Operating Instructions - Tecnica Industriale S.r.l.
Contents
1. Australia Assembly Melbourne SEW EURODRIVE PTY LTD Tel 61 3 9933 1000 Sales 27 Beverage Drive Fax 61 3 9933 1003 Service Tullamarine Victoria 3043 http Avwww sew eurodrive com au enquires sew eurodrive com au Sydney SEW EURODRIVE PTY LTD Tel 61 2 9725 9900 9 Sleigh Place Wetherill Park Fax 61 2 9725 9905 New South Wales 2164 enquires sew eurodrive com au Austria Assembly Wien SEW EURODRIVE Ges m b H Tel 48 1 617 55 00 0 Sales Richard Strauss Strasse 24 Fax 43 1 617 55 00 30 Service A 1230 Wien http sew eurodrive at sew sew eurodrive at Belgium Assembly Br ssel SEW Caron Vector S A Tel 32 10 231 311 Sales Avenue Eiffel 5 Fax 32 10 231 336 Service B 1300 Wavre http www caron vector be info caron vector be Brazil Production Sao Paulo SEW EURODRIVE Brasil Ltda Tel 55 11 6489 9133 Sales Avenida Am ncio Gaiolli 50 Fax 55 11 6480 3328 Service Caixa Postal 201 07111 970 http www sew com br Guarulhos SP Cep 07251 250 sew sew com br Additional addresses for service in Brazil provided on request Bulgaria Sales Sotia BEVER DRIVE GmbH Tel 359 2 9532565 Bogdanovetz Str 1 Fax 359 2 9549345 BG 1606 Sofia bever fastbg net Cameroon Sales Douala Electro Services Tel 237 4322 99 Rue Drouot Akwa Fax 237 4277 03 B P 2024 Douala Canada Assembly Toronto SEW EURODRIVE CO OF CANADA LTD Tel 1 905 791 1553 Sales 210 Walker Drive Fax2. Power cable Feedback cable Option output choke SL2 Basic SL2 Advance System Linear measuring system SL2 Power System AL1H 57630AEN Figure 1 System overview MOVIDRIVE MDX61B 5_3 4 08 with SL2 synchronous linear motors Operating Instructions MOVIDRIVEO MDX61B 5 3 4 08 with SL2 Synchronous Linear Motors Unit Design SL2 product designs 3 2 SL2 product designs SEW EURODRIVE offers three product designs for SL2 linear motors SL2 Basic Motor package and secondaries SL2 Advance Motor package integrated in motor cooling unit and secondary System Prepared for installation of linear guides and the linear encoder SL2 Power Motor package integrated in motor cooling unit with forced cooling System fan and secondaries Prepared for installation of linear guides and the linear encoder SL2 Basic 52619AXX Figure 2 SL2 Basic synchronous linear motor 1 Primary 2 Electrical connection in form of a cable extension 3 Secondary with permanent magnets SL2 Advance System SL2 Power System 55394AXX Figure 3 SL2 Advance System and SL2 Power System synchronous linear motor 1 Optional motor cooling unit 2 Prepared slots as retaining system for customer setup 3 Forced cooling fan of optional motor cooling unit 4 Electrical plug connector 5 Primary not visible installed in motor cooling unit 6 Secondary 7 Linear measuring system Operating Instructions MOVIDR
3. ele HINN EE MOVIDRIVE MDX61B 5 3 4 08 EA360000 with SL2 Synchronous Linear Motors Edition 12 2005 11397012 EN Operating nstructions SEW EURODRIVE Driving the world 4 2 Safety dicini 7 SUNIL DESIGN encuentre 8 3 1 System overview iii 8 3 2 SL2 product ele EE 9 3 3 MOVIDRIVE MDX61B 08 part 10 4 TE TO 12 4 1 Parameter settings nih nein Irene dd acti ec teda 12 5 Electrical Installation 19 Safety Noles 13 Mcr eI E E 16 6 1 Prerequisites for Startup eren 16 6 2 Commutation travel process oooooocccnnonoccccnnonoonncnnnnnnnnnnnnnnnnnnnnnnnnn nn cnnnnann cnn 16 6 3 Startup A AO 18 6 4 Calculating the travel parameters esses 27 7 Operation and Service sssssnennnnnrennnnnenenennennenss 30 7 1 Malfunction Sine EE 30 7 2 Faults during commutation search 31 7 3 Problems during operation 32 8 Index EE 33 Operating Instructions MOVIDRIVE MDX61B 5_3 4 08 with SL2 Synchronous Linear Motors Important Notes 1 Important Notes Safely and Always follow the safety and warning notes in this publication warning notes Electrical hazard Possible consequences Severe or fatal injuries Haza
4. Calculating the travel parameters Startup ago IPOSPIUSO sample program for an incremental measuring system BER E Function RT Task2 Main Loop while 1 H484 Li 1 while H458 0 2 Bit S H 3 i 4 11237AEN 1 Enable is reset 2 Wait for commutation search to finish 3 Enable is set 4 Continue program as usual Important notes Inthe case of absolute measuring systems ensure that the drive can be moved with out hindrance by the length of a pole pitch to the right during startup Incase of incremental measuring systems ensure that the drive can be moved with out hindrance by the length of a pole pitch to the right during startup The commutation search is started automatically when CONTROLLER INHIBT 1 H458 is then set to 1 and the IPOSP US program is executed Operating Instructions MOVIDRIVE MDX61B 5_3 4 08 with SL2 Synchronous Linear Motors 6 29 7 30 M e 7 7 1 7 lt Operation and Service Malfunctions Operation and Service Malfunctions The MOVIDRIVE MDX61B 5 3 4 08 inverter displays malfunctions by means of a 7 segment display and a fault code Refer to the MOVIDRIVE MDX60B 61B operating instructions for information on how to repair the faults The following notes offer addition al information for troubleshooting especially for SL2 synchronous linear motors Faults may be hard to localize if the EMC wiring i
