of the Braking Resistor The resistance of the braking resistor Rp can be calculated as follows _ UpclVI _ Re IW Ps W W max The selected resistance is not allowed to be less than the minimum resistance for the respective ACOPOS servo drive see Table 44 Braking resistors for ACOPOS servo drives on page 94 Rg 0 2 O If this condition is not met the maximum brake power required cannot be reached Typical resistances are 4 50 depending on the size of the ACOPOS device
128. ria B Lines for measurement and control functions in the process environment Tests according to IEC 61000 4 5 Surge IEC 61800 3 Power lines 1 kV 2 DM symmetrical criteria 2 kV 12 CM unsymmetrical criteria B Tests according to IEC 61000 4 6 HF Coupling IEC 61800 3 Power lines 0 15 80 MHz 10 V 80 amplitude modulation with 1 kHz criteria A Signal interfaces other lines Table 77 Electrical Limit Values for Immunity Tests according to IEC61800 3 Performance Criteria simplified Criteria A Test object not influenced during test Criteria B Test object only temporarily influenced during test Criteria C The system does not reboot automaticall 160 y reset required ACOPOS User s Manual V1 Standards and Certifications 4 Electrical Limit Values for Emission Tests according to IEC 61800 3 These emission tests are valid for industry 2nd environment Tests according to IEC 55011 conducted emissions Continuous Current on Motor Frequency Range MHz Quasi peak Value Average 0 15 lt lt 0 5 100 dB uV 90 dB uV 1 lt 100 0 5 lt lt 5 86 dB uV 76 dB uV 5 lt lt 30 90 dB uV 80 dB uV 0 15 f 0 5 130 dB uV 120 dB uV 100A I 05 lt f lt 5 125 dB uV 115 dB uV 5 lt f lt 30 115 dB uV 105 dB uV Tests according to IEC 55011 radiated emissions Frequency R
129. riented axis programming minimizes development time and increases reusability Integrated technology functions for branch specific tasks Operation of synchronous and asynchronous motors possible Input voltage range from 400 480 VAC 10 96 for use worldwide Four slots for plug in modules Connection possibilities for all standard encoder systems Reduced commissioning and service times using embedded motor parameter chip Current regulator scan time up to 50 us CAN fieldbus connection ACOPOS User s Manual V1 27 Chapter 2 Technical Data Technical Data ACOPOS Servo Family 1 2 General Description The ACOPOS servo drive series covers a current range from 2 2 128 A and a power range from 1 64 kW with 5 devices in 2 groups The devices in a group are designed using the same basic concept Group 8V1022 00 1 8V1640 00 1 8V1045 00 1 8V128M 00 1 8V1090 00 1 Power Connections Plug connection Fixed Integrated Power Filter Yes 1 Mains Failure Monitoring In preparation Yes DC Bus Connection Yes Yes 24 VDC Supply Extemal External or internal via DC bus 24 VDC Output No 24V 0 5A Integrated Brake Chopper Yes Yes Internal Braking Resistor Yes Yes 2 Connection of External Braking No Yes Resistor Possible Monitored Output for Motor Yes Yes Holding Brake Monitored Input for Motor Yes Yes Temperature Sensor Table 2 General description of the ACOPOS servo drive ser
130. ription Function 1 DC2 U DC bus 2 DC1 U DC bus 3 DC2 U DC bus 4 DC1 U DC bus Terminal Cross Sections see Table 48 Terminal cross sections for ACOPOS servo drives on page 107 Table 56 Pin assignments for X2 ACOPOS 1640 128M ACOPOS User s Manual V1 Chapter 5 Wiring 3 3 Pin Assignments for X3 Wiring Connections ACOPOS 1640 128M x3 Pin Description Function 1 L1 Power Mains Connection L1 2 L2 Power Mains Connection L2 3 L3 Power Mains Connection L3 4 PE Protective Ground Conductor Terminal Cross Sections see Table 48 Terminal cross sections for ACOPOS servo drives on page 107 Table 57 Pin assignments for X8 ACOPOS 1640 128M 3 4 Pin Assignments for Plug X4 x4 Pin Description Function 1 1 External activation of the holding brake 1 2 52 External activation of the holding brake 1 3 Brake 4 Brake 5 Temperature 6 Temperature eese 7 24V out 0 5A 24 V output 0 5 A TD 8 COM 7 9 10 Supply 0 V 9 24V 424V 10 24V 24 V 11 7 9 10 Supply 0 V 12 COM 7 9 10 Supply 0 V Terminal Cross Sections see Table 48 Terminal cross sections for ACOPOS servo drives on page 107 Table 58 Pin assignments for plug X4 ACOPOS 1640 128M 1 51 and S2 can be used to connect an external potential free contact typicall
