LEXIUM MHDA1004 User manual

Version 2.0 June 2003
31001643_K01_000_04
Lexium Servo Drive
17D Series
User Guide

Preface
890 USE 120 00 iii
Preface The data and illustrations found in this book are not binding. We reserve the right to
modify our products in line with our policy of continuous product development. The
information in this document is subject to change without notice and should not be
construed as a commitment by Schneider Electric.
Schneider Electric assumes no responsibility for any errors that may appear in this
document. If you have any suggestions for improvements or amendments or have
found errors in this publication, please notify us.
No part of this document may be reproduced in any form or by any means,
electronic or mechanical, including photocopying, without express written
permission of the Publisher, Schneider Electric.
CAUTION!
All pertinent state, regional, and local safety regulations must be observed when
installing and using this product. For reasons of safety and to assure compliance
with documented system data, repairs to components should be performed only by
the manufacturer.
Failure to observe this precaution can result in injury or equipment damage.
MODSOFT® is a registered trademark of Schneider Electric
The following are trademarks of Schneider Electric:
Modbus Modbus Plus Modicon 984 Quantum
DIGITAL® and DEC® are registered trademarks of Compaq Computer Corp.
IBM® and IBM AT® are registered trademarks of International Business Machines
Corporation.
Microsoft® and MS-DOS® and Windows® are registered trademarks of Microsoft
Corporation.
©Copyright 2003, Schneider Electric

Preface
iv 890USE12000

890 USE 120 00 v
Contents
Chapter 1 - Introduction 1
At a Glance...................................................................................................... 1
Document Scope ...................................................................................... 1
What’s in this Chapter ............................................................................... 1
About this User Guide .................................................................................... 2
Who Should Use this User Guide ............................................................. 2
How this User Guide Is Organized ............................................................ 2
Related System Components ......................................................................... 4
Single-Axis Motion Control System ........................................................... 4
UniLink Commissioning Software for 17D ................................................ 4
Related Documentation .................................................................................. 5
Documents ................................................................................................ 5
Hazards, Warnings and Guidelines ................................................................ 6
Hazards and Warnings ............................................................................. 6
Additional Safety Guidelines ..................................................................... 9
Qualified Personnel ................................................................................... 9
Standards and Compliances .......................................................................... 10
European Directives and Standards ......................................................... 10
EC Directive Compliance .......................................................................... 10
UL and cUL Compliance ........................................................................... 11
Conventions .................................................................................................... 12
Acronyms and Abbreviations .................................................................... 12

Contents
vi 890 USE 120 00
Chapter 2 - Product Overview 15
At a Glance...................................................................................................... 15
Introduction ............................................................................................... 15
What’s in this Chapter ............................................................................... 15
The 17D Series Servo Drive Family ............................................................... 16
Introducing the 17D Drive Family ............................................................. 16
Drives Available ........................................................................................ 16
Implementing the Drives ........................................................................... 16
Applicable Servo Motor Types .................................................................. 16
Connection to different mains supply networks ........................................ 17
Electrical Considerations .......................................................................... 18
17D Drive Family Portrait .......................................................................... 19
17D Drives Front View .............................................................................. 20
Equipment Supplied .................................................................................. 21
Equipment Available ................................................................................. 21
17D System Configuration Diagram ......................................................... 22
Overview of Usability Features........................................................................ 23
Digital Control ........................................................................................... 23
Usability Enhancements ........................................................................... 24
Restart lock -AS- (A00 drives only) ........................................................... 25
Overview of 17D Internal Electronics.............................................................. 26
17D Internal Electronics Block Diagram ................................................... 26
General Characteristics ............................................................................ 27
Primary Power .......................................................................................... 27
Bias Power ................................................................................................ 27
EMI Suppression ...................................................................................... 27
Internal Power Section .............................................................................. 28
DC Link Capacitor Reconditioning ............................................................ 28
Integrated Safe Electrical Separation ....................................................... 28
LED display ............................................................................................... 29
Overview of System Software ........................................................................ 30
Setup ........................................................................................................ 30
Setting Parameters ................................................................................... 30
Automatic Card Recognition ..................................................................... 30
Default Settings ........................................................................................ 30
UniLink Commissioning Software ............................................................. 31

