Korber Solutions LTI MOTION MotionOne 3 User guide

MotionOne 3
System manual
Automation system

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Id.-Nr.: 1556.212.1-07
MotionOne 3 Automation system System manual
Id.-Nr.: 1556.212.1-07

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Id.-Nr.: 1556.212.1-07
Table of contents
Table of contents
1 Introduction............................................................................. 6
1.1 Purpose of the document .................................................................................. 6
1.2 Preconditions .................................................................................................... 6
1.3 Intended use ..................................................................................................... 7
1.4 Notes on this document .................................................................................... 7
1.4.1 Contents of the document ................................................................... 7
1.4.2 Not contained in this document ........................................................... 7
1.5 Further documentation ...................................................................................... 7
1.6 Relevant countries and registrations................................................................. 7
2 Safety notes ........................................................................... 8
2.1 Representation.................................................................................................. 8
2.2 General safety insutructions.............................................................................. 8
2.3 Personnel safety ............................................................................................... 8
2.4 Safety instructions for projecting ....................................................................... 9
3 System overview .................................................................... 10
3.1 Hardware architecture....................................................................................... 11
3.2 Software architecture ........................................................................................ 11
3.3 Network design ................................................................................................. 12
3.4 Technical specification ...................................................................................... 14
3.5 MotionOne - CPU modules ............................................................................... 15
3.5.1 Extension modules .............................................................................. 15
3.6 ServoOne CM CM - Drive technique ................................................................. 15
3.7 Buses................................................................................................................. 16
3.7.1 EtherCAT .............................................................................................. 16
3.7.2 Profinet.................................................................................................. 17
3.7.3 EtherNet/IP ........................................................................................... 17
3.7.4 CAN ...................................................................................................... 17
3.7.5 Ethernet ................................................................................................ 17
3.8 VisuOne - Visualization components................................................................. 17
3.8.1 Stationary Visualization......................................................................... 17
3.8.2 Visualization systems............................................................................ 17
3.9 MotionCenter Toolsuite ..................................................................................... 17
3.9.1 MotionCenter ........................................................................................ 18
3.9.2 ViEditor ................................................................................................. 19
3.9.3 DriveManager ....................................................................................... 19
3.9.4 MotionCenter Scope ............................................................................. 19
3.10 Libraries and interfaces ..................................................................................... 19
3.10.1 IEC standard libraries ........................................................................... 19
3.10.2 MotionCenter libraries........................................................................... 20
3.10.3 OPC UA interface ................................................................................. 20
4 Assembly and removal ............................................................ 21
4.1 Space requirement ............................................................................................ 21
4.2 Air conditioning, ventilation................................................................................ 21
4.3 Use of air filters.................................................................................................. 21
5 Connections and wiring ........................................................... 22
5.1 Interfaces........................................................................................................... 22
5.1.1 CAN ...................................................................................................... 22
5.1.2 RS-232-C .............................................................................................. 23