5. Activate drive limits for initial startup Perform commutation travel with absolute or incremental encoder Optimize axle Taking the linear Make sure that the inverter is in controller inhibit or 24 V mode motor into In MOVITOOLS Shell call up the menu item Startup Linear motor gt following operation screenshot ESP S tz 8 Cummissiuning type Motor and encoder commissioning V7 controller commissioning Finish F Ne gt gt 10394AEN Select the option Motor and encoder commissioning V X controller commissioning Click Next to continue 18 Operating Instructions MOVIDRIVEO MDX61B 5 3 4 08 with SL2 Synchronous Linear Motors Startup ago Enter the date of the connected linear motor and the encoder system in the following Startup procedure 9 6 window Ex Linear Motor Commissioning E 5 x je CH Input values Motor M Type of motor Non SEW motor Output rated current 1 000 A Inductance lu ul mH Encoder system SEW encuder Nor SEW encuder Motor reod currant 9 Encoder type TTL Encoder Maximum current fo n A d E Signal period ps pm Pol pair distance mm 3607 Motor activity Power constant o 01 N A VMex 2 00 m s li lu UI Mains OFF response No mains off response ves icy d mn Du ADOR 0 4 11227AEN Click Next when you have entered all the req
6. Controller inhibit terminal is set to the value 1 Once commutation travel is complete the inverter sets variable H458 to 1 This value will be evaluated later in the IPOSP S program or in the PLC to permit the inverter enable Operating Instructions MOVIDRIVE MDX61B 5_3 4 08 with SL2 Synchronous Linear Motors 25 6 26 qu Optimizing the axle Additional settings Startup Startup procedure Write a short IPOSP 4S program to move the SL2 linear motor cyclically between two positions Start the IPOSPluse program In the linear motor startup window choose the radio button Only V X controller commissioning When the linear motor moves correctly set the current and force limits back to their original values and optimize the drive control loop section Taking the V X controller into operation using the Stiffness input field and the Estimate button Linear Motor Commissioning inixi Ge E Input values Total volume moved nnt ku estimate Extem inertia 0 00 Estimated total volume n Motor mass 0 01 ka Estimated friction n N Drive wilhoul backlash y Stiffness 1 05 1 2 0 Back Newt gt gt IT aoon o 10529BEN Figure 9 Screen for optimizing the axle using the Estimate button and the Stiffness input field If you have not selected the Encoder adjustment radio button an absolute encoder will behave like an incremental encoder This mean
7. 1 905 791 2999 Service Bramalea Ontario L6T3W1 http www sew eurodrive ca l reynoldsOsew eurodrive ca Vancouver SEW EURODRIVE CO OF CANADA LTD Tel 1 604 946 5535 7188 Honeyman Street Fax 1 604 946 2513 Delta B C V4G 1 E2 b wake sew eurodrive ca Montreal SEW EURODRIVE CO OF CANADA LTD Tel 1 514 367 1124 2555 Rue Leger Street Fax 1 514 367 3677 LaSalle Quebec H8N 2V9 a peluso sew eurodrive ca Additional addresses for service in Canada provided on request Chile Assembly Santiago de SEW EURODRIVE CHILE LTDA Tel 56 2 75770 00 Sales Chile Las Encinas 1295 Fax 56 2 75770 01 Service Parque Industrial Valle Grande ventas sew eurodrive cl LAMPA RCH Santiago de Chile P O Box Casilla 23 Correo Quilicura Santiago Chile China Production Tianjin SEW EURODRIVE Tianjin Co Ltd Tel 86 22 25322612 Assembly No 46 7th Avenue TEDA Fax 86 22 25322611 Sales Tianjin 300457 gm tianjin sew eurodrive cn Service http www sew com cn 35 36 i Address List China Assembly Suzhou SEW EURODRIVE Suzhou Co Ltd Tel 86 512 62581781 Sales 333 Suhong Middle Road Fax 86 512 62581783 Service Suzhou Industrial Park suzhou sew com cn Jiangsu Province 215021 P R China Additional addresses for service in China provided on rec Colombia Assembly Bogot SEW EURODRIVE COLOMBIA LTDA Tel 457 1 54750 50 Sales Calle 2
8. go 6 Commutation travel process Commutation 1 The SL2 linear motor moves to a random position This can be a distance of between travel process 0 mm to max 16 mm in either direction from the start position The SL2 linear motor stops here for approximately one second 16 mm lt 16 mm 53461AXX Figure 6 First cycle of the commutation travel 2 The SL2 linear motor is moved by 32 mm in the positive direction It stops here for about one second 53462AXX Figure 7 Second cycle of the commutation travel 3 The SL2 linear motor is moved by 32 mm in the negative direction It stops here for about one second 32 mm 53463AXX Figure 8 Third cycle of the commutation travel The inverter repeats the commutation process if the SL2 linear motor hits a hardware limit switch during commutation travel The SL2 linear motor then moves to a new start position 32 mm away from the limit switch The cycle restarts You will then hear a quiet cracking noise and the inverter switches from controlled to automatic mode Variable H458 is reset to 1 Operating Instructions MOVIDRIVE MDX61B 5_3 4 08 with SL2 Synchronous Linear Motors 17 6 go Startup Startup procedure 6 3 Startup procedure The startup procedure is divided into the following sections Take the linear motor into operation Take the V X controller into operation Checkthe encoder evaluation e Check the hardware limit switches
9. mounting with plastic distance plate Use an encoder system with a higher permitted operating temperature SL2 linear motor heats up excessively Overload Select the travel cycle so that the effective value of the output current is less than the rated current of the motor Insufficient cooling Improve cooling or install fan Air gap too large resulting in power loss at the same current see derating table in catalog SL2 Synchronous Lin ear Motors Adjust the air gap Ambient temperature is too high Select the travel cycle so that the effective value of the output current is less than the rated current of the SL2 linear motor HIPERFACE encoder fault Problems on encoder cable If the problems do not occur during manual sliding they are often caused by problems in the encoder or TF line See the MOVIDRIVE MDX60B 61B system manual and volume 9 of the Practical Drive Engineering series for information on trou bleshooting Check for correct shielding equipotential bond ing and read the note at the beginning of this section Encoder not installed correctly Check installation using the encoder manufacturer information 1 Air gap encoder measuring tape 2 Alignment encoder measuring tape 3 ForHIPERFACE encoder Check mounting direction so that cable output shows in direction smaller absolute values direction dot on the measuring tape if present Check rigidity of encode
