SEW-Eurodrive MOVIAXIS MXR User manual

Drive Technology \ Drive Automation \ System Integration \ Services
MOVIAXIS
®
Multi-Axis Servo Inverter
MXR Regenerative Power Module
Manual
Edition 10/2008
16607228 / EN

SEW-EURODRIVE – Driving the world

Manual – MOVIAXIS® MXR Regenerative Power Module 3
Content
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
1 General Information .......................................................................................... 5
1.1 Other applicable documentation ............................................................... 5
1.2 Structure of the safety notes ..................................................................... 5
1.3 Rights to claim under limited warranty ...................................................... 6
1.4 Exclusion of liability................................................................................... 6
2 Safety Notes ...................................................................................................... 7
2.1 General ..................................................................................................... 7
2.2 Target group ............................................................................................. 7
2.3 Designated use ......................................................................................... 7
2.4 Shipping, putting into storage ................................................................... 8
2.5 Installation................................................................................................. 8
2.6 Electrical connection ................................................................................. 9
2.7 Safe disconnection.................................................................................... 9
2.8 Operation .................................................................................................. 9
3 Unit Design ...................................................................................................... 10
3.1 Important information .............................................................................. 10
3.2 Nameplates, unit designations................................................................ 10
3.3 Unit design of the MXR regenerative power module .............................. 12
3.4 Combinations of MXR regenerative power modules with other units ..... 13
3.5 Standard accessories ............................................................................. 14
4 Installation ....................................................................................................... 16
4.1 Mechanical installation............................................................................ 16
4.2 UL-compliant installation......................................................................... 16
4.3 Installation/removal of the regenerative power module .......................... 18
4.4 Electrical installation ............................................................................... 18
4.5 Wiring diagrams ...................................................................................... 21
4.6 Terminal assignment............................................................................... 23
5 Startup.............................................................................................................. 26
5.1 General information ................................................................................ 26
5.2 Settings on regenerative power module for CAN-based system bus ..... 27
5.3 Settings on regenerative power module for
EtherCAT-based system bus XSE24A ................................................... 29
5.4 Settings on regenerative power module for EtherCAT fieldbus interface 30
5.5 Switch-on sequence of MXR regenerative power module ...................... 31
5.6 Process data assignment for fieldbus operation ..................................... 33
5.7 Startup of the MXR using MOVITOOLS®MotionStudio ......................... 36
5.8 Parameter description............................................................................. 39
6 Operation ......................................................................................................... 43
6.1 General information ................................................................................ 43
6.2 Operating displays and errors of the MXR regenerative power module . 44
7 Technical Data................................................................................................. 50
7.1 Technical data of the MXR regenerative power module ......................... 50
7.2 Dimension sheet of the MXR.. regenerative power module.................... 54
7.3 Drilling template of the MXR.. regenerative power module..................... 55
7.4 Technical data of additional components................................................ 56

4Manual – MOVIAXIS® MXR Regenerative Power Module
Content
8 Project Planning.............................................................................................. 62
8.1 General information ................................................................................ 62
8.2 Components for EMC-compliant installation........................................... 62
8.3 Line contactor and line fuses .................................................................. 63
8.4 Projecting the power supply.................................................................... 63
8.5 Projecting the cable cross sections......................................................... 64
8.6 Selecting the 24 V power supply............................................................. 65
8.7 Projecting the emergency braking resistor.............................................. 67
8.8 Dimensioning the MXR regenerative power module............................... 72
8.9 Output in case of a lower line voltage ..................................................... 72
8.10 Overload capacity ................................................................................... 73
8.11 Integrating a regenerative power module in a unit network .................... 74
8.12 Power supply .......................................................................................... 75
9 Index................................................................................................................. 76

Manual – MOVIAXIS® MXR Regenerative Power Module 5
1
Other applicable documentation
General Information
MOVIAXIS® Regenerative Power M odule MXR
1 General Information
1.1 Other applicable documentation
This manual describes the special properties of the MXR regenerative power module
For all other information and functionalities of MOVIAXIS®, refer to the following
documents:
•"MOVIAXIS
®Multi-Axis Servo Inverter" operating instructions
•"MOVIAXIS
®Multi-Axis Servo Inverter" project planning manual
1.2 Structure of the safety notes
The safety notes in this manual are designed as follows:
Pictogram SIGNAL WORD!
Type and source of danger.
Possible consequence(s) if disregarded.
• Measure(s) to prevent the danger.
Pictogram Signal word Meaning Consequences if
disregarded
Example:
General danger
Specific danger,
e.g. electric shock
DANGER! Imminent danger 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 drive system or its environ-
ment
TIP Useful information or tip
Simplifies handling of the drive
system.

