SEW-Eurodrive Movidrive MDX61B User manual

Drive Technology \ Drive Automation \ System Integration \ Services
Manual
MOVIDRIVE
®
MDX61B
Automotive AMA0801 Application Module
Edition 04/2009 16629612 / EN

SEW-EURODRIVE—Driving the world

Manual – MOVIDRIVE® MDX61B Automotive AMA0801 Application Module 3
1 General Notes......................................................................................................... 5
1.1 Structure of the safety notes .......................................................................... 5
1.2 Right to claim under warranty ........................................................................ 5
1.3 Exclusion of liability........................................................................................ 5
1.4 Copyright........................................................................................................ 6
1.5 Other applicable documentation .................................................................... 6
2 System Description................................................................................................ 7
2.1 Areas of application ....................................................................................... 7
2.2 Application examples ..................................................................................... 8
3 Project Planning................................................................................................... 10
3.1 Prerequisites ................................................................................................ 10
3.2 Functional description .................................................................................. 11
3.3 Scaling of the drive ...................................................................................... 13
3.4 Limit switches, reference cams and machine zero ...................................... 15
3.5 Process data assignment............................................................................. 16
3.5.1 Assignment of process output data in the "variable setpoint
specification" operating mode............................................................ 16
3.5.2 Assignment of process input data in the "variable setpoint
specification" operating mode............................................................ 17
3.5.3 Assignment of process output data in the "binary setpoint
specification" operating mode............................................................ 18
3.5.4 Assignment of process input data in the "binary
setpoint specification" operating mode .............................................. 19
3.5.5 Assignment of binary inputs and outputs on MOVIDRIVE®B ........... 20
3.6 Software limit switches................................................................................. 21
3.7 Safe stop...................................................................................................... 23
3.8 Functions ..................................................................................................... 24
3.8.1 "Position monitoring" function ............................................................ 24
3.8.2 "Smooth component transfer" function .............................................. 28
3.8.3 "Cam controller" function ................................................................... 30
3.8.4 "Automatic alignment" function .......................................................... 31
3.8.5 "Correction value" Function ............................................................... 32
3.8.6 "Actual position in user units" function ............................................... 32
3.8.7 "Run time control" function................................................................. 32
4 Installation ............................................................................................................ 33
4.1 MOVITOOLS®MotionStudio........................................................................ 33
4.2 MOVIDRIVE®MDX61B master (no synchronous operation)
wiring diagram.............................................................................................. 34
4.3 MOVIDRIVE®MDX61B bus installation...................................................... 35
4.4 Connecting the system bus (SBus 1)........................................................... 42
5 Startup................................................................................................................... 44
5.1 General prerequisites................................................................................... 44
5.2 Preliminary work........................................................................................... 44
5.3 Starting the "AMA0801" program................................................................. 45
5.4 Parameters and IPOSplus® variables ........................................................... 64

Manual – MOVIDRIVE® MDX61B Automotive AMA0801 Application Module 4
6 Operation and Service ......................................................................................... 70
6.1 Starting the drive.......................................................................................... 70
6.1.1 Operating modes with variable setpoint selection.............................. 71
6.1.2 Operating modes with binary setpoint specification........................... 72
6.2 Referencing mode........................................................................................ 73
6.3 Jog mode ..................................................................................................... 74
6.4 Teach operation (binary setpoint selection) ................................................. 75
6.5 Cycle diagrams ............................................................................................ 76
6.6 Error information .......................................................................................... 80
6.7 Error messages............................................................................................ 81
7 Index...................................................................................................................... 85

