SEW-Eurodrive Didactics User manual

*28521072_1218*
Drive Technology \ Drive Automation \ System Integration \ Services
Operating Instructions
Didactics – Electromechanics
Motor Load Diagnostics Module
Edition 12/2018 28521072/EN

SEW-EURODRIVE—Driving the world

Table of contents
Operating Instructions – Motor Load Diagnostics Module 3
Table of contents
1 General information.................................................................................................................. 4
1.1 About this documentation ...............................................................................................4
1.2 Structure of the safety notes ...........................................................................................4
1.3 Decimal separator in numerical values ...........................................................................5
1.4 Rights to claim under limited warranty ............................................................................5
1.5 Applicable documentation...............................................................................................5
1.6 Product names and trademarks......................................................................................6
1.7 Copyright notice ..............................................................................................................6
2 Safety notes .............................................................................................................................. 7
2.1 Preliminary information ...................................................................................................7
2.2 Target group ...................................................................................................................7
2.3 Designated use ...............................................................................................................7
2.4 Transport.........................................................................................................................8
2.5 Setup and installation......................................................................................................8
2.6 Electrical connection .......................................................................................................8
2.7 Startup and operation .....................................................................................................9
2.8 Inspection and maintenance ...........................................................................................9
3 Device structure ..................................................................................................................... 10
3.1 Scope of delivery ..........................................................................................................10
3.2 Short designation ..........................................................................................................10
3.3 Basic device..................................................................................................................11
3.4 Device components ......................................................................................................12
4 Installation............................................................................................................................... 13
4.1 Important information ....................................................................................................13
4.2 Electrical connections ...................................................................................................14
4.3 Wiring diagram..............................................................................................................18
5 Startup ..................................................................................................................................... 19
5.1 Important information ....................................................................................................19
5.2 Starting up the didactics module...................................................................................20
6 Operation................................................................................................................................. 21
6.1 Important information ....................................................................................................21
6.2 Evaluating diagnostic data ............................................................................................21
7 Service..................................................................................................................................... 22
7.1 Electronics Service by SEW‑EURODRIVE...................................................................22
7.2 Waste disposal..............................................................................................................22
8 Technical data......................................................................................................................... 23
9 Standards and certifications ................................................................................................. 24
9.1 EC declaration of conformity.........................................................................................24
9.2 Certifications .................................................................................................................24
10 Address list ............................................................................................................................. 25
Index ........................................................................................................................................ 26
28521072/EN – 12/2018

1General information
About this documentation
Operating Instructions – Motor Load Diagnostics Module
4
1 General information
1.1 About this documentation
The current version of the documentation is the original.
This documentation is an integral part of the product. The documentation is intended
for all employees who perform work on the product.
Make sure this documentation is accessible and legible. Ensure that persons respons-
ible for the systems and their operation as well as persons who work on the product
independently have read through the documentation carefully and understood it. If you
are unclear about any of the information in this documentation, or if you require further
information, contact SEW‑EURODRIVE.
1.2 Structure of the safety notes
1.2.1 Meaning of signal words
The following table shows the grading and meaning of the signal words for safety
notes.
Signal word Meaning Consequences if disregarded
DANGER Imminent hazard Severe or fatal injuries
WARNING Possible dangerous situation Severe or fatal injuries
CAUTION Possible dangerous situation Minor injuries
NOTICE Possible damage to property Damage to the product or its envi-
ronment
INFORMATION Useful information or tip: Simplifies
handling of the product.
1.2.2 Structure of section-related safety notes
Section-related safety notes do not apply to a specific action but to several actions
pertaining to one subject. The hazard symbols used either indicate a general hazard
or a specific hazard.
This is the formal structure of a safety note for a specific section:
SIGNAL WORD
Type and source of hazard.
Possible consequence(s) if disregarded.
• Measure(s) to prevent the hazard.
Meaning of the hazard symbols
The hazard symbols in the safety notes have the following meaning:
Hazard symbol Meaning
General hazard
28521072/EN – 12/2018