10. ssssssssssseeee 5 Safety Notes cid 4 7 SL2 Power System eee 9 SL2 product designs 9 SLE2 Advarice iia ded uis 9 ere ehe 9 Starting up the linear motor 18 Operating Instructions MOVIDRIVE amp MDX61B 5 3 4 08 with SL2 Synchronous Linear Motors 33 i Address List Address List SiemensstraBe 1 D 40764 Langenfeld near D sseldorf Germany Headquarters Bruchsal SEW EURODRIVE GmbH amp Co KG Tel 49 7251 75 0 Production Ernst Blickle StraBe 42 Fax 49 7251 75 1970 Sales D 76646 Bruchsal http www sew eurodrive de P O Box sewOsew eurodrive de Postfach 3023 D 76642 Bruchsal Service Central SEW EURODRIVE GmbH amp Co KG Tel 49 7251 75 1710 Competence Center Gear units Ernst Blickle StraBe 1 Fax 49 7251 75 1711 Motors D 76676 Graben Neudorf sc mitte gm sew eurodrive de Central SEW EURODRIVE GmbH amp Co KG Tel 49 7251 75 1780 Electronics Ernst Blickle StraBe 42 Fax 49 7251 75 1769 D 76646 Bruchsal sc mitte e sew eurodrive de North SEW EURODRIVE GmbH amp Co KG Tel 49 5137 8798 30 Alte Ricklinger StraBe 40 42 Fax 49 5137 8798 55 D 30823 Garbsen near Hannover sc nord sew eurodrive de East SEW EURODRIVE GmbH amp Co KG Tel 49 3764 7606 0 D nkritzer Weg 1 Fax 49 3764 7606 30 D 08393 Meerane near Zwickau sc ost sew eurodrive de South SEW EURODRIVE GmbH amp Co KG Tel 49 89 909552 10 DomagkstraBe 5 Fax 49 89 90
11. Operating Instructions MOVIDRIVE MDX61B 5_3 4 08 with SL2 Synchronous Linear Motors 57876AXX 15 6 16 go Startup 9 Prerequisites for startup 6 Startup 6 1 Prerequisites for startup You must comply with the safety notes in section 2 Before startup The primary moves along the entire travel distance easily without collisions and free make sure that from mechanical contact between the primary and secondary All connections have been made properly All protection devices have been installed correctly All motor protection devices are active The brake works correctly in hoists You have a MOVIDRIVE MDX61B 5 3 4 08 unit There are no other sources of danger present The MOVITOOLS startup software is installed on your PC 6 2 Commutation travel process Contrary to rotating systems there is initially no mechanical connection between the encoder system primary and secondary in SL2 linear motors This connection must be made during startup The SL2 synchronous linear motor can then be controlled directly by the inverter This process is referred to as commutation search or commutation travel This takes place once after encoder adjustment for absolute distance measuring systems every time the unit is turned on or reset in case of incremental distance measuring systems Operating Instructions MOVIDRIVEO MDX61B 5 3 4 08 with SL2 Synchronous Linear Motors Startup
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13. m s Based on the conversion factors shown above the following rotary information will be displayed in IPOSPIUSO or via fieldbus Speed velocity 0 0007 1428 1 min Distance 64 625 x 1000 102400 increments Ramp 2 000 5 0 4 sec Operating Instructions MOVIDRIVE MDX61B 5_3 4 08 with SL2 Synchronous Linear Motors 27 28 ego Startup Calculating the travel parameters o Linear Motor Lommissioning lol sl EE Suggestiun System values Maximum acceleration baam m s 2 Linear Rotatory Ramp up down ri bam 200 000 0 010 fs Stop ramp ban 200 000 m s 2 bm s Emergency ramp bam foco m s z 10 010 s Acceleration s22 Fest mea bn a Deceleration ham sg n y Travel speed CW pm Ram tes P8885 fo Travel speed COW bam fio m s mn rpm Take over proposal Finish lt lt Back Neat gt gt KA 10530AEN Figure 11 Screen in linear motor startup with internal conversion of linear values to rotary values The values inFigure 10 are rounded off You can calculate the exact rotary values for IPOSPIUSO from the linear values in the last screen of the V X controller startup In Figure 11 a set speed of 1500 rpm was calculated for IPOSPIUSO after the positioning velocity 1 m s was entered Operating Instructions MOVIDRIVEO MDX61B 5 3 4 08 with SL2 Synchronous Linear Motors
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19. IVE MDX61B 5_3 4 08 with SL2 Synchronous Linear Motors 3 Unit Design MOVIDRIVE MDX61B 08 part numbers 3 8 MOVIDRIVE MDX61B 08 part numbers The SL2 synchronous linear motors are offered together with the MOVIDRIVE9 MDX61B 5 3 4 08 drive inverters from SEW EURODRIVE MOVIDRIVE MDX61B 08 unit designation MDX61 B 0011 5 A 3 4 08 L Design 08 SL2 synchronous linear motor Quadrants 4 4Q with brake chopper Connection type 3 3 phase Radio interfer A Radio interference suppression A ence suppres sion on the line 0 No radio interference suppression side Supply voltage 5 AC 380 500 V Recommended 8 motor power 0011 1 1 KW Version B Series 61 options can be installed You must always use the HIPERFACE encoder card type DEH11B part number 824 310 7 to connect the AL1H motor encoder Refer to the MOVIDRIVE MDX60 61B system manual for more information The firmware supports the internal drive spline calculation for 20 curve points GetSys SS SPLINE var This feature enables a format independent cam disk to be calculated in the drive using curve points without having to transfer a complete curve point table from the higher level controller The MOVIDRIVE MDX61B 08 units have all the properties listed for the MOVIDRIVE MDX60B 61B 0T series MOVIDRIVE MDX60B 61B system manual 10 Operating Instructions MOVIDRIVEO MDX61B 5 3 4 08 with SL2 Synchronous Lin
