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Smitec Cosmos 315 Series, Installation, Use And Maintenance Manual

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Smitec Cosmos 315 Series Installation, Use And Maintenance Manual Download Page 8

COSMOS DRIVER SERIES 3000 - USE AND MAINTENANCE MANUAL

The safety prescriptions aim at establishing a series of behaviours and obligations to be complied with, while performing
the activities described later on in this manual.

These prescriptions constitute the prescribed method of operating the device, in a way that is safe for personnel,

equipments and environment.

Ver. 1.07

Pag. 8

Summary of Contents for Cosmos 315 Series

Page 1: ...ce manual BEFORE STARTING THE COSMOS 315X 325X 350X SERIES SERVO DRIVE CAREFULLY READ THIS MANUAL AND FOLLOW ALL INSTRUCTIONS IN ORDER TO ENSURE MAXIMUM SAFETY SERVODRIVES COSMOS SERIES 315X 325X 350X...

Page 2: ...ize of COSMOS Type 3500 1 first series 23 4 7 4 Size of COSMOS Type 3500 1 second series 24 4 7 5 Size of COSMOS Type 3502 25 5 INSTALLATION 26 5 1 POSITIONING AND INSTALLATION 26 5 1 1 COSMOS Type 31...

Page 3: ...N OF THE KEYS 54 7 2 INTERACTION 55 7 2 1 Status message 55 7 2 1 1 Controller Sercos III 55 7 2 1 2 Controller FLxIO 56 7 2 1 3 Controller Sercos II 56 7 2 1 4 Analogue controller 56 7 2 1 5 Service...

Page 4: ...DRESS FLXIO SERCOS III AND MODBUS TCP 86 8 1 ADDRESS SETTING 86 8 2 LEDS LINE AND 24VDC 87 8 3 LEDS FLT AND STS 87 8 4 LEDS I1 I2 AND TO 87 8 5 LEDS A AND L 87 8 6 LEDS FBS 88 8 6 1 Field bus FLxIO 88...

Page 5: ...rors 98 12 FIRMWARE UPDATE 100 12 1 UPDATE ON PC VIA USB CONNECTION 100 13 MAINTENANCE 105 13 1 REPLACEMENT OF FAN BLOWER 105 13 1 1 COSMOS Type 315X 325X 105 13 1 2 COSMOS Type 350X 106 13 2 REPLACEM...

Page 6: ...lowing professionals User User is a person a company or an institution that buys the equipment and uses it for the purposes it was designed for User operator User or operator is a person authorized by...

Page 7: ...ESCRIBED IN THIS MANUAL SMITEC S p A SHALL NOT BE HELD RESPONSIBLE FOR ANY DAMAGES INCONVENIENCES OR ACCIDENTS DUE TO THE NON COMPLIANCE WITH THESE PRESCRIPTIONS In order to make the manual consultati...

Page 8: ...blishing a series of behaviours and obligations to be complied with while performing the activities described later on in this manual These prescriptions constitute the prescribed method of operating...

Page 9: ...est version All upgrades can be requested to SMITEC S p A directly Make sure that the personnel is qualified and adequately informed about the risks he may run and how to avoid them The COSMOS 315X 32...

Page 10: ...the motor is still Avoid any metal components screws electrical cables fall into the driver during the installation because they might cause short circuits The driver is an electric generator The run...

Page 11: ...equipment in these cases or use special protections and precautions during handling Hot Surface Risk of Burn AVERTISSEMENT Les pi ces de l appareil peuvent atteindre une temp rature extr mement lev e...

Page 12: ...d in controlling precision motors Thanks to their design features the drivers can be considered as of digital type because they are completely controlled by the micro controller As a consequence the d...

Page 13: ...ssible to create the most appropriate model for your needs Ver 1 07 Pag 13 TYPE Series 3 3000 Peak current 01 14Apk 0 75kW 02 2 x 12Apk 0 37kW 15 15Apk 2 2kW 25 25Apk 5 5kW 50 50Apk 7 5kW HW Version S...

