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Metronix smartServo BL 4000-C Series, Product Manual

The Metronix smartServo BL 4000-C Series is a cutting-edge servo motor with advanced control features. Ensure seamless installation with the comprehensive Mounting Instructions manual, available to download for free from our website. Get the most out of your smartServo experience by accessing the manual at manualshive.com.

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Summary of Contents for smartServo BL 4000-C Series

Page 1: ...Important Read thoroughly before use Retain for future reference Product manual smartServo BL 4000 C ...

Page 2: ...nds and purposes or that they work together with other products selected by the buyer Metronix does not assume any liability for damage resulting from the combined use of its products with other products or resulting from improper handling of machines or systems Metronix reserves the right to modify amend or improve the document or the product without prior notification This document may neither e...

Page 3: ...unschweig Germany Telefon 49 0 531 8668 0 Telefax 49 0 531 8668 555 E mail vertrieb metronix de https www metronix de Revision Information Manual title Product manual BL 4000 C File name P HB_BL 4000 C_1p0_EN pdf Version 1 0 Year 2019 Product manual BL 4000 C Page 3 of 298 ...

Page 4: ...otes for installation and maintenance 19 2 7 Protection against contact with electrical parts 21 2 8 Protection against electric shock by way of protective extra low voltage PELV 22 2 9 Protection against dangerous movements 22 2 10 Protection against contact with hot parts 23 2 11 Protection during the handling and installation of the devices 23 3 Product description 24 3 1 Type designation 24 3 ...

Page 5: ...erature monitoring 52 4 4 7 Commutation encoder 53 4 4 8 Angle encoder settings 54 4 4 9 Angle encoder identification automatic determination 55 4 4 10 Automatic identification of the current controller 56 4 4 11 Configuring the polarity of the limit switches 56 4 4 12 Configuration of the speed controller auto tuning with FAST 57 4 4 13 Configuration of the position controller 59 4 4 14 Permanent...

Page 6: ...e to the reference switch 78 6 1 8 Methods 32 and 33 homing to the index pulse 78 6 1 9 Method 34 homing to the current position 79 6 1 10 Parameterisation of the homing method 79 6 1 11 Parameterisation of the homing run settings 80 6 1 12 Parameterisation of the homing run motion profile 82 6 1 13 Tab Index pulse control 83 6 1 14 Tab Torques 84 6 1 15 Tab Special functions 85 6 2 Positioning pr...

Page 7: ...meterisation and configuration 110 6 4 3 Synchronisation activation and deactivation example 111 6 4 4 Starting position position set 0 111 6 4 5 Gripping of the object position set 1 112 6 4 6 Depositing of the object position set 2 113 6 4 7 Starting position position set 0 113 6 4 8 Wiring 114 6 4 9 Compensation of constant delays 114 6 4 10 Mechanical compensation lead 114 6 4 11 Compensation ...

Page 8: ...isation via a microSD card 131 7 5 Angle encoder settings 134 7 5 1 Commutating generator tab 134 7 5 2 X2A tab 135 7 5 3 X2B X6 tab 136 7 5 3 1 General settings 137 7 5 3 2 Digital incremental encoders 139 7 5 3 3 Analogue incremental encoders 141 7 5 3 4 Serial EnDat 2 2 143 7 5 3 5 Serial HIPERFACE 144 7 5 3 6 Serial HIPERFACE DSL 145 7 5 3 7 Serial BiSS 146 7 5 3 8 Storing parameters in the en...

Page 9: ...173 7 8 2 Configuration of the messages for the digital outputs 174 7 8 2 1 Torque message window Comparison torque 174 7 8 2 2 Speed message window Comparison speed reached 175 7 8 2 3 Target position message window Xactual Xtarget 176 7 8 2 4 Following error message window Following error 177 7 9 Position triggers 178 7 9 1 Position triggers 180 7 9 2 Rotor position triggers 181 7 10 Brake contr...

Page 10: ...s STOA GNDA STOB GNDB X3 198 8 5 4 Discrepancy time 198 8 5 5 Test pulses 199 8 5 6 Auxiliary supply X3 199 8 5 7 Additional diagnostics functions 199 8 6 Circuit examples 201 8 6 1 Safe torque off STO 201 8 6 2 Deceleration and safe torque switch off SS1 Safe Stop 1 202 8 7 Prior to commissioning 204 8 8 Metronix ServoCommander safety functions 204 8 8 1 Servo drive type indication and safety fun...

Page 11: ... 11 STO X3 230 12 11 1 Electrical data of the STO function 230 12 11 2 Time response 231 12 11 2 1 Time response of the STO activation during operation with a restart 231 12 11 2 2 Time response of the SS1 activation during operation with a restart 233 12 12 MicroSD card 234 13 Electrical installation 235 13 1 Notes concerning the safe and EMC compliant installation 235 13 1 1 Explanations and ter...

Page 12: ...CAN bus X4 253 13 11 Connector I O interface X1 255 13 12 Connector STO X3 257 14 Maintenance cleaning repair and disposal 259 15 Appendix 260 15 1 CE conformity in accordance with the EMC and Low Voltage Directives 260 15 2 CE conformity in accordance with the Machinery Directive 261 15 3 cULus certification 263 15 4 Safety technology glossary 264 15 5 Risk reduction questions 266 15 6 Error mess...

Page 13: ...ollowing structure l Signal word l Type of hazard l Measures to prevent the hazard Signal words Indicates an imminent hazard If the situation is not avoided extremely serious and possibly fatal injuries will result Indicates a potentially hazardous situation If the situation is not avoided extremely serious and possibly fatal injuries may result Indicates a potentially hazardous situation If the s...

Page 14: ... Further information can be found in the following manuals l EtherCAT and CANopen manual BL 4000 C This manual describes the commissioning procedure for the servo drives ARS 2000 FS or BL 4100 C with a CANopen or EtherCAT control system l PROFIBUS PROFINET manual ARS 2000 FS smartServo BL 4000 C This manual describes the commissioning procedure for the servo drives ARS 2000 FS or BL 4100 C with a ...

Page 15: ...ts Electrical thermal and energy EN 61800 5 2 Adjustable speed electrical power drive systems Part 5 2 Safety requirements Functional EN 62061 Safety of machinery Functional safety of safety related electrical electronic and programmable electronic control systems EN ISO 12100 Safety of machinery General principles for design Risk assessment and risk reduction IEC 61508 Teil 1 7 Functional safety ...

Page 16: ...roper installation l Proper project planning taking in consideration all of the potential risks necessary protective and emergency measures and the installation l Careful operation and proper maintenance Only trained and qualified personnel in accordance with section 2 3 Target group on page 17 are authorised to work with or on the electrical systems The following instructions must be read and und...

Page 17: ...fe use of the servo drive 2 3 Target group Over its entire service life work on the servo drive with the exception of its operation may only be performed by specialist personnel and or instructed persons who have been trained for the required tasks The servo drive is to be operated by the user Trained and qualified personnel Qualified personnel in the sense of this product manual are persons who a...

Page 18: ... as well as the connection and installation conditions of the servo drive are stated in this document and must be complied with at all times l The servo drive has an IP20 protection rating and a pollution degree rating of 2 Ensure that the environment corresponds to this protection rating and pollution degree rating l Use only original accessories and original spare parts that have been approved b...

Page 19: ...y of the servo drive have been disconnected and secured against reconnection and that the DC bus has discharged During the operation of the servo drive and up to 10 minutes thereafter the corresponding connections and an external braking resistor carry dangerous DC bus voltages Contact with these voltages may result in serious or even fatal injuries Wait 10 minutes prior to performing any work on ...

Page 20: ...connection Wait until the DC bus has discharged in the following cases l maintenance and repairs l cleaning l long downtimes The standard motor holding brake that is included in the scope of supply or any other external motor holding brake that is actuated by the servo drive is not suitable for the protection of the operators if used alone Be particularly careful during the installation process Du...

Page 21: ...s and guards against accidental contact prior to switching the device system on Rack mounted devices must be protected against accidental contact by way of an enclosure e g a switch cabinet Prior to start up and even for brief measurements or tests connect the protective earth conductor ground conductor of all of the electrical devices in accordance with the circuit diagram see section 13 Electric...

Page 22: ...ovements can be caused by the faulty actuation of the connected motors Causes may be as follows l improper or faulty wiring or cabling l errors during the operation of the components l errors of the sensors and transducers l defective or non EMC compliant components l software errors in the superordinate control system These errors can occur directly after the activation of the device or after som...

Page 23: ... Always follow the safety instructions stated hereinbelow l When installing the servo drive ensure that it can be installed operated and removed without any danger l Appropriate installation clearances must also be defined l Comply with the intended use of the servo drive l When transporting the servo drive pay particular attention to the edges and corners of housings and other components Use suit...

Page 24: ...variety of different applications The connection to a superordinate control system can be realised by way of the integrated EtherCAT Profinet or CAN interface Parameter sets that have been created for the ARS 2000 FS series can be used for the BL 4100 C series and vice versa 3 1 Type designation Type key example BL 4100 C product family Figure 1 Nomenclature Pos Description 1 Type designation Basi...

Page 25: ...03 Status indicator LED READY ERROR ENABLE 10 X21 Real time Ethernet interface 04 Seven segment status indicator 11 X4 CANopen interface 05 X3 STO interface STOA STOB Limit switch DIN6 DIN7 Dig output DOUT0 12 Safety Symbols as per ISO 7000 06 X19 USB interface 13 Warnings 07 X18 Ethernet interface Product manual BL 4000 C Page 25 of 298 ...

Page 26: ...bottom view Figure 3 Top view Bottom view 14 X9 Power supply 17 X2A Resolver analogue Hall sensors 15 X6 Motor connection 18 Slot for microSD cards 16 X2B Multi encoder 19 X1 I O communication Product manual BL 4000 C Page 26 of 298 ...

Page 27: ...otors l Permanent magnet synchronous machines with sinusoidal EMF l Torque motors l Linear motors l Air core and iron core linear motors with a low motor inductance 0 5 4 mH l Automatic determination of the motor parameters User friendly parameterisation with the Metronix ServoCommander software l Adjustment of all of the parameters via a PC and online representation of operating parameters and di...

Page 28: ...homing methods l Rotor and position triggers Brake control and automatic brake l Direct control of a holding brake in the motor with high current As a result an external relay is not necessary In addition variable delays can be used l Automatic brake for deactivating the power section during longer breaks to save energy Electrical characteristics l Wide voltage range voltage rating as of 75 VAC po...

Page 29: ... for suppressing the natural frequency of the controlled system l Load torque compensation for vertical axes l Synchronisable internal clock system for the synchronisation with external clock sources for CANopen and EtherCAT fieldbus systems by way of an internal PLL Certification and qualification l Compliance with the current CE and EN standards without any additional external measures l UL cert...

Page 30: ...l Rotary encoder cable l Motor cable l Power supply cable l Emergency cut out switch at X3 l Connector set if required l USB cable or Ethernet cable Connecting the motor To connect the motor proceed as follows 1 Plug the connector of the motor cable into the corresponding socket of the motor and tighten the connection 2 The motor connector X6 including the shield must be connected as described in ...

Page 31: ...SB wiring and adapter Follow the USB adapter wiring instructions in the section 13 7 Connector USB X19 on page 250 To connect the PC proceed as follows 1 Connect the male connector B of the USB interface cable to the female connector for the USB interface of the PC 2 Connect the male connector A of the USB interface cable to the female connector X19 USB of the servo drive Alternative 1 Connect the...

Page 32: ...of the servo drive The program will be provided by your sales partner Usually any changes made in MSC will be transferred immediately to the servo drive As a result changes can be implemented without delay and the servo drive can be put into operation in an interactive manner 4 1 1 The user interface Figure 4 Main window of Metronix ServoCommander The upper area of the MSC main window includes a m...

Page 33: ...lick the desired device or click the button Establish connection to establish an online connection 4 1 2 1 Communication via USB If you connect the device to a PC for the first time the installation of the USB driver by the Windows operating system may take a few minutes It is only after this has been completed that the device will be displayed In case of problems you can use the Windows Device Ma...

Page 34: ... segment display of the selected servo drive displays the message HELLO Risk of damage to the servo drive due to an incorrect device The Ethernet connection may show numerous devices Be particularly careful when selecting the desired device If for example the default parameter set is loaded on a running machine damage may result This is why you should check carefully whether the device with which ...

