Wittenstein cyber dynamic system Operating Manual Download Page 2

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Operating manual

cyber

dynamic system

en-2

doc. no.: 5022-D056658

Revision: 01

Revision history

Revision

Date

Comment

Chapter

21/04/2020

New Version

All

Technical support

In the event of technical questions, contact the following address:

WITTENSTEIN cyber motor GmbH

Sales
Walter-Wittenstein-Str. 1
D-97999 Igersheim

Tel.: +49 (0) 79 31 / 493-15800
Fax: +49 (0) 79 31 / 493-10905
Email: [email protected]

If you have any questions about installation, commissioning or optimization, please contact our
support hotline.

WITTENSTEIN cyber motor GmbH support hotline

Tel.: +49 (0) 79 31 / 493-14800

In the event of technical malfunctions, contact us at the following address:

WITTENSTEIN cyber motor GmbH

Customer Service
Walter-Wittenstein-Str. 1
D-97999 Igersheim

Tel.: +49 (0) 79 31 / 493-15900
Email: [email protected]

Copyright

© WITTENSTEIN cyber motor GmbH 2020

This documentation is copyright protected.

WITTENSTEIN cyber motor GmbH

reserves all the rights to photo-mechanical reproduction,

copying, and the distribution by special processes (such as computers, file media,
data networks), even in parts.
Subject to technical and content changes without notice.

Summary of Contents for cyber dynamic system

Page 1: ...Doc no 5022 D056658 Revision 01 cyber dynamic system Operating manual ...

Page 2: ...tion please contact our support hotline WITTENSTEIN cyber motor GmbH support hotline Tel 49 0 79 31 493 14800 In the event of technical malfunctions contact us at the following address WITTENSTEIN cyber motor GmbH Customer Service Walter Wittenstein Str 1 D 97999 Igersheim Tel 49 0 79 31 493 15900 Email service wittenstein cyber motor de Copyright WITTENSTEIN cyber motor GmbH 2020 This documentati...

Page 3: ...storage 19 4 1 Scope of delivery 19 4 2 Packaging 19 4 3 Transport 19 4 4 Storage 19 5 Mechanical installation 20 5 1 Safety instructions 20 5 2 Assembly 20 5 2 1 Preparations 20 5 2 2 Preparations for CDSL series linear actuators with integrated servo drive 21 5 3 Attaching the CDSR to a machine 21 5 4 Components attached to the output side 22 6 Electrical installation 23 6 1 Safety instructions ...

Page 4: ... general mechanical engineering 41 11 STO safety function instructions 42 11 1 Important information for STO 42 11 2 Intended use of STO 42 11 3 Improper use of STO 43 11 4 Technical data and STO pin assignment 43 11 5 STO pin assignment 43 11 6 Function description 44 11 7 Safe operation sequence 45 11 8 Functional check 45 ...

Page 5: ...ust ensure that this operating manual is read through by all persons assigned to install operate or maintain the drive system and that they fully comprehend its content Store this manual within reach of the drive system Inform colleagues who work in the area around the machine about the safety instructions so that no one is hurt The original was prepared in German all other language versions are t...

Page 6: ...ctrostatically sensitive device Crushing No persons with pacemakers 1 3 Structure of the safety information Safety information in this manual has been structured according to the following template Explanatory text shows the consequences of disregarding this information Instructive text uses direct address to indicate what to do 1 4 Information symbols The following information symbols are used In...

Page 7: ...which this drive system is installed corresponds to the regulations within these directives In terms of interference immunity the drive system fulfills the requirement for the category second environment industrial environment In the area of interference emission the drive system fulfills the requirements for category C3 In a residential environment the drive system may cause radio interference ne...

Page 8: ...s been tested and subsequently assessed by TÜV Süd According to that assessment the circuit design used for the Safe Torque Off safety function in the drive system of the cyber dynamic system is suitable for meeting the requirements for SIL 3 in accordance with EN 61508 and category 4 PLe in accordance with EN ISO 13849 1 2015 The subsystems drive systems are fully described in terms of safety by ...

Page 9: ...ke They are used in industrial environments For use in residential areas additional EMC measures are necessary The user must prepare a hazard analysis of the final product 2 6 Improper use The drive system is not suitable for use in the following areas Life sustaining medical devices Applications in potentially explosive atmospheres Use in nuclear plants Use in airplanes 2 7 Risks The manufacturer...

Page 10: ...ective Operation of a heavily soiled drive system Modifications or reconstructions that have been carried out without written authorization from WITTENSTEIN cyber motor GmbH 2 11 Additional documents You have already received the following documents for your specific drive system Dimensional drawing 5007 System characteristics 5012 Encoder system data sheet 5093 For additional information please c...