131. rive power mains must be done according to Section Dimensioning the Power Mains and Overcurrent Protection cross section of the DC bus wiring 1 on the respective ACOPOS servo drives must be less than or equal to the cross section of the servo drive power mains The selected cross section must be within the range possible for the DC bus connection terminal X2 see chapter 5 Wiring Table 48 Terminal cross sections for ACOPOS servo drives on page 107 2 4 Equal Distribution of the Brake Power on the Braking Resistors The braking resistors integrated in the ACOPOS servo drives as well as braking resistors which can be connected externally are controlled using a specially developed procedure This guarantees that the brake power is optimally and equally distributed on the braking resistors when a DC bus connection is made between several units When using the integrated braking resistors additional configuration is not required When using external braking resistors the corresponding parameters must be defined see Section 4 4 Setting Brake Resistor Parameters 1 The cross section of the individual segments of the DC bus wiring must be dimensioned for the thermal equivalent effective value of the respective compensation current If information concerning the flow of the compensation current is available calculate the thermal equivalent effective value of the compensation current using 1 MAL rg DAP
132. rting Up an ACOPOS Servo Drive User Memory Before downloading the sample project we recommend clearing the user memory on the PLC e Inthe Project menu select Services and then Clear Memory B amp R Automation Studio Ele Inset Open Project Object Tools Window 7 Dg Bud 122 enToTag Change OS version AN 1 0 Permanent Description zo A UTE Version Transfer to Description EH cheme 22 7CP476 60 1 Save Scheme 9 v0 00 UserRAM 7676 y btc 16265 3 SOIN 22476 Wann 2188 5 Cold Restart 9 50 syscor Diagnostics UseROM 752 8AC110 60 1 1 10 UserROM 212 20 601 2 Transfer Operating System M 4 3 3 gcloac UserROM 5816 J ncgot Update MEMCARD User ROM 8020 9 M M acpl0mm UserROM 66388 acpl par V0472 UserROM 15700 55 2 ACPIO Real Axis 1 par v0 00 UserRAM 360 10 Enor Text Module 8 acpi etx v0 00 UserROM 5469 Debug Cleats memory on the target Line 16 of 18 COM 476 V224 RUN Figure 40 Clearing user memory on the PLC e Activate the checkbox Erase USER ROM e Acknowledge the selection by clicking the OK button Clear Memory x WARNING If the FIXRAM USER ROM MEMCARD or Permanent memory is erased the memory on the Target will be cleared Eras
133. s page 93 are calculated with the factor 0 91 given in the standard for use at 40 environmental temperature ACOPOS User s Manual V1 93 Chapter 4 Dimensioning 4 Braking Resistor 4 1 General Information Dimensioning Braking Resistor When braking servo motors power is returned to the servo drive This causes the capacitors in the DC bus to be charged to higher voltages Starting with a DC bus voltage of approx 800 V the ACOPOS servo drive links the braking resistor to the DC bus using the brake chopper and converts the braking power to heat For ACOPOS servo drives braking resistors are integrated for this purpose or external braking resistors can be connected The equipment differences can be found in the following table 8V1022 