Manual – MOVIDRIVE® MDX61B Automotive AMA 0801 Application Module 5
1
Structure of the safety notes
General Notes
1 General Notes
1.1 Structure of the safety notes
The safety notes in this manual are structured as follows:
1.2 Right to claim under 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 the operating instructions. There-
fore, read the operating instructions before you start operating the unit.
Make sure that the operating instructions are available to persons responsible for the
plant and its operation, as well as to person who work independently on the unit. You
must also ensure that the documentation is legible.
1.3 Exclusion of liability
You must comply with the information contained in this publication to ensure safe
operation of the MOVIDRIVE®MDX60B/61B inverters and to achieve the specified
product characteristics and performance requirements. SEW-EURODRIVE as-
sumes no liability for injury to persons or damage to equipment or property re-
sulting from non-observance of the operating instructions. In such cases, any li-
ability for defects is excluded.
Pictogram SIGNAL WORD
Type and source of danger.
Possible consequence(s) if the safety notes are 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
STOP Possible damage to property Damage to the drive system or its environ-
ment
TIP Useful information or tip.
Simplifies the handling of the
drive system.

6Manual – MOVIDRIVE® MDX61B Automotive AMA 0801 Application Module
1 Copyright
General Notes
1.4 Copyright
© 2008 - SEW-EURODRIVE. All rights reserved.
Copyright law prohibits the unauthorized duplication, modification, distribution, and use
of this document, in whole or in part.
1.5 Other applicable documentation
• This manual does not replace the detailed operating instructions and the correspond-
ing manuals.
• Installation and startup only by trained personnel observing the relevant accident
prevention regulations and the following documents:
–"'MOVIDRIVE
®MDX60B/61B' operating instructions and corresponding manuals

Manual – MOVIDRIVE® MDX61B Automotive AMA 0801 Application Module 7
2
Areas of application
System Description
2 System Description
2.1 Areas of application
The "Automotive AMA0801" application module makes it possible to implement lifting
devices, conveyor systems and machinery with drives that have to move at a synchro-
nous angle to one another occasionally or permanently.
The "Automotive AMA0801" application module has a selectable process data interface.
Optionally variable or binary setpoint selection.
The program is used to control individual drives. In "synchronous operation" mode,
these drives can be synchronized to a master drive.
The "Automotive AMA0801" application module has the following advantages:
• One program for master and slave drive.
• Guided startup and extensive diagnostics functions.
• Very similar to the "DriveSync via fieldbus" application module.
• The selected IPOS encoder source (X13, X14, DIP) is also effective in synchronous
operation.
• The master value for the "synchronous operation" mode can be adjusted.
• A mechanical vertical shaft can be replaced by transferring the virtual master value
via an SBus connection
• Configurable process data interface with "variable or binary setpoint selection".
• Binary coded operating mode selection with the following operating modes:
– Jog mode
–Teachmode
– Referencing mode
– Positioning mode
– Synchronous operation
• Additional functions (only with binary setpoint specification):
– Smooth component transfer
– Cam control
– Automatic alignment, for example when changing the position in position control
(if activated in the Automotive AMA0801 application module)
– Correction value, for example for averaging mounting positions
• Additional functions
– Software limit switch processing
– Hardware limit switch processing
Features of synchronous operation:
• The electrical connection of the master/slave can be made using the X14 connection
or an SBus connection.
• The contents of the send object can be adjusted when the S-bus connection is used.
For example, the value of any IPOSplus® variable can be transferred instead of the
IPOSplus® variable of the master drive.

8Manual – MOVIDRIVE® MDX61B Automotive AMA 0801 Application Module
2 Application examples
System Description
2.2 Application examples
The "Automotive AMA0801" application module offers a wide range of possible applica-
tions. Some examples are given in this section.
Finite (linear)
movement of the
master and slave
axis
Example 1: Lifting device with smooth component transfer (with binary setpoint specifi-
cation)
The component is transferred smoothly onto the removal position [2] (= [Smooth com-
ponent transfer] position) of the subsequent conveyor belt. Next, the component carrier
moves underneath the removal position [2] until it has reached the target position [3].
Example 2: Hoist
• Master axis: Linear axis
Operating mode: Positioning mode
• Slave axis: Linear axis
Operating mode: Synchronous operation
63442BXX
[1] Home position
[2] Removal position (= "smooth component transfer" position)
[3] Target position
57038AXX
[1]
[2]
[3]
Slave
Master