Page 14: ...KZ010321 3151SA Sercos III Three phase asynchronous motor Incremental encoder with differential line driver outputs 5V KZ010338 3250SA Sercos III Three phase asynchronous motor Incremental encoder wi...

Page 15: ...phase motor None or incremental encoder with differential line driver outputs 5V HD KZ010463 3151SB Sercos III Permanent magnet brushless motor None or incremental encoder with differential line driv...

Page 16: ...e Off STO system 0 Absent 1 Present Dynamic brake 0 Absent 1 Present Brake resistor 0 Absent 1 2 5kJ 2 5 0kJ 3 4 0kJ 4 0 8kJ Encoder 0 Absent 1 Incremental 5V diff phases and HALL TTL Hiperface 2 Hipe...

Page 17: ...m Order code VISIO 3000 KZ010262 Connector 24VDC J5 KF101054 Connector LINE J1 KF101042 Connector MOTOR J4 KF101045 Connector DC BUS J3 KF101044 Connector BRAKE R J2 KF101043 Connector STO except mode...

Page 18: ...480Vac 0 2kHz 8 75Arms sf 4KHz 7 0Arms sf 8KHz 5 25Arms sf 12KHz 3 85Arms sf 16KHz 0 480Vac 0 2kHz 12 6Arms sf 4KHz 12 6Arms sf 8KHz 10 45Arms sf 12KHz 7 7Arms sf 16KHz Maximum output current 15Apk 2...

Page 19: ...ssipated power The dissipated power mostly depends on the driver switching frequency in order to find intermediate values between those indicated in the graphics interpolate linearly The dissipated po...

Page 20: ...MOS DRIVER SERIES 3000 USE AND MAINTENANCE MANUAL Ver 1 07 Pag 20 0 0 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 0 10 0 11 0 12 0 13 0 14 0 15 0 16 0 17 0 18 0 0 50 100 150 200 250 300 350 400 COSMOS 35XX Arms...

Page 21: ...ctromagnetic compatibility EMC The drivers Cosmos 3000 comply with IEC 61800 3 2004 12 standards they can be used in the first environment category C2 and in the second environment category C3 on the...

Page 22: ...S 3000 USE AND MAINTENANCE MANUAL 4 7 Physical specifications 4 7 1 Weight COSMOS Type 315X 325X 350X first series 350X second series Weight 1 8 kg 2 0 kg 3 9kg 3 6kg 4 7 2 Size of COSMOS Type 315X 32...

Page 23: ...COSMOS DRIVER SERIES 3000 USE AND MAINTENANCE MANUAL 4 7 3 Size of COSMOS Type 3500 1 first series Ver 1 07 Pag 23...

Page 24: ...COSMOS DRIVER SERIES 3000 USE AND MAINTENANCE MANUAL 4 7 4 Size of COSMOS Type 3500 1 second series Ver 1 07 Pag 24...

Page 25: ...COSMOS DRIVER SERIES 3000 USE AND MAINTENANCE MANUAL 4 7 5 Size of COSMOS Type 3502 Ver 1 07 Pag 25...

Page 26: ...lso by natural convection a space of about 10 cm must be left above and below the driver In order to establish the electrical panel size consider the thermal dissipation depending on the required outp...

Page 27: ...IVER SERIES 3000 USE AND MAINTENANCE MANUAL 5 1 2 COSMOS Type 3500 1 first series Use the below template in order to prepare the wall and fix the device with 4 screws M5 by duly tightening them Ver 1...

Page 28: ...VER SERIES 3000 USE AND MAINTENANCE MANUAL 5 1 3 COSMOS Type 3500 1 second series Use the below template in order to prepare the wall and fix the device with 4 screws M5 by duly tightening them Ver 1...

Page 29: ...SMOS DRIVER SERIES 3000 USE AND MAINTENANCE MANUAL 5 1 4 COSMOS Type 3502 Use the below template in order to prepare the wall and fix the device with 4 screws M5 by duly tightening them Ver 1 07 Pag 2...

Page 30: ...en as an example 5 2 1 Power installation Due to the presence of high capacitance inside the driver all power wiring must be connected or disconnected when the main power supply is absent for at least...