Page 11: ...rcuit for which faults and associated hazards cannot be excluded When the motor shaft is still turning or when the motor is externally driven generator operation voltage is induced This can cause lethal current surges Ensure that no plugs or connections are exposed Connecting the power and signal supply lines under voltage is not permitted and can lead to machine damage serious injury or even deat...

Page 12: ...by moving components can cause serious injuries and death Remove objects and tools from the drive system before putting it into operation Moving components on the drive system can pull in or crush parts of the body and cause serious injuries and even death Keep a sufficient distance to moving machine components when the drive system is running Secure the machine against restarting and unintentiona...

Page 13: ...ication and during mechanical maintenance work handling errors can lead to severe crushing injuries as well as to damage to the drive system or the application Have all mechanical assembly and maintenance work carried out by trained personnel only Only use suitable tools for assembly and maintenance work During the mechanical assembly and maintenance of kit motors rotary motors without housings or...

Page 14: ... integrated threaded spindle and bearing The rotation of the drive system is transformed into a linear movement of the tappet via the threaded spindle Ball screws are used as threaded spindles The drive system can be optionally equipped with a holding brake The holding brake is not a safety brake Designation A Power connector B Motor housing C Orientation hole D Shaft pinion thrust tube E Motor fl...

Page 15: ... Material number C Serial number D Type code E Calendar week and year of production F Data matrix code DMC G Service portal code H CE mark I Intermediate circuit voltage UDC J Continuous stall current I0 K Continuous stall torque M0 L Maximum current Imax M No load speed n0 N Rated current In O Insulation class P Protection class Q Ambient temperature R Customer material number S Manufacturer T MA...

Page 16: ...R Customer material number S Manufacturer T MAC address U PWM frequency V Bus interface W TÜV logo X Gear ratio Table 3 CDSG name plate Designation A Product designation B Material number C Serial number D Type code E Calendar week and year of production F Data matrix code DMC G Service portal code H CE mark I Intermediate circuit voltage UDC J Continuous stall current I0 K Continuous stall torque...

Page 17: ...o 137 W and a peak output of up to 315 kW The housing with protection class IP65 enables decentralized assembly which means that the drive system can be integrated modularly and flexibly in the machine structure reducing wiring Depending on the device version CANopen according to DS402 EtherCAT with CoE PROFINET RT IRT Ethernet IP Cip Sync or SERCOS III with FSP Drive is available as a communicati...

Page 18: ...ements for cables and wiring In general use high quality shielded motor and encoder cables to avoid EMC problems Further requirements regarding NRTL compliance are listed in chapter 2 1 2 Conformity with TÜV NRTL 3 8 STO safety function The STO safety function Safe Torque Off is used for safe torque shutdown and to reliably protect drives from restarting The drive system is fitted with a two chann...

Page 19: ...tor gearbox combination with integrated servo drive Without brake NP gearbox Ratio 1 stage 5 10 Maximum weight kg 1 3 1 3 2 stage 25 Maximum weight kg 1 5 Without brake GCP gearbox Ratio 1 stage 4 Maximum weight kg 0 9 2 stage 12 25 20 25 30 67 Maximum weight kg 1 1 1 1 3 stage 49 64 100 Maximum weight kg 1 1 1 1 1 1 With brake NP gearbox Ratio 1 stage 5 10 Maximum weight kg 1 6 1 6 2 stage 25 Max...

Page 20: ...1 1 2 stage 12 25 20 25 30 67 Maximum weight kg 1 2 1 2 1 2 1 2 3 stage 49 64 100 Maximum weight kg 1 3 1 3 1 3 3 9 3 CDSL linear actuator with integrated servo drive Without brake Pitch mm 3 10 Stroke length mm 50 200 300 Maximum weight kg 2 0 3 3 3 1 With brake Pitch mm 3 10 Stroke length mm 50 200 300 Maximum weight kg 2 2 3 5 3 3 ...

Page 21: ...Only use hoisting equipment and lifting accessories with sufficient capacity Never exceed the maximum permissible loads for hoisting equipment Lower the drive system slowly Note the weight of the payload and use an appropriate transport device For specifications on the weights see chapter 3 9 Weight Transport temperature 40 70 C max 20 K hour fluctuation Transport air humidity Relative humidity ma...

Page 22: ...g to work see chapter 2 13 General safety instructions 5 2 1 Preparations Compressed air can damage the drive system seals Do not use compressed air to clean the drive system If present the temperature sensors and rotor position encoders particularly Hall effect sensors and encoders can be damaged by electrostatic discharge Observe the directives concerning ESD protection Clean de grease the outpu...

Page 23: ... at both the minimum and maximum position will damage the threaded spindle Limit the stroke of the drive system using appropriate measures e g stops or buffers for the extended and retracted end position These end stops must be dimensioned appropriately and be capable of absorbing the kinetic energy of the moving parts which may be moving at high speeds 5 3 Attaching the CDSx to a machine Observe ...