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Table of contents
5.1.3 RS-485/422 ......................................................................................... 23
5.1.4 SSI interface ........................................................................................ 24
5.1.5 Ethernet, Gigabit-Ethernet, EtherCAT, PROFINET............................. 24
5.1.6 Graphic interface ................................................................................. 25
5.1.7 USB ..................................................................................................... 25
5.2 Connecting the bus link module ........................................................................ 25
5.3 Connecting the stationary operating panel........................................................ 26
5.4 Connecting the Handterminal............................................................................ 26
5.5 Connecting axis modules .................................................................................. 26
5.6 Test of interference immunity............................................................................ 26
6 Displays and operating elements ........................................... 27
6.1 Button and display, general information............................................................ 27
7 Operating behavior................................................................. 28
7.1 Start-up ............................................................................................................. 28
7.1.1 Display during start-up......................................................................... 28
8 Software installation ............................................................... 29
8.1 Install firmware of the control ............................................................................ 29
8.2 Install simulation on the PC............................................................................... 29
9 Configuration .......................................................................... 30
9.1 Data exchange between control and visualization ............................................ 30
9.2 Device configuration via static operating device ............................................... 30
9.2.1 Diagnosis Data .................................................................................... 31
9.2.2 Display................................................................................................. 31
9.2.3 Licenses .............................................................................................. 32
9.2.4 Network ............................................................................................... 32
9.2.5 Reboot .................................................................................................. 33
9.2.6 Version info ........................................................................................... 33
10 Device Administration (DevAdmin) .......................................... 34
10.1 Tab "Diagnostics" .............................................................................................. 34
10.2 Tab "Configuration" ........................................................................................... 36
10.3 Tab "Backup/Restore" ....................................................................................... 37
10.4 Tab "Monitor"..................................................................................................... 38
10.5 Change password for DevAdmin....................................................................... 40
11 Program development ............................................................. 41
11.1 Task priorities .................................................................................................... 41
11.2 Fast control........................................................................................................ 41
12 Diagnosis ................................................................................. 42
12.1 Control diagnosis............................................................................................... 42
12.1.1 Error codes ........................................................................................... 42
12.2 Drive diagnosis .................................................................................................. 42
12.3 Diagnosis data for LTI ....................................................................................... 42
12.3.1 Status report ......................................................................................... 42
12.3.2 Crashreport ........................................................................................... 43
12.3.3 Access to flash storage medium ........................................................... 43
13 Maintenance ............................................................................ 45
14 Disposal ................................................................................... 46
14.1 Disposal of the module ...................................................................................... 46
14.2 Disposal of the battery....................................................................................... 46

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Table of contents
15 Technical data ........................................................................ 47
15.1 Ambient conditions............................................................................................ 47
16 EC directives and standards .................................................. 48
17 Appendix: EMC-resistant wiring ............................................. 49
17.1 Basic structure of EMC measures..................................................................... 49
17.2 Which EMC measures must be taken?............................................................. 49
17.3 Checklist of EMC measures.............................................................................. 50
18 Appendix: Tutorial - creating an IEC project .......................... 51
18.1 Creating a new project ...................................................................................... 51
18.2 Creating a simple program................................................................................ 53
18.3 Saving MotionCenter LX project ...................................................................... 55
18.4 Create target USB stick .................................................................................... 55
18.5 Configuration of the control ............................................................................... 57
18.6 Compiling project and uploading onto control ................................................... 58
18.7 Starting the project ............................................................................................ 59
18.8 Create and execute the simulation of a control................................................. 60
18.8.1 Create simulation................................................................................. 60
18.8.2 Execute simulation ............................................................................. 61
19 Appendix: Tutorial - Creating a visualization .......................... 62
19.1 Selecting variables for visualization .................................................................. 62
19.2 Adding the visualization to the control configuration ......................................... 62
19.3 Creating a new visualization project.................................................................. 63
19.4 Edit mask .......................................................................................................... 63
19.5 Generating code for the visualization project .................................................... 65
19.6 Load visualization onto the control .................................................................... 65
19.7 Restart of the control ......................................................................................... 66
20 Appendix: Connection examples ............................................. 67
20.1 MO CM with connected axis group.................................................................... 67
20.2 MO CM with directly added SO CMP with power unit and separate SO CMP
without power unit..............................................................................................
67
20.3 MO CM with directly added SO CMP with power unit and separate SO CMP
with power unit...................................................................................................
68
20.4 MO CM connected bus coupler module ............................................................ 69
21 Appendix: Addressing in the Ethernet (basics)........................ 70
22 Appendix: Terminology ............................................................ 71
Index ........................................................................................ 72