6Manual – MOVIAXIS® MXR Regenerative Power Module
1 Rights to claim under limited warranty
General Information
1.3 Rights to claim under limited warranty
A requirement of fault-free operation and fulfillment of any rights to claim under limit-
ed warranty is that you adhere to the information in this manual and the "MOVIAXIS®
Multi-Axis Servo Inverter" operating instructions. Read the operating instructions
before you start operating the unit!
Make sure that the operating instructions are available to persons responsible for the
system and its operation as well as to persons who work independently on the unit. You
must also ensure that the documentation is legible.
1.4 Exclusion of liability
You must comply with the information contained in the manual at hand and in the
"MOVIAXIS®Multi-Axis Servo Inverter" operating instructions to ensure safe op-
eration of the MXR regenerative power module in conjunction with the MOVIAXIS®
multi-axis servo inverter and to achieve the specified product characteristics and
performance requirements. SEW-EURODRIVE assumes no liability for injury to
persons or damage to equipment or property resulting from non-observance of
the operating instructions. In such cases, any liability for defects is excluded.

Manual – MOVIAXIS® MXR Regenerative Power Module 7
2
General
Safety Notes
2 Safety Notes
The following basic safety notes must be read carefully to prevent injury to persons and
damage to property. The operator must make sure that the basic safety notes are read
and observed. Make sure that persons responsible for the plant and its operation, as
well as persons who work independently on the unit, have read through the operating
instructions carefully and understood them. If you are unclear about any of the informa-
tion in this documentation, or if you require further information, please contact SEW-
EURODRIVE.
2.1 General
Never install damaged products and put them into operation. Submit a complaint to the
shipping company immediately in the event of damage.
During operation, multi-axis servo inverters can have live, bare and movable or rotating
parts as well as hot surfaces, depending on their enclosure.
Removing covers without authorization, improper use as well as incorrect installation or
operation may result in severe injuries to persons or damage to property.
Consult the documentation for further information.
2.2 Target group
Only qualified personnel are authorized to install, startup or service the units or correct
unit faults (observing IEC 60364 or CENELEC HD 384 or DIN VDE 0100 and IEC 60664
or DIN VDE 0110 as well as national accident prevention guidelines).
Qualified personnel in the context of these basic safety notes are persons familiar with
installation, assembly, startup and operation of the product who possess the necessary
qualifications.
All activity in the other areas of transportation, storage, operation, and disposal must be
carried out by persons who are appropriately trained.
2.3 Designated use
The MXR regenerative power module is designed for integration in the unit network of
the MOVIAXIS®MX multi-axis servo inverter.
The MOVIAXIS®MX multi-axis servo drives are units for use in industrial and commer-
cial systems to operate permanent-field synchronous AC motors and asynchronous AC
motors with encoder feedback. These motors must be suitable for operation with servo
inverters. Connect other loads to the units only after you have consulted the manufac-
turer.
TIP
Observe the information about the other modules of a MOVIAXIS®axis system in the
"MOVIAXIS®MX Multi-Axis Servo Inverter" operating instructions when installing,
starting up, and operating the MXR regenerative power module.