20. Pureland Ind Complex 2107 High Hill Road P O Box 481 Bridgeport New Jersey 08014 Tel 1 856 467 2277 Fax 1 856 845 3179 csbridgeport seweurodrive com Dayton SEW EURODRIVE INC 2001 West Main Street Troy Ohio 45373 Tel 1 937 335 0036 Fax 1 937 440 3799 cstroy seweurodrive com Dallas SEW EURODRIVE INC 3950 Platinum Way Dallas Texas 75237 Tel 1 214 330 4824 Fax 1 214 330 4724 csdallas seweurodrive com Additional addresses for service in the USA provided on request Address List 1 Venezuela Assembly Sales Service Valencia SEW EURODRIVE Venezuela S A Av Norte Sur No 3 Galpon 84 319 Zona Industrial Municipal Norte Valencia Estado Carabobo Tel 58 241 832 9804 Fax 58 241 838 6275 sewventas cantv net sewfinanzas cantv net 41 EURODRIVE SEW EURODRIVE Driving the world Gearmotors Industrial Gear Units 1 Drive Electronics Drive Automation Services How were driving the world With people who think fast and With a worldwide develop the service network that is future with you always close at hand TT With a global presence that offers responsive and reliable
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22. d and the encoder and limit switch checked to optimize the settings section Optimizing the axle Click Next to continue The default controller parameters are displayed following screenshot Ej Linear Motor Commissioning EE l Suggestion System values P gain speed controller 1 2 ba 0 1 2 32 Time constant v control bm 10 000 ms Gain accel feedforward pns joo Filter specd actual value ba joo ms Filter sotpoint joo 5000 mg Filter accel feedforward 10 joo ms P qain hold controller be ban Gain X controller be jn Take over proposal METE anor 0 11229AEN Click the Take over proposal button The suggested values are transferred to the sys tem values Click Next to continue 20 Operating Instructions MOVIDRIVE MDX61B 5_3 4 08 with SL2 Synchronous Linear Motors Startup procedure Startup 6 9 The suggested travel parameters left and the system values linear and rotary values are displayed following screenshot ist 181 E Suggestion System values Maximum acceleration 0 054 m s 2 Linear Rotatory Ramp up down rA po e Stop remp poa 0 640 ma P m Emergency remp bm 0 640 ma p m Acceleration ja 20 m Deceleration poa 2390 mea M m Travel speed CW kam 0 640 500 Travel speed CCW bam i500 from Toke ove
23. e end with a lamellar seal A commercial sub D EMC connector with pin contacts is used on the inverter end A 15 pin connector to fit the inverter is used The outer cable sheath on the motor and inverter end bears a nameplate with part num ber and logo of the prefabricated cable manufacturer The ordered length and permitted tolerance are interrelated as follows Cable length lt 10 m 200 mm tolerance e Cable length gt 10 m Tolerance 2 96 When configuring the maximum cable length refer to the data specified in the inverter System manual Operating Instructions MOVIDRIVEO MDX61B 5 3 4 08 with SL2 Synchronous Linear Motors Electrical Installation Safety notes Cable for AL1H encoders MOVIDRIVE B Figure 5 Connection cable for AL1H encoders 57871AXX Type Installation Part number SL2 Cable carrier installation MOVIDRIVE B 595 151 8 Connecting the The following illustration shows how the AL1H Hiperface encoder view onto encoder AL1H Hiperface plug is connected to the DEH11B option view onto unit socket encoder to DEH11B erm maxim DEHB X15 cost 8RD E ER C mum LN SS RE 1 cos 1BU i i g O sinc ia sin Ge Nag 13 95 1 H o DATA 7VT i tag oo DATA 2 BK P ane 1 i H i o L10GYPK rg 8 8 1 H o Us 12 RDBU i 115 o 9 ill 94 A i PK i f x sl GY t de O
24. e of the encoders please note The maximum total current carrying capacity of the DC 12 V supply at X14 X15 is 650 mA Useonly shielded cables with twisted pair cores Connect the shield to the PE potential on both ends over a large surface area Route the signal cables separately from the power cables or brake cables min dis tance 200 mm When SL2 synchronous linear motors are combined with MOVIDRIVE MDX61B 5 3 4 08 units the TF can be connected and evaluated directly on the inverter Full motor protection is only ensured when a TF is installed If you use a KTY tempera ture sensor KTY84 140 please contact SEW EURODRIVE Operating Instructions MOVIDRIVE MDX61B 5_3 4 08 with SL2 Synchronous Linear Motors 13 Electrical Installation Safety notes Design of the AL1H feedback cable for MOVIDRIVE MDX61B Prefabricated cables for inverter end Hybrid cables 57872AXX Figure 4 Design of the AL1H feedback cable 1 Connector Intercontec ASTA 2 Printed on connector SEW EURODRIVE 3 Nameplate 4 Cable length lt 10 m 200 mm tolerance Cable length gt 10 m 2 96 tolerance Permitted cable length according to the technical documents 5 Sub D plug A 12 pin EMC signal plug connector with socket contacts from Intercontec is used to connect the encoder system The shield is connected in the connector housing accord ing to the EMC standards All plug connectors seal the plug on the cabl