00 1 8V1045 00 1 8V1640 00 1 8V128M 00 1 8V1090 00 1 Integrated Brake Chopper Yes Yes Yes Yes Internal Braking Resistor Yes Yes Yes 1 Yes 1 Continuous Power Output 130W 200W 200W 240W Maximum Power 3 5 kW 7 kW 7 kW 8 5 kW Connection of External Braking Resistor 4 4 Yes Yes Possible Continuous Power Output 24 kW 24 kW Maximum Power 250 kW 250 kW Minimum Braking Resistor Value 2 250 250 Rated Current of the Built in Fuse 9 30 A fast acting 30 A fast acting lg Table 44 Braking resistors for ACOPOS servo drives 1 The braking resistor integrated in the ACOPOS servo drives 1640 and 128M is dimens
134. s Outputs 5 8 Max 50 us Outputs 9 10 Max 500 ys Switching Frequency resistive load Outputs 1 2 Max 10 kHz max 20 kHz in PWM mode Outputs 3 4 Max 10 kHz Outputs 5 8 Max 5 kHz Outputs 9 10 Max 100 Hz PWM Outputs 1 2 Resolution of the Pulse Width 13 bit Period Duration 50 us 400 us ACOPOS User s Manual V1 Table 22 Technical Data AC130 cont 49 Chapter 2 Technical Data Technical Data ACOPOS Plug in Modules Product ID 8AC130 60 1 Protection Short Circuit Protection Yes Overload Protection Yes Short Circuit Current at 24 V until cut off Outputs 1 4 Approx 1 Outputs 5 8 Approx 1 2A Outputs 9 10 Approx 24 A Readable Outputs Yes Operational Conditions Environmental Temperature during 0 to 50 C Operation Relative Humidity during Operation 5 to 95 non condensing Storage and Transport Conditions Storage Temperature 25 to 55 C Relative Humidity for Storage 5 to 95 non condensing Transport Temperature 25 to 70 C Relative Humidity for Transport 95 at 40 C non condensing Table 22 Technical Data AC130 cont 1 Shielded cables must be used for inputs 1 4 Both screws on the module must be tightened 50 ACOPOS User s Manual V1 Technical Data Cables 3 Cables 3 1 General Information B amp R offers the cables for ACOPOS servo drives in six different lengths
135. s automatically provided the correct motor parameters and limit values During start up the AC120 module is automatically identified configured and its parameters set by the ACOPOS operating system You only have to make sure that the maximum cable length is not exceeded When using a B amp R EnDat cable even this source of problems is avoided 38 ACOPOS User s Manual V1 2 4 2 Order Data Technical Data ACOPOS Plug in Modules Model Number Short Description Image Plug in Module 8AC120 60 1 ACOPOS plug in module EnDat encoder interface Accessories 8 005 12 1 cable length 5m 10 x 0 14mm 2 x 0 5mm EnDat connector 17 pin Intercon connector 15 pin DSUB plug can chains UL CSA listed ec Servo be used in cable drag 8 007 12 1 EnDat cable length 7m 10 x 0 1 EnDat connector 17 pin Intercon connector 15 pin DSUB plug can chains UL CSA listed ec 4mm 2 x 0 5mm Servo be used in cable drag 8CE010 12 1 EnDat cable length 10m 10 x 0 EnDat connector 17 pin Intercon connector 15 pin DSUB plug can chains UL CSA listed ec 14mm 2 x 0 5mm Servo be used in cable drag 8CE015 12 1 EnDat cable length 15m 10 x 0 EnDat connector 17 pin Intercon connector 15 pin DSUB plug can chains UL CSA listed ec 14mm 2 x 0 5mm Servo be used in cable drag 8
136. ser s Manual V1 29 Chapter 2 Technical Data Technical Data ACOPOS Servo Family 1 3 1 LED Status The following timing is used for the indication diagrams Block size 125 ms Repeats after 2500 ms Status changes when booting the operating system loader Status LED Indication green 1 Boot procedure for basic hardware orange active red green 2 Configuration of CAN plug in module orange active red green 3 Waiting for CAN telegram orange red green 4 CAN communication active orange Table 5 Status changes when booting the operating system loader Error status with reference to the CAN plug in module AC110 Status LED Indication green Boot error on CAN basic hardware orange NEN FETI green Bus Off orange NNI green CAN node number is 0 orange Table 6 Error status with reference to the CAN plug in module AC110 30 ACOPOS User s Manual V1 1 4 ACOPOS 1022 1045 and 1090 1 4 1 Order Data Technical Data ACOPOS Servo Family Model Number Short Description Image Servo Drives 8V1022 00 1 Servo drive 3 x 400 480V