Page 35: ...ess the option Use the following IP address must be selected Then the following parameters can be entered Parameter Description IP address IP address for the Ethernet communication This address must be unique in the network segment of the servo drive Subnet mask The subnet mask is used to divide a network into subnets connected to routers gateways Gateway IP of the gateway on the subnet of the ser...

Page 36: ...instead of USB 6 If necessary disable the servo drive and check whether the communication can be restored In this case faults concerning the output stage cause the problems Check whether the machine servo drive and motor are properly connected to earth Deactivate parts of the system one after the other to isolate the error source Another parameterisation program communicates with the device Close ...

Page 37: ...adjustment l Clicking the areas between the grey boxes and the arrow buttons The value changes in large steps rough adjustment l Clicking the grey box and moving the mouse with the left mouse button pressed The value can easily be preset quickly over the entire value range The input field shows the desired value that needs to be set The value shown on a green background is the currently active val...

Page 38: ...ase of the homing run 0 Search phase 1 Crawling phase 2 Movement to home position The numbers are successively displayed Delivery status When delivered the servo drive must be parameterised Error message Error messages always start with the letter E The first two numbers after the letter E are the index and the last number is the subindex In this example here error 12 3 is indicated Warning The fi...

Page 39: ...an error message You need to eliminate the cause of the indicated error To do so read section 9 Fault messages on page 208 If the device displays nothing at all follow these steps 1 Switch the power supply off 2 Wait for 10 minutes so that the DC bus can discharge 3 Check all of the connecting cables 4 Check whether the 24 V supply is ready for operation current limitation polarity 5 Disconnect al...

Page 40: ...ns concerning the correct installation of the servo drive in section 13 1 Notes concerning the safe and EMC compliant installation on page 235 You can also start the commissioning process for a servo drive that is already in use To do so select the menu item File Commissioning It is also possible to load a suitable preset parameter set Status not commissioned When it is delivered the servo drive h...

Page 41: ...ue compensation must be ticked if the application is subject to stress due to permanent torque in one direction e g weight in the case of a vertical axis In this case the holding torque of a servo drive will be used as a feedforward value when the holding brake is released in speed control or position control mode or during a positioning run in order to minimise the sagging of the axis due to its ...

Page 42: ... allows you to set a positioning range and to specify the behavior of the interpolator when positioning in this range Translatory The button Feed constant display units opens the menu Display units where you can enter values for your gear see section 4 4 2 Configuration of the display unit on page 45 The field displayed in light blue shows the display units that are currently used The button Setti...

Page 43: ...ion the drive may jerk This method is not suitable for vertical axes Reaction method recommended This method is suitable for all types of drives without a braking system It is suitable for horizontal and vertical applications Only minimal mobility the system is more or less motionless is sufficient for determining the commutation position Saturation method This method is not suitable for air core ...

Page 44: ...function is realised by way of different mechanisms Operating mode Mechanism Torque control Comparison with the current actual speed value as no reasonable speed setpoint has been provided Speed control Positioning Comparison with the difference between the set speed value and actual speed value Mix up of parameter The parameter is not identical with the motor overspeed protection function that ca...

Page 45: ...egrees s or rad s In rotatory mode you can enter a gear ratio if you want to adjust your application to the unit at the output To do so tick the checkbox with gear 4 4 2 2 Translatory operation The following is possible for translatory systems l Position values in units of length m mm or µm l Speed values in m s mm s or µm s l Acceleration values in m s mm s or µm s In translatory mode you need to...

Page 46: ...1 Input limits Enter the maximum speed and acceleration values that you are expecting for your application The Metronix ServoCommander program uses these values for limiting the entries into the program Any values that are already present in the servo drive will not be limited by this process Product manual BL 4000 C Page 46 of 298 ...

Page 47: ...er the current values based on the data on the type plate Risk of damage to the motor Please note that the values to be entered for the maximum current and rated current are effective values If the current values are too high the motor will be destroyed as the permanent magnets inside the motor will be demagnetised The current limits stated by the manufacturer must not be exceeded If in doubt use ...

Page 48: ...l the I t integral has reached 0 once I t value When the I t value reaches 100 the motor current will be limited to the nominal current value In positioning applications this may cause a following error as the drive cannot perform the motion profile as intended In critical cases perform a test under full load to see whether the I t value reaches 100 In addition you can enter the number of poles Nu...

Page 49: ...lt the speed of movement stored in the position set multiplied by the override factor is taken into consideration during the cyclic calculation The override applies to all of the position sets and is also used during the homing run If it has a value of 100 it has practically no effect The override is mainly used by fieldbus systems which set this value cyclically It is also useful during a commiss...

Page 50: ... effective speed limit depends on the settings for the override and thread speed set up speed see Set up mode Speed limit negative Here you can enter the maximum negative speed of your application However the effective speed limit depends on the settings for the override and thread speed set up speed see Set up mode Set up mode Here you can specify a speed limitation in per cent It refers to the l...

Page 51: ... greater than the set threshold value The reaction must be parameterised accordingly in the error management system see section 9 1 Error management on page 210 The button Settings in the field Absolute positioning range opens the menu Global positioning settings see section 6 2 1 Global positioning settings on page 86 Product manual BL 4000 C Page 51 of 298 ...

Page 52: ...on linear characteristic curves with up to 10 interpolation points can be parameterised The parameterisation of such a characteristic curve and of other monitoring functions short circuit and wire break are described in detail in section 7 17 Motor temperature monitoring system on page 190 Dangerous electrical voltage The signals for the temperature sensor MT and MT at the motor connector X6 must ...

Page 53: ...gle encoder is assigned to these signals in the angle encoder menu Settings button You can define separate angle encoders for the acquisition of the actual position value Actual position value commutation Commutating encoder and synchronisation See section 6 3 Applications with several angle encoders on page 104 The selected configuration is shown in the form of an overview The setpoint selector a...

Page 54: ...u need to tick the checkbox active so that the servo drive will evaluate the encoder information of this connection You can use the tab Encoder list to select your specific encoder type or encoder series from a list of predefined encoders In the case of encoders with serial connection for communication with the servo drive all of the relevant information will then be read out of the encoder Howeve...

Page 55: ...ltage is present l The servo drive is free from errors l The STO inputs are connected to the 24 V supply l The shaft can move freely Damage to property caused by incorrect data Incorrect angle encoder data may lead to uncontrolled movements of the drive This may cause damage to the motor or to the entire system A failure of the automatic identification may be due to the following l The parameteris...

Page 56: ... can also be accessed via Parameters Device parameters Limit switches Adjust your drive such that no limit switch is active Ensure that no LED is active in the menu shown below You can configure this by clicking Normally closed or Normally open The switch symbols indicate the recognised state of the inputs Figure 17 Limit switches window The checkbox Change limit switch can be used to swap the ass...

Page 57: ...am and the auto tuning tool FAST Flexible Advanced Servodrive Tuning can be used for the automatic determination of the parameters for the speed and position controller with regard to the application System damage caused by oscillations Using this method for adjusting the speed and position controllers will briefly cause oscillations of the drive and mechanical components In extreme cases the syst...

Page 58: ...tem identification Simply click the button New controller dimensioning The expert mode can be used for the manual configuration of the stiffness of the speed controller Speed controller stiffness and the overshooting of the position controller Position controller overshooting If the automatic controller dimensioning process fails a brief change of the nominal current e g a reduction in the case of...

Page 59: ... optimised manually This is described in section 7 6 4 Manual optimisation of the controllers on page 162 The following values can be changed l Gain Proportional gain of the position controller l Max correction speed Here you can define the speed to be added to the speed of movement in the event of a following error l Dead range negative and positive dead range Here you can specify a permissible d...

Page 60: ... If this limit is exceeded the drive will be switched off The reaction must be configured accordingly in the fault management system Following error suitable parameterisation The following error should always be parameterised in a suitable manner to ensure that the drive will be switched off as quickly as possible in the event of overload The switch off threshold can be determined for example by d...

Page 61: ...As a result other drive systems with the same servo drive motor combination can be commissioned particularly quickly and easily In addition the parameters can be restored easily in the event of a fault or service All of the adjustable parameters combined are known as a parameter set see section 7 4 Parameter sets on page 128 To save a parameter set as a DCO file on the PC click Next Enter a file n...

Page 62: ... enable logic will be automatically configured for the bus system after a reset when the bus system is activated As a result the servo drive can only be enabled via the bus system To enable the drive via MSC for test purposes you need to deactivate the bus system and change the servo drive enable logic The default parameter set switches the operating mode to positioning This is why it is recommend...

Page 63: ...he slide does not touch any of the stops Do not switch on the mains power supply until the wiring is complete and the servo drive and motor are properly connected to earth Damage to the system Prior to switching on the drive read the manual completely and thoroughly Especially the settings concerning the current limits and operating mode must be complied with Incorrect settings may destroy the ser...

Page 64: ...an be enabled by clicking Controller enable If you click again the drive will be disabled Figure 23 Commands window The drive is in its selected operating mode In positioning mode for example it remains in its actual position i e in the position it was in when the servo drive was enabled Product manual BL 4000 C Page 64 of 298 ...

Page 65: ...m This can be selected under Options Display units The associated actual value and set value menus will then automatically adopt the selected unit If you want to use the unit Nm for the torque you have to specify the torque constant i e the conversion factor between the current and torque The torque constant must be entered under Parameters Device parameters Motor data In general it can be calcula...

Page 66: ...t be selected in the Commands window The menu Operating mode Controller overview provides a simplified control related overview of this operating mode to help you with using the associated menus Figure 25 Controller overview window This operating mode is used if the servo drive is controlled by a superordinate control system e g via an analogue input or via a fieldbus so that positioning processes...

Page 67: ...e to the speed controller Usually the position controller is only used in conjunction with a positioning control or the synchronisation control It is a P controller with parameterisable input and output limits Using the position controller without a positioning control Using the position controller without a positioning control only makes sense in combination with a synchronisation via the master ...

Page 68: ...igure 26 Go to destination window If the servo drive is in Positioning mode the drive can be moved manually by clicking and holding the arrow buttons The speed and acceleration of the motion profile can be configured in the Destination parameters window see section 6 2 Positioning process on page 86 Product manual BL 4000 C Page 68 of 298 ...

Page 69: ...ogic l Synchronous speed l Master frequency input as PWM input If no setpoint source is activated the setpoint is zero Two additional selectors Selector B and Selector C can be used to select additional sources as setpoints and or limit values These will not be fed through the ramp generator however The total setpoint is the sum of all of the values The ramp can be parameterised as the acceleratio...

Page 70: ... to specify the setpoints You can also access the menu via Operating mode Setpoint value speed Figure 28 Setpoint value speed window Here you can enter numerical values for the setpoints and limitation values If you want to cancel incorrect inputs immediately click the red STOP symbol The setpoint will be set to 0 and transferred immediately Product manual BL 4000 C Page 70 of 298 ...

Page 71: ...r for the conversion between the input voltage and setpoint The three fields Torque setpoint Torque limitation Speed setpoint Speed limit and Position setpoint are used to specify the conversion of the input voltage into a torque speed or position value The small blue arrow indicates the parameter that is currently controlled by the analogue input In the field Filter time constant noisy signals ca...

Page 72: ...arameter Safe zero provides the symmetric voltage threshold below which the input value will be considered zero This is shown in the following illustrations The scaling is 10 V 1000 rpm The characteristic without a Safe zero is shown as a dashed line Safe zero 2 V Safe zero 2 V with an offset shift 3 V Figure 30 Analogue input Offset shift and Safe zero Even if the safe zero is used the parameteri...

Page 73: ...ated so that the system moves to the determined home position at the end of the homing run If this option is not activated this would not always be the case due to the deceleration process and the use of additional reference points If a homing process is started via CANopen there will be no follow up positioning to the home position The ramps and speed values for the homing run can be parameterise...

Page 74: ...the parameterised maximum current The home position refers directly to the stop Since in this case the home position would be located directly at the stop the parameter Offset start position should be used to shift the home position in a suitable manner Figure 31 Homing run to the stop Figure 32 Use of Offset start position 6 1 2 Methods 1 and 2 stop with index pulse evaluation These methods corre...

