Lenord, Bauer PowerDRIVE-Positioning GEL 6113 Manual

PowerDRIVE-Positioning
GEL 6113
Positioning drive with through hollow shaft
Technical information Issued 2017-08
... automates motion.
LENORD
+ BAUER
Subject to technical modifications and typographical errors.
Internet: www.lenord.com
E-Mail: [e-mail]
Phone: [phone]
Fax: [phone]
Lenord, Bauer & Co. GmbH
Dohlenstraße 32
46145 Oberhausen, Germany
DS22-6113
Variable type of connection and interface
PowerDRIVE-Box
On usage with the PowerDRIVE-Box all common
communication interfaces are available
General
The PowerDRIVE-Positioning GEL 6113 forms a compact
mechatronic unit comprising a brushless DCmotor, a 32-bit
microprocessor, a compact power amplifier and a powerful
gear, as well as a magnetic multiturn encoder.
Active system protection against thermal overload and
comprehensive system software allow load-dependent
duty cycles well above 25 %.
The rigid aluminium housing with its high degree of
protection (IP 67) is suitable for a wide range of
applications in various industrial areas.
Features

Nominal torques 5 Nm, 7 Nm, 10 Nm

Aluminium housing

Operating temperature -10 °C to +60 °C

BLDC motor

Magnetic-absolute multiturn encoder
- Accuracy: ±1.8° in the de-energised state
- Detection range: 114 turns, also in de-energised
state

Degree of protection IP67

Integrated communication interfaces
CANopen (CiA 402); PROFIBUS-DP (V0/V1);
Sercos III; POWERLINK; PROFINET IO / RT;
EtherCAT; EtherNet/IP

Optionally with cULus component recognition
Advantages

Either hybrid cable or plug outlet

Onboard joystick for straightforward commissioning

Monitoring of important system parameters ensures
reliable operation (overload protection)

Ready for use immediately after power on due to
absolute multiturn position detection

Maintenance-free due to sealed-for-life lubrication
Fields of application

Packaging machines

Food and bottling plants

Wood and plastic working machines

Printing presses and book binding machines

Extensive production plants

Description
2DS22-6113 / (2017-08)
System concept
The positioning drives belong to the product group
PowerDRIVE-Positioning and are a component of the
PowerDRIVE system.
Each positioning drive in the GEL 6113 series is an
intelligent adjustment unit for pushing onto the end of a
shaft or for attachment to a shaft or spindle.
The positioning drive can be integrated directly into a plant
control system via the communication interfaces
integrated.
PowerDRIVE-System
The PowerDRIVE-System is suitable for the efficient
integration of several positioning drives in a machine or
plant. The system consists of the following components:

PowerDRIVE-Positioning:
Positioning drive for fully automatic format adjustment

PowerDRIVE-Motion:
Positioning drive for cyclic operation

PowerDRIVE-Box:
Decentral control unit for up to 5 drives

PowerDRIVE-Connect:
Single cable concept (hybrid cable suitable for drag
chain)

PowerDRIVE-Lib:
Ready-made function blocks for integration in the
machine control system

PowerDRIVE-Support Tool:
Software for advanced commissioning and configuration
The usage of PowerDRIVE-Box and PowerDRIVE-
Connect significantly reduces the cabling effort for the
positioning drives. Instead of the usual two separate
cables for internal bus communication and a third cable to
supply power to the positioning drives, only ONE hybrid
cable suitable for use in drag chains is connected. In the
maximum configuration with 5 positioning drives
connected, the number of cables typically reduces from 15
to 5 due to PowerDRIVE-Connect. With the aid of the
PowerDRIVE-Box the overall system offers a high degree
of flexibility during integration, as it supports all common
communication interfaces.
Construction
The PowerDRIVE-Positioning GEL 6113 is operated with a
supply voltage of 24 V DC and supports fieldbus profiles
(CANopen (CiA 402); PROFIBUS-DP (V0/V1)) and
Industrial Ethernet protocols (Sercos III; POWERLINK;
PROFINET IO / RT; EtherCAT; EtherNet/IP).
PowerDRIVE-Connect is available with either a plug
connection or hybrid cable.
The rigid housing made of anodised aluminium is
particularly robust and achieves the degree of protection
IP 67 due to the Viton shaft sealing ring.
The positioning drive is equipped with mechanical manual
adjustment so that the positioning drive can be actuated if
there is a fault, e.g. a power failure.
A USB service connector is accessible on the rear of the
device for service purposes.
The device variants with integrated fieldbus (CANopen
(CiA 402); PROFIBUS-DP (V0/V1)) have rotary selection
switches for setting the device ID and baud rate, as well as
an onboard joystick. The positioning drive can be operated
in the set-up mode using the joystick without prior PLC
programming. All elements are accessible on the rear of
the device.
Integrated absolute rotary encoder
A magnetic-absolute multiturn rotary encoder makes
reference search routines after a power failure or
emergency stop unnecessary. Due to the batteryless
encoder, the positioning drive detects its position after
power on and is immediately ready for use.
In the switched off state the drive shaft can be moved by
±57 turns without loss of the absolute position.
The absolute rotary encoder withstands high shock/
vibration loads.