137. some limitations mm ACOFOS 1045 mmm 4 0 05 1045 4CUFUS 1045 Bm 4CUFUS 1045 4 mum AULUFUS 1045 Figure 7 CAN Configuration 1 20 ACOPOS User s Manual V1 General Information ACOPOS Configurations 2 1 2 Configuration 2 Functionality The following ACOPOS functions are possible with this configuration e Point to Point Electronic Gears Electronic Compensation Gears Cross Cutter e Electronic Cam Profiles Flying Saw Line Shaft e B amp R SYSTEM 2005 B amp R SYSTEM 2005 with CP260 IF260 and NC157 CAN Bus mum ACOPOS 1045 ACOFOS 1045 4 mum ACDPOS 1045 Liz AULUFUS 1045 max 4 shafts Figure 8 CAN Configuration 2 ACOPOS User s Manual V1 21 Chapter 1 General Information General Information Safety Guidelines 3 Safety Guidelines 3 1 General Information Danger Servo drives and servo motors can have bare parts with voltages applied e g terminals or hot surfaces Additional sources of danger result from moving machine parts Improperly removing the required covers inappropriate use incorrect installation or incorrect operation can result in severe personal injury or damage to property All tasks such as transport installation commissioning and service are only allowed to be carried out by qualified personnel Qualified personnel are persons familiar with t
138. sport and Storage During transport and storage the devices must be protected from excessive stress mechanical load temperature humidity aggressive atmosphere Servo drives contain components sensitive to electrostatic charges which can be damaged by inappropriate handling During installation removal of servo drives provide the necessary safety precautions against electrostatic discharges 3 4 Installation The installation must take place according to the documentation using suitable equipment and tools The devices are only allowed to be installed without voltage applied and by qualified personnel Voltage to the switching cabinet should be switched off and prevented from being switched on again The general safety regulations and national accident prevention guidelines e g VBG 4 must be observed when working with high voltage systems The electrical installation must be carried out according to the relevant guidelines e g line cross section fuse protective ground connection also see chapter 4 Dimensioning 3 5 Operation 3 5 1 Protection against Touching Electrical Parts Danger To operate servo drives it is necessary that certain parts are carrying voltages over 42 VDC A life threatening electrical shock could occur if you touch these parts This could result in death severe injury or material damage Before turning on the servo drive make sure that the housing is properly connected to protective ground PE
139. stop are activated logical 1 This allows the motor shaft to be moved without wiring the hardware end Switches and a quickstop The procedure is shown here in an example for pos hw end Inthe right part of the window position the mouse pointer on level ncACTIV_LO for the shaft parameter pos hw end ax par Value Unit reference pos hw end neg hw end ncACTIV LO trigger ncACTIV HI trigger LO ncQUICKSTOP Figure 50 Place mouse pointer on level LO ACOPOS User s Manual V1 143 Chapter 6 Getting Started Getting Started Starting Up an ACOPOS Servo Drive Open the selection list by clicking with the left mouse button Select ncACTIV by clicking with the left mouse button wl par Value Unit reference neACTIV_HI pos hw end ncACTIV LO end ncACTIV LO tigger ncACTIV LO ncFORCE ncACTIV_HI ncF RCE ncACTIV HI ncQUICKSTOP ncACTIV HI ncFORCE ncQU ncACTIV LO ncQUICKSTOP ncACTIV LO ncF RCE ncQ Figure 51 Change the level for the positive hardware end switch e Acknowledge the selection by pressing the ENTER key ax par Value Unit reference ncACTIV HI pos hw end neg hw end ncACTIV LO trigger ncACTIV HI trigger2 ncACTIV LO ncQUICKSTOP Figure 52 Acknowledge level change Use the same procedure for the other two parameters neg hw and trigger2