Manual – MOVIDRIVE® MDX61B Automotive AMA 0801 Application Module 9
2
Application examples
System Description
Example 3: Gantry crane with slip compensation through absolute encoder evaluation
• Master axis: Linear axis
Operating mode: Positioning mode using additional absolute encoder (IPOS encod-
er)
• Slave axis: Linear axis
Operating mode: Synchronous operation using an additional absolute encoder
• Master value: Master position (absolute value encoder position) is transferred via
SBus
• Features: Slip between motor and absolute encoder is compensated by the firmware.
Additional performance is achieved by controlling the master and slave axis using the
virtual encoder. Both drives are controlled in "Synchronous operation" mode for this
purpose. The master drive is started with the master value "virtual encoder" and
transfers the setpoint position to the slave drive via SBus.
57039AXX
Slave
Master

10 Manual – MOVIDRIVE® MDX61B Automotive AMA 0801 Application Module
3 Prerequisites
Project Planning
3 Project Planning
3.1 Prerequisites
PC and software The "Automotive AMA0801" application module is implemented as IPOSplus® program
and is part of the SEW MOVITOOLS®MotionStudio software package from version
5.5x. To run MOVITOOLS®MotionStudio, you need a PC with one of the following op-
erating systems: Windows®95, Windows®98, Windows®NT 4.0, Windows®XP, Win-
dows®2000 or Windows®Vista.
Inverters, motors
and encoders
•Inverter
The "Automotive AMA0801" application module is controlled via fieldbus with 6 pro-
cess data words and can only be operated with MOVIDRIVE®MDX61B in applica-
tion version (...0T).
•Motors and encoders
All motors with a connected motor encoder are supported.
Possible combi-
nations
•MOVIDRIVE
®MDX61B with the following fieldbus interfaces
General informa-
tion
• The source of the actual position is the motor encoder. In systems subject to slip, an
external encoder can additionally be fitted or an absolute encoder can be used in
combination with the "DIP11B/DEH21B absolute encoder cards/ option.
• If operated with asynchronous motors, the inverter must be started up in the "VFC n-
control & IPOS" or "CFC & IPOS" mode.
• If operated with synchronous motors, the inverter must be started up in the "SERVO
& IPOS" mode.
Connection of motor shaft and load
Interlocking:
External encoder is not
required
Non-positive:
External encoder required
Encoder type (exter-
nal encoder)
- Incremental
encoder
Absolute encoder
Bus type
(required option)
PROFIBUS →DFP / INTERBUS →DFI / CAN bus →DFC / DeviceNet →DFD /
ETHERNET →DFE / system bus (SBus) →no option required
Additional
MOVIDRIVE®option
required
DEH11B or DER11B DIP11B / DEH21B /
DEH11B / DER11B

Manual – MOVIDRIVE® MDX61B Automotive AMA 0801 Application Module 11
3
Functional description
Project Planning
3.2 Functional description
Functional char-
acteristics
The "Automotive AMA0801" application module offers the following functional charac-
teristics:
•Jog mode
The drive is moved clockwise or counterclockwise using two bits for direction selec-
tion. When activating variable setpoint specification, you can change velocity and
ramp via fieldbus during ongoing movement.
•Referencing mode
Reference travel is started with the start signal. Reference travel establishes the ref-
erence point (machine zero) for absolute positioning operations. The axis must be
referenced for selecting "positioning mode".
•Positioning mode
The target position is specified by the higher-level controller. You can change veloc-
ity and ramp via fieldbus during ongoing movement. The current actual position is re-
ported back via process input data words PI2 and PI3.
The program cyclically queries the target position so that position changes are pos-
sible during positioning. Positioning is only performed when the axis has been refer-
enced.
When activating "binary setpoint specification", the position reference can be offset
using the "correction value" function.
•Synchronous operation
"Synchronous mode" is motion control based on the Internal synchronous operation
technology function (ISYNC).
The "synchronous operation" mode can be started without prior reference travel.
The synchronization process is started once "synchronous operation" is selected.
Once the slave drive has been synchronized with the master, the slave moves syn-
chronously with the master.
Synchronous operation is terminated by resetting the "start bit" or by deselecting
synchronous operation.
In addition, you can offset the reference to the master drive without having to exit the
operating mode by specifying a correction value SyncOffset (PO6).
•Teach mode (only with binary setpoint specification)
Movement can be performed to every individual position in jog mode and then stored
in teach mode.