Contents
890 USE 120 00 vii
Chapter 3 - Mounting and Physical Dimensions 33
At a Glance...................................................................................................... 33
What’s in this Chapter................................................................................ 33
Installation Safety Precautions ....................................................................... 34
Power Supply Overcurrent Protection ....................................................... 36
Earth Connections .................................................................................... 36
Cable Separation ...................................................................................... 36
Air Flow ..................................................................................................... 36
Drive Mounting and Physical Dimensions ...................................................... 37
17D Height, Width and Depth Dimensions ............................................... 37
17D Drive and Mounting Area Dimensions ............................................... 38
External Regen Resistor Assembly Dimensions ....................................... 39
External regen resistor assembly .............................................................. 40
Motor Choke Assembly Dimensions ......................................................... 41
Chapter 4 - Wiring and I/O 43
At a Glance...................................................................................................... 43
Introduction 43
What’s in this Chapter................................................................................ 44
Wiring and I/O Initial Considerations .............................................................. 45
Initial Considerations ................................................................................. 45
Grounding ................................................................................................. 45
Wiring Overview ............................................................................................. 46
Overview of 17D Wiring Connections ....................................................... 46
Connection diagram for LEXIUM 17D ....................................................... 47
Pin assignments for LEXIUM 17D ............................................................ 48
Cable Shield Connections .............................................................................. 49
Connecting Cable Shields to the Front Panel ........................................... 49
Cable Shield Connection Diagram ............................................................ 50
Power Wiring .................................................................................................. 51
AC Mains Power Supply Connection ........................................................ 51
Bias Supply Connection............................................................................. 51
Serial Power Connections.......................................................................... 52
External Regen Resistor Connection......................................................... 53
Regen Circuit Functional Description ........................................................ 53
Lexium BPH Servo Motor Connection (excluded BPH055) ...................... 54
Lexium BPH 055 Servo Motor Connection................................................ 55

Contents
viii 890 USE 120 00
Lexium SER Servo Motor Connection ...................................................... 56
Servo Motor (with Optional Dynamic Brake Resistors and Contactor)
Connection................................................................................................ 57
Servo Motor Holding-Brake Control Functional Description ..................... 58
Signal Wiring .................................................................................................. 60
Lexium BPH Resolver Connection (excluded BPH055) ........................... 60
Lexium BPH055 Resolver Connection ..................................................... 61
Lexium SER Resolver Connection ........................................................... 62
Lexium BPH Encoder Connection ............................................................ 63
Lexium SER Encoder Connection ............................................................ 64
Incremental Encoder Emulation ................................................................ 65
Incremental Encoder Output Functional Description ................................ 65
SSI Encoder emulation ............................................................................. 66
SSI Encoder Output Functional Description ............................................. 66
Diagram of master-slave operation ........................................................... 67
Incremental encoder emulation ................................................................ 67
SSI encoder emulation ............................................................................. 67
External Incremental encoder connection ................................................ 68
External SSI encoder connection ............................................................. 69
Analog I/O Connection ................................................................................... 70
Analog Inputs ............................................................................................ 70
Servo Motor Rotation Direction ................................................................. 70
Analog Outputs ......................................................................................... 71
Fault Relay and Digital I/O Connection .......................................................... 72
Digital Inputs and Outputs ........................................................................ 72
Using Functions Pre-programmed into the Drive ...................................... 73
Serial Communications Connection................................................................ 74
Serial Communications Connection Diagram ........................................... 74
CANopen Interface ................................................................................... 75
CAN bus cable .......................................................................................... 76
Stepper Motor Control Interface Connection................................................... 77
Stepper-Motor Control Interface Connection Functional Description ....... 77
Stepper-Motor Control Interface Connection Diagram ............................. 77
Stepper-Motor Speed Profile and Signal Diagram .................................... 78