Page 75: ...tion refers to the falling edge of the limit switch Figure 34 Homing run to the limit switch 6 1 4 Methods 1 and 2 positive and negative limit switch with index pulse evaluation Like in the case of the previous method the system tries to find the limit switch However in this case the home position refers to the first index pulse of the angle encoder in the negative 1 or positive 2 direction as see...

Page 76: ...sitive direction 23 or negative direction 27 at search speed until it reaches the reference switch Then the drive moves back at crawl speed and tries to find the exact position of the reference switch The home position refers to the falling edge of the reference switch If at the beginning the drive moves away from the reference switch the associated limit switch causes a reversal of the direction ...

Page 77: ...d 27 methods 7 and 11 use the reference switch In addition however the home position refers to the first index pulse in the negative or positive direction as seen from the reference switch Figure 37 Homing run to the reference switch with index pulse evaluation Product manual BL 4000 C Page 77 of 298 ...

Page 78: ...n will be used as the reference switch In the case of method 23 the drive moves in the positive direction first and in the case of method 27 it moves in the negative direction first The home position refers to the edge of the reference switch Figure 38 Reference switch with an initial movement in the positive and negative direction 6 1 8 Methods 32 and 33 homing to the index pulse In the case of m...

Page 79: ...tion of the drive is set to zero 6 1 10 Parameterisation of the homing method Parameters Positioning Homing position The homing run can be parameterised in the Homing position menu This is where you can select your homing method See also section 6 1 Homing process on page 73 Figure 40 Homing position window Mode tab Product manual BL 4000 C Page 79 of 298 ...

Page 80: ...ing run takes longer than the specified timeout time an error will be generated The time will be monitored at intervals of 10 ms No homing after detection of the commutation offset This option does not become effective unless the drive is a drive without any commutation signals In the default configuration a homing run will be started automatically after the successful determination of the commuta...

Page 81: ...lue leads to a shift of the actual position To ensure that the drive actually moves to this position Go to zero position after homing see above must be activated Actual position of multi turn encoders In the case of multi turn encoders the current actual position is preserved even if the supply voltage is switched off provided that the multi turn range is not exceeded However it is useful to shift...

Page 82: ...on values as well as jerk free parameters for the following processes l Search Movement of the drive until it reaches the target limit switch reference switch stop l Crawl Reversal of the movement at low speed to determine the contact threshold l Running Optional movement to the zero point reference point of the application Product manual BL 4000 C Page 82 of 298 ...

Page 83: ...to be used as the reference point or home position during the next homing run The index pulse control index pulse monitoring function is used to indicate the distance between the target and the index pulse The following window will be displayed Figure 43 Homing position window Index pulse control tab You can indicate the current distance between the target and index pulse In addition you can confi...

Page 84: ... the system no longer uses the criterion 50 increase of the i t value Figure 44 Homing position window Torques tab The reference value for the comparison torque that is monitored by the system must be specified in the field Threshold value During the Tolerance time the system ignores the fact that the reference torque is reached The checkbox Use threshold value for mode stop is used to enable the ...

Page 85: ... an internal zero offset will be calculated It can be stored in the EEPROM of the angle encoder so that it remains active after every reset Alternatively the motor shaft can be turned so that the current actual position has the desired value before the motor is connected to the driven component l The speed of movement during the homing run should be selected so that the reference marks can actuall...

Page 86: ...tioning settings window In the case of absolute positioning runs the new target position is checked to see whether it lies between the limits for the absolute positioning range The parameters Minimum and Maximum in the field Positioning range indicate the absolute position limits for the position setpoint and actual position The positioning range always refers to the home position of the drive see...

Page 87: ...start a positioning run with the position set that is currently displayed The button Copy can be used to copy all of the settings for a specific target position to another target position The following window will be displayed Figure 48 Copy parameters of positions window You can copy a source position to a single target position To do so enter data into the two upper fields If you want to copy a ...

Page 88: ...rget The current positioning run will be completed before the new positioning process is started The next positioning run can be selected prior to the running positioning run The new positioning run will be started automatically when the current positioning run is completed If a relative positioning run is started the reference position for relative usually is the last target position l Immediatel...

Page 89: ... the positioning runs This variable must be determined experimentally for the present load case The default setting is 0 The checkbox Synchronised is used for the Flying saw function see section 6 4 Flying saw on page 108 When the Flying saw mode is active the synchronisation can be activated or deactivated by starting a position set If the synchronisation is active the position of the encoder mas...

Page 90: ... optionally smoothed by way of a filter This leads to a jerk limited or jerk free positioning run The associated filter time can be defined in the field Jerk free positioning The acceleration or deceleration process will be extended by this period of time The total duration of the positioning run will also be extended by this filter time If the jerk free time exceeds the acceleration or decelerati...

Page 91: ...the final speed of the first set has been set to the profile speed v2 of the second set As a result the drive will not be decelerated to zero between the positioning runs Figure 51 Positioning motion profile The fields Acceleration and Deceleration can be used to configure the acceleration and deceleration values for the drive The area Times shows the resulting time values Product manual BL 4000 C...

Page 92: ...ion becomes effective in combination with other options e g rotary axes or SW limit switches as the target position During a normal relative or absolute positioning run the positioning control determines the direction of rotation itself The following options are available l Positive The drive always moves in the direction of the positive limit switch regardless of the target position value In gene...

Page 93: ...ow any changes at analogue input AIN0 Otherwise the position would be used only when the start command is issued As a result of this option the current positioning run will not be completed The system will not issue any Target reached message As a result a new positioning run can only be started if the start option Immediately go to new target is activated If necessary the torque for the position ...

Page 94: ...igher level of precision when the synchronous target is determined as jitter during the start of the synchronisation process is reduced Start command The start command can be issued prior to reaching the range of movement of the master position In this case the drive will not start the positioning run until the lead has been covered This may lead to unwanted positioning runs If a start command is ...

Page 95: ...rvo drives have 4 digital inputs DIN0 DIN3 for the target selection based on 16 positions In addition the assignment of functions to the digital inputs of the basic device can be changed see section 7 7 Digital inputs on page 168 Depending on the application other digital inputs than DIN0 DIN3 can also be used for the position selection 6 2 6 2 Positioning via the parameterisation interface USB Et...

Page 96: ...O button to move to the corresponding position l Start homing Click the button to start the homing run Jog mode These buttons left and right can be used to move the drive The drive stops when the buttons are released This function is useful during the start up process when the drive needs to be moved manually in a position controlled manner Save actual position to position set Here the current act...

Page 97: ...pending on the status of the digital inputs NEXT1 NEXT2 l The motion program can control two digital outputs Three different messages target reached remaining distance message and position set active are available for every step of the motion program l A motion program can be started via two default start points HOME START or directly via the target selector see section 6 2 6 1 Positioning via dig...

Page 98: ...linked Up to two following positions can be specified field Following position 1 and Following position 2 The following position that the system branches off to depends on the state of the digital inputs Position 1 Following position 1 NEXT1 3 Digital Input DIN2 Folgeposition 2 NEXT2 6 Digital Input DIN3 The assignment of the NEXT1 NEXT2 signals to the digital inputs DIN2 and DIN3 is explained in ...

Page 99: ...d then to pos 9 Following position Following position 1 6 Following position 2 9 Reaction to NEXT1 NEXT2 Ignore if target is not yet reached 8 If NEXT1 1 first move to pos 8 and then to pos 6 If NEXT2 1 first move to pos 8 and then to pos 9 Changes concerning NEXT1 NEXT2 are saved during the movement to pos 8 When pos 8 is reached the most recent signal flank at NEXT1 NEXT2 is evaluated Following ...

Page 100: ...termines whether positions will be linked or not The element is the same as the checkbox Course program in the command window The inputs fields Positioning set HOME and Positioning set START can be used to define the entry points into the motion program To link the position sets with the corresponding digital inputs click Digital inputs see section 6 2 7 3 Digital inputs Motion program on page 101...

Page 101: ...d to define the two digital inputs that are responsible for branching Use the field Stop to specify the digital input for stopping the motion program Use the field Combined start stop to specify the digital input for starting and stopping the motion program Motion program A motion program can also be started directly by starting a position set With the aid of the 1 of N assignment of the available...

Page 102: ...to specify one input for jogging in the positive direction and one input for jogging in the negative direction The jog mode must be activated in the command window The speed of movement and the acceleration values in the positive and negative direction are parameterised in the position window Parameters Positioning Destination parameters The digital inputs are assigned in the window Parameters IOs...

Page 103: ... position is concerned it is possible to define a tolerance window in which the digital output will be set See section 7 8 2 Configuration of the messages for the digital outputs on page 174 For option 3 trigger messages can be parameterised in the field Message under Parameters Positioning Destination parameters These messages can then be output via a digital output These trigger messages indicat...

Page 104: ...ts accuracy The positioning mechanism has a high resolution angle encoder In this case it makes sense to use this information for the determination of the current position while the speed and commutation position information is still provided by the motor encoder Another class of applications can be summarised under the concept of synchronisation In this case several servo drives are synchronised ...

Page 105: ...ring function for the rest of the start up process To configure a system with two angle encoders proceed as follows The first encoder system 1 drive provides the commutation position and actual speed value This is why this encoder should be used for the start up process To add the second encoder 4 output for the superimposed position control it must be ensured that the adaptation of the transmissi...

Page 106: ...y the parameters in the menu Operating mode Incremental encoder emulation 6 3 3 Synchronisation parameterisation of the slave In synchronisation mode the slave must be informed that the angle encoder information will be provided via the master frequency input X1 This can be done in the command window where the option Synchronised for position and speed synchronous applications or Flying saw only f...

Page 107: ... control value for the speed controller speed setpoint To set up the purely position synchronous operation select the option Synchronised in the field Synchronisation of the command window Positioning must be selected as the operating mode 6 3 5 Special considerations concerning the resolution of the master frequency In most cases the setting for the resolution of the incremental signal must be co...

Page 108: ...bust test setup with limit switches emergency cut out switches and non bouncing trigger signals l Knowledge about electronic components light barriers and the operation of an oscilloscope l Safe use of the external control system Flying saw is a term used for cases in which the synchronisation is activated or deactivated depending on a position set Synchronous position sets for synchronisation wit...

Page 109: ...ons which may damage the system Since the servo drive can follow the abrupt setpoint change only slowly rather large temporary following errors result This is why activating the synchronisation while the motor is running is not permissible in most cases In the Flying saw mode the synchronisation activation and deactivation is performed during a positioning run As a result there will be no abrupt s...

Page 110: ...index pulse during a synchronous motion may cause jerking as the position will be reset The line of the incremental encoder or the master frequency of the master drive must be entered into the menu Parameters Device parameters Angle encoder settings on the X1 tab To ensure that the linear drive moves at the same speed as the conveyor belt during a synchronous run the gear ratio of the linear drive...

Page 111: ...e The gripping process is triggered by a light barrier Figure 62 Flying saw overview Pos Description 1 Motor 2 Linear unit here spindle axis 3 Gripper 4 Light barrier 5 Deposit area 6 4 4 Starting position position set 0 The gripper must move to its starting position P0 This is an absolute positioning process without any synchronisation Only the starting position P0 speed of movement V0 and accele...

Page 112: ...t will be compensated in a controlled manner The speed of movement which is used for this purpose corresponds to the speed of the master plus the speed of movement that is specified in the position set Figure 64 Gripping of the object and synchronous movement When the gripper has reached the object and is located precisely above it it signals to the system that it has reached its target For exampl...

Page 113: ...ion Synchronised must be deselected As a result the synchronisation will be deactivated when the positioning process begins The positioning process begins with the current speed setpoint i e with the speed of the master This results in a controlled synchronisation deactivation 6 4 7 Starting position position set 0 When the object has been placed on the pallet the gripper can return to the startin...

Page 114: ...e system is started 6 4 10 Mechanical compensation lead If the system runs at a speed of 2000 rpm 500 rpm for example the light barrier can be positioned in such a manner that the delay is exactly compensated at 2000 rpm At other speeds only the speed difference will be taken into consideration If for example the system which is compensated at a speed of 2000 rpm runs at 2200 rpm the following err...