Page 31: ...em STO the general I O modules the USB connection USB the connection for the VISIO 3000 HMI the connections for the field bus F1 F2 FRX FTX They are all situated on the front side In order to avoid da...

Page 32: ...rs fonctionner avec la connexion PE Ground connect e risque d lectrocution et ou de dysfonctionnement de l appareil Protective earth wiring must be made by means of the specific contact areas on the d...

Page 33: ...he voltage limits indicated in the specifications in order to avoid bad operation and or irreversible damages ATTENTION Il est n cessaire de respecter scrupuleusement la polarit de connexion de la ten...

Page 34: ...est n cessaire de respecter les limites de tension indiqu es dans les sp cifications afin de ne pas provoquer de dysfonctionnements et ou de pannes irr m diables du variateur CAUTION Risk of Electric...

Page 35: ...ed max 6mm Insulating material PA Stranded ferrule without plastic sleeve min 0 25mm Flammability rating Standard UL 94 V0 Stranded ferrule without plastic sleeve max 6mm Stripping length 15mm Strande...

Page 36: ...Phoenix Contact SPC5 3 ST 1996029 Order code KF101045 Features Conductor cross section Connection in accordance with EN VDE Solid min 0 2mm Rated voltage 1000V Solid max 10mm Rated current 41A Strand...

Page 37: ...de l alimentation DC BUS doit tre scrupuleusement respect e afin de ne pas risquer des pannes irr versibles de l entra nement Connector type Phoenix Contact SPC5 3 ST 1996029 Order code KF101044 Featu...

Page 38: ...F101043 Features Connector cross section Connection in accordance with EN VDE Solid min 0 2mm Rated voltage 900V Solid max 2 5mm Rated current 12A Stranded min 0 2mm Stranded max 2 5mm Insulating mate...

Page 39: ...type depends on the driver model see chapter 3 2 2 5 3 6 1 COSMOS Type 3XXX first series Connector type D SUB SD15 M not supplied Order code Features Conductor cross section 5 3 6 1 1 Encoder connecti...

Page 40: ...6 2 2 Differential Encoder 5V connections except Type 3502 Connector E1 Label Signal 1 NTC 2 NTC 3 5Vdc 4 GND 5 Shield 6 Phase A 7 Phase B 8 Hall U 1 9 Hall V 1 10 Hall W 1 11 Phase A 12 Phase B 13 Ha...

Page 41: ...ector E1 Label Signal 1 NTC 2 NTC 3 5Vdc 4 GND 5 Shield 6 Phase A 7 Phase B 8 Hall U 1 9 Hall V 1 10 Hall W 1 11 Phase A 12 Phase B 13 Signal Z 14 Signal Z 15 SHELL Shield 1 The circuitry in these mod...

Page 42: ...Features Allowed conductor section 5 3 7 1 Encoder input This input is used in mutual exclusion with encoder 1 input E1 it is useful for the driver or for the process controlling device in order to k...

Page 43: ...ignals are to be connected to acquisition devices for control processes Please note that the output signals on connector E2 as well as the input signals on connector E1 are not insulated from the 24VD...

Page 44: ...tion STO afin d viter tout risque de d faillance irr versible du variateur Il est n cessaire de respecter les limites de tension indiqu es dans les sp cifications afin de ne pas provoquer de dysfoncti...

Page 45: ...limites de tension indiqu es dans les sp cifications afin de ne pas provoquer de dysfonctionnements et ou de pannes irr m diables du variateur Connettor type Phoenix Contact FMCD1 5 11 ST 3 5 1738898...

Page 46: ...ant to strictly adhere to the series connection sequence of the devices Connector F1 must be used for the bus connection on the master side whereas connector F2 must be used for the connection of next...

Page 47: ...onnector FRX Colour Signal Dark grey Reception Connector FTX Colour Signal Light grey Transmission 5 3 12 Operator interface HMI This is a specific connection for the operator interface VISIO 3000 5 3...

Page 48: ...MANUAL 5 4 Wiring diagram Ver 1 07 Pag 48 L1 L2 L3 FUSES LINE FILTER COSMOS 3XXX COSMOS 3XXX OPTIONAL VBUS CONNECTION OPTIONAL EXTERNAL BRAKE RESISTOR PREVIOUS BUS DEVICE NEXT BUS DEVICE MOTOR PE FE E...