25. ear Motors Unit Design MOVIDRIVE MDX61B 08 part numbers Part numbers MOVIDRIVE MDX61B Part number MDX61B0005 5A3 4 08 828 625 6 MDX61B0008 5A3 4 08 828 626 4 MDX61B0011 5A3 4 08 828 627 2 MDX61B0014 5A3 4 08 828 628 0 MDX61B0015 5A3 4 08 828 629 9 MDX61B0022 5A3 4 08 828 630 2 MDX61B0030 5A3 4 08 828 631 0 MDX61B0040 5A3 4 08 828 632 9 MDX61B0055 5A3 4 08 828 633 7 MDX61B0075 5A3 4 08 828 634 5 MDX61B0110 5A3 4 08 828 635 3 MDX61B0150 503 4 08 828 636 1 MDX61B0220 503 4 08 828 638 8 MDX61B0300 503 4 08 828 639 6 MDX61B0370 503 4 08 828 641 8 MDX61B0450 503 4 08 828 642 6 MDX61B0550 503 4 08 828 643 4 MDX61B0750 503 4 08 828 644 2 MDX61B0900 503 4 08 828 645 0 MDX61B1100 503 4 08 828 646 9 MDX61B1320 503 4 08 828 647 7 Operating Instructions MOVIDRIVE MDX61B 5_3 4 08 with SL2 Synchronous Linear Motors 11 12 4 4 1 Parameters Parameter settings Parameters Parameter settings All parameters of the standard MOVIDRIVE MDX60B 61B units are available The following rotary values must be converted to linear values Ramps Speeds The conversions are dependent on the signal periods of the connected encoder To prevent rounding errors enter the values in the startup screen following figure f Linear Motor Commissioning 5 xj lale o Suggestion System values Maximum accelera
26. for a defined distance and check whether the displayed increments correspond to the calcu lated value using the calculation displayed by MOVITOOLS Perform the checks at several spots and check the distance between scanner and measuring tape Operating Instructions MOVIDRIVE MDX61B 5_3 4 08 with SL2 Synchronous Linear Motors 31 ER bes lt Operation and Service Problems during operation 7 3 Problems during operation Fault Possible cause Remedy SL2 linear motor does not start Motor cable interrupted Check the motor connection Brake does not release Check the brake control Check the air supply for pneumatic brakes SL2 linear motor makes humming noise or does not run smoothly Fault on encoder cable See the MOVIDRIVE MDX60B 61B System manual and vol ume 9 of the Practical Drive Engineering series Check for correct shielding equipotential bonding and read the note at the beginning of this section Controller parameters set incorrectly Start up the control loop again Encoder connection with primary not rigid enough Check to see if mechanical connection between encoder and primary is rigid enough Permitted operating temperature of encoder exceeded Select the travel cycle so that the effective value of the output current is less than the rated current of the motor Improve heat dissipation from the primary Decouple encoder thermally
27. gn of the ALTH feedback cable 14 System overview 8 EA 13 EMG measures seras 13 T Encoder connection 13 Taking the V X controller into operation 20 TF evaluation 13 TF evaluation 13 Wiring diagram for connecting AL 1H U Hiperface encoder to DEH11B 15 feto Unit d Sign ce tete treten 8 E W Faults during commutation search 31 Faults during operation 32 Warning notes sto Rte 4 Waste disposal 6 l IPOSPIUS sample program for an incremental measuring system 29 M Malfunctions ropisee re a pSr E EANES EAE 30 MOVIDRIVE MDX61B 08 part numbers x oe tenet 10 11 MOVIDRIVE MDX61B 08 unit designation 10 Operation and service Faults during commutation search 31 Faults during operation 32 Malfunctions 30 Operational 5 Optimizing the axle sse 26 P Parameter settings REENEN 12 S Safety function
28. he operating instructions in particular the safety notes section carefully and ensure that they understand and comply with them Operating Instructions MOVIDRIVE MDX61B 5_3 4 08 with SL2 Synchronous Linear Motors Important Notes Liability for Incorrect handling or undertaking any action that is not specified in the operating instruc defects tions could impair the properties of the product In this case you lose any right to claim under limited warranty against SEW EURODRIVE GmbH amp Co KG Product names The brands and product names contained within the operating instructions are trade and trademarks marks or registered trademarks of the titleholders Waste disposal Dispose of materials separately in accordance with the current regulations in force for example Electronics scrap circuit boards Plastic housing Sheet metal Copper etc Operating Instructions MOVIDRIVEO MDX61B 5 3 4 08 with SL2 Synchronous Linear Motors Safety Notes 2 Safety Notes Comply with the safety notes in the following operating instructions SL2 Synchronous Linear Motors MOVIDRIVE MDX60B 61B Operating Instructions MOVIDRIVE MDX61B 5_3 4 08 with SL2 Synchronous Linear Motors Unit Design System overview 3 Unit Design 3 1 System overview 3 x AC 380 500 V Option line filter Opti LI line GC MOVIDRIVE MDX641B 5 3 4 08
29. mhof A G Tel 41 61 417 1717 Sales Jurastrasse 10 Fax 41 61 417 1700 Service CH 4142 M nchenstein bei Basel http Awww imhof sew ch info imhof sew ch Thailand Assembly Chon Buri SEW EURODRIVE Thailand Lid Tel 66 38 454281 Sales Bangpakong Industrial Park 2 Fax 66 38 454288 Service 700 456 Moo 7 Tambol Donhuaroh sewthailand sew eurodrive co th Muang District Chon Buri 20000 Tunisia Sales Tunis T M S Technic Marketing Service Tel 216 1 4340 64 1 4320 29 7 rue Ibn EI Heithem Fax 216 1 4329 76 SMMT 2014 M grine Erriadh Turkey Assembly Istanbul SEW EURODRIVE Tel 90 216 4419163 216 4419164 Sales Hareket Sistemleri Sirketi 216 3838014 Service Bagdat Cad Koruma Cikmazi No 3 Fax 90 216 3055867 TR 34846 Maltepe ISTANBUL sew sew eurodrive com tr Ukraine Sales Dnepropetrovsk SEW EURODRIVE Tel 380 56 370 3211 Service Str Rabochaja 23 B Office 409 Fax 380 56 372 2078 49008 Dnepropetrovsk sew sew eurodrive ua USA Production Greenville SEW EURODRIVE INC Tel 1 864 439 7537 Assembly 1295 Old Spartanburg Highway Fax Sales 1 864 439 7830 Sales P O Box 518 Fax Manuf 1 864 439 9948 Service Lyman S C 29365 Fax Ass 1 864 439 0566 Telex 805 550 http www seweurodrive com cslymanOseweurodrive com Assembly San Francisco SEW EURODRIVE INC Tel 1 510 487 3560 Sales 30599 San Antonio St Fax 1 510 487 6381 Service Hayward California 94544 7101 cshayward seweurodrive com Philadelphia PA SEW EURODRIVE INC