Contents
890 USE 120 00 ix
Chapter 5 - System Operation 79
At a Glance...................................................................................................... 79
What’s in this Chapter................................................................................ 79
Powering Up and Powering Down the System ............................................... 80
Power-on and Power-off Characteristics .................................................. 80
Stop Function ............................................................................................ 81
Emergency Stop strategies ....................................................................... 82
Wiring example ......................................................................................... 83
Description of the restart lock -AS- (MHDA••••A00 drives only) ..................... 84
Advantages of the restart lock .................................................................. 84
Description of the restart lock -AS- ................................................................. 85
Functional description ............................................................................... 85
Block diagram............................................................................................ 86
Signal diagram (sequence)........................................................................ 87
Installation / Commissioning...................................................................... 88
Connection diagram .................................................................................. 89
Application examples ................................................................................ 90
Control circuit example ............................................................................. 91
Procedure for Verifying System Operation ..................................................... 92
Overview ................................................................................................... 92
Quick Tuning Procedure ........................................................................... 93
Parameter setting ...................................................................................... 95
Multi-axis system ....................................................................................... 95
Front Panel Controls and Indicators ............................................................... 96
Keypad Operation...................................................................................... 96
LED Display .............................................................................................. 97
Chapter 6 - Troubleshooting 99
At a Glance...................................................................................................... 99
What’s in this Chapter ............................................................................... 99
Warning Messages ......................................................................................... 100
Warning Identification and Description ..................................................... 100
Error Messages .............................................................................................. 101
Error Identification and Description............................................................ 101
Troubleshooting .............................................................................................. 105
Problems, Possible Causes and Corrective Actions ................................. 105

Contents
x890 USE 120 00
Appendix A - Specifications 107
At a Glance...................................................................................................... 107
What’s in this Appendix ............................................................................ 107
Performance Specifications ............................................................................ 108
Performance Specifications Table............................................................. 108
Environmental and Mechanical Specifications ............................................... 109
Environmental Specifications Table .......................................................... 109
Mechanical Specifications Table .............................................................. 110
Electrical Specifications .................................................................................. 111
What’s in this Section ............................................................................... 111
Electrical Specifications - Power..................................................................... 112
Line Input Specifications Table ................................................................. 112
Bias Input Specifications Table ................................................................. 113
Limit supply values of the servodrive MHDA associated with a
BHP motor with brake .............................................................................. 113
External Fuse Specifications Table .......................................................... 114
Motor Output Specifications Table ............................................................ 115
Internal Power Dissipation Specifications Table ....................................... 116
Electrical Specifications - Regen Resistor ...................................................... 117
Regen Circuit Specifications ..................................................................... 117
Electrical Specifications - Signal .................................................................... 118
Motor Overtemperature Input Specifications Table .................................. 118
Resolver Input Specifications Table ......................................................... 118
Encoder Input Specifications Table .......................................................... 119
Emulated Encoder Output (Incremental Format) Specifications Table ..... 119
Encoder Output (Incremental Format) Timing Diagram ............................ 120
Encoder Output (SSI Format) Specifications Table .................................. 120
Encoder Input (Slave) Specifications Table .............................................. 121
Discrete Input Specifications Table .......................................................... 121
Discrete Output Specifications Table ........................................................ 122
Fault Relay Output Specifications Table ................................................... 122
Brake Output Specifications Table ........................................................... 122
Analog Input Specifications Table ............................................................ 123
Analog Output Specifications Table .......................................................... 123
Serial Communications Specifications Table ............................................ 124
Wire Specifications (Recommended) ............................................................. 125
Wire Specifications ................................................................................... 125

