BERGER WDP3-01X Installation instructions

Positioning and
Sequence Control Unit for
3-phase Stepping Motors
WDP3-01X
with OED3
Doc. no. 214.157/DGB
Ident. no.: 00441110002
Edition:e220 09.2003
Software version: 03.1XX

Safety instructions
Please read the following safety instructions prior to installation, operation, maintenance and repair
of the device.
•The intended use of the device under is described “Purpose” and must be observed.
•Installation, maintenance and repair of the device shall be performed by a qualified electrician.
National regulations concerning
– accident prevention
– installation of electrical and mechanical systems
– radio interference suppression
shall be observed.
•The technical data of the device, particularly the ambient conditions, shall be observed.
•The device shall only be operated by trained personnel.
•The warranty is invalidated in case of unauthorized modification or opening of the device.
•Please ask your technical consultant prior to installing accessories not listed under “Accessories”.
•The safety symbols and notes on the device and in the manual shall be observed.
Explanation of symbols
ATTENTION
Reference to a danger for the device or components, possibly resulting in the
endangering of human life.
DANGER
Reference to a direct endangering of human life.
DANGER
High voltage at component, do not touch.
DANGER
High temperature at component, do not touch.
ATTENTION
Warning against electrostatic discharge (ESD).
Only touch the PC-board or component in an electrostatically-protected
environment.
NOTE
Important or additional information concerning the device or the manual.

Proposals
Improvements
Berger Lahr GmbH & Co. KGWDP3-01X with OED3
Breslauer Str. 7
Postfach 1180
D-77901 Lahr Edition: d156 08.03
Doc. no. 214.157/DGB
Sender: Please inform us, using this form, if
you have discovered any errors
when reading this document.
We should also appreciate any new
ideas and proposals.
Name:
Company/department:
Address:
Telephone no.:
Proposal and/or improvements:


Table of contents
Page
1 General description 1-1
1.1 Structure and characteristics 1-1
1.2 Function 1-2
1.2.1 Hardware components 1-2
1.2.2 Operating modes 1-4
1.3 Technical data 1-6
1.3.1 General data 1-6
1.3.2 Electrical data 1-6
1.3.3 Mechanical data 1-8
1.3.4 Ambient conditions 1-8
1.3.5 Regulations 1-9
1.3.6 Approvals 1-9
2 Installation 2-1
2.1 Scope of supply 2-1
2.2 Accessories 2-2
2.3 Assembly 2-3
2.4 Wiring 2-5
2.4.1 Mains connection 2-7
2.4.2 Motor connection 2-8
2.4.3 Signal interface 2-9
2.4.3.1 Signal connection pin assignment 2-10
2.4.4 RS 232 serial interface (OPT.1) 2-12
2.4.5 RS 485 serial interface (OPT.1) 2-14
2.4.6 Encoder interface (OPT.2) 2-16
2.5 Setup 2-19
2.5.1 Defaults 2-19
2.5.2 Motor test 2-21
Table of contents
WDP3-01X with OED3 Doc. no. 214.157/DGB

Page
3 Operation 3-1
3.1 Controller operating modes 3-1
3.2 Switching ON 3-2
3.3 Controller STOP 3-4
3.4 Editing mode 3-4
3.5 Setting the motor phase current 3-5
3.6 Manual mode via front panel 3-6
3.7 Automatic mode 3-7
3.8 Programming 3-8
3.9 Switching OFF 3-8
4 Malfunctions 4-1
4.1 Status indicators 4-1
4.2 Troubleshooting tables 4-2
4.3 Repair work 4-5
4.4 Storage, shipment 4-5
5 Customer service 5-1
Table of contents
WDP3-01X with OED3 Doc. no. 214.157/DGB