Page 24: ...rawing 5007 5 4 Components attached to the output side Distortions during mounting operations can damage the drive system Do not use force when mounting gearwheels and toothed belt pulleys onto the output shaft Never attempt to assemble by force or hammering Only use suitable tools and devices for assembly For additional information please contact our Sales department Always state the serial numbe...

Page 25: ...h protection class IP65 connections which are not being used must be fitted with dummy connectors which are included in delivery The drive system does not include integrated ballast resistance which means that an extra brake stopper including brake resistance must be connected for feedback Observe the separate instructions for the STO safety function see chapter11 STO safety function instructions ...

Page 26: ...stallation of the drive system 6 2 4 Environmental conditions for vibration shock The drive system fulfills the following specifications Vibration according to DIN EN 60068 2 6 2008 Frequency range 10 Hz 150 Hz Acceleration 5 g Shock according to DIN EN 60068 2 27 2010 Shock form semi sinusoidal Acceleration 50 g Shock duration 11 ms 6 3 Requirements for power adapters and supply voltage The drive...

Page 27: ...t CAN M12 5 pin female A coded Ethernet based M12 4 pin female D coded CAN M12 5 pin male A coded Ethernet based M12 4 pin male D coded X2 Input fieldbus interface CAN M12 5 pin male A coded Ethernet based M12 4 pin female D coded CAN M12 5 pin female A coded Ethernet based M12 4 pin male D coded X3 USB diagnostic interface M12 4 pin female A coded M12 4 pin male A coded X4 Digital inputs outputs ...

Page 28: ...y units cdsx 40xxxx xxxxx xxx xxx Axx X1 Fieldbus OUT M12 4 5 pin X2 Fieldbus IN M12 4 5 pin PLC fieldbus Master X4 1 DIN1 Digital inputs outputs 2 DIN2 3 DIN3 4 DIN4 M12 8 pin PLC outputs switches or PLC inputs actuators 24 VDC 5 DOUT1 6 DOUT2 7 VCC24 8 GND 24 VDC X5 1 DC Bus Supply 2 DC Bus FE 3 LOGIC 4 STO M12 6 pin 5 STO GND Power supply 12 60 VDC 48 VDC nom GND F1 4 GND X3 1 VCC USB 2 D 3 D M...

Page 29: ...ital inputs outputs 2 DIN2 3 DIN3 4 DIN4 M12 8 pin PLC outputs switches or PLC inputs actuators 24 VDC 5 DOUT1 6 DOUT2 7 VCC24 8 GND 24 VDC X5 Supply 4 STO M12 6 pin 5 STO GND Power supply 12 60 VDC 48 VDC nom GND F1 Safety control DOUT DOUT GND Optional power supply unit 12 60 VDC 24 VDC nom GND F2 12 60 VDC 1 DC Bus 2 DC Bus FE 3 LOGIC 4 GND X3 1 VCC USB 2 D 3 D M12 4 pin PC MotionGUI 2 USB ...

Page 30: ...und reference 4 CAN_H CAN High 5 CAN_L CAN Low Plug type on drive amplifier M12 5 pin female A coded at X1 Connection Feature Unit Minimum value Nominal value Maximum value Baud rate kbaud 100 500 1000 6 4 5 X2 CANopen fieldbus interface input The CAN ground reference is identical to the logic ground reference Figure Pin no Signal Function 1 Shield Screen 2 N C 3 CAN_GND CAN ground reference 4 CAN...

Page 31: ...ital outputs The digital outputs are galvanically isolated from the logic and power of the drive amplifier The digital outputs are short circuit proof Figure Pin no Signal name Function Input output 6 DIN1 Digital input 1 Input 1 DIN2 Digital input 2 Input 8 DIN3 Digital input 3 Input 2 DIN4 Digital input 4 Input 7 GND Ground reference 3 DOUT1 Digital output 1 Output 4 DOUT2 Digital output 2 Outpu...

Page 32: ...Fuses Logic supply F2 X5 pin 3 Fuse or similar with max 4 AT Power supply F1 X5 pin 1 Fuse or similar with max 10 AT Further requirements regarding NRTL compliance are listed in chapter 2 1 2 Conformity with TÜV NRTL Circuit breaker hardware to protect the drive system is not required as the drive system is protected from overloading by an I t function in the software Connection Feature Unit Minim...

Page 33: ...e with electrical and electronic systems and drive technology may start up the drive system 7 2 Data for the electrical startup Moving the drive system during the switch on process of the encoder system can lead to malfunctions When commissioning the drive system make sure that the motor shaft is not moved during the switch on process of the encoder system The switch on process is complete as soon...