140. t of 100 mA 4 standard high side outputs with a maximum current of 400 mA and 2 low speed high side outputs with a maximum current of 2 A All outputs can be read 2 7 2 Order Data 7TB712 91 02 Terminal block 12 pin 20 pcs cage clamps Model Number Short Description Image 8AC130 60 1 ACOPOS plug in module 8 digital 1 0 configurable in pairs as 24V input or as output 400 100 2 digital outputs 2A Order TB712 terminal block separately Accessories 7TB712 9 Terminal block 12 pin screw clamps 7TB712 91 Terminal block 12 pin cage clamps 7TB712 90 02 Terminal block 12 pin 20 pcs screw clamps Table 21 Order Data AC130 ACOPOS User s Manual V1 47 Chapter 2 Technical Data 2 7 3 Technical Data Technical Data ACOPOS Plug in Modules Product ID 8AC130 60 1 General Information C UL US Listed Yes Module Type ACOPOS plug in module Slot Currently limited to slots 3 and 4 Power Consumption 0 8 W Inputs Outputs Connection Module Side 12 conductor pin connector Configuration of the Inputs Outputs Configured in pairs as input or output Indication 24 V LED Immunity 1 IEC 61000 4 2 ESD 15 kV IEC 61000 4 4 Burst 2kV Power Supply Power Supply Minimum 18 VDC Nominal 24 VDC Maximum 30 VDC Reverse Polarity Protection Yes Voltage Monitoring 24 V LED Yes supply voltage gt 18 V
141. the maximum power output module Pmax 2202 Y P The power consumption of the individual modules can be found in the technical data for the modules see chapter 2 Technical Data 100 ACOPOS User s Manual V1 Dimensioning Formula Variables Used 6 Formula Variables Used Term Unit Product ID Cp F Discharge capacitance for ACOPOS 1022 1045 1090 Cp 660 nF for ACOPOS 1064 128M mains Hz Mains frequency lA A Discharge current via protective ground conductor PE lp A Rated current for overcurrent protection Imains A Mains current phase current lq A Thermal equivalent current effective value lz A Maximum current load on a cable M Nm Torque general Mar Nm Effective load torque n min Speed general Naver min Average speed rad s Angular speed P Power or true power general Brake power Por x Maximum brake power Braver Average brake power Re Maximum load on the external braking resistor P Nominal power of the external braking resistor Pen Prax P module Power consumption of the plug in modules Pi 3 1415 Rey Q Braking resistance Ra e Minimum braking resistance S VA Apparent power t 5 Time general Brake time Toyde 5 Cycle time Upc V DC bus voltage Umains V Supply voltage phase to phase Table 46 Formula variables
142. the motors cannot prevent hoists from allowing the load to sink 3 6 Safety Notices Safety notices are organized as follows Safety Notice Description Danger Disregarding the safety regulations and guidelines can be life threatening Warning Disregarding the safety regulations and guidelines can result in severe injury or heavy damage to material Caution Disregarding the safety regulations and guidelines can result in injury or damage to material Information Important information used to prevent errors Table 1 Description of the safety notices used in this manual ACOPOS User s Manual V1 25 Chapter 1 General Information 26 General Information Safety Guidelines ACOPOS User s Manual V1 Technical Data ACOPOS Servo Family CHAPTER 2 TECHNICAL DATA 1 ACOPOS Servo Family 1 1 Modular Servo Drive Concept Controlling your power transmission system with the new B amp R ACOPOS servo drives allows you to fully use the advantages of an optimized system architecture Applications that require additional positioning tasks such as torque limitation or torque control can be created quickly and elegantly The flexible system concept for B amp R servo drives is achieved using matched hardware and software components You can select the optimal system configuration for your application and increase your competitiveness Perfect integration in the B amp R 2000 product family Object o