Contents
890 USE 120 00 xi
Appendix B - Parts List 127
At a Glance...................................................................................................... 127
What’s in this Appendix ............................................................................. 127
Lexium 17D Drives ......................................................................................... 128
Drives Available ........................................................................................ 128
External 24 Vdc supply ................................................................................... 129
External 24Vdc supply .............................................................................. 129
Drive Cables ................................................................................................... 130
Drive to Motor Cables ............................................................................... 130
RS-232 Serial Communications Cable Part Table .................................... 130
Encoder Output Cables Parts Table ......................................................... 130
Regen Resistor Assemblies ............................................................................ 131
Regen Resistor Assembly Part Table........................................................ 131
Servo Motor Choke.......................................................................................... 132
Servo Motor Choke Part Table (when cable length exceeds 25m)............ 132
Spare Parts ..................................................................................................... 133
Spare Parts Table ..................................................................................... 133
Appendix C - Drive-to-Controller Wiring Diagrams 135
At a Glance...................................................................................................... 135
What’s in this Appendix ............................................................................. 135
Typical Motion Controller Interface Connections ............................................ 136
Motion Controller Interface Diagram ......................................................... 136
Wiring a 17D Drive to Premium CAY Motion Modules ................................... 137
Premium CAY Single Axis Drive Option Diagram ..................................... 137
Premium CAY Multi-Axis Breakout Module Wiring Diagram ..................... 138
Premium CAY Multi-Axis and Breakout Module Diagram, First of 4 Axes. 139
Wiring a 17D Drive to a MOT 201 Motion Module .......................................... 140
MOT 201 Control Wiring Diagram ............................................................. 140
MOT 201 Encoder Wiring Diagram: Option 1 ........................................... 141
MOT 201 Encoder Wiring Diagram: Option 2 ........................................... 142
Wiring a 17D Drive to Quantum 140 MSx Motion Modules ............................ 143
Quantum 140 MSx Control and Encoder Wiring Diagram ........................ 143

Contents
xii 890 USE 120 00
Wiring a 17D Drive to B885-11x Motion Modules .......................................... 144
B885-11x Control Wiring Diagram ............................................................ 144
B885-11x Encoder Wiring Diagram: Option 1 ........................................... 145
B885-11x Encoder Wiring Diagram: Option 2 ........................................... 146
Appendix D - Cable Connection Wiring Diagrams 147
At a Glance...................................................................................................... 147
What’s in this Appendix ............................................................................ 147
Wiring a Sub-D Connector with Shielding (drive side) .................................... 148
Wiring the Sub-D Connector ..................................................................... 148
Wiring the feedback connector of the motors ................................................. 150
Wiring the feedback connector of the BPH motors (excluded BPH055) ... 150
Wiring the feedback connector of the BPH055 motors ............................. 151
Wiring the feedback connector of the SER motors ................................... 152
Wiring the Motor Power Connector (Drive end) .............................................. 153
Wiring the Motor Power Connector ........................................................... 153
Wiring the BPH Motor Power Connector (excluded BPH055)................... 154
Wiring the BPH055 Motor Power Connector ............................................ 155
Wiring the SER Motor Power Connector .................................................. 156
Serial Communication Interface Connection (X6) RS 232 ............................. 157
Serial Communication Interface Cable Connectors .................................. 157
Appendix E - Servo Loop Diagrams 159
At a Glance...................................................................................................... 159
What’s in this Appendix ............................................................................ 159
17D Current Controller Overview ................................................................... 160
17D Current Controller Diagram................................................................ 160
17D Velocity Controller Loop .......................................................................... 161
17D Velocity Controller Loop Diagram ..................................................... 161
17D Analog Input Loop Diagrams................................................................... 162
Overview ................................................................................................... 162
17D Analog Input Mode 0 Loop Diagram .................................................. 162
17D Analog Input Mode 1 Loop Diagram ................................................. 163
17D Analog Input Mode 3 Loop Diagram .................................................. 164
17D Analog Input Mode 4 Loop Diagram ................................................. 165
17D Analog Input Mode 5 Loop Diagram ................................................. 166