Description
DS22-6113 / (2017-08) 3
Mounting
The mounting concept comprises a fixed-moving bearing.
The machine shaft supports the weight of the positioning
drive via the fixed bearing. For this purpose the positioning
drive is mounted directly and positively on the machine
shaft using a clamp coupling with a form-fit via the hollow
shaft. The torque support prevents the positioning drive
rotating and, as the moving bearing, compensates any
movements that occur on the drive shaft due to imbalance,
if necessary. The shape and design of the torque support
are order-specific. Various accessories are available for
mounting.
12
Recording imbalance movements at the moving bearing
(example with standard torque support from Lenord +
Bauer)
1 Torque support
2 Plain bearing
Modes of operation
The drive is designed for positioning at nominal torque.
The following intervals are valid for a duty cycle (ED) of

Duty cycle = 25 % at 100 % load torque, positioning
mode S2
(base time 4 minutes: ED = 1 minute, PD = 3 minutes)

Duty cycle ≤50 % with reduced load torque, dependent
on ambient parameters and application
Other methods of operation are protected by I
2
t and
temperature monitoring as well as an adjustable current
limit. This protection permits a briefly increased breakaway
torque.
Reliability
Important parameters such as motor power and device
temperature are monitored and in this way the positioning
drive actively protected against overload. The following
monitoring devices ensure trouble-free operation:

Soft start and shutdown via acceleration and
deceleration ramps

Over / undervoltage detection on the power circuit
supply and logic circuit supply

Lag error detection (drive shaft in relation to motor
shaft)

Temperature monitoring on the power amplifier and
inside the housing

Motor and power amplifier overload protection via I
2
t
monitoring and in combination with the PowerDRIVE-
Box by means of the maximum current.
General information on PowerDRIVE-
Connect
The hybrid cable PowerDRIVE-Connect is designed for
flexible application in drag chains. It is available in the
foodgrade, halogen-free and cULus recognised variants.
The hybrid cable is screened under the outer sheath. The
internal communication cores are fully insulated and
multiply screened.
All positioning drives are available with hybrid cable and
connectors and can be connected quickly and
straightforwardly to the PowerDRIVE-Box via the pre-
assembled hybrid connecting cables that can be
configured as required.
Connectors with a quick-release coupling permit quick
connection and disconnection. The positioning drive is
therefore reliably and quickly disconnected from the power
supply for maintenance and service work in a matter of
seconds. Pre-assembled connection cables are available
for the connection, see "Technical information BZK".

Technical data
4DS22-6113 / (2017-08)
Nominal torque (housing size) 05 (K) 07 (K) 10 (L)
Electrical data
Nominal voltage logic circuits 24 V DC -5% / +25%
Nominal voltage power circuits 24 V DC -5 % / +25%
(Attention: max. motor speed is voltage dependent!)
Nominal current logic circuits Max. 400 mA, external fuse required
Nominal current power circuits 2.0 A (max. 7.0 A),
external fuse required
2.8 A (max. 7.5 A),
external fuse required
4.1 A (max. 10 A),
external fuse required
Duty cycle in % (load-dependent ) Duty cycle = 25 % at 100 % load torque, positioning mode S2
(base time 4 minutes: ED = 1 minute, PD
(1)
= 3 minutes)
Duty cycle ≤50 % with reduced load torque, dependent on ambient
parameters and application
Positioning range Unlimited
(2)
Fieldbus interfaces CANopen (CiA 402); PROFIBUS-DP (V0/V1)
Industrial Ethernet Sercos III; POWERLINK ; PROFINET IO / RT ; EtherCAT ;
EtherNet/IP
Dielectric strength √2 × 500 V DC; as per DIN EN 61439-1:2012-06
EMC
(3)
Electromagnetic immunity EN 61000-6-1:2007-10 /
EN 61000-6-2:2006-03
Electromagnetic emissions EN 61000-6-4:2011-09
Encoder data
Resolution 1000 increments per 360°
Accuracy ±1.8° in the de-energised state
Detection range 114 turns, also in de-energised state
Mechanical data
Nominal torque output shaft 5 Nm at 55 min
-1
7 Nm at 55 min
-1
10 Nm at 55 min
-1
Drive shaft Through hollow shaft Ø D = 20 mm
Shaft materials 1.4305
Housing material A: Aluminium AlMgSi
Weight Min. 2.33 kg
(4)
Degree of protection IP 67, EN 60529:2014-09, shaft sealing ring made of Viton
UL protection class
(design C)
Type 1
Shock resistance 150 m/s
2
(approx. 15 g); as per DIN EN 60068-2-27:2010-02
Vibration resistance 50 m/s
2
(approx. 5 g), 10 to 50 Hz; as per DIN EN 60068-2-6:2008-10
Ambient data
Assured operating temperature range 0 °C to +60 °C
Operating temperature range -10 °C to +60 °C
Storage temperature range -20 °C to +85 °C
Max. relative humidity of air 95%
Condensation Not permitted (condensation protection upon request)
(1)
PD length of space
(2)
If the supply voltage is present, an electronic counter measures the positioning range over the detection range of the
measuring system.
(3)
Use only screened cables.
(4)
Depending on the type of connection and the housing size