Page
6 Appendix 6-1
6.1 Device variants 6-1
6.2 Description of accessories 6-2
6.2.1 Fan 6-4
6.2.2 Mains filter 6-5
6.2.3 MP 923 interface converter 6-6
6.2.3.1 General description 6-6
6.2.3.2 Technical data 6-6
6.2.3.3 Setup 6-7
6.2.3.4 Status indicators 6-7
6.2.4 Additional bleed resistor 6-9
6.3 Glossary 6-10
6.4 Abbreviations 6-13
7 Index 7-1
8 Corrections and additions 8-1
Table of contents
WDP3-01X with OED3 Doc. no. 214.157/DGB

Table of contents
WDP3-01X with OED3 Doc. no. 214.157/DGB

1 General description
1.1 Structure and characteristics
The WDP3-01X positioning and sequence control unit, which comprises
the OED3 operating system, can be used for controlling the following
BERGER LAHR 3-phase steppingmotors:
Purpose
– with WDP3-014, motors of type size 90, (VRDM 39xx/50 LW.)
– with WDP3-018, motors of type size 110, (VRDM 311xx/50 LW.)
Each unit is used for controlling one axis. The difference between the
positioning and sequence control units WDP3-014 and WDP3-018 con-
sists in their power ratings.
The controller can be freely programmed using a PC and the ProOED3
programming software. A PLC with integrated movement programming is
possible.
An electronic gear or rotation monitoring can be implemented via the
optional encoder interface.
This documentation describes installation and operation via the front
panel keys, the inputs/outputs of the signal interface and the encoder
interface.
Programming of the device is described in the documentation of the
ProOED3 programming software.
Documentation
L
N
PE
Serial interface (c1)
for programming
and communication
230V
Motor connector
Mains
connector
Selector switch
for mains voltage
115 VAC or 230 VAC
Status display
Front panel keys
Bleed resistor connection
(only at units < RS 40)
Signal interface
Encoder interface (p2)
for electronic gear
or rotation monitoring
(option)
Fig. 1-1 WDP3-01X positioning
and sequence control unit
with OED3
General description
WDP3-01X with OED3 Doc. no. 214.157/DGB 1-1

1.2 Function
1.2.1 Hardware components A built-in PC board in Eurocard format type size 6 HU accommodates
the processor unit, the power controller and the power supply unit. The
mostimportantfunctionblocksoftheunitareevidentintheblockdiagram
(fig. 1-2).
Thepowersupplyunitisahigh-performanceAC/DCconverterwhichcan
be connected to 115 VAC or 230 VAC supply voltages. The energy
recovered by a motor during braking can be temporarily stored up to a
certain extent. To dissipate a higher amount of braking energy, an
external bleed resistor must be connected.
Power supply unit
External bleed resistor
ADC/DCpowersupplyunit generatesvariousvoltagelevelsforsupplying
the internal electronic circuits of the processor unit from the 24 VDC
voltage supply.
DC/DC power supply unit
NOTE
The electronic circuitry of the processor unit consists of PELV circuits as
defined in the DIN standard VDE 0160.
Various interface configurations are possible according to the actual
requirements.
Interface configuration
NOTE
The interfaces installed in the device are indicated on the type plate. The
following abbreviations are used:
RS 232 Serial interface RS 232
RS 485 LS Serial interface RS 485
LRS 422 IN Encoder interface RS 422
WDP3-01X with OED3
Inputs
RS 232, RS 485
Outputs
24 VDC
Interface
OPT.1
Signal
interface Management
processor
Software
indexer
(movement
profile
generator)
Rotation
monitoring
Power
controller
Processor unit ( P control)
M
E
DC
DC
Bleed resistor
115 VAC/230 VAC Power supply
325 VDC
AC
EEPROM
FRAM
A/B or
Pulse/direction
signals (RS 422)
Encoder
interface
OPT.2
+
Option
µ
Fig. 1-2 Block diagram
General description
1-2 WDP3-01X with OED3 Doc. no. 214.157/DGB