12 Manual – MOVIDRIVE® MDX61B Automotive AMA 0801 Application Module
3 Functional description
Project Planning
•Binary setpoint specification
– Fieldbuses with 6 process data words are supported.
– Up to 16 target positions are selected by requesting a table position.
– Each target position is fed back as an individual bit. The following applies:
Position n + position window > position (n + 1) + position window > ....
– You can change the traveling velocity and ramp by switching to another operating
speed/creep speed or ramp.
– The target position can be changed during ongoing movement.
– The actual position is reported back via two process data words.
– Referenced axes can evaluate 16 cams in a process data word independent of
the operating mode.
•Variable setpoint specification
– Fieldbuses with 6 process data words are supported.
– The target positions are selected via two process data words.
– Traveling velocity and ramp can be selected via one process data word each.
– The target position can be changed during ongoing movement.
– The actual position is reported back via two process data words.
•"Smooth component transfer" function implemented with startup with binary
setpoint specification.
Using the "smooth component transfer" function lets you influence the travel profile
of a positioning process in such a way that the drive is briefly decelerated to standstill
at the specified "smooth component transfer" position. This function can be used in
one of the following directions of movement:
– Both ends
– Positive
– Negative
The function is inactive if the position of the smooth component transfer lies outside
the travel range.
•"Cam controller" function implemented with startup with binary setpoint spec-
ification.
– Output cams are mirrored to process output data word 5 via IPOS encoder status
queries.
– Cam area entries are sorted automatically as follows:
– Cam CCW < cam CW
If the actual position is located between the cam areas, the output bit is set to
TRUE.
– Cam CCW > cam CW
If the actual position is located between the cam areas, the output bit is set to
FALSE.
•"Automatic alignment" function implemented with startup with binary setpoint
specification.
To activate this function, the drive must be enabled and "positioning mode" selected.
This function allows for detecting and correcting even minor deviations from the last
target position (for example caused by a sagging hoist with brake application and re-
lease).

Manual – MOVIDRIVE® MDX61B Automotive AMA 0801 Application Module 13
3
Scaling of the drive
Project Planning
The following steps are carried out each time the inverter re-enters position control:
– Check whether the actual position is located within one of the stored table posi-
tions. Search always begins from table position 0 to 15 and is aborted as soon as
the first valid position is found.
– The table position for the referenced axis is written to the target position and ad-
justment is started.
– The position is maintained.
•"Correction value" function implemented with startup with binary setpoint
specification.
– Using the "correction value" function allows for correcting the setpoint positions
stored in the table by the variable correction value (adding the correction value to
the table value). If assigning the value"0", no offset will be performed.
– Specifying a "positive" correction value will move the position reference by the
given value in "positive direction". A "negative" value will move the value in the
"negative direction".
– If you want to store the correction value remanently, you have to call the startup
wizard.
– You can use this function, for example, to average a mounting position.
•"Runtime control" function
– The runtime is measured independent of the selected operating mode by compar-
ing the two system variables H491 TargetPos and H492 SetpointPos. Runtime
control is started with the condition H491 TargetPos unequal H492 SetpointPos
and is ended with the condition H491 TargetPos equal H492 SetpointPos.
3.3 Scaling of the drive
The controller must be able to detect the number of encoder pulses (increments) per
travel unit to position the drive. The scaling function is used to set a user unit suitable to
the application.
Drive without
external encoder
(positive connec-
tion)
In drives without an external encoder, the system can calculate the scaling automatically
during startup of the application module. Enter the following data:
• Diameter of the drive wheel (ddrive wheel) or slope of the spindle (sspindle)
• Gear ratio of the gear unit (igear unit, speed-reduction)
• Gear ratio of the additional gear (iadditional gear speed-reduction)
The following scaling factors are calculated:
• Pulses / distance scaling factor [inc/mm] using the formula:
Pulses = 4096 × igear unit ×iadditional gear
Distance = Π× ddrive wheel or sspindle
• Speed scaling factor
Numerator factor in [1/min] and denominator value in "speed unit".
You can also enter the distance and velocity scaling factors directly. If you enter a unit
other than [mm] or [1/10 mm] as the travel unit, this user unit will also be used for the
position of the software limit switches, the reference offset and the maximum travel dis-
tances.