Technical data
DS22-6113 / (2017-08) 5
Connector M23
Type of connection H1 / H2 / H3
Technical data – coupling / connector (connector size M23)
Rated voltage Max. 30 V AC / DC
Current carrying capacity According to DIN EN 60512
Contact type (coupling / connector) Male / female
Housing material coupling / connector Nickel-plated brass (others upon request)
Union nut material Nickel-plated brass
Ambient temperature -20 °C to +130 °C
Degree of protection
(1)
IP 66 / IP 67
Mating cycles > 500
Vibration resistance ≤200 m/s
2
Approval cULus recognised component (no. E247738)
Connector M17
Type of connection HS / S1 / S2 / S3
Technical data – coupling / connector (connector size M17)
Rated voltage Max. 30 V AC / DC
Current carrying capacity According to DIN EN 60512
Contact type (coupling / connector) Male / female
Housing material coupling / connector Brass, die-cast zinc and encapsulated in plastic
Ambient temperature -20 °C to +130 °C
Degree of protection
(1)
IP 66 / IP 67
Mating cycles > 500
Approval cULus recognised component (no. E247738)
Technical data, cables
Hybrid cable Design 0
(standard)
Design 1
(separate fuse protection)
Design C
(cULus recognised
component)
Sheath material PUR, black, glossy PUR, black, matt PUR, black, matt
Cable properties Screened Screened Screened
Suitable for drag
chains
Yes Yes Yes
Food grade Yes No No
Halogen-free No Yes Yes
Cable diameter (d) 9.5 mm 9.5 mm 9.5 mm
Bending radius Permanently flexible: 10 × d
Fixed routing: 5 × d
Permanently flexible: 15 × d
Freely moving: 10 × d
Fixed routing: 5 × d
Permanently flexible: 15 × d
Freely moving: 10 × d
Fixed routing: 5 × d
Peak operating
voltage
Max. 350 V CAN bus
Max. 30 V DC (logic / power)
Max. 300 V CAN bus
Max. 30 V DC (logic / power)
Max. 300 V CAN bus
Max. 30 V DC (logic / power)
Temperature range -40 °C to +80 °C -40 °C to +80 °C -40 °C to +80 °C
(1)
In the screwed-in state, according to DIN EN 60529 / DIN 40050

Device overview — types of connection
6DS22-6113 / (2017-08)
ST xx: Cable length can be selected
(1 m to 20 m)
Vx: Cable length can be selected
(1 m to 20 m)
Plug outlet Flying lead Cable with spring-cage terminals for
the PowerDRIVE-Box connection
Communication interfaces:
CO (CANopen)
DP (PROFIBUS-DP)
EC (EtherCAT)
IP (EtherNet/IP)
PL (POWERLINK)
RT (PROFINET IO / RT)
SC (SERCOS III)
Communication interface
CO (CANopen)
Communication interface
CO (CANopen)
H1: Cable length 30 cm
H2: Cable length 50 cm
H3: Cable length 100 cm
HS S1: Cable length 30 cm
S2: Cable length 50 cm
S3: Cable length 100 cm
Cable with M23 connector (coupling
with pin contacts)
M17 panel-mounting socket (pin
contacts)
Cable with M17 connector (coupling
with pin contacts)
Communication interface
CO (CANopen)
Communication interface
CO (CANopen)
Communication interface
CO (CANopen)

Type of connection ST
DS22-6113 / (2017-08) 7
Rear side
Type of connection ST (here for PROFIBUS-DP)