143. timally and equally distributed on the braking resistors when a DC bus connection is made between several units When using the integrated braking resistors additional configuration is not required When using external braking resistors the following resistor data must be known Resistor Data Term Unit Continuous power for the resistance IW Maximum power for the resistance IW Ohmic resistance Maximum switch on time at maximum power s Maximum temperature of the resistor 1 Table 45 Resistor data when using external braking resistors 1 If available Then the parameters to be set on the ACOPOS servo drive can be determined with the configuration tool RESISTPARAM XLS ParlD 10 Ohmic resistance W 11 Max temperature of the resistor ParlD 12 Thermal resistance C W ParlD 13 Heat capacity of the resistor Ws C ACOPOS User s Manual V1 99 Chapter 4 Dimensioning Dimensioning Current Consumption of ACOPOS Plug in Modules 5 Current Consumption of ACOPOS Plug in Modules The plug in modules for ACOPOS servo drives allow the servo drives to be individually configured according to the requirements of the application When putting together plug in module combinations the power consumption must be checked The maximum power output for all 4 slots is 22 W The total power consumption for all plug in modules must be less than or equal to
144. tions see Table 48 Terminal cross sections for ACOPOS servo drives on page 107 Table 49 Pin assignments for plug X1 ACOPOS 1022 1045 1090 2 2 Pin Assignments for Plug X2 drives on page 107 X2 Pin Description Function 1 DC1 U DC bus 2 UDC bus 3 DC2 U DC bus 2 4 DC2 U DC bus D02 652 551 2001 Terminal Cross Sections see Table 48 Terminal cross sections for ACOPOS servo Table 50 Pin assignments for plug X2 ACOPOS 1022 1045 1090 ACOPOS User s Manual V1 109 Chapter 5 Wiring Wiring Connections ACOPOS 1022 1045 1090 2 3 Pin Assignments for Plug X3 x3 Pin Description Function 1 L1 Power Mains Connection L1 2 L2 Power Mains Connection L2 3 L3 Power Mains Connection L3 4 PE Protective Ground Conductor 0000 i CS EC Terminal Cross Sections see Table 48 Terminal cross sections for ACOPOS servo drives on page 107 Table 51 Pin assignments for plug X8 ACOPOS 1022 1045 1090 2 4 Pin Assignments for Plug X4 x4 Pin Description Function 1 T Temperature Sensor 2 Temperature Sensor 3 B Brake B T T nA 4 B Brake Terminal Cross Sections see Table 48 Terminal cross sections for ACOPOS servo drives on page 107
145. ts Nominal Current 30A Nominal Voltage 250 VAC VDC Isolation Voltage L L 4000 V Contact Resistance lt 3 MQ Mechanical Characteristics Temperature Range 40 C to 130 C Housing Material Aluminum nickel plated Gaskets Viton Crimp Range 4 1 5 10 mm 4 x 0 5 2 5 mm Cable 17 26 mm Manufacturer Information Manufacturer INTERCONTEC Internet Address http www intercontec com Manufacturer s Product ID CSTA 264 FR 48 25 0001 000 Table 32 Specifications for motor connector 8 003 00 1 64 ACOPOS User s Manual V1 4 3 Encoder Connectors 4 3 1 Order Data Technical Data Connectors Model Number Short Description Image EnDat Connector 8 001 00 1 EnDat Connector 17 pin Intercontec socket crimp range 17 x 0 06 1 0mm for cable o 9 12mm IP67 UL CSA listed Resolver Connector 8PR001 00 1 Resolver connector 12 pin Intercontec socket crimp range 12 x 0 06 1 0mm for cable o 5 5 10 5mm IP67 UL CSA listed Table 33 Order data for encoder connectors ACOPOS User s Manual V1 65 Chapter 2 Technical Data Technical Data Connectors 4 3 2 Specifications for EnDat Connector 8 001 00 1 Product ID 8 001 00 1 General Information Contacts 17 signal contacts Degree of Pollution 3 Installation Altitude up to 2 000 m Insulator PBT UL94 VO listed Contacts Gold pl