8Manual – MOVIAXIS® MXR Regenerative Power Module
2 Shipping, putting into storage
Safety Notes
The MOVIAXIS®MX multi-axis servo drives are intended for use in metal control cabi-
nets. These metal control cabinets represent the necessary enclosure for the application
as well as the grounding over a large area required for EMC purposes.
For installation in machines, startup of the multi-axis servo inverter (meaning the start of
designated use) is prohibited until it is determined that the machine meets the require-
ments stipulated in the EC Directive 98/37/EC (machine directive); observe EN 60204.
Startup (i.e. start of designated operation) is only permitted with adherence to the EMC
guideline (89/336/EEC).
The multi-axis servo inverters meet the requirements stipulated in the low voltage guide-
line 200695EC. The harmonized standards of the EN 61800-5-1 DIN VDE/T105 series
in connection with EN 60439-1 VDE 0660 part 500 and EN 60146 VDE/0558 are applied
to the multi-axis servo inverters.
Technical data and information on the connection requirements are given on the name-
plate and in the documentation; they must be observed under all circumstances.
2.3.1 Safety functions
MOVIAXIS®multi-axis servo inverters may not take on safety functions without a higher-
level safety system. Use higher-level safety systems to ensure protection of equipment
and personnel.
For safety applications, refer to the information in the following publications:
• Safe Disconnection for MOVIAXIS®– Conditions.
• Safe Disconnection for MOVIAXIS®– Applications.
2.4 Shipping, putting into storage
Observe the notes on transportation, storage and proper handling. Observe the climatic
conditions as stated in the "MOVIAXIS®Multi-Axis Servo Inverter" operating instructions
in the "General technical data" chapter.
2.5 Installation
The units must be installed and cooled according to the regulations and specifications
in the corresponding documentation.
Protect the multi-axis servo inverters from excessive strain. Especially during transpor-
tation and handling, do not allow the components to be deformed and/or insulation spac-
es altered. Avoid contact with electronic components and contacts.
Multi-axis servo inverters contain components that can be damaged by electrostatic en-
ergy and could be destroyed in case of improper handling. Prevent mechanical damage
or destruction of electric components (may pose health risk).

Manual – MOVIAXIS® MXR Regenerative Power Module 9
2
Electrical connection
Safety Notes
The following applications are prohibited unless the unit is explicitly designed for such
use:
• Use in potentially explosive areas.
• Use in areas exposed to harmful oils, acids, gases, vapors, dust, radiation, etc.
• Use in non-stationary applications that are subject to mechanical vibration and shock
loads in excess of the requirements in EN 61800-5-1.
2.6 Electrical connection
Observe the applicable national accident prevention guidelines when working on live
multi-axis servo inverters (for example, BGV A3).
Perform electrical installation according to the pertinent regulations (e.g. cable cross
sections, fusing, protective conductor connection). Additional information is contained in
the documentation.
You will find notes on EMC-compliant installation, such as shielding, grounding, ar-
rangement of filters and routing of lines, in the documentation of the multi-axis servo in-
verters. Always observe these notes even with multi-axis servo inverters bearing the CE
marking. The manufacturer of the system or machine is responsible for maintaining the
limits established by EMC legislation.
Preventive measures and protection devices must correspond to the regulations in force
(e.g. EN 60204 or EN 61800-5-1).
Required preventive measures: Grounding the unit.
2.7 Safe disconnection
MOVIAXIS®meets all requirements for safe disconnection of power and electronic con-
nections in accordance with EN 61800-5-1. All connected circuits must also satisfy the
requirements for safe disconnection.
2.8 Operation
Systems with multi-axis servo inverters must be equipped with additional monitoring and
protection devices, as applicable, according to the relevant safety guidelines and regu-
lations, such as legislation governing technical equipment, accident prevention regula-
tions, etc. Changes to the multi-axis servo inverter using the software are permitted.
Do not touch live components or power connections immediately after disconnecting the
multi-axis servo inverters from the supply voltage because there may still be some
charged capacitors. Note the respective labels on the multi-axis servo inverter.
Keep all covers and doors closed during operation.
The fact that the status LED and other display elements are no longer illuminated does
not indicate that the unit has been disconnected from the supply system and no longer
carries any voltage.
Mechanical blocking or internal safety functions of the unit can cause a motor standstill.
Eliminating the cause of the problem or performing a reset may result in the drive re-
starting automatically. If, for safety reasons, this is not permitted for the driven machine,
disconnect the unit from the supply system before correcting the fault.