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Introduction
1 Introduction
1.1 Purpose of the document
This document describes the structure of the MotionOne system..
In addition, it describes the assembly and installation, the wiring aswell as the opera-
tion and displays of the modules.
The installation and configuration is described enough to obtain an operationally
ready system. "Ready for operation" means that the system and/or the respective
CPU modules are ready for loading the customer application.
1.2 Preconditions
The system manual is intended for all those using a MotionOne 3 system or those
who plan to use such a system.
Only electrically trained personnel, as specified by VDE 1000-10, are authorized to
install and maintain a system.
Target group Prerequisite knowledge and ability
Safety engineer
for"Functional safety"
Technical training (university of applied science, engineering training
or corresponding professional experience).
Knowledge about:
• Principles of functional safety
• Relevant standards and safety regulations for the machine/sys-
tem, particularly knowledge about validation according to EN ISO
13849,
• Special risk potential of the machine/system and the production
process
• Specific protective measures to avert machine-specific hazards
(based on hazard and risk analysis)
• Functioning and application limits of the safety components (in-
cluding safety PLC)
• In-depth knowledge of national accident prevention regulations.
Target group Prerequisite knowledge and ability
Project engineer
Technical basic education (advanced technical education, engineering
degree or corresponding professional experience),
Knowledge about:
• the method of operation of a PLC,
• current valid safety regulations
• the application.
Electrician
Professional training in electrical engineering (based on industry-stan-
dard training guidelines).
Knowledge about:
• Current valid safety regulations,
• Wiring guidelines,
• Circuit diagrams,
• System analysis and troubleshooting,
• Professional installation of electrical connections according to na-
tional and international directives
Programmer
Technical training (University of Applied Science, engineering degree
or corresponding professional experience).
Knowledge about:
• Method of operation of a PLC,
• Current valid safety regulations,
• Programming of a PLC (IEC61131).
Start-up technician
Basic technical training (technical college, engineer training or corre-
sponding professional experience).
Knowledge about:
• Current valid safety regulations,
• Method of operation of the machine or plant,
• Fundamental functions of the application,
• System analysis and troubleshooting,
• Setting options on the operating devices.
Service technician
Basic technical training (technical college, engineer training or corre-
sponding professional experience).
Knowledge about:
• Method of operation of a PLC,
• current valid safety regulations
• Method of operation of the machine or plant,
• Diagnostic options,
• Systematic fault analysis and remedial action.

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Introduction
1.3 Intended use
A MotionOne system may only be used for the types of use described in the technical
descriptions and only in conjunction with recommended/approved third-party equip-
ment/installations.
All modules of the MotionOne system have been developed, manufactured, tested
and documented in accordance with the appropriate safety standards. Therefore, the
products do not pose any danger to the health of persons or a risk of damage to
other property or equipment under normal circumstances, provided that the instruc-
tions and safety precautions relating to the intended use are properly observed.
The system is intended for installation in a control cabinet and may only be used in
the following way:
• Only in the industrial sector
• in accordance with regulations
• In a faultless technical condition
• In its original state without unauthorized modifications.
Only alterations and modifications described in the accompanying documentation are
authorized.
Preconditions for correct operation with functional safety are:
• The correct projection of the system
• The correct and complete installing of all components under the designation of
the specified environmental conditions.
• Creation of a complete safety application
• Verification and validation of all safety functions
• Compliance of the requirements of the machine directive and local law for the
complete machine if necessary.
1.4 Notes on this document
Information
If necessary, also adhere to the documentation accompanying the mod-
ules.
1.4.1 Contents of the document
• System overview
• Explanation of all operating elements and displays
• Description of the assembly and installation
• Operating behavior
• Description of the software installation
• Description of the software interfaces
• Diagnosis and maintenance information
• Technical data
• EMC and wiring guidelines
• Terminology
1.4.2 Not contained in this document
• Programming instruction
• Application diagnosis
• Firmware description
1.5 Further documentation
Documents for systems components (drive technology, teach pendants, controls, IO-
modules, ...) are included in your shipment. For each product an operation manual
exists, which includes detailed information about start-up and operation. Documenta-
tion of the tools is integrated as online help.
1.6 Relevant countries and registrations
Standards and test values which the product conforms to and meets are contained in
the chapters "Technical Data" and "EC directives and standards". For the EU guide-
lines relevant to the product please see the declaration of conformity.