Contents
890 USE 120 00 xiii
Appendix F - Expansion Options 167
At a Glance...................................................................................................... 167
What’s in this Appendix ............................................................................. 167
Expansion Cards ............................................................................................ 168
Overview ................................................................................................... 168
Fitting expansion card................................................................................ 168
I/O Expansion Cards ...................................................................................... 169
24 Vdc Discrete I/O Expansion Card......................................................... 169
IConnector and LED Location Diagram..................................................... 169
Light-Emitting Diodes (LEDs)..................................................................... 170
Terminal Assignments .............................................................................. 170
Controlling Pre-programmed Motion Tasks............................................... 172
Programming the PLC .............................................................................. 172
Motion Task Coordination.......................................................................... 172
Motion Task Application Examples ........................................................... 173
Example of a Motion Task Number............................................................ 173
Connection Diagram ................................................................................. 174
Appendix G - External Regen Resistor Sizing 175
At a Glance...................................................................................................... 175
What’s in this Appendix ............................................................................. 175
Overview ................................................................................................... 176
Determining When Energy Is Absorbed .................................................... 176
Determining External Regen Resistor Size..................................................... 177
Power Dissipation Calculation Procedure ................................................. 177
Drive Energy Absorption Capability .......................................................... 178
Example Regen Resistor Power Dissipation Calculation................................ 179
Example Motor and Drive Specifications .................................................. 179
Example Step 1.......................................................................................... 180
Example Step 2 ......................................................................................... 181
Example Step 3 ......................................................................................... 181
Example Step 4 ......................................................................................... 182
Example Step 5 ......................................................................................... 182
Example Step 6 ......................................................................................... 182
Example Step 7 ......................................................................................... 182
Example Step 8 ......................................................................................... 183

Contents
xiv 890 USE 120 00

1
1
Introduction
At a Glance
Document Scope This user guide contains complete installation, wiring interconnection, power
application, test and maintenance information on the Lexium 17D series servo
drive.
What’s in this
Chapter This chapter provides general information about this user guide and contains the following topics:
Topic Page
About this user guide 2
Related system components 4
Related documentation 5
Hazards, warnings, and guidelines 6
Standards and compliances 10
Conventions 12

2
About this User Guide
Who Should Use
this User Guide This user guide is written for any qualified person at your site who is responsible for installing (mounting and interconnecting), operating, testing and maintaining your
Lexium 17D servo drive and the servo system equipment with which it interfaces. In
addition, the following precautions are advised:
lTransportation of the servo drive to, or from, an installation site should only be
performed by personnel knowledgeable in handling electrostatically sensitive
components.
lCommissioning of the equipment should only be performed by personnel
having extensive knowledge of, and experience with, electrical and servo drive
technologies.
You are expected to have some overall understanding of what your 17D servo drive
does and how it will function in a high-performance, single-axis motion control
system. Accordingly, be sure you read and understand the general information,
detailed descriptions and associated procedures presented in this manual, as well
as those provided in other relevant manuals, before installing your 17D. (See
Related System Components later in this chapter.)
If you have questions, please consult your Schneider Electric customer
representative.
How this User
Guide Is
Organized
This manual is organized as follows.
Continued on next page
Chapter/Appendix Description
Chapter 1
About this User Guide
An introduction to this manual — whoshould use
this manual, how this manual is organized,
related publications, hazards and warnings.
Chapter 2
Lexium 17D Product Overview
General descriptions of the 17D servo drives,
descriptions of components that are supplied by
Schneider in a typical 17D system, and a block
diagram for internal electronics.
Chapter 3
Mounting and Physical Dimensions
Physical dimensions and information for
mounting the servo drive, Regen resistor and
servo motor choke.