10 Manual – MOVIAXIS® MXR Regenerative Power Module
3 Important information
Unit Design
3 Unit Design
3.1 Important information
Protective measures and protective equipment have to meet the respective national
regulations in effect.
3.2 Nameplates, unit designations
3.2.1 Nameplate of MXR regenerative power module
TIP
Follow the specific operating instructions during installation and startup of the motor
and the brake!
WARNING!
The following "Unit design" illustrations represent the units without the provided protec-
tion cover (touch guard). The protection cover protects the area of the line and braking
resistor connections.
Uncovered power connections.
Severe or fatal injuries from electric shock.
• Install the touch guard according to the regulations.
• Never start the unit if the touch guard is not installed.
62919AXX
Figure 1: Sample nameplate of a MOVIAXIS®MXR regenerative power module
IPart "I" of the nameplate: Located on the
upper fastening plate of the module [1] Unit designation, see page 11
III Part "III" of the nameplate: Located at the side
of the module housing [2] Production number
[3] Status
I
[2][1]
[2]
[1]
[3]
III
[3]
100 A
250 A

Manual – MOVIAXIS® MXR Regenerative Power Module 11
3
Nameplates, unit designations
Unit Design
3.2.2 Unit designation of MXR regenerative power module
MX R80 A-075 -50 3- 00
00 =
XX =
Standard design
Special design
3 = 3-phase connection type
50 = U = AC 380 - 480 V connection voltage
Power 75 KW
Version
80 = Standard variant
Unit type: R = Regenerative power module
MOVIAXIS®

12 Manual – MOVIAXIS® MXR Regenerative Power Module
3 Unit design of the MXR regenerative power module
Unit Design
3.3 Unit design of the MXR regenerative power module
The following illustration shows the unit without protective cover.
3.3.1 MXR regenerative power module
62921AXX
Figure 2: Unit design of MXR regenerative power module
AView from top B View from front C View from bottom
[1] Signaling bus
X9a: Input, green plug on cable
X9b: Output, red plug on cable
[2] Electronics shield clamps [15] X18: Line voltage measure-
ment
[3] X12: System bus CAN [16] X19: Enable contact for line
contactor
[4] S1, S2: DIP switches
[5] S3, S4: Address switches
[6] X10: Binary inputs (pins 1 – 6)
X11: Binary outputs (pins 7 – 11)
[7] X17: CAN2 bus
[8] 2 x 7-segment display
[9] X5a, X5b: 24 V voltage supply
[10] X4: DC link connection
[11] X1: Line connection
[12] Housing grounding point
[13] Power shield clamp
[14] X3: Braking resistor connection
X9a
X9b
B
A
[1]
[4]
[10]
[3]
[15]
[16]
C
[2]
[5]
[6]
[8]
[7]
[9]
[11]
[13]
[12] [14]

Manual – MOVIAXIS® MXR Regenerative Power Module 13
3
Combinations of MXR regenerative power modules with other units
Unit Design
3.4 Combinations of MXR regenerative power modules with other units
Unit Combination possible? Quantity
MXP – –
MXA X 8
MXC – –
MXB In preparation
MXD X 1
MXS In preparation
MXZ – –
MXM X 1

14 Manual – MOVIAXIS® MXR Regenerative Power Module
3 Standard accessories
Unit Design
3.5 Standard accessories
Standard accessories are included with the basic unit at delivery.
The corresponding mating connectors for all connectors are installed at the factory. An
exception are the D-sub connectors; they are supplied without mating connector.
63518axx
Figure 3: Standard accessories
[1]
[2]
[3]
[4]
[5]
[6]
[7]
[8]
[9]
[10]
[12]
[15]
[30]
[16]
[11]
[18]
[19]
[20]
[21]
[22]
[24]
[25]
[26]
[27]
[17]
[23]
[29]
[28]
[13]
[14]
[31]