Page 49: ...the device and power supply conductors in compliance with IEC 60204 1 the use of fuses in series with both power supply lines is recommended The protective conductor PE Ground must never be sectioned...

Page 50: ...R69V25 Class gR IEC 60269 4 Dimension 10x38 mm Rated current 25 A Working voltage 700 V AC COSMOS 350X Manufacturer Mersen Ferraz Model FR14GR69V40 Class gR IEC 60269 4 Dimension 14x51 mm Rated curren...

Page 51: ...ions National Electrical Code and any additional local codes The drive does not provide Motor Overload protection External or remote Motor Overload protection shall be provided in the end use applicat...

Page 52: ...rate 1 hardware break down the level of safety integrity is SIL2 with PFH Probability of random Failure per Hour 1x10 9 The STO mission time is 20 years The required ambient conditions the use and mai...

Page 53: ...X X OFF OPEN DISABLED X Not consistent The driver can be enabled only with a correctly powered safety circuit free from failures with EN1 and EN2 inputs active 6 2 4 Intervention times The drivers COS...

Page 54: ...ication by pressing this key for at least 1 second you activate the mode to modify the selected parameter hereinafter indicated by the symbol This mode is identified by the presence of the tab below t...

Page 55: ...e driver is disabled the main power supply is present and the driver is waiting for the enabling command ENABLED Driver enabled ERROR xx Error condition xx is the code identifying the error see follow...

Page 56: ...n decimal figures 001 in this example The second field in normal conditions indicates the communication phase CP0 CP4 otherwise it displays EXX XX indicates the error number 7 2 1 4 Analogue controlle...

Page 57: ...y the entries displayed the minimum level necessary for the modification and the description Menu Entry Lev Description 1 PARAM This section lists all entries that enable you to set the driver paramet...

Page 58: ...se current 1 1 9 IQ RMS MEAN A 1 1 10 IRMS MEAN MAX A 1 1 11 SPEED rpm Motor rotation speed 1 1 12 SPEED MAX rpm 1 1 13 SPEED REF rpm Preset motor rotation speed 1 1 14 TORQUE Nm Torque generated by t...

Page 59: ...1 1 8 SPEED MAX rpm Maximum value detected of motor rotation speed 1 1 9 DRIVE TEMP C Driver dissipator temperature 1 1 10 DRIVE TEMP MAX C Maximum driver dissipator temperature 1 1 11 MOTOR TEMP C Mo...

Page 60: ...afety limit the driver will signal error 10 1 1 5 IQ RMS A Calculation of the rms direct current by measuring the motor phase currents This is the index of absorption required by the motor 1 1 6 IQ MA...

Page 61: ...enu Entry Lev Description 1 2 STATUS This section includes detailed information about the driver status 1 2 1 DRIVE STATE Driver status see chapter 9 2 in order to decode any errors 1 2 2 LAST ERRORS...

Page 62: ...imum current required by the motor Min 0 00Nm Max 58 00Nm 1 3 3 SPEED LIM rpm 2 Motor speed positive limit Min 0rpm Max 7000rpm 1 3 4 SPEED LIM rpm 2 Motor speed negative limit Min 0rpm Max 7000rpm 1...

Page 63: ...motors Min 0 000A rpm Max 3 430A rpm 1 3 7 KIV A G 2 Speed integrative gain The angular difference between the reference and the rotor is integrated and multiplied by this factor in order to determin...

Page 64: ...or begins to be unsteady depending on the motor noise and vibrations Once you reached the limit decrease the gain by 10 20 as a safety margin Min 0 0rpm Gr Max 2500 4rpm Gr 1 3 9 KDP 2 Reserved 1 3 10...

Page 65: ...ired frequency 1 3 5 FREQ NOM Hz 2 Rated frequency in hertz Together with the value VRMS NOM it determines one of the points defining the line V f that determines the voltage generated depending on th...