Page 34: ...therwise the delay effect of the brake may not be enough to stop the axle The holding brake may become worn if used for emergency stop For this reason it is recommended that the required holding torque for the axle is at most 60 of the static holding torque M4 of the holding brake used Running in the holding brake The holding brake may no longer reach the specified holding torque M4 due to the eff...

Page 35: ...IM4 to the drive system If movement does occur the user should ideally switch off the current supply automatically to avoid uncontrolled movement of the axle If the holding torque M4 is not reached perform the grinding in process described by the brake manufacturer After the grinding in process check again the holding torque M4 If the holding torque M4 specified in the brake s technical data is re...

Page 36: ...load free approx 30 vmax 5 min with increased speed load free approx 60 vmax If a stop occurs as a result of the switch off due to excessive heating a pause between the individual stroke cycles is recommended Due to the stroke movement of the piston rod a certain amount of lubricant leakage is possible with the CDSL version 7 5 Startup software For parameterization and startup of the drive the sta...

Page 37: ...ble 7 Displays on the drive system 7 6 1 LED codes DS LED DS is the drive LED which is identical for all bus system types Status LED LED DS Meaning Off Drive amplifier has no power supply or drive is defective Flash Green Drive amplifier is in functional state but output stage is disabled Flash Red Drive amplifier is in fault state and output stage is disabled Flash Yellow Drive amplifier is in wa...

Page 38: ...ernet IP LED MS indicates the module state Stauts LED LED MS Meaning Off The bus module has no power supply or is defective Flash Green Red Green The bus module is performing its power up testing Flash Green Standby The bus module is not configured e g no network cable connected Flash Red The bus module is in fault state but fault can be reset Constant Red The bus module is in fault state and faul...

Page 39: ...ve changed its state independent Maybe a host watchdog timeout or synchronisation error occured Flash Red double flash Process data watchdog timeoug Table 12 LED codes NS EtherCAT Ethernet IP LED NS indicates the fieldbus state Status LED LED NS Meaning Off The bus module has no IP addrress or has no power supply or is defective Flash Green Red Off The bus module is performing ist power up testing...

Page 40: ...PROFINET LED NS BF indicates the bus failure Status LED LED NS Meaning Off The device has no error or has no power supply or is defective Flash Red 2 Hz No data exchange Constant Red No configuration or low speed physical link or no physical link Table 14 LED codes NS PROFINET ...

Page 41: ... controller It is recommended that the holding torque M4 of the brake is checked at least once a day Details can be found in chapter 7 3 Holding brake 8 1 3 Visual inspection Perform a monthly visual inspection Check the drive system and moving cables for damage Check whether the cable ends are completely labeled 8 2 Repairs The drive system may only be repaired by the manufacturer Opening the dri...

Page 42: ...ck the motor data record in the power electronics Increased operating temperature Drive system is heavily soiled Clean the outside of the drive system Ambient temperature too high air pressure too low due to altitude Ensure adequate cooling Drive system becomes very hot Consult our Customer Service department Threaded spindle heavily worn Consult our Customer Service department Increased operating...

Page 43: ...µ 0 10 Utilization of the yield stress 90 Torque tools type II classes A and D in accordance with ISO 6789 The settings are values rounded to usual commercial scale gradations or settings Use the exact values in this table to set your tools Tightening torque Nm with thread Property class of screw nut M1 6 M2 M2 5 M3 M4 M5 A2 70 0 109 0 227 0 460 0 806 1 86 3 68 Table 16 Tightening torques for set ...

Page 44: ... cyber dynamic system series drive systems are suitable for meeting the requirements for SIL 3 in accordance with EN 61508 and category 4 PLe in accordance with EN ISO 13849 1 2015 11 1 Important information for STO If the STO function is actuated during operation the drive will coast to a stop in an uncontrolled manner and the drive system reports the Error_amp_sto_active fault Controlled braking...

Page 45: ...cy stop situations the power supply must be cut off by a line contactor Emergency stop push button 11 4 Technical data and STO pin assignment STO input Data STO inactive input voltage 12 60 VDC STO active input voltage Open Input current 25 45 mA Response time time between activation of STO function and drive system being free of torque 16 ms Test time for STO dark test at 24 VDC STO power supply ...

Page 46: ...th two channel control of the STO safety function the STO and STO GND shutdowns are switched separately by two outputs of a safety control STO 24 V status STO GND status Motor torque possible Open Open No 24 VDC 0 VDC Yes When wiring the STO inputs inside an installation space make sure that both the wiring used and the installation space itself meet the requirements of EN 60204 1 If the wiring is...

Page 47: ...anically as well e g with a suitable holding brake If the STO function is actuated during operation the drive will coast to a stop in an uncontrolled manner Controlled braking of the drive will not be possible Danger from uncontrolled movement 11 8 Functional check The STO function must be checked at initial startup after any work on the system s wiring and after replacing one or more components o...

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