1
General information
Decimal separator in numerical values
Operating Instructions – Motor Load Diagnostics Module 5
Hazard symbol Meaning
Warning of dangerous electrical voltage
Warning of hot surfaces
Warning of automatic restart
1.2.3 Structure of embedded safety notes
Embedded safety notes are directly integrated into the instructions just before the de-
scription of the dangerous action.
This is the formal structure of an embedded safety note:
SIGNAL WORD Type and source of hazard. Possible consequence(s) if disregar-
ded. Measure(s) to prevent the hazard.
1.3 Decimal separator in numerical values
In this document, a period is used to indicate the decimal separator.
Example: 30.5kg
1.4 Rights to claim under limited warranty
Read the information in this documentation. This is essential for fault-free operation
and fulfillment of any rights to claim under limited warranty. Read the documentation
before you start working with the product.
1.5 Applicable documentation
Observe the following applicable documents:
• Operating instructions of the motor in use
• "PACKB.EMM 3.../500AC(-16)-IFS Elektronische Motormanagement-Module /
Electronic motor management modules" package insert
• "UM DE CONTACTRON Motor Management" manual from Phoenix Contact
• "PACKB.ELR H5-IES-SC-.../500AC... Hybrid-Motorstarter mit Wendefunktion / Hy-
brid motor starter with reversing function" package insert from Phoenix Contact
• "PACKB.IFS-USB-PROG-ADAPTER Hinweis zur Verwendung des Programmi-
eradapters / Note about programming adapter" package insert from Phoenix Con-
tact
Always use the latest edition of documentation and software.
28521072/EN – 12/2018

1General information
Product names and trademarks
Operating Instructions – Motor Load Diagnostics Module
6
The SEW‑EURODRIVE website (www.sew‑eurodrive.com) provides a wide selection
of documents for download in various languages. If required, you can also order prin-
ted and bound copies of the documentation from SEW‑EURODRIVE.
1.6 Product names and trademarks
The brands and product names in this documentation are trademarks or registered
trademarks of their respective titleholders.
1.7 Copyright notice
©2018SEW‑EURODRIVE. All rights reserved. Unauthorized reproduction, modifica-
tion, distribution or any other use of the whole or any part of this documentation is
strictly prohibited.
28521072/EN – 12/2018

2
Safety notes
Preliminary information
Operating Instructions – Motor Load Diagnostics Module 7
2 Safety notes
2.1 Preliminary information
The following general safety notes serve the purpose of preventing injury to persons
and damage to property. They primarily apply to the use of products described in this
documentation. If you use additional components, also observe the relevant warning
and safety notes.
2.2 Target group
The product is intended for persons in training facilities that are equipped with the ap-
propriate furnishings in classrooms and laboratories. Furnishings are, for example, ex-
perimental stands, laboratory benches, energy cells, control panels and control con-
soles as well as control cabinets with pick-up positions for electrical energy.
The focus is on the transfer of knowledge to non-specialists. Before using the
products, non-specialists must be instructed about the safety-relevant aspects des-
cribed in this document.
Specialist for me-
chanical work
Any mechanical work on the products must be carried out by a qualified specialist.
Specialists in the context of this documentation are persons familiar with the design,
mechanical installation, troubleshooting, and maintenance of the product who possess
the following qualifications:
• Qualification in the field of mechanical engineering in accordance with the national
regulations.
• They are familiar with this documentation.
Specialist for elec-
trotechnical work
Any electrical work on the products must be carried out by adequately qualified electri-
cians. Qualified electricians in the context of this documentation are persons familiar
with electrical installation, startup, troubleshooting, and maintenance of the product
who possess the following qualifications:
• Qualification in the field of electrical engineering in accordance with the national
regulations.
• They are familiar with this documentation.
Additional qualifi-
cation
In addition to that, these persons must be familiar with the valid safety regulations and
laws, as well as with the requirements of the standards, directives, and laws specified
in this documentation. The persons must have the express authorization of the com-
pany to operate, program, parameterize, label, and ground units, systems, and circuits
in accordance with the standards of safety technology.
Instructed persons All work in the areas of transportation, storage, operation and waste disposal must be
carried out by persons who are trained appropriately. The purpose of the instruction is
that the persons are capable of performing the required tasks and work steps in a safe
and correct manner.
2.3 Designated use
The product is designed for training purposes only. Operating the product in private,
craft, trade or for industrial purposes is not permitted. The product is not intended for
installation in electrical plants or machines. The product is not intended for use in ap-
plications (such as lifting applications).
The product can be used for operating ACasynchronous motors with squirrel-cage ro-
tors. The product is not suited for operating ACsynchronous motors.
28521072/EN – 12/2018