Page 66: ...he maximum level the timer decreases If the timer exceeds the pre set value the error signal is enabled This is a safety function that the user has at his disposal in order to protect the application...

Page 67: ...acturer and set in the parameter TORQUE MAX 1 4 7 please also refer to parameter KT 1 4 17 in order to determine the max current required by the motor Min 0 00Nm Max 58 00Nm 1 3 3 SPEED LIM rpm 2 Moto...

Page 68: ...motors Min 0 000A rpm Max 3 430A rpm 1 3 7 KIV A G 2 Speed integrative value The angular difference between the reference and the rotor is integrated and multiplied by this factor in order to determin...

Page 69: ...n derivative gain This gain allows inferring the speed set point from the difference between two consecutive positions The derivative gain considerably improves the position control performance Min 0...

Page 70: ...7000rpm 1 4 10 TEMP MAX C 3 Motor maximum temperature beyond this value the error motor temperature too high is displayed This parameter is important for the protection of the motor this value must be...

Page 71: ...3 Motor rated current 1 4 2 I PEAK MAX mA 3 Motor maximum peak current This is the limit for the maximum instant current that can be supplied to the motor This parameter is a protection for the appli...

Page 72: ...062 ms 0 125 ms or integer multiples of 0 25 ms in our application it is set to 1 ms A control unit can service several ring structures thanks to a master for each ring The master allows synchronizin...

Page 73: ...nt to the driver by the axes board 02 RESET IN Reset signal sent to the driver by an external system for example a push button It is used for cancelling the error if any in the driver 03 ENABLE OUT Ac...

Page 74: ...ed algebraically to the voltage representing the speed analogue reference sent to the driver In any case this sum can not exceed the limits of the analogue input 10V For further information please ref...

Page 75: ...e the motor will be energized If the values of the parameters RAMP and SPEED REF 1 5 5 and 1 5 6 are different from zero the motor will be operated WARNING if the setting of the parameters RAMP and SP...

Page 76: ...lier Min 30 Max 500 1 8 2 RTH C W 3 Thermal coefficient of the external resistance It represents the temperature increase expressed in C depending on the power that the resistor must dissipate express...

Page 77: ...ents the temperature increase expressed in C depending on the power that the resistor must dissipate expressed in W The best dissipation conditions are possible with low values of this constant This d...

Page 78: ...output only this parameter defines whether the user will use current output 4 20mA or voltage output 0 10V If you set current output the voltage value will display a calibration error The same proble...

Page 79: ...alue Grif according to the following formula where Vout analogue output voltage Grif reference value IQ VEL and ABS VEL ERR VEL ERR POS K VOUT GRif proportionality constant OFFSET V offset value added...

Page 80: ...nts as well as of the offset value allows defining the analog output dynamics and consequently the full scale value 1 9 10 K IOUT IQ 2 Proportionality constant of the IQ current expressed in A per mA...

Page 81: ...IRMS NOM A 3 It sets the rms rated current that will be supplied to the driver This parameter allows you to limit the current depending on the application to be controlled and according to the exigenc...

Page 82: ...Cosmos Menu Entry Lev Description 1 10 DRIVE This section includes the parameters for the driver configuration 1 10 1 MODEL Code indicating the driver features as per chapter 3 2 2 1 10 2 VRMS NOMINAL...

Page 83: ...f it is set to Yes the driver will use the external one Warning if you set the external resistor use but you connect the internal one you can damage it Options No Yes 1 10 12 PWM FREQ KHz 4 It disable...

Page 84: ...ameters for the encoder 1 12 1 ENCODER TYPE 3 Type of encoder present Options None Incr 1 12 2 ENCODER DIR 3 Encoder direction This parameter gives you the possibility to reverse or not the reference...

Page 85: ...s of the VISIO 3000 1 13 1 LANGUAGE 2 It sets the language of the messages Options English Italian 1 13 2 ALWAYS LIGHT ON 1 It sets the LCD lighting always on or with the possibility to switch off by...

Page 86: ...set by means of rotary selectors installed on the front side The address must be unequivocal otherwise the bus will not operate correctly Rotary selectors feature an hexadecimal notation Here is the d...