30. ndow is displayed following screenshot Operating Instructions MOVIDRIVE MDX61B 5_3 4 08 with SL2 Synchronous Linear Motors 23 Startup Startup procedure Click the Start button 11235AEN Deactivate the controller inhibit DIOO 1 The encoder adjustment process starts Once the encoder adjustment is complete the following window is displayed 24 SEW Operating Instructions MOVIDRIVEO MDX61B 5 3 4 08 with SL2 Synchronous Linear Motors EURODRIVE Startup go 6 Startup procedure 9 amp D Encoder adjustment Measurement completed Commutation offset 2641 al ma sw sm MTS aor o 11234AEN The calibration process is complete the encoder is adjusted Once commutation travel is complete the inverter sets the IPOSPIUS variable H458 to 1 This value will be evaluated later in the IPOSPISO program or in the PLC to permit the inverter enable Motor with incremental encoder Please read the following notes carefully Make sure that the motor can be moved by the length of a pole pitch to the right each time the power supply is switched on or the inverter is reset Only enable the drive when the IPOSPISO variable H458 is set to 1 If the motor is equipped with an incremental encoder the relative position of the encoder in relation to the motor must be determined each time the power supply is switched on Commutation travel starts automatically when the
31. r mounting Observe the manufacturer tolerances even with fast accelerations Operating Instructions MOVIDRIVEO MDX61B 5 3 4 08 with SL2 Synchronous Linear Motors Index 8 Index A Startup Activating drive limits for initial startup 22 Activating drive limits for initial startup 22 Calculating the travel parameters 27 Checking the encoder evaluation 22 Calculating the travel parameters 27 Checking the hardware limit switches 22 Checking the encoder evaluation 22 Commutation travel for motor with Checking the hardware limit switches 22 Hiperface encoder 23 Commutation travel for motor with Hiperface Commutation travel for motor with lee 23 incremental encoder 25 Commutation travel for motor with incremental Commutation travel process 16 eriCOder teinte 25 IPOSPUS sample program for an incremental Commutation travel process 16 measuring 5 29 E Optimizing the axle 26 Xue Prerequisites 4 io eia etie e 16 Electrical installation Starting up the linear motor 18 Cable part number for AL1H encoder 15 Taking the V X controller into operation 20 Desi
32. r proposal META ooo 11230AEN If you want to accept the proposals click the Take over proposal button You also have the option to adjust the values Click Next to continue ois mE a In order lo complete the commissioning please select download Finish Back labor o 4 11231AEN To complete startup and load the data into the inverter click the Download button Operating Instructions MOVIDRIVE MDX61B 5_3 4 08 with SL2 Synchronous Linear Motors 21 6 22 qu Startup Startup procedure Checking the encoder evaluation Checking the hardware limit switches Activating drive limits for initial startup Move the primary in one direction manually and observe parameter P003 Actual position in MOVITOOLS Determine the positive direction of movement Then slide the SL2 linear motor once over the entire travel distance to check if the encoder works correctly in all areas Set the parameters for the hardware limit switches following screenshot Check the function of the limit switches by moving the primary manually to the limit switches 60 Binary inputs basic Belt 2 600 Binary input DIO1 ENABLE RAP STOP 601 Binary input DIO2 No FUNCTION y 602 Binary input DIO3 o FuscrioN d 603 Binary input DIO4 LIm swircH cw 604 Binary input DIOS LIm swrrcH ccw v 605 Binary input DIO6 No FuscrioN 606 Bina
33. rd Possible consequences Severe or fatal injuries Hazardous situation Possible consequences Slight or minor injuries Harmful situation Possible consequences Damage to the unit and the environ ment Tips and useful information KOREA You must observe the following operating instructions as a prerequisite for fault free operation and fulfillment of any right to claim under warranty Consequently read the operating instructions before you start operating the drive SN MOVIDRIVE MDX61 B 5_3 4 08 operating instructions MOVIDRIVE MDX60B 61B operating instructions SL2 synchronous linear motors operating instructions The operating instructions contain important information about servicing and should be kept close to the unit You can download up to date documentation from the SEW homepage http www sew eurodrive de Additional For information on project planning as well as technical data and dimension sheets documentation refer to the SL2 Synchronous Linear Motors catalog MOVIDRIVE MDX60 61B System manual Operating Instructions MOVIDRIVEO MDX61B 5 3 4 08 with SL2 Synchronous Linear Motors Important Notes Designated use Operational envi ronment Safety functions Qualified personnel The MOVIDRIVE9 MDX61B 5 3 4 08 drive inverters are designed for use with 512 synchronous linear motors Motor utilization other than that specified and areas of application other than indu