2Safety notes
Transport
Operating Instructions – Motor Load Diagnostics Module
8
The motors must be suitable for operation with drive inverters. Do not connect any
other loads to the product.
Startup (i.e. start of regular operation) is permitted with adherence to EMC guideline
only.
Technical data and information on the connection conditions are provided on the
nameplate and in the documentation. Comply with the data and conditions.
2.4 Transport
Inspect the shipment for damage as soon as you receive the delivery. Inform the ship-
ping company immediately about any damage. If the product is damaged, it must not
be assembled, installed or started up.
Observe the following notes when transporting the device:
• Before transportation, cover the connections with the supplied protection caps.
• Place the product only on the base plate during transport.
• Ensure that the product is not subject to mechanical impact.
If necessary, use suitable, sufficiently dimensioned handling equipment.
2.5 Setup and installation
Ensure that the product is installed and cooled according to the regulations in the doc-
umentation.
The product is suited for operation on laboratory benches and on tables. Use standard
laboratory or training equipment where the products can be placed properly and safely
without posing any risk to the learners.
Protect the product from strong mechanical strain. The product and its mounting parts
must never protrude into the path of persons or vehicles. Ensure that components are
not deformed and insulation spaces are not changed, particularly during transportation
and handling. Electric components must not be mechanically damaged or destroyed.
The following applications are prohibited unless the device is explicitly designed for
such use:
• Use in potentially explosive atmospheres
• Use in areas exposed to harmful oils, acids, gases, vapors, dust, and radiation
• Operation in applications with impermissibly high mechanical vibration and shock
loads in excess of the regulations stipulated in EN61800-5-1
• Use at an elevation of more than 4000m above sea level
2.6 Electrical connection
Familiarize yourself with the applicable national accident prevention regulations before
working on the product.
Perform electrical installation according to the pertinent regulations (e.g. cable cross-
sections, fusing, protective conductor connection).
Ensure that all of the required covers are correctly attached after the electrical installa-
tion.
28521072/EN – 12/2018

2
Safety notes
Startup and operation
Operating Instructions – Motor Load Diagnostics Module 9
The preventive measures and protection devices must comply with the applicable reg-
ulations (e.g. EN60204-1 or EN61800-5-1).
Ground connections are required as preventive measures.
2.7 Startup and operation
Before startup, make sure that the 4mm sockets, buttons, and switches are intact.
It might be necessary to equip locations where such devices are used with additional
monitoring and protection devices in accordance with the respective applicable safety
regulations, e.g. the law governing technical equipment, accident prevention regula-
tions, etc.
Depending on the degree of protection, products may have live, uninsulated, and
sometimes moving or rotating parts, as well as hot surfaces during operation.
Cover unused connections with the supplied protection caps during operation.
Make sure the connection boxes are closed and screwed before connecting the sup-
ply voltage.
When the device is switched on, dangerous voltages are present at all power connec-
tions as well as at any connected cables and terminals. This also applies even when
the product is inhibited and the motor is at standstill.
Electric shock due to moving the device while voltage is applied. Do not move the
product while voltage is applied.
Do not separate the connection to the product during operation. This may result in
dangerous electric arcs damaging the product.
If you disconnect the product from the voltage supply, do not touch any live compon-
ents or power connections because capacitors might still be charged. Observe the fol-
lowing minimum switch-off time:
10 minutes.
Observe the corresponding information signs on the product.
The fact that the operation LED and other display elements are no longer illuminated
does not indicate that the product has been disconnected from the supply system and
no longer carries any voltage.
Mechanical blocking or internal protective functions of the product can cause a motor
standstill. Eliminating the cause of the problem or performing a reset may result in the
drive restarting automatically. If, for safety reasons, this is not permitted for the drive-
controlled machine, first disconnect the product from the supply system and then start
troubleshooting.
2.8 Inspection and maintenance
Only perform maintenance and repair work once the product has been secured and
disconnected from the power supply. Ensure a de-energized state of the product be-
fore you start working on it. Ensure a de-energized state for the entire time you work
on the product.
Repair work may only be carried out by SEW‑EURODRIVE.
28521072/EN – 12/2018