The signal interface carries the input and output signals as well as the
24 VDC signal voltage.
Signal interface
The encoder interface RS 422 (OPT.2) can be usedfor implementing an
electronic gear or for rotation monitoring.
Encoder interface
The RS 232 or RS 485 serial interface can be used for programming the
controller (in editing mode) using a PC and the ProOED3 programming
software. In addition, programmed communication, e.g. with an operating
terminal, can be implemented via the serial interface (in automatic mode).
Serial interface
The management processor is used in controller automatic mode for
editing the application program and addressing the corresponding inter-
faces. In order to retain the application program on the controller after
disconnecting the supply voltage, it must be written to the controller’s
EEPROM using a PC and the ProOED3 programming software. In the
controller’s FRAM, 3 variables can be stored to beretained even incase
of power failure.
Management processor
Three seven-segment displays indicate operating states and any mal-
functions.
Status display
Three keys are provided on the front panel for operation and error
acknowledgement.
Keys
The indexer (movement profile generator) generates a pulse sequence
from the current movement parameters (travel, speed and acceleration).
This pulse sequence is passed on to the power controller.
Indexer
Thepowercontrollerconvertsthepulsesequencereceivedfromtheindexer
into a current pattern for controllingthe 3-phasestepping motor. The motor
phase current can be set on the front panel; see chapter 3.5.
Power controller
General description
WDP3-01X with OED3 Doc. no. 214.157/DGB 1-3

1.2.2 Operating modes The following operating modes can be set on the front panel.
– Manual mode via front panel
– Automatic mode
– Editing mode
In manual mode via front panel, you can move the motor to the left or
right using the front panel keys.
Manual mode via front panel
NOTE
In controller automatic mode, manual mode and teach-in mode is possible
viathesignalinputsofthecontrollerifthecorrespondingapplicationprogram
was loaded into the controller; see ProOED3 documentation.
In automatic mode, you can start an application program which isloaded
in the controller. The application program must previously have been
createdusingaPCandtheProOED3programmingsoftwareandloaded
into the controller (download).
Automatic mode
NOTE
Since the controller does not have a battery-buffered main memory, the
application program must be written to the controller’s EEPROM after
downloading. When switching on the controller, the application program
is automatically loaded from the EEPROM into the main memory of the
controller.
In controller editing mode, you can load an application program created
with the PC and the ProOED3 programming software on the controller
and test it in on-line mode.
Editing mode
Setting the operating modes
and the motor phase current
Signal
inputs/outputs
20
_+
21
OPT.1
22
OPT.2
23
Signal/
24 V DC
24
V
W
U
L
N
3-phase
stepping motor
Encoder
M
E
PC with ProOED3
programming software
Fig. 1-3 System environment
General description
1-4 WDP3-01X with OED3 Doc. no. 214.157/DGB

Axis operating modes
In controller automatic mode, you can use the ProOED3 command
“mode” in the applicationprogram toactivate the following axis operating
modes:
– Point-to-point mode
Positioning the axis from a given point A to a given point B at a
programmed acceleration, speed and travel. Positioning can be
effected with absolute values (relative to a reference point) or with
incremental values (relative to the current position).
– Position following mode (electronic gear)
In position following mode, you can implement an electronic gear
via the encoder interface of the controller ora variable. The pulses
fed to the encoder interface or stored in the variable aremultiplied
with a gear ratio and used for controlling the stepping motor.
Rotation monitoring
If the controller is equipped with an encoder interface (RS 422 IN), you
can activate motor rotation monitoringfromthe applicationprogram; see
ProOED3 documentation. For rotation monitoring, the motor must be
fitted with an encoder. The rotation monitoring feature compares the set
and actual positions of the motor and reports a rotation monitoring error
if the difference between set and actual position exceeds a certain limit
value (19 steps).
General description
WDP3-01X with OED3 Doc. no. 214.157/DGB 1-5