Manual – MOVIAXIS® MXR Regenerative Power Module 15
3
Standard accessories
Unit Design
3.5.1 Standard accessory assignment table
No. Dimensions1)
1) Length of the cables: Length of the bulk cable without
connector
MXR
Touch guard
[1] –
DC link connection
[2] 76 mm –
[3] 106 mm –
[4] 136 mm –
[5] 160 mm –
[6] 226 mm 3x
Electronics shield clamp
[7] 60 mm 1x
[8] 90 mm –
[9] 120 mm –
[10] 150 mm 1x
[11] 210 mm –
Power shield clamp
[12] 60 mm –
[13] 60 mm2)
2) Clamp with short support, 60 mm wide
–
[14] 60 mm3)
3) Clamp with long support, 60 mm wide
–
[15] 105 mm –
[16] 105 mm 1x
24 V supply cable
[17] 40 mm –
[18] 50 mm –
[19] 80 mm –
[20] 110 mm –
[21] 140 mm –
[22] 200 mm 1x
Signal bus connection cable (suitable for CAN-/
EtherCAT-based system bus)
[23] 200 mm –
[24] 230 mm –
[25] 260 mm –
[26] 290 mm –
[27] 350 mm 1x
Connection cable CAN – master module
[28] 520 mm –
CAN terminating resistor
[29] –
Cable lugs
[30] –
Measurement cable connector
[31] 1x

16 Manual – MOVIAXIS® MXR Regenerative Power Module
4 Mechanical installation
Installation
4 Installation
4.1 Mechanical installation
• Check to make sure that the delivery is complete.
4.2 UL-compliant installation
Note the following points for UL-compliant installation:
• Use only copper cables with the temperature range 60 / 75 °C as connection cables.
• The permitted tightening torques for MOVIAXIS®power terminals are:
Permitted tight-
ening torques
The permitted tightening torque
– of the signal terminals X10, X11 for all units is 0.5 - 0.6 Nm.
– for all DC link connections X4 is 3.0 - 4.0 Nm.
– of the terminals for 24 V voltage supply is 0.5 - 0.6 Nm.
CAUTION!
Do not install defective or damaged modules; they can possibly result in injuries or
damage parts of the production system.
• Check the unit network of the MOVIAXIS®MX multi-axis servo inverter and the re-
generative power module prior to installation for external damage and replace any
damaged modules.
NOTICE
The mounting plate in the control cabinet must be conductive over a large area for the
mounting surface of the servo inverter system (metallically pure, good conductivity). An
EMC compliant installation of the MOVIAXIS®MX multi-axis servo inverter can only be
accomplished with a mounting plate that is conductive over a large area.
NOTES
UL certification is in preparation.
Tightening torque
Regenerative power module Line connection X1 Emergency braking resistor
terminals
One size 6.0 - 10.0 Nm 3.0 - 4.0 Nm

Manual – MOVIAXIS® MXR Regenerative Power Module 17
4
UL-compliant installation
Installation
•MOVIAXIS
®MX multi-axis servo inverters are suitable for operation in voltage net-
works with earthed star point (TN and TT networks), a maximum line current of
42,000 A and a maximum line voltage of AC 480 V.
• The maximum permitted value of the line fuse is:
• Only use melting fuses as input fuses.
• If you use cable cross sections that are dimensioned for a smaller current than the
rated current of the unit, make sure that the fuse is dimensioned for the used cable
cross section.
• For information on selecting cable cross sections, refer to the project planning man-
ual.
• Comply with the country-specific installation regulations in addition to the above
notes.
• The plug-in connections of the 24 V supply are limited to 10 A.
NOTICE
Regenerative power module can possibly be damaged!.
• Only use the stipulated connection elements and observe the prescribed tightening
torques. Otherwise, excessive heat can develop which would damage the regener-
ative power module.
MXR regenerative power module "Maximum Power" variant "Clean Power" variant
PN75 kW 50 kW
IN110 A 73 A
Input fuse 125 A 80 A
NOTICE
We recommend protection of the emergency braking resistor with a thermal overload
relay to implement an UL approved application design.
NOTES
Observe the technical data for operation of the required line filters (page 56) and line
chokes (page 59).
The cross section of the measuring cable X18 of the line filter must be AWG12, see
wiring diagram on page 22.