3Device structure
Scope of delivery
Operating Instructions – Motor Load Diagnostics Module
10
3 Device structure
3.1 Scope of delivery
The following components are included in the scope of delivery:
• Affixed front panel
• Housing
• Assembled and checked printed circuit board for the power section
3.2 Short designation
The following short designations are used in this documentation:
Device Designation
Phoenix Contact ELR H5-IES-
SC-24CD/500AC-2
Hybrid motor starter
Phoenix Contact EMM
3-24DC/500AC-16-IFS
Electronic motor management
Phoenix Contact IFS-USB-PROG-AD-
APTER
Programming adapter
28521072/EN – 12/2018

3
Device structure
Basic device
Operating Instructions – Motor Load Diagnostics Module 11
3.3 Basic device
L1
1/L1 2/L2
4/T1 5/T2 6/T3
U1V1W1
4/T1 5/T2 6/T3
3/L31/L1 2/L2 3/L3
MAN
E
L
R
E
M
M
RES
AUT
R
L
979695
L2
O 1
O 2
O 3
O 4
IN 1
IN 2
IN 3
IN 4
TH1 TH2
L3
N
24 V
0 V
24 V
0 V
230 V
24 V
PE
L1
L2
L3
N
PE
PE
Motor Load Diagnostics Module (MLD)
[1] [3] [4] [6] [7]
[2] [5]
[12][13] [11] [10] [9] [8]
9007208498797963
[1] Power section connection [8] 24V control voltage as bridge connection for
another didactics module
[2] Hybrid motor starter (ELR) [9] PE: PE connection
[3] Power section connection ELR [10] Motor connection EMM
[4] Power section connection EMM [11] Motor connection
[5] Electronic motor management (EMM) [12] Motor connection ELR
[6] Switch for input simulation [13] PE: PE connection
[7] Power section connection as bridge connection
for another didactics module
28521072/EN – 12/2018

3Device structure
Device components
Operating Instructions – Motor Load Diagnostics Module
12
3.4 Device components
3.4.1 Motor types
SEW-EURODRIVE recommends the following motor type for training on an asynchro-
nous motor with simple encoder technology:
• DR.. series AC motor
Recommendation: Didactics motor assembly DRS71S4
3.4.2 Hybrid motor starter
It is possible to implement the following functions, among others, with the hybrid motor
starter with reversing function:
• CW rotation
• CCW rotation
• Thermal motor protection
• Emergency stop
For further information, refer to the documentation of the manufacturer, Phoenix Con-
tact (see the chapter "Applicable documentation"(→25)).
3.4.3 Electronic motor management
The electronic motor management with load relay and overload or underload monitor-
ing provides continuous monitoring of the status.
For further information, refer to the documentation of the manufacturer, Phoenix Con-
tact (see the chapter "Applicable documentation"(→25)).
3.4.4 Programming adapter
With the programming adapter with USB interface, you can parameterize the elec-
tronic motor management with the software from Phoenix Contact.
For further information, refer to the documentation of the manufacturer, Phoenix Con-
tact (see the chapter "Applicable documentation"(→25)).
28521072/EN – 12/2018