1.3 Technical data
1.3.1 General data Power fail safe application program memory EEPROM
Power fail safe memory for 3 variables FRAM
ATTENTION
After power-off, the contents of the FRAM variables is retained only
for a certain period:
– at an ambient temperature of 30°C: approx. 250 days
– at an ambient temperature of 50°C: approx. 60 days
Memory space for sequence program 2000 instructions
Memory space for PLC program 1000 instructions
Time for a PLC instruction approx. 1.5 ms
1.3.2 Electrical data Supply voltage, selectable 115 VAC
230 VAC to 240 VAC
Mains connection
Power loss
WDP3-014 60 W max.
WDP3-018 110 W max.
Mains frequency 50 to 60 Hz
Mains error protection one period
Overvoltage stability acc. to DIN VDE 0160 Class 1
Nominal power consumption
WDP3-014 3.6 A at 115 VAC
2.0 A at 230 VAC
WDP3-018 6.5 A at 115 VAC
3.5 A at 230 VAC
Starting current 70 A max.
General description
Leakage current (IEC60990) Motor cable <5m : <10mA
Motor cable 5-50m : <50mA
External fuse 6 A at 230 VAC
10 A at 115 VAC
(“K” characteristic)
NOTE
The devices may only be operated with fuse protection as specified
above.
If necessary, use r.c.c.b. protection according to DIN VDE 0664,
part 1/10.85.
Supply voltage 20 VDC to 30 VDC
System supply
via signal interface
Power consumption 1 A max.
Ripple voltage < 2 V
pp
NOTE
The 24 V voltage supply must meet the specifications of the DIN standard
VDE 0160 on safety extra-low voltage.
1-6 WDP3-01X with OED3 Doc. no. 214.157/DGB

Phase current
WDP3-014 0.1 A to 2.5 A
WDP3-018 0.1 A to 6.8 A
Motor connection
No. of steps 1000 steps per revolution
Pulse rate 40 kHz max.
Motor voltage 3 x 325 VDC (connected to mains)
Motor cable (observe EN 60204 standard)
Length maximum 50 m
Cross-section ≥0.75 mm2at cable length ≤30 m
≥1.5 mm2at cable length > 30 m
Shield connection On both ends
Electrical characteristics of the inputs
Signal interface
Polarity reversal protection, hardware debounce (settling time
0.8 ms to 1.5 ms)
Signal voltage Uhigh 15 VDC to 30 VDC
Signal voltage Ulow < 3 VDC
Input current at 24 VDC 7 mA
Electrical characteristics of the outputs
Short-circuit protected, inductive loadability
Maximum output voltage 30 VDC
Maximum switching current on output Q0 400 mA
Voltage drop at 400 mA < 2 VDC
Maximum switching current on outputs Q1 to Q3 50 mA
Voltage drop at 50 mA < 2 VDC
DANGER
The signal inputs and the 24 VDC supply voltages on the signal
connection must be definitely isolated from mains. The maximum
voltage towards ground must not exceed 60 VDC or 25 VAC.
RS 232 interface (option)
Serial interfaces
Internal leakage resistance towards ground 1 Mohm
RS 485 four-wire interface (option)
Short-circuit protected 150 mA max. at short-circuit
Internal leakage resistance towards ground 1 Mohm
Supply voltage output 12 VDC
for MP 923 (10 VDC min., 18 VDC max.)
General description
WDP3-01X with OED3 Doc. no. 214.157/DGB 1-7

RS 422 IN signal level (option)
Encoder interface
Short-circuit protected
Internal leakage resistance towards ground 1 Mohm
Maximum cable length 100 m
Wire cross-section 2 x 0.5 mm2and 10 x 0.25 mm2
Shield connection On both ends
Supply voltage output 5 VDC ±5% (300 mA max.)
or
12 VDC, 10 VDC min./18 VDC max. (200 mA max.)
Protection and monitoring circuits: Power amplifier overtemperature,
short-circuit between motor leads (no ground fault protection), under-
voltage and overvoltage
Device protection
Type of protection IP 20 acc. to EN 60529: 1991
1.3.3 Mechanical data Dimensions (fig. 1-4) 249 x 240 x 52 mm
Weight approx. 3200 g
1.3.4 Ambient conditions Ambient temperature 0°C to +50°C
Storage temperature -25°C to +70°C
Relative humidity 15% to 85%
(non-condensing)
52
279.5
12
24025.5
187
19
249
32
0
92
147
183
Fig. 1-4 Dimensions
General description
1-8 WDP3-01X with OED3 Doc. no. 214.157/DGB