146. tures which cannot be measured directly to be calculated One example is the junction temperature This is a decisive value for the maximum load of a semiconductor Using these models a sufficiently precise value can be determined for each IGBT Hot spots can be ruled out and the full dynamic properties of the device can be used at low rpm values and when stalled The brake resistor and motor windings are monitored in the same way This form of monitoring allows better use of absolute limits on the drive and provides the user with the advantages of higher performance at lower costs 14 ACOPOS User s Manual V1 General Information ACOPOS Servo Family 1 3 Individual Configurations The I O points needed to operate a servo axis are part of the standard equipment for ACOPOS drives The user is provided two trigger inputs for tasks requiring precise measurements or print mark control Sensor and actuator configurations are made using modular plug in modules This modular concept allows the optimum configuration to be selected to meet the requirements of the application Figure 2 Individual Configurations 1 4 Configuring Instead of Programming Long term cooperation with our customers has provided us with fundamental knowledge in many positioning application areas This knowledge can be passed on to our customers in the form of clear and easy to use function blocks Industry specific functionality can be quickly and easi
147. ual V1 General Information ACOPOS Servo Family 1 8 Simple Function Test The built in NC test allows an axis to be used without a line of program code being written As seen in the picture several editors are grouped together as a single window All movements ranging from point to point movements to gear functions can be carried out using an NC Action The reaction of the axis can be seen online in the monitor window If the trace function is turned on relevant data from position to motor temperature is recorded on the drive The multiple curve display in the trace window allows simple evaluation of the movement results B amp R Automation Studio ax4 waf File View Insert Open Project Test Obi JE th we EXER Be bass mm parameter Subject tion 9 stop ncHOMING ncSTART ncCONTROL ncSWITCH_ON ncREL MOVE neSTART ncSIMULATION ncSWITCH ON neBASIS_MOVE ncINIT ncLIMITS nclNIT ncPOS MOVE ncSTART ncCONTROL ncSWITCH OFF ncCONTROL nclNIT neSERVICE _ ncREAD 2 ax4 Current controller Set stator current quadrature component time s Sud monitors monitor v 0 ax4 network service data_text ax4 network service requestparid 0 ax4 network service response par 4 0 A oai tnt re 0 01 deg Metri uiri comi 260 V224 RUN
148. ue 10 mm D rog m U black 10 mm T 67 pog brown 10 mm Yd H 10 mme Lv E yellow green 10 mm E 2 Eu i 2 m i white 1 5 mm c rit M Lj i white red 1 5 mm OE AP white blue 1 5 mme EE LIT XOT PACEM i ET white green 1 5 o B RENS ow Figure 28 Cable schematic for motor cables 8CMxxx 12 5 124 ACOPOS User s Manual V1 Wiring Cables 5 2 EnDat Encoder Cables 5 2 1 EnDat Encoder Cable Construction 5 Pos Amount Product ID Remark 1 1 Encoder cable 10 x 0 14 mm 2 x 0 50 mm 2 1 Circular connector 17 pin socket ASTA 035 FR 11 12 0005 000 3 1 DSUB housing 45 metal plated 15 pin plug 4 1 Shrink wrap Table 69 EnDat encoder cable construction 5 2 2 Pin Assignments Circular connector Pin Product ID Function Pin DSUB plug 15 A Channel A 1 10 COM 1 3 9 11 13 15 Encoder supply 0 V 2 12 B Channel B 3 7 5V out 0 25A Encoder supply 5 V 4 14 D Data input 5 9 llo 3 1 8 1 Clock output 8 5 Channel A inverted 9 59 4 Sense Sense input 0 V 10 15 4 13 Channel B inverted 11 1 Sense 45V Sense input 5 V 12 17 D Data inverted 13 9 n Clock output inverted 15 Table 70 Pin assignments for EnDat encoder cables ACOPOS User s Manua