4
Installation
Important information
Operating Instructions – Motor Load Diagnostics Module 13
4 Installation
4.1 Important information
INFORMATION
• Observe the documentation of components connected or mounted to the module
(e.g. motor, inverter).
• Comply with all instructions referring to the technical data and the permissible
conditions where the device is operated.
WARNING
Electric shock when disconnecting or connecting voltage-carrying plug connectors.
Severe or fatal injuries.
• Disconnect all supply voltages.
• Make sure that the device is de-energized.
• Never plug or unplug the plug connectors while they are energized.
CAUTION
Short circuit due to incorrectly set jumpers.
Damage to property and injury.
• Insert the jumpers only in the contact points provided for this purpose.
INFORMATION
Only connect ACasynchronous motors to the device output.
4.1.1 Device output
Only connect ohmic/inductive load (motor).
4.1.2 Digital outputs
The digital outputs are short-circuit proof and protected against external voltage up to
30V. Higher external voltages can destroy the digital outputs.
4.1.3 Cable
Use the following cables:
• Standardized safety cables for use in classrooms or laboratories.
• 4mm laboratory safety plug connectors with rigid insulating sleeve, suited for nom-
inal voltages of up to 1000V.
• Didactics connection cable from SEW‑EURODRIVE.
The cable must not be longer than 3m.
28521072/EN – 12/2018

4Installation
Electrical connections
Operating Instructions – Motor Load Diagnostics Module
14
4.1.4 PE line connection according to EN61800‑5‑1
Earth-leakage currents of ≥3.5mA can occur during normal operation. Observe the
following for reliable PE connection:
• Supply system cable <10mm2:
– Second PE conductor with the same cross section as the supply system cable
routed parallel to the protective earth via separate terminals, or
– Copper PE conductor with a cross section of 10mm2
• Supply system cable 10to16mm2:
– Copper protective earth conductor with the same cross section as the supply
system cable.
• Supply system cable 16to35mm2:
– Copper PE conductor with a cross section of 16mm2
• Supply system cable>35mm2:
– Copper PE conductor with half the cross section of the supply system cable.
4.1.5 Interference emission
Recommendation: Use shielded motor cables for EMC compliant installation.
4.2 Electrical connections
4.2.1 Power section connection
L1
L2
L3
N
PE
[1]
[2]
[3]
9250651019
[1] L1, L2, L3: Line connection phase
[2] N: Line connection of neutral conductor
[3] PE: PE connection
4.2.2 X2: Motor connection
NOTICE
Damage to the didactics module due to overload.
Damage to property.
• Only connect one motor to the didactics module.
28521072/EN – 12/2018

4
Installation
Electrical connections
Operating Instructions – Motor Load Diagnostics Module 15
U1V1W1
PE
[2]
[1]
[3]
9250653707
[1] PE: PE connection
[2] Motor phases U, V, W
[3] Motor connection HARTING connector type Han®Q5 EMC female
Article no.: Connector: 09620030301, insert: 09120053101
To connect the motor, use either the connections for the U, V, and W motor phases or
the connector.
4.2.3 Hybrid motor starter connections
4/T1 5/T2 6/T3
1/L1 2/L2 3/L3
MAN
E
L
R
RES
AUT
R
L
979695
[1]
[2]
[3]
[4]
9250659083
[1] Power section connection
[2] Hybrid motor starter
[3] Motor connection
[4] Connections of the hybrid motor starter
For further information, refer to the documentation of the manufacturer, Phoenix Con-
tact (see the chapter "Applicable documentation"(→25)).
28521072/EN – 12/2018

4Installation
Electrical connections
Operating Instructions – Motor Load Diagnostics Module
16
4.2.4 Connections of the electronic motor management
1/L1 2/L2
4/T1 5/T2 6/T3
3/L3
E
M
M
O 1
O 2
O 3
O 4
IN 1
IN 2
IN 3
IN 4
TH1 TH2
24 V
0 V
[1]
[2]
[3]
[4]
[5]
9293763723
[1] Power section connection
[2] Electronic motor management
[3] Connections of the electronic motor management:
• O 1 – O 4: digital outputs
• TH1, TH2: Connection for PTC thermistors
• IN 1 – IN 4: digital inputs
[4] Motor connection
[5] 24V control voltage
For further information, refer to the documentation of the manufacturer, Phoenix Con-
tact (see the chapter "Applicable documentation"(→25)).
28521072/EN – 12/2018

4
Installation
Electrical connections
Operating Instructions – Motor Load Diagnostics Module 17
4.2.5 Connection of power jumper to another didactics module
L1
L2
L3
N
24 V
0 V
230 V
24 V
PE
[1]
[3]
[4]
[2]
9250656395
[1] L: Line connection phase
[2] N: Line connection of neutral conductor
[3] PE: PE connection
[4] 24V control voltage
28521072/EN – 12/2018