1.3.5 Regulations Insofar as the other equipment complies with the machinery direc-
tive 89/392/EWG and the configuration meets the EMC testing
requirements of BERGER LAHR, conformity with the machinery
directive is hereby certified.
Machinery directive
In a configuration which meets the EMC testing requirements of
BERGERLAHR, conformitywith the following standards can be
certified in accordance with the EMC directive 89/336/EWG:
EMC directive
Radio interference suppression according to EN 50081-2: 1993
(when using a mains filter, see Accessories)
Static discharge according to EN 60801-2: 1993, class 3
Burst according to IEC 801-4: 1988, class 4
–Use motor leads supplied byBERGER LAHR.
Motor lead length is 10 m.
BERGER LAHR
EMC testing requirements
–Insert a mains filter supplied by BERGER LAHR into the
mains power supply line.
– Install the unit in a switch cabinet.
–UsesignallinessuppliedbyBERGERLAHRandwireaccord-
ing to the documentation.
– Run signal, mains and motor cables separately (non-parallel) and
establish a large surface area contact between the cable shield
and ground/earth.
– Install the mains filter directly at the unit. If thisis not possible, use
a shielded connection cable (1 m max.) between the filter and the
unit.
– Establish a large surface area contact between filter/device and
ground (mount on a grounded metal plate or on the switch cabinet
rear wall or use a ground strap).
Pursuant to the low-voltage equipment directive 73/23/EEC, the
products are in conformity with the following standards:
Low-voltage equipment directive
Protection class 1 acc. to prEN 50178: 1994
Overvoltage Category III acc. to prEN 50178: 1994
Contamination Grade 2 acc. to prEN 50178: 1994
1.3.6 Approvals prEN 50178 classification VDE 0160/11.94
EN 60950 classification VDE 0805: 1993 + A2: 1994
UL 508 file no. 153 659
General description
WDP3-01X with OED3 Doc. no. 214.157/DGB 1-9

General description
1-10 WDP3-01X with OED3 Doc. no. 214.157/DGB

2 Installation
2.1 Scope of supply
Check that the delivery is complete.
The scope of supply (fig. 2-1) comprises:
Qty. Designation
1 Positioning and sequence control unit WDP3-014 with OED3
or WDP3-018 with OED3
1 Product insert
1 Ground strap
4 Mounting bracket
1 Fan for WDP3-018 with OED3
Fig. 2-1 Scope of supply
Installation
WDP3-01X with OED3 Doc. no. 214.157/DGB 2-1

2.2 Accessories
The following accessories are available and must be ordered separately
(for a description of accessories, see chapter 6.2):
– ProOED3 programming software (documentation with diskettes)
– 3-phase stepping motor
– Cable for encoder
– Fan for WDP3-018
– Motor cable 3 x 1.5 mm and 2 x 1.0 mm
– Motor cable 3 x 2.5 mm and 2 x 1.5 mm
– Mains filter
– MP 923 interface converter RS 232/RS 485
– RS 232/PC signal cable
– RS 422 IN/customer signal cable
– MP 924 interface distributor RS 485
– RS 485 LS/MP 923 signal cable
– Signal connection/customer signal cable
– Signal connection cable
– Signal cable for adapter slot option 1
– Signal cable (encoder) for adapter slot option 2
– Signal cable (pulse, direction) for adapter slot option 2
– Set of connectors (all sub-D connectors)
– Electronic gear cable
NOTE
Refer to the sales documentation for the positioning and sequence
control unit WDP3-01X with OED3 for the accessory order numbers.
Installation
2-2 WDP3-01X with OED3 Doc. no. 214.157/DGB
Table of contents
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