34. rrupted Check linear motor connection Brake function P730 ON P730 must be set to OFF during the commutation search Only for HIPERFACE encoder The inverter shows that the encoder has already been adjusted H458 1 If you want to perform commutation travel select Encoder adjustment in the startup screen In the case the inverter will reset the bit automatically n monitoring lag error dur ing commutation travel inverter is not assigned the status NO ENABLE because enable is set in addition to CONTROLLER INHIBIT or a terminal has been programmed to ENABLE Assign binary input directly on unit via IPOSPUS control word or via fieldbus with ENABLE e g P603 ENABLE STOP EMC problems See the MOVIDRIVE MDX60B 61B system manual and vol ume 9 of the Practical Drive Engineering series Check for correct shielding equipotential bonding and read the note at the beginning of this section Encoder error after commu tation travel in positive direc tion 2nd movement Counting direction of the encoder does not correspond to U V W phase sequence of motor Check whether the encoder counts positively in the direction that the primary was moving If not swap the U and W con nections in the motor cables Resolution of encoder system incor rect Encoder defective Slide the SL2 linear motor for a defined distance and check whether the displayed increments correspond to the calcu lated
35. ry input DIO No FuNCTION 11236AEN For initial startup limit the maximum speed in parameter P302 Max speed 1 and the maximum force in parameter P304 Torque limit so that the motor cannot develop its full force and speed in case of an uncontrolled axle movement Do not limit the maximum force in parameter P303 Current limit 1 or the maximum speedin the first dialog box of the linear motor startup as this affects internal system val ues Operating Instructions MOVIDRIVEO MDX61B 5 3 4 08 with SL2 Synchronous Linear Motors Startup go 6 Startup procedure Commutation Please read the following notes carefully travel Always set one binary input to the Enable signal Never activate an enable signal on the inverter during commutation travel Make sure that the motor can be moved by the length of a pole pitch to the right Motor with Hiperface encoder If the motor is equipped with a Hiperface encoder you must determine the rel ative position of the motor in relation to the encoder once To do so choose the op tion Encoder adjustment following screenshot during startup of the linear motor l amp i EI Commissioning type C Motor and encoder commissioning VA controller commissioning C Only M controller commissioning Encoder adjustment Finish Bach Next 11232AEN me arse Click Next to continue The Encoder adjustment wi
36. s not carried out correctly These faults often cause problems in the inverter as the TF lines run in the motor cable We recom mend disconnecting the TF for test purposes and setting P835 to No response during commutation travel to exclude this error Motor monitoring is deactivated P835 is set to No response Make sure that there is no thermal overload in the SL2 linear motor Otherwise the SL2 linear motor will suffer irreparable damage Make sure you reconnect the TF monitoring after successful troubleshooting and set parameter P835 to EMERGENCY STOP FAULT Operating Instructions MOVIDRIVEO MDX61B 5 3 4 08 with SL2 Synchronous Linear Motors Faults during commutation search Operation and Service E a 7 2 Faults during commutation search Fault Possible cause Remedy Encoder error 14 when SL2 linear motor is moved manually Encoder not installed correctly Check installation using the encoder manufacturer informa tion 1 Air gap encoder measuring tape 2 Alignment encoder measuring tape 3 For HIPERFACE encoder Check mounting direction so that cable output shows in the direction of the smaller absolute values direction dot on the measuring tape if available Encoder not connected correctly Check pin assignment operate HIPERFACE encoder as sin cos encoder for test purposes SL2 linear motor does not start after removal of CON TROLLER INHIBIT Motor cable inte
37. s the SL2 linear motor will perform com mutation travel each time the unit is turned on when the controller inhibit is removed If you need a different positive encoder counting direction for your linear axis activate the reversal option for the motor rotation via parameter P350 Remove the TF line from the inverter when the motor is at a standstill or enabled Check whether TF monitoring responds Error 31 TF trigger If the drive has an external brake we recommend that you control it directly Set the brake control using parameters P730 P732 Operating Instructions MOVIDRIVEO MDX61B 5 3 4 08 with SL2 Synchronous Linear Motors Startup go 6 Calculating the travel parameters 6 4 Calculating the travel parameters The inverter and the integrated IPOSPUS sequence control work internally with rotary values During startup the program determines conversion factors for linear values to rotary values EA Linear Motor Lommussioning al x eg Conversion factors Lincar Rotatory Speed m s lt gt 0 0007 Speed rpm 2 Acceleration rm s 2 lt gt Remp values s 1 inc lt gt lim 10395AEN Figure 10 Conversion factors for SL2 100M 030 with HIPERFA CE encoder displayed at the end of linear motor startup Example An SL2 100M 030 synchronous linear motor with HIPERFACE encoder is to be oper ated with the following travel information v 1 m s s 1000 mm a 5
38. solutions Anywhere With drives and controls that automatically improve your productivity With innovative technology that solves tomorrow s problems today With comprehensive knowledge in virtually every branch of industry today With online information and software updates 8 p With uncompromising quality that reduces the cost and complexity of daily operations A SEW EURODRIVE Driving the world J j via the Internet available around the clock Se SEW EURODRIVE GmbH amp Co KG P O Box 3023 D 76642 Bruchsal Germany Phone 49 7251 75 0 Fax 49 7251 75 1970 sew sew eurodrive com gt WWW Sew eurodrive com