Page 115: ...ion speed are available in their entirety only at specific points of time and it is only at these points of time that a synchronisation process can be initiated The system inherent inaccuracy jitter results in a position error as follows To compensate for this the sampling function can be used For this purpose the light barrier must be connected to the sample input When a sampling event occurs the...

Page 116: ...corresponds to the speed of the master plus the speed of movement that is specified in the position set As far as the acceleration values are concerned the values stored in the position set that has been started will be used If the checkbox in the position set is not ticked the synchronisation process will be stopped when the positioning process starts The positioning process begins with the curre...

Page 117: ... continuous indexing in the same direction this requires a gear factor that can be represented as an integer numerator and denominator l Sequences for retracting movements can be implemented by way of motion programs l Position triggers inform the superordinate control system about specific positions or zero positions of the indexing rotary table l Reduced programming at the control system side Fi...

Page 118: ...t 1 Direction from position set The rotary axis is active The direction of rotation is specified in the position set See also section 6 2 5 Destination parameters Experts tab on page 92 Direction always positive The rotary axis is active The system always selects the positive direction of movement for all of the positioning processes and movements movement 1 Direction always negative The rotary ax...

Page 119: ...w The BL 4100 C servo drive has an integrated Bluetooth interface via which the control state actual values error message etc can be displayed on an Android device smartphone tablet PC etc The interface is activated by default It can be deactivated under Options Communication Communication parameters Bluetooth Configuration servo drive The deactivation of the Bluetooth interface can be stored perm...

Page 120: ...Figure 71 Oscilloscope window Oscilloscope buttons The oscilloscope has several buttons to start specific activities Symbol Meaning Shifts the displayed area in the horizontal direction Opens the reversing generator menu Stops the zoom function Zoom function Zooms in to the area of the oscilloscope window that has been selected by way of the mouse Opens Excel and creates a spreadsheet containing t...

Page 121: ... oscilloscope is activated or deactivated Indicates whether the oscilloscope waits for a trigger event green or whether it reads out data red Refreshes the representation manually Immediately initiates a trigger event Can be used for testing the channel settings The current settings are displayed in the right hand side area of the oscilloscope window Double clicking a channel opens the associated ...

Page 122: ... in detail in the following sections 7 2 2 1 Tabs CH1 CH8 Figure 72 Oscilloscope window CHx tab The oscilloscope has up to eight channels The following settings can be selected on the tabs CH1 CH8 for the corresponding channels Measured quantity to be displayed Click the drop down list of the channel and select the physical quantity or event that you would like to display Colour Click the coloured...

Page 123: ...selected as the quantity to be displayed you can display any parameter of the servo drive communication object by way of the oscilloscope function The following additional information is required l The object number of the communication object l Information as to whether the object returns a value with a sign In this case the checkbox signed must be selected l The physical unit of the object l A m...

Page 124: ...trigger event will be displayed on the left hand edge of the oscilloscope screen A negative delay value means that the events prior to the occurrence of the trigger condition will also be recorded pretrigger In the case of a negative value the trigger mark will be shifted to the right into the oscilloscope screen The drop down list Number of samples in the field Samples can be used to change the n...

Page 125: ...e used for triggering Depending on the selected trigger source this means Analogue trigger source Digital trigger source Rising edge The threshold will be reached when the values increase The event occurs Falling edge The threshold will be reached when the values decrease The event disappears Three different trigger modes can be selected in the field Mode Auto The system triggers continuously and ...

Page 126: ...mander They have no effect on the scaling of data that are transferred via a fieldbus e g CANopen Factor Group 7 3 1 User defined display units All user defined units User defined are displayed with The scaling of the user defined units per revolution can be defined in the field Feed constant on the tab Display units In addition the input fields Time base and Time base acceleration are available F...

Page 127: ...acceleration provided that you have selected Direct input under Options Display units Figure 76 Display units direct input window In addition you can select the following display units for the Metronix ServoCommander parameterisation program l Increments l Degree l Radian l Revolution l Metre l Millimetre l Micrometre l User defined l No unit Product manual BL 4000 C Page 127 of 298 ...

Page 128: ...ram However it can also be used offline In this case changes will not be transferred to the servo drive Instead only a parameter set file DCO file will be changed 7 4 1 Online parameterisation Overview File Parameter set Save parameter set FLASH The following Figure 77 shows all of the setting options of the servo drive i e the parameter set management system Figure 77 Parameter set management wit...

Page 129: ... This is why parameter files are often referred to as DCO files DCO files can be read or saved in Metronix ServoCommander as follows l Reading a DCO file File Parameter set Load into servo drive l Writing a DCO file File Parameter set Save as file Please note that when you save a parameter set to a file you can fill in the fields Motor type and Description In addition you can enter a comment of up...

Page 130: ...oCommander will not be transferred online Instead they will be saved in a DCO file To activate the offline parameterisation click Options Communication Offline parameterisation Specify the DCO file that you would like to open Select a corresponding file The DCO file has been created for a specific type of servo drive If you want to use it for another type select the new type now Risk of irreparabl...

Page 131: ...ile or a DCO file with a specific name will be loaded Firmware update via a microSD card The servo drive can update the firmware via the microSD card See the section 7 19 Firmware download on page 192 Figure 79 Parameterisation via a microSD card Status The LEDs indicate the status of the SD card Ready The LED lights up green when an SD card is connected and ready Write protected This LED is irrel...

Page 132: ... all of the eight characters of the file name The file extension DCO however cannot be changed File name conventions The system does not support any directories subdirectories and file names must comply with the 8 3 file name convention Lowercase letters will be automatically converted when they are entered SD card servo button When all of the necessary settings have been made click SD card servo ...

Page 133: ...ertain internal parameters or states of the servo drive It is possible for example to use the status of the digital inputs The required AUTORUN INI file can be created and customised with the aid of an Excel spreadsheet Please contact the Technical Support team for detailed information about the AUTORUN INI file and its creation AUTORUN INI file on the microSD card If there is an AUTORUN INI file ...

Page 134: ... offset is determined automatically The phase sequence indicates the way of counting direction of rotation of the angle encoders and depends on the wiring The correct setting of the phase sequence is essential for the operation of the system The phase sequence is also determined during the automatic determination of the angle encoder offset The automatic identification can be started with the butt...

Page 135: ...solver combinations If the checkbox active is ticked the firmware will analyse the encoder information provided via this connection The checkbox must be ticked if the angle encoder is used for commutation and or for determining position or speed values The default setting for the Gear factor is 1 1 These settings apply only to a gear factor between angle encoder and motor If you want to parameteri...

Page 136: ...485 level e g EnDat HIPERFACE BISS It is also possible to evaluate an optional error signal AS NAS via pin 6 Hiperface DSL encoders that are connected to X6 can also be parameterised via this tab To force the servo drive to evaluate an encoder connected to X2B X6 the checkbox Active must be ticked The angle encoder can be used for commutation speed determination and position determination In addit...

Page 137: ...ply Risk of destruction due to excessive voltage If the voltage is too high the angle encoder may be destroyed Ensure that you have selected the correct supply voltage prior to connecting the encoder to the X2B connector Please state whether the angle encoder is supplied with 5 V or 10 V You can find this information on the data sheet In general Hiperface encoders are supplied with 7 V to 12V Heid...

Page 138: ...mutating encoder tab Auto detect Note After the completion of the parameter identification process close the window and reopen it to refresh the Line count parameter Gear factor The default setting of the gear factor is 1 1 It may be necessary to change it for example if the angle encoder provides more than 1 index pulse per revolution These settings apply only to a gear factor between angle encod...

Page 139: ...sistent precision in the case of incremental encoder systems If counting errors occur due to external interferences they are corrected when the index pulse occurs Information as to whether the angle encoder has such a pulse can be found on the data sheet of the angle encoder If an index track is included and connected the index pulse function can be suppressed by deselecting this checkbox Risk of ...

Page 140: ...ion see above l Size of segment The segment size indicates the angular range covered by one segment of a Hall signal e g U Information about the segment size can be found on the data sheet of the angle encoder Standard Hall systems have a segment size of 120 A segment size of 60 is reserved for special variants l After Hall segment switch Here you can select various options to specify how the comm...

Page 141: ...out the Z0 track can be found on the data sheet of the angle encoder l Encoder with Z1 track The Z1 track is the commutation track of an analogue incremental encoder It consists of two signal pairs that enable a clear angle determination referred to 1 revolution This method is used for determining the commutation position after a reset Some encoder manufacturers use the terms sine_1 and cosine_1 t...

Page 142: ...gle encoder Risk of injury due to uncontrolled drive movements The servo drive corrects the actual position if the index pulse is activated In the case of encoders with unsymmetrical index pulses this may cause the drive to overspeed This is why if in doubt the index pulse evaluation should be deactivated Usually linear motors do not include cyclic index pulses However there may be a single index ...

Page 143: ...o read out certain characteristics such as the line count for example As a result the line count does not need to be parameterised in the case of EnDat 2 2 encoders The EEPROM which is often included in this type of encoder can be used for saving and loading parameters in the servo drive see section 7 5 3 8 Storing parameters in the encoder on page 148 Figure 86 Angle encoder settings window X2B X...

Page 144: ...characteristics such as the line count for example As a result the line count does not need to be parameterised in the case of Hiperface encoders The EEPROM which is often included in this type of encoder can be used for saving and loading parameters in the servo drive see section 7 5 3 8 Storing parameters in the encoder on page 148 Figure 87 Angle encoder settings window X2B X6 tab Settings Enco...

Page 145: ...ired The serial channel is used for the purely digital transfer of the position values from the encoder In addition it is possible to access the type plate of the encoder to read out certain characteristics such as the line count for example As a result the line count does not need to be parameterised in the case of Hiperface DSL encoders Figure 88 Angle encoder settings window X2B X6 tab Settings...

Page 146: ...h absolute position information of 32 bits maximum in a 40 bit frame l Generator polynomial 0x43 6 bits Balluff encoders have a parallel analogue track This track will not be evaluated in parallel to the BiSS encoder The encoder can be connected either as an analogue encoder or as a BiSS encoder Data storage in the encoder and the read out of type plates are not supported Figure 89 Angle encoder s...

Page 147: ... be mapped to a rotary system with a freely selectable line count no power of two The encoder is installed on a linear motor It is not necessary to determine the commutation position and homing is not required Start up notes 1 Perform the bit adaptation for single turn und multi turn revolutions in accordance with the encoder data sheet There should not be any encoder error and the firmware can pe...

Page 148: ...ce and angle encoder offset l Nominal and maximum current and the current control settings l Lateral displacement parameters concerning the actual position e g after homing l Gear factor for the angle encoder Figure 90 Angle encoder settings window X2B X6 tab Parameter set management Status Encoder initialised This LED lights up when the initialisation of the encoder is complete The time required ...

Page 149: ...set is selected the parameter set in the EEPROM will be deleted The deletion process may take several seconds The completion of the process will be indicated in the associated status window Then the servo drive must be reset Save Reset After the reset the servo drive will use the parameters that are stored in its EEPROM Options Load parameter set from encoder EEPROM after reset This option can be ...

Page 150: ...ate the option Load parameter set from encoder EEPROM after reset 4 Click the Save Reset button 5 Reconnect the encoder connector 6 Perform a reset to initialise the encoder Notes concerning the activation of the option The option can be activated when an encoder is connected as in this case the parameters of the servo drive will be overwritten with the encoder parameter set from the encoder EEPRO...

Page 151: ... Input is selected you can either connect the master frequency output of another BL 4100 C servo drive or an incremental encoder quadrature evaluation Alternatively the connector can be used as a pulse direction interface or up down counter Gear factor The factory setting of the gear factor is 1 The gear factor determines the conversion of an external position setpoint with regard to the actual po...

Page 152: ...own counter This mode uses two signals that provide information about the change in position for a specific direction of rotation This is why one of the signal lines should always be at rest when a pulse sequence is transmitted via the other signal line Due to the quadruple evaluation the line count referred to 90 must be specified here Options Ignore counter signals The incremental signals will b...

Page 153: ...ct an external oscilloscope with differential voltage probes to the motor phases Accelerate the drive to approx 3 000 rpm and then switch the power section to passive e g by activating the STO function or by switching off the mains power supply As a result the motor supplies an induced voltage oscilloscope that should match the specifications on the data sheet It must be identical for all of the p...