18 Manual – MOVIAXIS® MXR Regenerative Power Module
4 Installation/removal of the regenerative power module
Installation
4.3 Installation/removal of the regenerative power module
Refer to the "MOVIAXIS®MX Multi-Axis Servo Inverter" operation instructions for a de-
scription how to install a module in an axis system and how to remove it. Adhere to the
instructions for installing/removing a module.
4.4 Electrical installation
This chapter specifically describes the electrical installation of the MXR regenerative
power module.
For detailed information on the electrical installation of the MOVIAXIS®axis system, re-
fer to the "MOVIAXIS®MX Multi-Axis Servo Inverter" operating instructions.
DANGER!
Dangerous voltage levels may still be present inside the unit and at the terminal strips
up to 10 minutes after the complete axis system has been disconnected from the sup-
ply system.
Severe or fatal injuries from electric shock.
To prevent electric shocks:
• Disconnect the axis system from the supply system and wait ten minutes before re-
moving the protective covers.
• Secure the motor against unintended power-up.
• After maintenance work, do not operate the axis system unless you have replaced
the protective cover because the unit only has degree of protection IP00 without
protective cover.
DANGER!
A leakage current > 3.5 mA can occur during operation of the MOVIAXIS®MX multi-
axis servo inverter.
Severe or fatal injuries from electric shock.
To prevent electric shock:
• With a supply system lead < 10 mm2, route a second PE conductor with the same
cross section as the supply system lead via separate terminals. Alternatively, you
can use a PE conductor with a copper cross section ≥10 mm2or aluminum
≥16 mm2.
• With an incoming supply line ≥10 mm2, it is sufficient to install a PE conductor with
a copper cross section ≥10 mm2or aluminum ≥10 mm2.
• If an earth leakage circuit breaker can be used for protection against direct and in-
direct contact, it must be universal current sensitive (RCD type B).

Manual – MOVIAXIS® MXR Regenerative Power Module 19
4
Electrical installation
Installation
4.4.1 Line contactor and cable cross sections
• Supply cable: Cross section according to rated input current Iline at rated load.
4.4.2 Measuring cable X18 of the line filter
For the measuring cable X18, we recommend a cross section of 2.5 mm2.
The requirements for UL-compliant installation of the measuring cable X18 are listed on
page 16 ff.
The measuring cable may only be fused up to 120 A.
4.4.3 Emergency braking resistor connection
• Protect the emergency braking resistor with an overload relay. Set the trip current
according to the technical data of the emergency braking resistor, see
"MOVIAXIS®MX Multi-Axis Servo Inverter" operating instructions.
• SEW-EURODRIVE recommends to connect the emergency braking resistor as
shown in the "MOVIAXIS®MX Multi-Axis Servo Inverter" operating instructions. In-
stall switch F16 close to the unit network. If an unshielded cable is used for connect-
ing switch F16 with the regenerative power module, keep the length as short as pos-
sible. Preferably use a shielded line cable or drilled individual lines as connection ca-
ble to the emergency braking resistor. The cross section must be selected depending
on the rated current of the emergency braking resistor.
TIP
Installation with reliable isolation.
The unit meets all requirements for reliable isolation between power and electronic
connections according to EN 61800-5-1. The connected signal circuits have to meet
the requirements according to SELV (Safe Extremly Low Voltage) or PELV (Protective
Extra Low Voltage) to ensure reliable isolation. The installation must meet the require-
ments for reliable isolation.
NOTICE
• Use a line contactor in utilization category AC-3 (IEC 158-1) or better. For infor-
mation on the current carrying capacity, refer to chapter "MXR regenerative
power module" (page 52).
NOTICE
Observe the notes in chapter "Project planning" (page 62) when using an emergency
braking resistor.

20 Manual – MOVIAXIS® MXR Regenerative Power Module
4 Electrical installation
Installation
4.4.4 Operation of the emergency braking resistor
• The connection lead to the emergency braking resistor carries a high DC voltage of
about 970 V during rated operation.
4.4.5 Permitted voltage supply systems
•MOVIAXIS
®is intended for operation on voltage supply systems with a directly
grounded star point (TN and TT power systems).
• Operation on voltage supply systems with a non-grounded star point (for example IT
power systems) is not permitted.
• Autonomous power systems are not permitted.
An autonomous power system has no connection to the public grid.
WARNING!
The surfaces of the emergency braking resistor will reach temperatures of up to 250°C
when the braking resistor is loaded with PN.
Risk of burns and fire.
• Choose a suitable installation location. Emergency braking resistors are usually
mounted on top of the control cabinet.
• Do not touch any emergency braking resistor.