14 Manual – MOVIDRIVE® MDX61B Automotive AMA 0801 Application Module
3 Scaling of the drive
Project Planning
Drive with exter-
nal encoder (non-
positive connec-
tion)
In this case, you must have activated and scaled the external encoder before starting
up the "AMA0801" application module. To do so, make the following settings in the Shell
program before starting the Automotive AMA0801 application module (siehe following
figure).
• P941 Source actual position
If an incremental encoder or an absolute encoder (DIP11) is connected, set P941 to
"EXT. ENCODER (X14)". You can also make this setting during the startup proce-
dure of the application module.
• P942 Encoder factor numerator / P943 Encoder factor denominator / P944 Encoder
scaling ext. Encoders
10091ADE
TIPS
• For more information about scaling an external encoder, refer to the "IPOSplus® Po-
sitioning and Sequence Control System" manual.
• When using an absolute encoder, note the startup instructions in the
"MOVIDRIVE®MDX61B0 Absolute Encoder Card DIP11B" manual.

Manual – MOVIDRIVE® MDX61B Automotive AMA 0801 Application Module 15
3
Limit switches, reference cams and machine zero
Project Planning
3.4 Limit switches, reference cams and machine zero
Note the following points during project planning:
• The software limit switches must be located within the travel range of the hardware
limit switches.
• When defining the reference position (position of the reference cam) and the soft-
ware limit switches, make sure they do not overlap. Fault message F78 "IPOS SW
limit switch" is generated in the event of an overlap during referencing.
• You can enter a reference offset during startup if you do not want the machine zero
to be located on the reference cam. The following formula applies: Machine zero =
reference position + reference offset. This way, you can alter the machine zero with-
out having to move the reference cam.
TIP
Please also refer to the information in Sec. "Software limit switches."

16 Manual – MOVIDRIVE® MDX61B Automotive AMA 0801 Application Module
3 Process data assignment
Project Planning
3.5 Process data assignment
The higher-level controller (PLC) sends 6 process output data words via fieldbus (PO1
... PO6) to the inverter and receives six process input data words (PI1 ... PI6) from the
inverter.
3.5.1 Assignment of process output data in the "variable setpoint specification" operating mode
• PO1: Control word 2
• PO2 + PO3: Target position
• PO4: Setpoint speed
• PO5: Ramp up (high byte) and down (low byte)
• PO6: SyncOffset
56163AXX
Figure 1: Data exchange via 6 process data
PI
PO
PO1
PI1
PO2
PI2
PO3 PO4 PO5 PO6
PI3 PI4 PI5 PI6
1514131211109876543210
/SWLS off Controller inhibit/Enable
SyncOffset Enable/Rapid stop
Mode 22Enable/stop
Mode 21Reserved
Mode 20Ramp scaling
False: 10 ms/digit
TRUE: 100 ms/digit
Jog - Reserved
Jog + Error reset
Start Reserved
PO2 Target position high PO3 Target position low
31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
Target position [User unit]
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
Setpoint speed [User-defined unit]
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
Ramp up [10 ms or 100 ms] Ramp down [10 ms or 100 ms]
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
SyncOffset [User units]