149. ur causing personal injury and damage to contacts 3 5 2 Protection from Dangerous Movements Danger Incorrect control of motors can cause unwanted and dangerous movements Such incorrect behavior can have various causes e Incorrect installation or an error when handling the components Incorrect or incomplete wiring Defective devices servo drive motor position encoder cable brake Incorrect control e g caused by software error Some of these causes can be recognized and prevented by the servo drive using internal monitoring However it is generally possible for the motor shaft to move every time the device is switched on Therefore protection of personnel and the machine can only be guaranteed using higher level safety precautions The movement area of machines is must be protected to prevent accidental access This type of protection can be obtained by using stabile mechanical protection such as protective covers protective fences protective gates or photocells Removing bridging or bypassing these safety features and entering the movement area is prohibited A sufficient number of emergency stop switches are to be installed directly next to the machine The emergency stop equipment must be checked before commissioning the machine 24 ACOPOS User s Manual V1 General Information Safety Guidelines Remove shaft keys on free running motors or prevent them from being catapulted The holding brake built into
150. urations auiem p EE 20 Connections 4 108 Connector See Connectors Danger 22 DIMENSIONING eee 81 Dimensions sess 71 Drive Oscilloscope 18 Function 17 155 General Information 13 27 Installation 23 69 103 Installation Dimensions 71 4 4242 0 16 Order Data acie ce De itn 31 Plug in Modules 14 35 74 100 116 Programming eee 15 Safety Guidelines 22 Sample 130 SeIViCO 1 cei ridere tete 15 Software ee eese tee 15 129 Status LEDs 29 Storage eani rip 22 Technical 31 17 155 Transporterna 22 WAGs tn ER 18 eicere datos 103 167 Index Index Shield 105 SoftWare be a 15 Software End Switches 151 Standards seh uetus 159 Startsups ua tea 129 Status LEDs 29 Storage dice Peter eds 22 168 T Terminal Cross Sections
151. y normally closed This makes it possible to activate the holding brake using an external safety circuit independent of the control integrated in the ACOPOS servo drive If this function is not used a jumper must be placed between S1 and S2 114 ACOPOS User s Manual V1 3 5 Pin Assignments for X5 Wiring Connections ACOPOS 1640 128M X5 Pin Description Function 1 PE Protective Ground Conductor 2 Motor Connection W 3 V Motor Connection V 4 U Motor Connection U Terminal Cross Sections see Table 48 Terminal cross sections for ACOPOS servo drives on page 107 Table 59 Pin assignments for X5 ACOPOS 1640 128M 3 6 Pin Assignments for X6 X6 Pin Description Function 1 RB Brake Resistance 2 RB Brake Resistance 3 PE Protective Ground Conductor e OPE RB RB Terminal Cross Sections see Table 48 Terminal cross sections for ACOPOS servo drives on page 107 Table 60 Pin assignments for 6 ACOPOS 1640 128M ACOPOS User s Manual V1 Chapter 5 Wiring 4 Plug in Module Connections 4 1 AC110 CAN Interface 4 1 1 Pin Assignments Wiring Plug in Module Connections Image Connection Pin Description Function 1 2 CAN L CAN Low 3 COM 2 7 CANOV 4 OC CY 6 e 5 7 CANH CAN High 6 0 A o 2o 8

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