39. strial and commercial systems can only be used after consul tation with SEW EURODRIVE Do not start up the unit take it into operation in the designated fashion until you have established that the machine complies with the EMC Directive 89 336 EEC and that the conformity of the end product has been determined in accordance with the Machinery Directive 98 37 EEC with reference to EN 60204 The following uses are prohibited unless the units are expressly designed for the purpose Usein potentially explosive areas Usein areas exposed to harmful oils acids gases vapors dust radiation Please contact SEW EURODRIVE if you have any questions on the environmental conditions Use in non stationary applications that are subject to mechanical vibration and shock loads in excess of the requirements in EN 61800 The MOVIDRIVE MDX61B 5 3 4 08 drive inverters and SL2 linear motors may not execute any safety functions without higher level safety systems Use higher level safety systems to ensure protection of equipment and personnel SL2 linear motors represent a potential hazard for persons and property Consequently assembly installation startup and service work may only be performed by trained per sonnel who are aware of the potential hazards The personnel must be appropriately qualified for the task in hand and must be familiar with the assembly installation startup and operation of the product The personnel must read t
40. tion baam m s 2 Linear Rotatory Ramp up down i pono bam ms oo Stop remp 00 000 200 000 mz bam Emergency ramp bam bm m s 2 imo s AG ab pa pen Rem Decoleration pea paz m s bam s Travel speed CW hm Row ma bann Travel speed COW 0 300 fi 000 m s 5000 rpm Take over proposal ZA 10530AEN Operating Instructions MOVIDRIVEO MDX61B 5 3 4 08 with SL2 Synchronous Linear Motors Electrical Installation Safety notes 5 Electrical Installation You must comply with the safety notes in the operating instructions for the inverter during installation 5 1 Safety notes EMC measures Encoder connec tion TF evaluation SL2 synchronous linear motors and MOVIDRIVE MDX61B 5 3 4 08 from SEW EURODRIVE are components designed for installation in machinery and systems The designer of the machine or system is responsible for complying with the EMC Directive 89 336 EEC For more detailed information on this topic refer to the SEW pub lications Drive Engineering Practical Implementation Volume 7 Project Planning for Drives and Drive Engineering Practical Implementation Volume 9 EMC in Drive Engineering Observe the following instructions when connecting an encoder f another encoder is connected to option DEH11B at X14 in addition to the AL1H Hiperface encoder at X15 you must connect an external voltage to on
41. uired data The Conversion factors win dow is displayed following screenshot BER mE E Conversion factors Linear Rotatory Speed m s lt gt 0 0004 Speed rpm 1 2800 Acceleration m s lt gt Romp values s 25 1 inc lt gt pm 4 Finish Back P Neb ADOR 0 a 11228AEN The linear rotary conversion factors are displayed Click Next to continue To transfer the data to the inverter click the Download button in the following window The startup screen for the V X controller is then started automatically following screen shot Operating Instructions MOVIDRIVE MDX61B 5_3 4 08 with SL2 Synchronous Linear Motors 19 6 go Startup Startup procedure Taking the V X controller into operation 5 Linear Motor Commissioning 2 i 88 9 a Input values Total volume moved a n estimate Extem inertia oo ka Estimated total volume a ky Motor mass 001 ka Estimated friction a N Drive without backlash Stiffness 05 1 2 0 10529BEN In the Total volume moved input field enter the weight of the volume to be moved In the Drive selection field select whether the drive is with or without backlash In the Stiffness input field enter the stiffness of the drive starting with the value 1 This procedure can be repeated once startup has been performe
42. value using the calculation displayed by MOVITOOLSS Adjust the encoder resolution in the linear motor startup if necessary and check the distance between scanner and measuring tape Current limit reduced too far Reset P303 to the value set by linear motor startup Use parameter P304 to reduce the force Encoder error after commu tation travel in negative direction 3rd movement Travel distances are not identical because axle is mechanically sluggish Make sure that the drive travels with easy movement for the entire distance and no other forces are involved process forces weight forces Travel distances are not identical because encoder is defective Slide the SL2 linear motor for a defined distance and check whether the displayed increments correspond to the calcu lated value using the calculation displayed by MOVITOOLSS Adjust the encoder resolution in the linear motor startup if necessary and check the distance between scanner and measuring tape Current limit reduced too far Reset P303 to the value set by linear motor startup Use parameter P304 to reduce the force SL2 linear motor continues to rotate EMC problems See the MOVIDRIVE MDX60B 61B system manual and vol ume 9 of the Practical Drive Engineering series Check for correct shielding equipotential bonding and read the note at the beginning of this section Defective spot in linear scale Slide the SL2 linear motor
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