3
About this User Guide, continued
How this User
Guide Is
Organized,
continued Chapter/Appendix Description
Chapter 4
Wiring and I/O
Wiring diagrams for the power connections and
wiring diagrams and descriptions for all signal
wiring connections — encoder, resolver, analog
I/O, discrete I/O, and serial communications
cable.
Chapter 5
System Initialization, Commissioning
and Operation
Detailed procedures and associated descriptions
on how to initialize, commission and operate a
typical 17D system.
Chapter 6
Troubleshooting
Description of faults, probable causes and
recommended corrective actions.
Appendix A
Specifications
Specifications for the servo drives, including
general, electrical, signal, and power
specifications.
Appendix B
Parts List
Part numbers related to the 17D servo drive
system.
Appendix C
Drive to Controller Wiring Diagrams
Wiring diagrams that show signal wiring between
a 17D servo drive and MOT 201, Quantum MSx,
B885-11x, and Premium CAY motion modules.
Appendix D
Cable Connection Wiring Diagrams
Procedures and associated diagrams that show
how to wire Sub-D and power cable connectors
as well as the serial communication cable used
with the drive.
Appendix E
Servo Loop Diagrams
Illustrations of the 17D servo drive and single-
axis motion module servo loops.
Appendix F
Expansion Options
Description and procedure for using the I/O
expansion card with the drive.
Appendix G
External Regen Resistor Sizing
Description and procedure for determining the
power dissipation requirement for the external
Regen resistor.

4
Related System Components
Single-Axis
Motion Control
System
The 17D servo drive is typically only one component in a larger, single-axis motion
control system. A single axis comprises one motion module, one servo drive, and
one motor.
Compatible Schneider motion modules include:
lQuantum 140 MSx series motion modules
lCompact MOT 201 motion modules
lB885-11x series motion modules
lPremium CAY motion modules
UniLink
Commissioning
Software for 17D
To configure your single-axis system, you will be using the UniLink
axis
commissioning software, which Schneider supplies.
UniLink allows you to configure your 17D servo drive axis and tune the motor
quickly and easily. With its graphical user interface and oscilloscope tuning
features, UniLink provides an easy point-and-click method for configuring motion
setup parameters. UniLink minimizes or eliminates cumbersome programming
tasks.
For complete information on UniLink, please see the UniLink online help.

5
Related Documentation
Documents Related documentation that covers all these system components is illustrated
below.
You will need these:
Unilink
Online Help
(included
in software)
Depending on which motion module you have, you will also need one of these:
MOT 201,
202 Motion
Modules
User Guide
GI-BMOT-20X
Quantum
140MSx 101
Single Axis
Motion
Module
Reference
Guide
840 USE 105 X
If you have a Premium motion module CAY, you will also need this:
PL7 Junior/Pro
Premium PLCs
Specific
Functions
V4
TLX DS 57 PL7 40
If you have a BPH motor, you will also need this:
Lexium BPH
Serie
servo motors
Motors Reference
Guide
*AMOMAN001U
* included in AM0 CSW 001V•00 (CDROM)
B885-1xx
Motion
Modules
User Guide
GI-B885-1XX
Premium PLCs
Installation
Manual
TSX DM 57 40

6
Hazards, Warnings and Guidelines
Hazards and
Warnings Read the following precautions very carefully to ensure the safety of personnel at your site. Failure to comply will result in death, serious injury or equipment damage.
DANGER!
ELECTRIC SHOCK HAZARDS
lDuring operation, keep all covers and cabinet doors closed.
lDo not open the servo drives; depending on degree of enclosure protection,
the servo drives may have exposed components.
lControl and power connections on the drive may be energized even if the
motor is not rotating.
lNever attempt to disconnect the electrical connections to the servo drive with
power applied. Failure to comply may result in arcing at the contacts.
lWait at least five minutes after disconnecting the servo drive from the mains
supply voltage before touching energized sections of the equipment (for
example, contacts) or disconnecting electrical connections. Capacitors can still
have dangerous voltages present up to five minutes after switching off the
supply voltages. To ensure safety, measure the voltage in the DC Link circuit
and wait until it has fallen below 40V before proceeding.
lCheck to ensure all energized connecting elements are protected from
accidental contact. Lethal voltages up to 900V can be present. Never
disconnect any electrical connections to the servo drive with power applied;
capacitors can retain residual and dangerous voltage levels for up to five
minutes after switching off the supply power.
Failure to follow any one of these instructions will result in death, serious
injury or equipment damage.
Continued on next page