Page 87: ...occurs Seq Meaning STS 1 Error code start FLASH FLASH 2 It indicates the tens in the error code FLASH D OFF 3 It indicates the units in the error code OFF FLASH U 4 Repetition of the sequence from po...

Page 88: ...Field bus Sercos III The signal is given according to the specifications included in the document Generic Device Profile version 1 1 2 1 1 dated 31 March 2009 developed by SERCOS III Working Group TW...

Page 89: ...Status FBS Driver error ON Seq Seq If LED F is flashing LEDs B and S indicate the Sercos error codes see chapter 10 2 for the error decodification Status FBS Sercos error FLASH Seq Seq In both cases...

Page 90: ...LASH 03 FATAL_ERROR_EXT_RAM Error in the test of the external RAM 04 FATAL_ERROR_EXT_FLASH Error in the test of the external FLASH 05 FATAL_ERROR_ILLEGAL_OP SW HW error in the execution of the CPU ins...

Page 91: ...ure exceeds the limit set in the parameter 1 4 10 Make sure that the load applied to the motor is correct no obstructions nor frictions If everything is OK or if you are testing the motor and it has n...

Page 92: ...tage different from driver voltage The rated voltage set for the driver is different from the motor voltage This problem causes an excessive power supply to the motor windings 22 Excessive current for...

Page 93: ...ng up wrong connections of the earth lines If the error persists it will be necessary to replace the driver 09 Maximum current overtaken This error indicates that the current supplied to the motor exc...

Page 94: ...ure the mains voltage is supplied to the connector of the safety circuit 30 STO circuit enabling The driver safety circuit has no external consent signals 10 3 Warnings 10 3 1 Models for brushless mot...

Page 95: ...ected properly 6 Motor temperature too high The motor temperature exceeds the limit set in MOTOR TEMP MAX Make sure that the load applied to the motor is correct no obstructions nor frictions If every...

Page 96: ...not properly installed or when a too high integrative gain implies an excessive adjustment which leads the motor out of the limits permitted 17 SW non longer under control Irretrievable The microproc...

Page 97: ...the transition from phase 1 to phase 2 23 e 24 Communication error during the transition from phase 2 to phase 3 25 Communication error during the transition from phase 3 to phase 4 28 Transition to a...

Page 98: ...4 25 was not possible This is due to wrong exchange of configuration parameters time structure of the cyclic message unsuccessful procedural commands Check the control unit programme 11 2 2 2 Errors...

Page 99: ...ons of optical fiber EXAMPLE 2 COSMOS 1 COSMOS 2 COSMOS 3 COSMOS 4 ERROR 32 ERROR 32 ERROR 32 ERROR 32 The problem occurs between the control unit and the first device in the ring It is recommended to...

Page 100: ...To carry out this operation you need a PC running Windows XP or later OS with a free USB port Smitec proprietary software Winmicro and the drivers for the USB port of COSMOS 3000 must be already insta...

Page 101: ...left icon 7 Unflag the option Enable Profiler 8 Click on the Settings button 9 The Settings window will open set the serial port number you will use for the programming the Cosmos 3000 USB port is rec...

Page 102: ...ler window and set the microcontroller type which in COSMOS 3000 is SH7211F 11 Click on the OK button 12 Click on the button in the main window 13 The window for the selection of the file for the firm...

Page 103: ...d controller if the COSMOS 3000 is switched on the USB cable is properly connected to the PC and to the servodrive and the selected port is correct the USB symbol will pop up beside the word Port 15 C...

Page 104: ...notify the operation success and the time employed 18 In case of failure with message Synchronization Error make sure that the microcontroller type the selected file and port number are correct 19 On...

Page 105: ...AINTENANCE MANUAL 13 Maintenance Before performing any type of maintenance remove power to the device wait 6 minutes and disconnect all electrical connections 13 1 Replacement of fan blower 13 1 1 COS...

Page 106: ...e by the user 13 2 Replacement of dynamic brake resistor 13 2 1 COSMOS Type 325X Disconnect the wires of the resistor from BRAKE R J2 connector Unscrew the two screw that hold resistor on the back of...

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