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Safety notes
2 Safety notes
2.1 Representation
At various points in this manual, you will see notes and precautionary warnings re-
garding possible hazards. The symbols used have the following meaning:
DANGER!
indicates an imminently hazardous situation, which will result in death or
serious bodily injury if the corresponding precautions are not taken.
WARNING!
indicates a potentially hazardous situation, which can result in death or se-
rious bodily injury if the corresponding precautions are not taken.
CAUTION!
means that if the corresponding safety measures are not taken, a poten-
tially hazardous situation can occur that may result in slight bodily injury.
Caution
means that damage to property can occur if the corresponding safety mea-
sures are not taken.
ESD
This symbol reminds you of the possible consequences of touching electro-
statically sensitive components.
Safety information
Describes important safety-related requirements or informs about
essential safety-related coherences.
Information
Identifies practical tips and useful information. No information that warns
about potentially dangerous or harmful functions is contained.
2.2 General safety insutructions
The documentation contains information necessary for planning the use of the Mo-
tionOne system.
Familiarity with and correct application of the information contained in these manuals
is a prerequisite for successful planning and safe installation, commissioning and
maintenance of automation systems. Only properly qualified personnel have the re-
quired specialist knowledge to correctly interpret and implement the instructions
given in this manual.
Not every single detail of every version of the products described is listed nor can ev-
ery conceivable practical situation be taken into consideration. Should you require
additional information, please contact LTI.
When installing, commissioning and servicing MotionOne products the instructions
given in the relevant part of the documentation must be observed.
2.3 Personnel safety
WARNING!
Unqualified interventions in the control may cause abnormal behavior of
the machine/plant or personal injury or damage to the equipment. Only
specially qualified staff may carry out activities on the control system.

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Safety notes
2.4 Safety instructions for projecting
CAUTION!
• The instructions contained in the further delivered must be precisely
followed in all circumstances. Failure to do so could result in the cre-
ation of potential sources of danger or the disabling of protective cir-
cuits integrated in the MotionOne 3 system.
• Apart from the safety instructions given in these manuals, safety pre-
cautions and accident prevention measures appropriate to the situation
in question must also be observed.
• Measures must be taken to ensure that in the event of power dips or
power failures, an interrupted program can be properly restarted. In
such situations, dangerous operating conditions must not be allowed to
occur even temporarily.
• In all situations where faults occurring on the automation system could
cause personal injury or significant damage to machinery and equip-
ment, additional external safety measures must be taken in order to
ensure the system as a whole remains in a safe operating condition
even in the event of a fault.

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System overview
3 System overview
The field of application of the MotionOne 3 system is general machine and plant au-
tomation. The system is based on a modular concept and can be structured accord-
ing to specific functional requirements.
Furthermore the system provides a development platform with which own software
developments can be created. This platform consists of a Linux operating system ad-
justed for the hardware, a central tool for projecting and diagosis and a tool for safe
programming and configuration of the modules.
The system consists of the following components:
• MotionOne: PLC, various CPU modules with variable performance and charac-
teristics.
• COconnect: Modular I/O system with attachable modules for various applica-
tions. Bus link modules allow decentralized placement of the modules.
• VisuOne: Stationary operating panels and mobile handheld terminals for the op-
eration of machines.
• ServoOne CM: Drive technology with integrated safety features for machines.
• MotionCenter: Toolsuite for automation challenges, consisting of tools for config-
uration, programming, visualization, startup and diagnosis. To facilitate program-
ming there are software libraries available.
Fig.31: Example for a system structure
1 Control 2 Power module
3 Axis module 4 Tool suite
5 Stationary operating device 6 Mobile handheld terminal
7 External peripherie (e.g. USB stick) 8 Bus link module with attachable IO
modules
9 IO modules 10 Drive technology
a Ethernet b DVI
c USB d Field buses
e EtherCAT f Power cable