Page 154: ...e They convert the rotatory motion of a standard servo drive into the desired linear motion by way of toothed belt drives or ball type linear drives However these additional mechanical components lead to mechanical losses and are subject the mechanical restrictions This in turn has a negative effect on the process cycle times Linear motors are part of the group of direct drives They convert the su...

Page 155: ...n determined The end of the process can be read out by way of the DOUT function Linear motor identified or via a fieldbus Figure 92 General configuration window In order to obtain a translatory representation of the values in the Metronix ServoCommander parameterisation program open the window Parameters Application parameters General configuration and select the option translatory motion and tick...

Page 156: ... very high peak currents These current values should not be integrated in the configuration without prior testing We recommend beginning with only of the stated nominal current and selecting a und peak current that is only 10 higher than the nominal current Configuring the number of pole pairs A number of pole pairs 1 is necessary for example if the period length of an analogue angle encoder is no...

Page 157: ... signal example Signal period 4 µm pole pair length 30 48 mm number of pole pairs 1 line count number of pole pairs pole pair length signal period 30 48 mm 4 µm 7620 Analogue signal example Signal period 20 µm pole pair length 40 mm number of pole pairs 1 line count number of pole pairs pole pair length signal period 40 mm 20 µm 2000 In the case of purely serial evaluation only EnDat 2 2 the measu...

Page 158: ...an be specified in the window Parameters Application parameters General configuration on the Extension tab Figure 93 General configuration window Configuration of the parameter The configuration of the parameter Motor overspeed protection for the commutation position determination process is not the same as the configuration of the overspeed protection function that can be accessed via the menu Pa...

Page 159: ...you during the configuration of the parameters When the Commutation position valid status is reset the process will be started when the servo drive is enabled This means that the methods can be repeatedly activated in a targeted manner Most linear motors are air core motors This is why the so called reaction method is optimally suitable for these motors It also works well for motors that are verti...

Page 160: ...he first time it is possible to read in a reference pulse via the index pulse track at connector X2B see below However in this case it must be ensured that only one reference pulse occurs over the range of movement Figure 94 Homing position window We recommend performing a homing run with an offset 1 mm if a stop is used for homing see section 6 1 1 Methods 17 and 18 Stop on page 74 Otherwise the ...

Page 161: ...is error occurs the encoder system its supply line and the setting must be checked Parameters Device parameters Angle encoder tab X2B X6 17 0 Max following error exceeded Stop at maximum current To perform the setting open the menu Parameters Safety parameters 27 0 Following error warning threshold Stop at maximum current To perform the setting open the menu Parameters Signals and select the tab F...

Page 162: ...uency of the servo drive should be increased e g by selecting a faster current controller cycle time ti or by deactivating the option Half power stage frequency during the parameterisation process For a thorough analysis the motor should be used at a standstill for a longer period of time to be able to analyse the temperature rise Excessive armature resistance Often rather thin enamelled wires usu...

Page 163: ...o reduce current peaks is to increase the motor inductance by way of chokes The chokes reduce the current ripple and thereby the stress on the motor caused by harmonics In some cases the use of ferrite cores is sufficient for a strong reduction of the current ripple To avoid damage to the motor winding damage these current harmonics should be taken into consideration right from the outset The curr...

Page 164: ...e The speed controller can only be optimised after a successful completion of the commissioning process Otherwise the motor and servo drive may be damaged See chapter 4 Quick start guide on page 30 Risk of damage to the motor in reversing mode In reversing mode a drive coupled to the motor may be damaged This is why the motor must be uncoupled To configure the speed controller define a setpoint ra...

Page 165: ...t limits and select the maximum possible value for Speed values Maximum acceleration to set Start the Oscilloscope Display Oscilloscope Set the following values Channel Scaling Offset Channel 1 Actual speed value 1 000 rpm div 1 div Channel 2 Speed setpoint 1 000 rpm div 1 div Channel 3 Following error 0 2 rpm div 1 div Channel 4 Real current actual value 5 A div 2 div Time base 100 ms div delay 1...

Page 166: ...ntil the controller is sufficiently stable and rigid at setpoint 0 Optimising the speed controller The drive does not need to be completely installed for the speed controller to be optimised If you parameterise the speed controller with an idling motor shaft the only thing you need to do after the installation is to increase the controller gain Optimising the speed filter To optimise the control r...

Page 167: ...position controller Parameters Controller parameters Position controller The position controller calculates a resulting speed based on the difference between the set position and actual position and transfers this speed value as a set value to the speed controller The various functions of the position controller are described in section 4 4 13 Configuration of the position controller on page 59 Th...

Page 168: ...ts one input is used for enabling the servo drive Two high speed sampling inputs DIN4 and DIN8 are used for position sampling The digital inputs can be universally assigned to various functions e g positioning start reference switch etc The menu Display Digital inputs provides an overview of the available digital inputs and their current assignment Figure 97 Digital inputs Functional overview wind...

Page 169: ...clearly to only one digital input This means that it is not possible to activate the same function via two different digital inputs However it is possible to trigger two functions simultaneously via the same digital input In this case the user must ensure that no conflict ensues Figure 98 Digital inputs window Position selector To address a target position based on the 256 programmable targets a p...

Page 170: ...the various functions and digital inputs Digital input 0 1 2 3 4 5 6 7 8 Function Position selector bit 0 Position selector bit 1 Position selector bit 2 Position selector bit 3 Position selector bit 4 Position selector bit 5 Position selector bit 6 Position selector bit 7 Sample input Positioning start Controller enable signal H Limit switch 0 H Limit switch 1 H Digital stop Jog left Jog right St...

Page 171: ...age 73 Reference switch Homing process 6 1 Homing process Page 73 HOME program Motion program 6 2 7 3 Digital inputs Motion program Page 101 START program Motion program 6 2 7 3 Digital inputs Motion program Page 101 NEXT1 program Motion program 6 2 7 3 Digital inputs Motion program Page 101 NEXT2 program Motion program 6 2 7 3 Digital inputs Motion program Page 101 Program stop Motion program 6 2...

Page 172: ...safety oriented applications There are three digital outputs available for displaying the operating states of the servo drive The menu Display Digital outputs provides an overview of the available digital outputs and their current function assignment Figure 99 Digital outputs windows Product manual BL 4000 C Page 172 of 298 ...

Page 173: ...age 7 11 Configuration of the DC bus monitoring function Page 184 Following error 4 4 13 Configuration of the position controller Page 59 Output stage enabled 5 Enabling the servo drive and selecting the set values Page 62 Holding brake released 7 10 Brake control and automatic brake Page 182 Linear motor identified 4 4 1 General configuration Page 41 Position triggers 1 4 7 9 Position triggers Pa...

Page 174: ...offers the following setting options Figure 100 Signals window Comparison torque tab The parameters Comparison torque Signal window and Filter time constant can be used to control the function Comparison torque reached of a digital output The output becomes active when the filtered actual current is in the range of Icomparison Imessage Icomparison Imessage The actual current is filtered by way of ...

Page 175: ...ction Speed reached of a digital output The output becomes active when the current speed is in the range of ncomparison nmessage ncomparison nmessage However it will only be activated if the speed remains within this range at least for the time tresponse Response delay The parameter Threshold value is used for the configuration of a second comparison speed At present it is evaluated only by fieldb...

Page 176: ...ched message The output will become active when the current position is within the range of Xtarget Xneg Xtarget Xpos However it will only be activated if the position remains within this range at least for the time that is specified under Response delay The output will not become inactive until the position leaves the range of the target window For example the output remains active when a positio...

Page 177: ...or message The output becomes active when the actual position is out of range Xset Xneg Xset Xpos However it will only be activated if the position remains within this range at least for the time that is specified under Response delay Following error message The Following error message and the Shutdown level of following error are not identical The latter must be configured in the Safety parameter...

Page 178: ...n page 180 n 4 rotor position triggers see section 7 9 2 Rotor position triggers on page 181 The function of a digital output in the Digital outputs menu must be set to Position trigger 1 4 to ensure that the information can be transferred to a digital output see section 7 8 1 Configuration of the digital outputs on page 173 In order to assign a source to a position trigger output tick the associa...

Page 179: ... greyed out a connection with a higher ranking group is not possible In this case clear all of the checkboxes that are located above this line If there is no checkbox at all this means that the source cannot be selected as it has not been activated If you want to activate a source tick the corresponding checkbox on the left Options button parameter The options button can be used for a precise conf...

Page 180: ...elect the position trigger that is to be parameterised Input field left hand edge If the actual position is smaller than the position of the left hand edge in the example 1 00 revolutions the position trigger has the logic value 0 if the profile is not inverted see below If the profile is inverted the value is 1 Input field right hand edge If the actual position is greater than the position of the...

Page 181: ...re you can select the rotor position trigger that is to be parameterised Input field left hand edge If the encoder angle is smaller than the value of the left hand edge in the example 13 22 the rotor position trigger has the logic value 0 if the profile is not inverted see below If the profile is inverted the value is 1 You can enter values between 180 0 and 180 0 Input field right hand edge If th...

Page 182: ...igure 109 Brake functions window One of the digital outputs is reserved for controlling the holding brake of the motor The brake will be enabled when the servo drive is enabled Delays can be configured for holding brakes with high mechanical inertia Figure 110 Brake control run delay and stop delay The Run delay tF is used to adapt the actuation of the holding brake to its mechanical inertia If th...

Page 183: ... the brake and or the system may be damaged when the automatic brake is activated Always check the conditions of use before you activate the automatic brake The servo drive has an Automatic brake function If the drive has not moved during a parameterisable time tE Activation after the servo drive will automatically activate the brake and deactivate the output stage The automatic brake helps you to...

Page 184: ...r analysis check the I t indicator in the status window in order to be able to detect an overload of the internal brake resistor in time The overvoltage switch off threshold is factory set and cannot be changed In addition it is possible to trigger an error if the DC bus voltage is too low provided that this has been parameterised by the operator The menu can be activated under Parameters Device p...

Page 185: ...a certain limit there is an electronic switch brake chopper that discharges the DC bus via the so called braking resistor As a result the excess energy of the application will be converted into heat by the braking resistor I2t monitoring function The I2t monitoring function protects the integrated braking resistor and switches the brake chopper off before the internal braking resistor will be over...

Page 186: ... voltages single phase three phase and DC bus voltages This is why all of the device variants cannot be coupled with one another via the DC bus Even for devices with the same DC bus voltage there are certain restrictions in terms of the possible combinations The type of supply must be known In addition the circuit related characteristics for the inrush current limitation must be taken into conside...

Page 187: ... settings Only experienced users should change the configuration Incorrect settings can cause the drive to oscillate thereby destroying the motor Use the menu Parameters Controller parameters Cycle times to change the cycle times of the internal control circuits e g of the current control circuit The following window will be displayed Figure 113 Cycle times window Setpoints tab To open the Setpoin...

Page 188: ...support functions requiring for example a synchronisation of the current controller intervals of several devices via a fieldbus system In this case the cycle time of the current controller is set to a certain value based on experience During operation the cycle time will be automatically and continuously adapted within a very narrow correction range To extend the computing time reserve we recommen...

Page 189: ...ttings Only experienced users should change the configuration Incorrect settings can cause the drive to oscillate thereby destroying the motor Band stop filters are used to suppress resonant frequencies Figure 114 Notch filter window Enter the centre frequency of the band pass filter highest dampening level into the Notch frequency fields The Bandwidth fields are used to specify the frequency rang...

Page 190: ...ion system This is why it is not possible to connect more than one sensor at a time Dangerous electrical voltage The signals for the temperature sensor MT and MT at the motor connector X6 must be connected to protective extra low voltage PELV on the motor side and they must be insulated against the motor phases 7 17 1 Parameterising the characteristic linear non linear sensor If your motor tempera...

Page 191: ...Overtemperature motor defines the temperature at which error 03 0 will be issued The value stated for Warning threshold motor temperature indicates the temperature at which error 18 0 will be issued While in the case of error 03 0 the servo drive will be disabled error 18 0 can be parameterised as a warning In addition the following monitoring functions can be activated and parameterised Short cir...

Page 192: ...es can benefit from new features by way of a firmware update Select a suitable firmware file under File Firmware download If the selected firmware file is not suitable for the device a corresponding message will be displayed This may be the case for example if the firmware is intended for a different device series The firmware download itself is a completely automatic process Do not interrupt the ...