Manual – MOVIDRIVE® MDX61B Automotive AMA 0801 Application Module 17
3
Process data assignment
Project Planning
3.5.2 Assignment of process input data in the "variable setpoint specification" operating mode
• PI1: Status word
• PI2 + PI3: Actual position
• PI4: Actual speed
• PI5: Master/slave position difference
• PI6: Active current
1514131211109876543210
Inverter status/fault code Drive synchronous
Inverter ready
IPOS reference (= drive referenced)
Target position reached
Brake released
Fault/warning
Limit switch CW
Limit switch CCW
TIP
The fault code is displayed in the high byte (bits 8 to 15) of the status word if bit 5
"Fault/warning" is set.. If there is no fault, the current unit status is displayed in the high
byte of the status word.
PI2 Actual position high PI3 Actual position low
31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
Speed [User-defined units]
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
Lag distance [User-defined units]
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
Active current [% IN]

18 Manual – MOVIDRIVE® MDX61B Automotive AMA 0801 Application Module
3 Process data assignment
Project Planning
3.5.3 Assignment of process output data in the "binary setpoint specification" operating mode
• PO1: Control word 2
• PO2: 16 single-bit positions
• PO3 + PO4: Correction value
• PO5: Reserved
• PO6: SyncOffset
1514131211109876543210
/SWLS off Controller inhibit/Enable
SyncOffset Enable/Rapid stop
Mode 22Enable/stop
Mode 21Reserved
Mode 20Ramp scaling
FALSE: 10 ms/digit
TRUE: 100 ms/digit
Jog - Reserved
Jog + Error reset
Start
Switch-over operating/creep
speed
FALSE: Creep speed
TRUE: Operating speed
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
PO3 Correction value high PO4 Correction value low
31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
Correction value [User unit]
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
Reserved
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
SyncOffset [User units]

Manual – MOVIDRIVE® MDX61B Automotive AMA 0801 Application Module 19
3
Process data assignment
Project Planning
3.5.4 Assignment of process input data in the "binary setpoint specification" operating mode
• PI1: Status word
• PI2 + PI3: Actual position
• PI4: 16 single bit position signal & drive does not rotate
• PI5: 16 Single-bit cam
• PI6: Active current
1514131211109876543210
Inverter status/fault code Drive synchronous
Inverter ready
IPOS reference (= drive referenced)
Target position reached
Brake released
Fault/warning
Limit switch CW
Limit switch CCW
TIP
The fault code is displayed in the high byte (bits 8 to 15) of the status word if bit 5
"Fault/warning" is set.. If there is no fault, the current unit status is displayed in the high
byte of the status word.
PI2 Actual position high PI3 Actual position low
31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
Active current [% IN]

20 Manual – MOVIDRIVE® MDX61B Automotive AMA 0801 Application Module
3 Process data assignment
Project Planning
3.5.5 Assignment of binary inputs and outputs on MOVIDRIVE®B
Binary input Assignment
X13:1 (DI00) /Controller inhibit
X13:2 (DI01) Enable/Stop
X13:3 (DI02 Error reset
X13:4 (DI03) Reference cam
X13:5 (DI04) /LIM. SWITCH CW
X13.6 (DI05) /LIM. SWITCH CCW
X16:1 (DI06) Reserved
X16:2 (DI07) /Ext. error (is activated in the "External Error" selection field under "Synchronous
operation interface master" during startup in the event of an "Error on slave axis")
Binary output Assignment
X10:3 (DB00) Brake output
X10:5 (DO01) Ready for operation
X10:7 (DO02 No malfunction
X16:3 (DO03) Reserved
X16:4 (DO04) Reserved
X16.5 (DO05) Reserved