Key
1 Status indication — device
2 Status indication — communication
3 Communication interface (IN)
4 Communication interface (OUT)
5 Function earth (stud M4)
6 Removable blanking plug for the setting elements
7 Removable blanking plug for manual adjustment
8 Supply connector
Setting elements, fieldbus variants (communication interface CO and DP)
a
c
d
b
e
6
a Manual emergency adjustment
b Rotary switch bus address units
c Service connector (mini USB)
d Rotary switch configuration
0 to 8 Baud rate
9 Service mode
(no bus operation; jog mode via joystick
possible)
e Rotary switch bus address decades
Manuelle Verstellung Feldbus-Varianten (Kommunikationsschnittstelle CO und DP)
7
a
b
c
Joystick
a Tippbetrieb Rechtslauf
b Fehlerquittierung (Druck)
c Tippbetrieb Linkslauf

Type of connection ST
8DS22-6113 / (2017-08)
Setting elements for Industrial Ethernet variants (communication interfaces EC, SC, PL, RT and IP)
a
b
c
6
a Manual emergency adjustment
b Service connector (mini USB)
c Push-button (for service purposes)
Pin layout – supply connector
Supply connector Pin identifier Signal identifier
M23
1
2
3
4
5
6
7
8
9
Pins
1 + 24 V DC logic circuits
2 GND logic circuits
6 + 24 V DC power circuits
8 GND power circuits
GND wires connected internally.
Pin layout – communication interfaces
CANopen PROFIBUS-DP Industrial Ethernet
Sercos III; POWERLINK;
PROFINET IO / RT; EtherCAT;
EtherNet/IP
M12 A-coded
1
23
4
52
14
3
5
IN OUT
Male Female
Pin IN / OUT
1 Cable screen
2n.c.
3CANGND
4CANhigh
5CANlow
M12 B-coded
1
2
4
3
5
1
23
4
5
IN OUT
Male Female
Pin IN OUT
1 n.c. 5 V bus voltage
2A-wire A-wire
3 n. c. GND Bus
4B-wire B-wire
5CablescreenCablescreen
2 × M12 D-coded
1
2
4
3
Switch sockets
Pin IN / OUT
1 Transmission Data+
2ReceiveData+
3 Transmission Data-
4 Receive Data-

Type of connection ST
DS22-6113 / (2017-08) 9
Connection accessories for type of connection ST
(1)
Description Item no.
Mating connector PROFIBUS-DP, M12, B-coded input (female) FS 3016
Mating connector PROFIBUS-DP, M12, B-coded output (male) FS 3017
Terminating resistor PROFIBUS-DP, M12, B-coded (male) FS 3041
Mating connector CANopen, M12, A-coded input (female) FS 3020
Mating connector CANopen, M12, A-coded output (male) FS 3021
Terminating resistor CANopen, M12, A-coded (male) FS 3040
Mating connector Industrial Ethernet input/output, M12, D-coded (male) FS 3039
PROFIBUS-DP, 1 connector, male, 10 m cable FS 3024
PROFIBUS-DP, 1 connector, female, 10 m cable FS 3025
PROFIBUS-DP, 1 connector, male, 2 m cable FS 3026
PROFIBUS-DP, 1 connector, female, 2 m cable FS 3027
PROFIBUS-DP, 2 connectors, female/male, 2 m cable FS 3028
Mating connector power supply M23 (female) FS 3038
Mating connector power supply M23 (female, angled) FS 3067
Connection cable power supply M23 (female) and flying lead BZK23S1N_ _ L
(a)
(a)
for _ _ cable length, state in m (min. 3 m / max. 20 m)
Power supply cable connection accessories (see Technical information BZK)
Connection cable BZK23S1NxxL / BZK23S1UxxL /
BZK23S1CxxL
(xx = length in m)
1
3
ST
2
4
Power supply cable for the
positioning drive with type of connection ST
ST Positioning drive with type of connection ST
1 Supply connector on the positioning drive
2 Connector 1/connector design S1
3Design
N16 AWG food grade
U16 AWG halogen-free or
C14 AWG cULus recognised
4 Connector 2: L
(flying lead)
(1)
Other accessories: fieldbus cable, couplings etc. upon request

Type of connection H1 / H2 / H3 / S1 / S2 / S3 / xx / Vx
10 DS22-6113 / (2017-08)
Rear side
Type of connection H1 / H2 / H3 / S1 / S2 / S3 / xx / Vx






Key
1 Status indication — device
2 Status indication — communication
3 Function earth (stud M4)
4 M16 cable gland
5 Removable blanking plug for the setting elements
6 Removable blanking plug for manual adjustment
Setting elements CANopen (communication interface CO)
a
c
d
b
e
5
a Manual emergency adjustment
b Rotary switch bus address units
c Service connector (mini USB)
d Rotary switch configuration
0 to 8 Baud rate
9 Service mode
(no bus operation; jog mode via joystick possible)
e Rotary switch bus address decades
Manual adjustment CANopen (communication interface CO)
6
Joystick
a Jog mode clockwise rotation
b Acknowledge error (pressure)
c Jog mode counter-clockwise