Page 193: ...e lost This may lead to injuries in the worst case Always comply with the specified ambient and connection conditions This applies particularly to the input voltage tolerances See section 12 11 STO X3 on page 230 8 2 Certification safety level The BL 4100 C servo drive with an integrated safety function is a safety device in accordance with the EC Machinery Directive 2006 42 EC and it bears the CE...

Page 194: ...afety category This can be realised for example by way of an external safety relay 8 3 1 Qualification of the specialist personnel personnel requirements The device may only be set into operation by a qualified electrical technician who is familiar with l the installation and operation of electrical control systems l the applicable regulations for operating safety oriented systems l the applicable...

Page 195: ...in certain operating modes e g during set up persons are required to be present in these danger areas In these situations the machine operator must be protected by way of drive and control system related measures The integrated functional safety technology provides the control system and drive specific conditions for the optimal realisation of protective functions As a result planning and installa...

Page 196: ...peration When the Safe Torque Off STO function is active the energy supply to the drive is interrupted in a safe manner The drive can neither generate any torque nor any dangerous movements In the case of suspended loads or other external forces additional measures must be taken in order to prevent the load from sagging e g mechanical holding brakes In the Safe Torque Off STO state the standstill ...

Page 197: ...tion is requested exclusively via the two digital control inputs STOA and STOB The safety oriented integration of additional interfaces is not necessary intended The servo drive does not monitor the input circuit for cross circuit faults The X3 interface enables the direct connection of active and passive sensors as DOUT0 GND provide a short circuit proof 24 V supply voltage see section 13 12 Conn...

Page 198: ...ance time with regard to the OSSD signals buffer time These values depend on the input voltage The time response is described in section 12 11 2 Time response on page 231 8 5 4 Discrepancy time The transition between the safe and unsafe state is initiated by level changes at the control inputs STOA and STOB of the servo drive In accordance with the specification of the safety function both levels ...

Page 199: ...e absolutely guaranteed that the power output stage has been switched off safely The integrated STO function does not have any inherent error assessment mechanisms and it cannot indicate any errors Acknowledgement of error messages When error messages are acknowledged all of the acknowledgeable errors concerning the functional safety technology will also be acknowledged at the same time See sectio...

Page 200: ...s a result the machine will be damaged Connect the holding brake to the servo drive Undersized holding brake Check whether your motors with a holding brake are suitable for braking and stopping the motor in the event of an error by way of the holding brake It is possible to request the safe state while the actuation of the power semiconductors PWM is active However an acknowledgeable error message...

Page 201: ...nction only the relevant connections are shown 2a Emergency stop button 2b Safety gate 2c Light grid 2d Safety relay The Safe Torque Off STO safety function can be requested by various devices Switch S1 can be for example an emergency stop switch a switch of a protective gate a light grid or a safety relay The safety request is realised via two channels and via the switch S1 As a result the output...

Page 202: ...table for category 3 and 4 if additional measures are implemented The additional measures depend on the area of application and on the safety concept of the machine 8 6 2 Deceleration and safe torque switch off SS1 Safe Stop 1 Figure 120 Circuit example Deceleration and safe torque switch off SS1 Safe Stop 1 single phase servo drive Pos Description 1 Servo drive with an integrated STO function onl...

Page 203: ...elected in line with the safety category will result in a loss of the safety function Perform a risk assessment for your application and select the circuitry and components accordingly Notes concerning the circuit example l The safety relay that is used must switch off the servo drive enable signal X1 pin 9 DIN5 without any delay and the inputs STOA and STOB X3 pin 1 pin 3 with a delay l The neces...

Page 204: ... integrated of Metronix ServoCommander can be used to view status data concerning the integrated STO safety function The integrated STO safety function itself does not require any parameterisation 8 8 1 Servo drive type indication and safety function At the lower edge of the MSC main screen there is a status bar This is where the servo drive type and information about the integrated safety functio...

Page 205: ...n of the electrical status of the two STO inputs though Instead it is an indication of the status of the finite state machine that results from the evaluation of the driver supply voltages of the integrated STO safety function Regardless of the indication the power output stage may have already been switched off safely by the integrated STO safety function The status of the internal finite state m...

Page 206: ...egrated window The window has several areas The first three LEDs indicate the status of the functional safety system in the servo drive firmware as it has been recognised by the finite state machine of the servo drive The LEDs Input STOA and Input STOB indicate the state of the digital inputs as it has been recognised by the servo drive firmware The indication in ServoCommander is of an informativ...

Page 207: ...e intervals in the specified time period The check is to be conducted such that the correct operation of the safety system can be verified based on an interaction of all of the components Maintenance and care The BL 4100 C servo drive with an integrated STO function is maintenance free 8 11 Diagnostics and fault clearance The servo drive indicates the safe state as well as error messages by way of...

Page 208: ... e g E 0 1 0 Warnings have the same number as an error message As a distinguishing feature warnings have centre segment before and after the number e g 1 7 0 A complete list of events warnings and error messages can be found in section 15 6 Error messages and warnings on page 268 Damage to property caused by errors In most cases the drive will be caused to coast down if an error occurs However if ...

Page 209: ...m Risk of damage to property Clearing an error via MSC can lead to a sudden restart if the superordinate control system or an external logic system enables the power automatically If the drive is checked in order to find the cause of an error suitable interrupting devices STO inputs deactivation of the power supply must be present and activated The following precautionary measures can be applied l...

Page 210: ...t be displayed and the application continues to run without being affected by the event Warning The event will be displayed briefly on the seven segment display of the servo drive Disable servo drive The application will be stopped by way of the emergency stop ramp see also section 4 4 5 Safety parameters on page 49 Stop at maximum current The drive will be stopped with maximum current Disable pow...

Page 211: ...r messages windows Error messages for the Application Engineering department If you want to forward an error to the Application Engineering department you should always save the error messages as a file and hand over this file as well The file includes all of the relevant information system time constant free parameter that can be useful for the quick identification of the error cause The tab Perm...

Page 212: ...servo drive l Transport the servo drive only in its original packaging l Use only suitable transport equipment l Use suitable personal protective equipment l If you notice that the packaging is damaged notify the carrier without delay Then inspect the servo drive for any signs of external or internal damage Transport damage Dangerous electrical voltage Transport damage to the servo drive may compr...

Page 213: ...11 Installation 11 Installation Figure 126 Servo drive BL 4100 C with mounting plate Product manual BL 4000 C Page 213 of 298 ...

Page 214: ...with supply lines X9 on top l The BL 4100 C servo drives have fastening tabs at the top and bottom These tabs are used to mount the servo drive vertically to a control cabinet plate l Recommended tightening torque for an M5 screw of property class 5 6 2 8 Nm l Keep a minimum distance of 100 mm above and under the device with regard to other components in order to ensure sufficient ventilation For ...

Page 215: ... m as of 1 000 m above MSL Atmospheric humidity Relative humidity up to 90 non condensing Type of enclosure IP20 Protection class I Pollution degree rating 2 Compliance with the pollution degree rating The integrated safety technology requires compliance with pollution degree rating 2 and thus a protected enclosure IP54 This must always be ensured through appropriate measures e g through installat...

Page 216: ...ust be installed in the mains power supply line l If low voltage operation is necessary we recommend using a series transformer or isolating transformer for decreasing the voltage Internal braking resistor Characteristic Value Braking resistor 75 Ω Peak power 2 kW Continuous power 8 W External braking resistor Characteristic Value Braking resistor 75 Ω Nominal power 8 W Peak power 2 5 kW Additiona...

Page 217: ...k frequency of the power output stage The higher the clock frequency is the shorter the permissible time will be l Rotational frequency of the motor The lower the rotational frequency is the shorter the permissible time will be The current derating begins as of a PWM frequency of 10 kHz fPWM and is linear between the reference values that are stated in the following table PWM frequency fPWM BL 410...

Page 218: ...tor connector X6 must be connected to protective extra low voltage PELV on the motor side and they must be insulated against the motor phases Electronic overload protection of the motor The servo drive has an electronic cut out for overload protection combined with thermal memory retention For an effective protection the nominal motor current maximum motor current and overload time I2t time must b...

Page 219: ...ate 9 37 MHz Frame rate 12 1 to 27 µs Supply voltage 10 V 250 mA Supported transfer modes Transfer of short and long messages with storage of the set of parameters in the encoder Characteristic impedance of the cable and line termination 110 Ω 12 4 Resolver connector X2A Characteristic Value Transformation ratio 1 2 to 1 4 Carrier frequency 5 10 kHz Excitation voltage 5 6 Veff short circuit proof ...

Page 220: ...nnector Characteristic Value A Value B Output voltage 5 4 V 10 4 V Output current 250 mA 200 mA Short circuit strength Yes Yes Control via sense leads Yes Yes Digital incremental encoders Digital incremental encoders with RS422 compatible A B N signals with a line count of up to 16 384 lines can be connected e g ERN 420 In addition Hall generator signals with a TTL level for determining the commut...

Page 221: ...k 1 2 VSS differential Error input pin 6 TTL level 0 5 V Low 2 V Hi 2 kΩ pull up Track signal input impedance Differential input 120 Ω Z0 track limit frequency flimit 300 kHz Z1 track limit frequency flimit approx 10 kHz commutation track HIPERFACE encoders Shaft encoders with HIPERFACE made by Sick Stegmann are supported in the single turn and multi turn variants The following encoder models can ...

Page 222: ...iperface Angle encoders made by Sick with the Hiperface DSL interface e g EKM36 are supported They must be connected to X6 See section 12 3 Motor connector X6 on page 217 EnDat encoders Incremental and absolute encoders by Heidenhain can be evaluated The following encoder models can be connected l Analogue incremental encoders ROD 400 ERO 1200 1300 1400 ERN 100 400 1100 1300 l Single turn encoders...

Page 223: ...AT The support of these fieldbus types is integrated in the servo drive Additional modules are not required The parameterisation is performed with the aid of Metronix ServoCommander For further information about the fieldbus connection see the fieldbus specific product manuals see the section 1 2 Additional documents on page 14 Suitable EDS CANopen GSDML PROFINET and XML EtherCAT files for the int...

Page 224: ...Value Nominal voltage 24 V as per DIN EN 61131 2 15 V 10 V low to 30 V high Current consumption 3 2 mA max The mode of operation of the digital outputs can be configured to a large extent The default setting is stated in brackets Characteristic Value Filter time Max jitter DIN0 DIN3 Freely configurable position selector 4 x tx 1 x tx DIN5 Controller enable signal 4 x tx 1 x tx DIN6 DIN7 Limit swit...

Page 225: ...TTL encoders are used it must be taken into consideration that the hysteresis is negligible In addition the requirements concerning the signal shield must be fulfilled As an alternative the A and B track signals of the device are interpreted as pulse direction signals by the device so that the servo drive can also be controlled by stepper motor control boards Ensure the correct configuration of th...

Page 226: ...nt In addition to the track signals A and B the master frequency output also provides an index pulse Once per revolution this index pulse turns high for the programmed number of lines for half of a signal period Please also note that the track signals will not be automatically output with a constant frequency They may also be generated as so called pulse packets depending on the covered rotational...

Page 227: ...ment will be performed within the interpolation cycle time matrix tp Figure 127 Filter time mechanism in the case of digital inputs Parameter Max Maximum delay until the start of a position set becomes active tstart 5 tx tp Current rise time with current feedforward control tn ti tpwm tx position controller cycle time typically 200 µs with a current controller cycle time ti of 50 µs tn speed contr...

Page 228: ...y caused by the firmware tDOUT_ON tDOUT_OFF tx DOUT tHW ON typically 100 µs DOUT tHW OFF typically 300 µs tRISE typically 100 ms with 2 A and inductive load tFALL typically 100 ms with 2 A and inductive load tx position controller cycle time typically 200 µs with a current controller cycle time ti of 50 µs Product manual BL 4000 C Page 228 of 298 ...

Page 229: ...mware after power ON tboot 4 s Encoder start time tenc 0 7 s resolver 2 s Hiperface DSL DC bus charging time tUZK 1 s Output stage active after servo drive enabling tRF 6 ms Movement start delay tF parameterisable 0 32 s Stop delay tA parameterisable 0 32 s Detection of mains power OFF tNoff 0 6 s Product manual BL 4000 C Page 229 of 298 ...