4Installation
Wiring diagram
Operating Instructions – Motor Load Diagnostics Module
18
4.3 Wiring diagram
S1S2S3S4
IFS Port Reset
X28 X27
X33
X19
PE
PE
U1
V1
W1
X13
X14
X15
X16
X17
X18 W1
V1
U1
P
X32
EMM 3-24DC/500AC-16-IFS
µP
X37
Power supply 230/24V
µP
ELR H5-IES-SC-24DC/500AC-2
Reset
X44
X6
L1
X7
L2
X8
L3
X9
N
X10 PE
H3 230V
H2 230V
H1 230V
PE
PE
X11 PE
X12 PE
X1 L1 X2 L2 X4 N
X3 L3
X5 PE
X61
T Bus
L1 N
X126
24 V
X26
1/L1 2/L2 3/3L 4/T1 5/T2 6/T3
X29
X30
X31
X59
Th1
X60
Th2
X68
Us
24 VDC
X50
Digital IN
In1 In2
In3
In4
X49
Out1 Out2 Out3 Out4
Digital OUT
Us
X69
Out1 Out2 Out3 Out4
X45 X46
X47
X48
X55 X56 X57 X58
X51 X52 X53 X54
In1 In2 In3 In4
X62
+24 V
X64
+24 V
H4 24 V
X63
0 V
X65
0 V
X20
1/L1 3/L2 5/L3
X21 X22 X23 X24 X25
2/T1 4/T2 6/T3
X41
95
X42
96
X43
97
95
96 97
X34
MAN
RES
X35
AUT
MAN
RES
AUT
X36
X230
X200
X66
24 VDC
Us
R
R
L
L
X40
X38 X39
9007208500415371
28521072/EN – 12/2018

5
Startup
Important information
Operating Instructions – Motor Load Diagnostics Module 19
5 Startup
5.1 Important information
INFORMATION
• Before startup, make sure that the product is not damaged.
• Check that all protective covers are installed correctly.
• Observe the documentation of components connected or mounted to the module
(e.g. motor, inverter).
WARNING
Danger of electric shock due to open connections.
Severe or fatal injuries.
• Never start the device if the touch guard is not installed.
WARNING
Risk of injury due to device malfunction caused by incorrect device setting.
Severe or fatal injuries.
• Make sure that the installation was carried out by trained specialists.
• Check the parameters and data sets.
• Only use settings that are correct for the function.
WARNING
Risk of crushing if the motor starts up unintentionally.
Severe or fatal injuries.
• Ensure that the motor cannot start unintentionally, by removing the X12 electron-
ics terminal block for example.
• Additional safety precautions must be taken depending on the application, such
as monitoring systems or mechanical protection devices, to avoid injury to people
and damage to machinery.
NOTICE
Danger due to arcing.
Damage to electrical components.
• Do not disconnect power connections during operation.
• Do not connect power connections during operation.
INFORMATION
To ensure fault-free operation, do not disconnect or connect signal cables during
operation.
28521072/EN – 12/2018

5Startup
Starting up the didactics module
Operating Instructions – Motor Load Diagnostics Module
20
5.2 Starting up the didactics module
Correct project planning for the drive is a prerequisite for successful startup. During
startup of the motor, take note of the parameterization notes in the documentation of
the components in use.
1. Connect the PE protective earth to the didactics module.
2. Connect the N to the didactics module.
3. Connect the L1, L2, and L3 phases to the didactics module.
4. Connect the line voltage (3-phase / 400V / 50Hz) to the electronic motor manage-
ment and to the hybrid motor starter.
5. Do not connect the motor cable to the didactics module.
6. Define the connection type of the motor and wire the motor accordingly. Refer to
the documentation for the motor for this purpose.
7. Connect the connections to the didactics module. Do not connect the connections
during ongoing operation.
8. In the case of external control, set all toggle switches of the didactics module to
"0" (zero) position for input simulation.
9. Apply the line voltage.
For further information, refer to the documentation of the manufacturer, Phoenix Con-
tact (see the chapter "Applicable documentation"(→25)).
28521072/EN – 12/2018