Page 230: ...n Comply with the following test intervals in order to reach the specified values l For SIL 2 PL d category 3 1x per year l For SIL 3 PL e category 3 every 3 months l For SIL 3 PL e category 4 daily 12 11 1 Electrical data of the STO function Control inputs STOA STOB X3 Characteristic Value Nominal voltage 24 V referred to GNDA GNDB Voltage range 19 2 V 28 8 V Permissible ripple 2 referred to a no...

Page 231: ...ing sequence of STOA STOB is interchangeable in all of the diagrams 12 11 2 1 Time response of the STO activation during operation with a restart The illustration shows the time response starting with the disconnection of the control voltage at STOA B and the sequence that is necessary for restarting the device l The actuation of the holding brake is realised via the basic device and not in a safe...

Page 232: ...onse time 5 ms tSTOA BON STOA B switching time from low to high 0 6 ms typ 1 ms max tDRV Delay of the internal sequence control of the servo drive 10 ms max tENABLO Time that the servo drive enable signal DIN5 or bus enable signal must be low before STOA B will be activated 0 tENABHI Time that the servo drive enable signal DIN5 or bus enable signal must be low after STOA B has been reactivated and...

Page 233: ...Description Value tK1 Delay between the switching of S1 and the closing of the undelayed contact K1 See the data sheet of the safety relay tK1_delay Delay between S1 and the opening of the off delayed contacts K1 Can be adjusted on the safety relay tSTOA BOFF STOA B switching time from high to low See also section Response time until power output stage inactive and maximum OSSD test pulse duration...

Page 234: ... tA Switch off delay of the holding brake See section 7 10 Brake control and automatic brake on page 182 tF Switch on delay of the holding brake See section 7 10 Brake control and automatic brake on page 182 12 12 MicroSD card Communication interface Value File system FAT16 FAT32 Connector type microSD card File names Only file and folder names that comply with the 8 3 standard are supported Produ...

Page 235: ...fficiently small unwanted emission of electrical magnetic or electromagnetic interference from an electrical installation or an electrical device to other devices in the vicinity via cables or the environment 13 1 2 General information about electromagnetic compatibility The interference emission and interference immunity of a servo drive always depend on the overall drive concept consisting of th...

Page 236: ...or must be connected to the PE connection point of the supply connector X9 l The earthing grounding screw of the mounting plate see section 3 2 Device view on page 25 must also be connected to the mains side PE connector via a separate earth lead l The cross section of each earth lead must not be smaller than the cross section of the supply leads L N or L1 L3 l The inner PE conductor of the motor ...

Page 237: ... and sensors may be overloaded 13 1 5 ESD protection Damage to property due to ESD electrostatic discharge At unassigned plug connectors damage can occur to the device or to other system parts as a result of ESD electrostatic discharge To prevent this type of damage comply with the following l Ensure proper earthing of all of the system components and wire the servo drive completely prior to switc...

Page 238: ...codes Suitable For Use On A Circuit Capable Of Delivering Not More Than 5 000 rms Symmetrical Amperes 240 Volts Maximum When Protected by A Circuit Breaker Having An Interrupt Rating Not Less Than 10 rms Symmetrical Amperes 240 Volts Maximum Observe the following specification for the main fuse Listed Circuit Breaker according to UL 489 rated 277 Vac 10 A SCR 10 kA Wiring requirements and environm...

Page 239: ... are required for operation Direct DC coupling of the DC buses of several devices is possible by way of the terminals ZK and ZK The terminals MT and MT can be used for the connection of a motor temperature sensor NTC PTC or normally closed contact A shaft encoder can be connected via the D Sub connector at X2A X2B If motors with a Hiperface DSL encoder are used this encoder must be connected via X...

Page 240: ... earth ground conductor of the mains power supply 4 R_CH Braking resistor connection 5 R_EXT Braking resistor connection 6 ZK Pos DC bus voltage 7 ZK Neg DC bus voltage 8 N Neutral conductor 9 L Phase conductor mains phase Cable type and configuration X9 The cable names that are stated refer to cables made by Lapp They have proved to be reliable and are successfully used in many applications Howev...

Page 241: ...signment motor with a motor temperature sensor Figure 134 Pin assignment motor connector motor temperature sensor X6 Pin Name Specification 1 U Motor phase U 2 V Motor phase V 3 W Motor phase W 4 PE Protective earth conductor of the motor 5 MT Motor temperature sensor 6 MT DSL Motor temperature sensor 7 DSL 8 BR Holding brake 9 BR Holding brake Product manual BL 4000 C Page 241 of 298 ...

Page 242: ...able names that are stated refer to cables made by Lapp However it is also possible to use comparable cables from other manufacturers for example Lütze or Helukabel LAPP KABEL ÖLFLEX SERVO 719 CY 4 G 1 5 2 x 2 x 0 75 For highly flexible use in drag chains LAPP KABEL ÖLFLEX SERVO FD 796 CP 4 G 1 5 2 x 2 x 0 75 Comply with the required minimum cross section The minimum cross section of the lines U V...

Page 243: ...is provided by the servo drive Dangerous electrical voltage The signals for the temperature sensor MT and MT at the motor connector X6 must be connected to protective extra low voltage PELV on the motor side and they must be insulated against the motor phases Risk of injury The brake output of the servo drive BR BR must not be used as the sole stop element in safety oriented applications Risk of d...

Page 244: ...tion and it is possible to read in higher amplitudes Configuration on the device X2A D SUB connector 9 pin type female Mating connector X2A l D SUB connector 9 pin type male l Housing for a 9 pin D SUB connector with locking screws of type 4 40 UNC Pin assignment X2A Figure 136 Pin assignment resolver connector X2A l The outer shield is always connected to PE connector housing on the servo drive s...

Page 245: ...shield must be connected to the housing of the angle encoder connector with the greatest possible surface area with low impedance Cable type and configuration X2A The cable names that are stated refer to cables made by Lapp However it is also possible to use comparable cables from other manufacturers for example Lütze or Helukabel LAPP KABEL ÖLFLEX SERVO 728 CY 3 x 2 x 0 14 2 x 0 5 with an overall...

Page 246: ...ental encoders In the case of analogue incremental encoders the evaluation is only possible if no commutation track Z1 is parameterised and connected The evaluation of the error signal can be inverted Configuration on the device X2B D SUB connector 15 pin type female Mating connector X2B l D SUB connector 15 pin type male l Housing for a 15 pin D SUB connector with locking screws of type 4 40 UNC ...

Page 247: ...of the high resolution incremental encoder 4 R 12 COS_Z1 D COSINE commutation signal differential of the high resolution incremental encoder 5 COS_Z1 D 13 SIN_Z1 C SINE commutation signal differential of the high resolution incremental encoder 6 SIN_Z1 C 14 COS_Z0 B COSINE track signal differential of the high resolution incremental encoder 7 COS_Z0 B 15 SIN_Z0 A SINE track signal differential of ...

Page 248: ...ociated reference potential 11 4 12 DATA SL Bidirectional RS485 data line differential EnDat HIPERFACE BISS 5 DATA SL 13 SCLK MA Clock pulse output RS485 differential EnDat BiSS 6 SCLK MA 14 COS_Z0 B COSINE track signal differential of the high resolution incremental encoder 7 COS_Z0 B 15 SIN_Z0 A SINE track signal differential of the high resolution incremental encoder 8 SIN_Z0 A Avoiding EMC int...

Page 249: ...incremental encoder 4 N Ua0 12 H_U Phase U of the Hall sensor for commutation 5 H_V Phase V of the Hall sensor for commutation 13 H_W Phase W of the Hall sensor for commutation 6 14 A Ua1 A track signal RS422 differential of the digital incremental encoder 7 A Ua1 15 B Ua2 B track signal RS422 differential of the digital incremental encoder 8 B Ua2 Avoiding EMC interferences The outer cable shield...

Page 250: ...ielded connectors Non EMC compliant wiring of the servo drive and motor In case of non EMC compliant wiring of the servo drive and motor compensating electric current may flow via the connected computer and the USB interface This may lead to communication problems To avoid this we recommend using an electrically isolated USB adapter Delock USB Isolator type 62588 by Delock or a comparable adapter ...

Page 251: ...or cat 6 Mating connector X18 Male RJ45 connector Pin assignment of the network connector X18 Cat 6 patch cable RJ45 LAN cable S FTP PIMF Figure 142 Pin assignment of the network connector Pin Name Description Colour 1 TX Transmission signal Yellow 2 TX Transmission signal Orange 3 RX Reception signal White 4 5 6 RX Reception signal Blue 7 8 Product manual BL 4000 C Page 251 of 298 ...

Page 252: ...ice X21 Female RJ45 connector cat 6 Mating connector X21 Male RJ45 connector Pin assignment of the real time Ethernet connector X21 Cat 6 patch cable RJ45 LAN cable S FTP PIMF Figure 143 Pin assignment of the real time Ethernet connector Pin Name Description Colour 1 TX Transmission signal Yellow 2 TX Transmission signal Orange 3 RX Reception signal White 4 5 6 RX Reception signal Blue 7 8 Product...

Page 253: ...twisted pair to connect CAN H and CAN L l The cores of the other pair are used jointly for CAN GND l The shield of the cable is led to the CAN shield connections for all nodes l We advise against the use of plug adaptors for cabling the CAN bus However if this is necessary use metal connector housings for connecting the cable shield In order to keep interferences as low as possible ensure that l t...

Page 254: ...or the cable shield To terminate the CAN bus at both ends an external terminating resistor is required Cable type and configuration X4 The cable names that are stated refer to cables made by Lapp However it is also possible to use comparable cables from other manufacturers for example Lütze or Helukabel Technical data of the CAN bus cable 2 pairs of 2 twisted cores d 0 22 mm2 shielded loop resista...

Page 255: ...ge interferences of the converters can reach high amplitudes The 24 V connections inside the control cabinet can be made without a shield In the case of long cables l 2 m towards the PLC or outside the control cabinet shielded cables must be used The shields of these cables must be connected to PE on both ends The cable shield can then be connected to the back panel of the control cabinet for exam...

Page 256: ...nput 0 target 0 7 DIN1 Digital input 1 target 1 20 DIN2 Digital input 2 target 2 8 DIN3 Digital input 3 target 3 21 DIN4 Digital input 4 input 9 DIN5 Digital input 5 servo drive enable signal 22 DIN6 Digital input 6 limit switch 0 10 DIN7 Digital input 7 limit switch 1 23 DIN8 Input flying saw 11 5 V Encoder supply see pin 3 to 18 24 24 V Auxiliary voltage for I Os at X1 12 DOUT0 Freely programmab...

Page 257: ...ure 145 STO connector X3 Pin Name Description 1 STOA Control input A for the STO function 2 GNDA Reference potential for STO A 3 STOB Control input B for the STO function 4 GNDB Reference potential for STO B 5 DIN6 Connected to X1 pin 22 6 DIN7 Connected to X1 pin 10 7 DOUT0 Connected to X1 pin 12 8 GND Reference potential for the auxiliary supply voltage To ensure the STO Safe Torque Off function...

Page 258: ...ng collar one conductor 0 25 mm 0 5 mm Minimum wiring for commissioning X3 Danger to life due to bypassed safety functions Safety functions must never be bypassed For the commissioning of the system without any safety systems STOA and STOB can be connected to the 24 V supply and GNDA and GNDB can be connected to GND in a fixed manner Perform the minimum wiring of the inputs STOA STOB and GNDA GNDB...

Page 259: ...ise the insulation with regard to the high voltage part Stop using the device immediately if this is the case Repair Opening the device is not permissible and will render the warranty null and void Only the manufacturer is authorised to perform repairs Please contact your sales partner Disposal removal decommissioning replacement Dangerous electrical voltage Following the instructions stated herei...

Page 260: ...15 Appendix 15 Appendix 15 1 CE conformity in accordance with the EMC and Low Voltage Directives Product manual BL 4000 C Page 260 of 298 ...

Page 261: ...15 Appendix 15 2 CE conformity in accordance with the Machinery Directive Product manual BL 4000 C Page 261 of 298 ...

Page 262: ...15 Appendix Product manual BL 4000 C Page 262 of 298 ...

Page 263: ...15 Appendix 15 3 cULus certification Product manual BL 4000 C Page 263 of 298 ...

Page 264: ...afety is ensured by stopping a machine or moving parts An emergency stop is used to stop a process or a movement which has become hazardous OSSD Output signal switching device output signals with 24 V level cycle rates for error detection PFD Probability of failure on demand in accordance with IEC 61508 PFH Probability of dangerous failures per hour in accordance with IEC 61508 PL Performance leve...

Page 265: ...tegrity of safety functions in accordance with IEC 61508 EN 62061 and EN ISO 13849 SIL CL Maximum SIL that can be required from a sub system SS1 Safe stop 1 in accordance with EN 61800 5 2 STO Safe torque off in accordance with EN 61800 5 2 T Duration of use in accordance with EN ISO 13849 1 Product manual BL 4000 C Page 265 of 298 ...

Page 266: ...actically possible Yes No 4 Can it be guaranteed that the implemented measures will not pose new hazards Yes No 5 Have the users been adequately informed and warned about the residual risks Yes No 6 Can it be guaranteed that the operators working conditions have not deteriorated due to the safeguarding undertaken Yes No 7 Is the safeguarding mutually compatible Yes No 8 Has adequate consideration ...

Page 267: ...safety relay been certified and wired in accordance with the requirements of the application Yes No c Functional tests Actuation of the emergency cut out switch of the system Does the drive stop Yes No If only STO A is activated does the drive stop immediately and is the error Discrepancy time 52 1 signalled after the discrepancy time has elapsed Yes No If only STO B is activated does the drive st...

Page 268: ...ory No measures required 0 8 Servo drive switched on Log entry proving that the servo drive has been switched on Entry in the permanent event memory No measures required 0 9 Servo drive safety parameters changed Logging of the parameterisation of the FSM 2 0 MOV Entry in the permanent event memory No measures required 0 11 FSM module replacement previous type Logging of the module replacement Entr...

Page 269: ...alue Group 4 Overtemperature 4 0 Overtemperature power output stage Plausible temperature indication Check the installation conditions Are the filter mats of the control cabinet fan soiled Is the fan defective 4 1 Overtemperature DC bus circuit Group 5 Internal voltage supply 5 0 Failure of internal voltage 1 Disconnect the servo drive from the entire periphery and check whether the error is still...

Page 270: ...check the voltage at the main power input Check the quality of the power supply voltage peaks Group 8 Angle encoder 8 0 Resolver Hall angle encoder error See the measures for 08 2 to 08 8 8 1 Rotating direction of serial and incremental position evaluation not identical Have the A and B tracks been mixed up Check the connection of the track signals 8 2 Incremental encoder Z0 track signals error Is...

Page 271: ...red Perform a homing run and save the parameter set in the angle encoder Then save it in the servo drive Motor replaced Parameterise the servo drive perform a homing run save the data in the angle encoder and then save to the servo drive 9 5 Encoder parameter set read write error Please contact the Technical Support team 9 7 Encoder EEPROM is write protected Please contact the Technical Support te...

Page 272: ...mum cable length exceeded correct terminating resistors cable shield earthed all signals connected 12 2 CAN communication error sending 12 3 CAN communication error receiving 12 4 CAN Node Guarding Failure of the PLC or the cycle time of the remote frames of the servo drive and PLC do not match 12 5 CAN RPDO too short The number of bytes of a received RPDO is smaller than the number that is parame...

Page 273: ...umber of pole pairs The calculated number of pole pairs is beyond the parameterisation range Check the data sheet of the motor Please contact the Technical Support team Group 15 Mathematics 15 0 Division by zero Please contact the Technical Support team 15 1 Out of range error 15 2 Mathematical underflow Group 16 Program execution 16 0 Incorrect program execution Please contact the Technical Suppo...

Page 274: ...fied slave address Check the bus termination Check the wiring 22 3 PROFIBUS invalid slave address The communication has been started with slave address 126 Select another slave address 22 4 PROFIBUS range overflow Mathematical error during the conversion of physical units The value ranges of the data and of the physical units do not match Please contact the Technical Support team 22 5 PROFIBUS acc...

Page 275: ...chnical Support team 26 2 Flash write error 26 3 Flash erase error 26 4 Flash error in internal flash 26 5 No calibration data 26 6 No user position data sets Save the parameter set and perform a reset If the error is still present contact the Technical Support team 26 7 Error in data tables CAM Load the default parameter set If the error is still present contact the Technical Support team Group 2...

Page 276: ...led Check the connection of the external braking resistor Please contact the Technical Support team 32 1 Undervoltage for active PFC Check whether the power supply complies with the nominal data 32 5 Brake chopper overload DC bus circuit could not be discharged Check the power on off cycles of the power supply Check the braking resistor 32 6 Discharging period DC bus circuit exceeded Bridge for th...

Page 277: ...ng twice Check the Sercos wiring fiber optic cables Check the control system are all of the MSTs being transmitted 37 3 Sercos invalid phase requested by master Check the program in the Sercos master 37 4 Sercos MDT missing twice Check the Sercos wiring optical fibre Check the control system Are all of the MDTs being sent 37 5 Sercos unknown operation mode selected Check the settings for the opera...

Page 278: ...tive Replace the technology module Please contact the Technical Support team Group 39 Sercos 39 0 Sercos list S 0 0370 incorrect configuration of the MDT data container Please contact the Technical Support team 39 1 Sercos list S 0 0371 incorrect configuration of the AT data container 39 2 Sercos error in the cyclic channel MDT 39 3 Sercos error in the cyclic channel AT 39 4 Sercos error in the cy...

Page 279: ...heck the selected mode 42 9 Error at positioning start Check the speed and acceleration parameters Please contact the Technical Support team Group 43 HW limit switches 43 0 Limit switch negative setpoint inhibited The drive has left the intended range of movement Technical defect of the system Check the limit switches 43 1 Limit switch positive setpoint inhibited 43 2 Limit switch positioning supp...

Page 280: ...t the Technical Support team 50 1 SDO error occurred Please contact the Technical Support team Group 51 FSM 2 0 51 0 No unknown FSM module or driver supply faulty Cause No safety module detected or unknown module type Measure Install a safety module or fieldbus activation module that is suitable for the firmware and hardware Load a firmware that is suitable for the safety module or fieldbus activa...

Page 281: ... firmware appropriate for the module into the servo drive see type designation on the module 51 4 FSM error in SSIO communication Cause Error in the internal communication connection between the servo drive and the safety module Measure Identify any source of interfering radiation in the environment of the servo drive Replace the module or the servo drive Please contact the Technical Support team ...

Page 282: ...discrepancy time Cause Control ports STO A and STO B are not wired in the same way Measure Check circuitry of the inputs Cause Upper and lower switch supply not simultaneously activated discrepancy time exceeded Error in control external circuitry of safety module Error in safety module Measure Check circuitry of the safety module are the inputs STO A and STO B switched off on two channels and sim...

Page 283: ...curs a During dynamic braking to safe rotational speed b After the drive has reached the safe speed With a Check of braking ramp record the speed can the drive follow the ramp Change parameters for the slowdown ramp or start time delay times for monitoring With b Check how far the current speed is from the monitored limit speed increase distance if necessary parameter in safety module or correct s...

Page 284: ...follow the ramp Change parameters for the slowdown ramp or start time delay times for monitoring With a If the option Activate quick stop ramp in base device is activated Check of the servo drive s quick stop ramp With b Check whether the drive continues to oscillate after reaching the zero speed or remains at idle and stable increase monitoring tolerance time if necessary With b If the actual spe...

Page 285: ...ase monitoring tolerance time if necessary With b If the actual speed value is very noisy when at rest Check and if necessary adjust expert parameters for speed recording and detection of standstill 54 5 STO safety condition violated Cause Internal hardware error voltage error of the safety module Measure Module presumably defective If possible replace with another module Cause Error in driver cir...

Page 286: ...ng this time Group 55 FSM Actual value evaluation 1 55 0 FSM no actual speed position value available or standstill for 24 hrs Cause Subsequent error when a position encoder fails Safety function SSF SS1 SS2 or SOS requested and actual rotational speed value is not valid Measure Check the function of the position encoder s see following error 55 1 FSM SINCOS encoder X2B signal error Cause Vector l...

Page 287: ...oken wire short between two signals or signal shield Check for a failure of the exciting current Check the motor and encoder cable shield connection on motor and drive side EMC malfunctions can trigger the error 55 7 FSM other encoder X2B Faulty angle information Cause Angle faulty message is sent from servo drive when status lasts for longer than the allowed time Encoder at X2B is analysed by the...

Page 288: ...ration monitoring P06 07 Check whether the limit value for acceleration monitoring was parameterised correctly the limit value P06 07 should be at least 30 50 above the maximum acceleration actually occurring In case of an angle jump in the position data transmitted from the servo drive acknowledge error once Group 56 FSM Actual value evaluation 2 56 8 FSM speed angle difference encoder 1 2 Cause ...

Page 289: ...brake short circuit cross circuit etc Brake connection The error may occur with long motor cables if 1 The brake output X6 was configured for the brake this is the case with factory settings and 2 A motor without a holding brake is used and the brake connection lines in the motor cable are terminated at X6 In this case Disconnect the brake connection lines at X6 If there is no error in the connect...

Page 290: ...h power consumption output to motor large number of occupied slots a servo drive of the next higher output level should be used Group 58 FSM Communication Parameterisation 58 0 FSM plausibility check of parameters Cause The plausibility check in the safety module has revealed errors e g an impermissible angle encoder configuration the error is triggered when a validation code is requested by the S...

Page 291: ... and the safety module during a parameterisation session This may overload the communication connection Check whether the firmware versions of safety module and servo drive and the versions of parameterisation program and SafetyTool are compatible 58 5 FSM communication safety module servo drive Cause Packet counter error during transmission between μC1 and μC2 Checksum error during transmission b...

Page 292: ...le that should not occur during operation Check the operating conditions temperature air humidity condensation Check the EMC wiring as specified and shield design are there any external interference sources Safety module may be defective is error eliminated after replacing the module Check whether a new firmware for the servo drive or a new version of the safety module is available Group 59 FSM In...

Page 293: ...ions Measure Check whether the error recurs after a reset If it does parameterise the module again and validate the parameter set again If error persists safety module defective replace 59 8 FSM internal monitoring processor 1 2 Cause Serious internal error in the safety module Error detected while dynamising internal signals Disrupted programme sequence stack error or OP code test failed processo...

Page 294: ...d clocks active Check whether the control system supports the Distributed Clocks feature Please contact the Technical Support team 63 4 EtherCAT Missing SYNC message in IPO cycle Check the cycle times of the servo drive and PLC 63 5 EtherCAT wrong firmware found Please contact the Technical Support team 63 6 EtherCAT mode of operation requires DC Activate Distributed Clocks DC in the PLC or select...

Page 295: ...iguration of the master 67 4 Modbus message length too long Check the configuration of the master Group 68 Ethernet IP 68 0 Ethernet IP general error Replace the module Please contact the Technical Support team 68 1 Ethernet IP communication error Check the connection to the PLC 68 2 Ethernet IP connection closed Re establish the connection 68 3 Ethernet IP connection timeout Check the wiring 68 4...

Page 296: ...lengths set in the PROFINET telegram editor match the setting in the master 72 8 PROFINET failure in cyclic data Check wiring 72 9 PROFINET communication error Check the telegram configuration in the master Group 73 PROFINET 73 0 PROFIenergy state not possible Request the PROFIenergy state again when the motor is stopped 73 1 PROFINET wrong firmware found Please contact the Technical Support team ...

Page 297: ...m 83 1 Technology module not supported Load the most recent firmware 83 2 Technology module HW revision not supported Load the most recent firmware 83 3 Service module write error Please contact the Technical Support team 83 4 MC2000 Watchdog Please contact the Technical Support team Group 84 Internal sequence control 84 0 Conditions for controller enable not fulfilled Enable the servo drive again...

Page 298: ...itialisation error Please contact the Technical Support team 91 1 Memory error copy 91 2 Reading of the controller power output stage type failed 91 3 Internal software initialization error Group 92 Bootloader Firmware update 92 0 Error during firmware download The firmware file is corrupted e g due to a mail client or virus scanner Request the firmware file again or transfer it as a ZIP file If t...

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