SEW-Eurodrive MOVIPRO ADC User manual

Drive Technology \ Drive Automation \ System Integration \ Services
Operating Instructions
Decentralized Drive and Application Controller
MOVIPRO
®
ADC
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Operating Instructions – MOVIPRO® ADC 3
Contents
Contents
1 General Information............................................................................................ 6
1.1 Use of this documentation .......................................................................... 6
1.2 Structure of the safety notes....................................................................... 6
1.3 Rights to claim under limited warranty........................................................ 7
1.4 Exclusion of liability..................................................................................... 7
1.5 Copyright..................................................................................................... 7
2 Safety notes......................................................................................................... 8
2.1 Preliminary information ............................................................................... 8
2.2 General information .................................................................................... 8
2.3 Target group ............................................................................................... 9
2.4 Designated use........................................................................................... 9
2.5 Functional safety technology ...................................................................... 9
2.6 Transport................................................................................................... 10
2.7 Installation/assembly................................................................................. 10
2.8 Electrical connection................................................................................. 11
2.9 Safe disconnection.................................................................................... 11
2.10 Startup/operation ...................................................................................... 12
2.11 Inspection/maintenance............................................................................ 12
3 Unit Structure .................................................................................................... 13
3.1 Type designation....................................................................................... 13
3.2 Short designations .................................................................................... 14
3.3 Scope of delivery ...................................................................................... 14
3.4 Nameplates............................................................................................... 15
3.5 Function units............................................................................................ 16
3.6 Basic unit .................................................................................................. 19
3.7 Accessories............................................................................................... 23
3.8 Unit components....................................................................................... 28
4 Integrated Safety Technology.......................................................................... 33
4.1 Standards.................................................................................................. 33
4.2 Safety functions ........................................................................................ 33
4.3 Safety concepts ........................................................................................ 33
4.4 Additional information ............................................................................... 33
5 Project Planning for Units with R15 Regenerative Power Supply................ 34
5.1 Supply system requirements..................................................................... 34
5.2 Installation................................................................................................. 34
5.3 System configuration ................................................................................ 34
6 Mechanical Installation..................................................................................... 35
6.1 General information .................................................................................. 35
6.2 Minimum clearance................................................................................... 35
6.3 Cooling...................................................................................................... 36
6.4 Mounting position...................................................................................... 37
6.5 Assembly .................................................................................................. 38
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4Operating Instructions – MOVIPRO® ADC
Contents
7 Electrical Installation ........................................................................................ 46
7.1 General information .................................................................................. 46
7.2 Low-voltage supply systems..................................................................... 46
7.3 Electromagnetic compatibility (EMC)........................................................ 46
7.4 Cable installation....................................................................................... 46
7.5 Information regarding UL .......................................................................... 47
7.6 Shielding................................................................................................... 48
7.7 Unit output................................................................................................. 49
7.8 Installation altitudes higher than 1000 m asl............................................. 49
7.9 Protective measures against electrical hazards........................................ 50
7.10 Connection blocks..................................................................................... 54
7.11 Electrical connections ............................................................................... 60
7.12 Power distribution with network supply................................................... 117
8 Startup.............................................................................................................. 118
8.1 General information ................................................................................ 118
8.2 Prerequisites........................................................................................... 119
8.3 Sequence................................................................................................ 120
8.4 Setting the station address (PROFIBUS)................................................ 121
8.5 Setting the station address (DeviceNet) ................................................. 123
8.6 Connection to a PC/laptop...................................................................... 125
8.7 Programming .......................................................................................... 125
9 Operation ......................................................................................................... 126
9.1 Cyclic duration factor (cdf) ...................................................................... 126
9.2 Operating modes .................................................................................... 127
9.3 Brake control operation........................................................................... 128
9.4 Status and error messages..................................................................... 129
9.5 Status LED.............................................................................................. 132
10 Service ............................................................................................................. 136
10.1 Inspection/maintenance.......................................................................... 136
10.2 Unit replacement..................................................................................... 137
10.3 Encoder exchange.................................................................................. 140
10.4 Fault information of the frequency inverter ............................................. 140
10.5 MOVIPRO®ADC error list ...................................................................... 142
10.6 SEW Electronics Service ........................................................................ 153
10.7 Shutdown................................................................................................ 153
10.8 Storage ................................................................................................... 154
10.9 Disposal .................................................................................................. 154
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Operating Instructions – MOVIPRO® ADC 5
Contents
11 Technical Data................................................................................................. 155
11.1 Standards and certification ..................................................................... 155
11.2 Design with 400 V/50 Hz operating point................................................ 156
11.3 Brake control........................................................................................... 157
11.4 Digital inputs ........................................................................................... 158
11.5 Digital outputs ......................................................................................... 158
11.6 General electronics ................................................................................ 158
11.7 Safety technology ................................................................................... 158
11.8 Communication and control unit ............................................................. 159
11.9 Dimension drawings................................................................................ 162
11.10 Hybrid cable type "D".............................................................................. 166
11.11 Hybrid cable type "E" .............................................................................. 168
11.12 Additional documentation........................................................................ 169
12 Declaration of Conformity.............................................................................. 170
13 Address List .................................................................................................... 171
Index................................................................................................................. 182
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6Operating Instructions – MOVIPRO® ADC
1Use of this documentation
General Information
1 General Information
1.1 Use of this documentation
The documentation is an integral part of the product and contains important information
on operation and service. The documentation is written for all employees who assemble,
install, startup, and service this product.
The documentation must be accessible and legible. Make sure that persons responsible
for the system and its operation, as well as personswho workindependently on the unit,
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 the signal words
The following table shows the grading and meaning of the signal words for safety notes,
notes on potential risks of damage to property, and other notes.
1.2.2 Structure of the section-related safety notes
Section safety notes do not apply to a specific action, but to several actions pertaining
to one subject. The used symbols indicate either a general or a specific hazard.
This is the formal structure of a section safety note:
1.2.3 Structure of the embedded safety notes
Embedded safety notes aredirectly integrated in the instructions just before the descrip-
tion of the dangerous action.
This is the formal structure of an embedded safety note:
•SIGNAL WORD Nature and source of hazard.
Possible consequence(s) if disregarded.
– Measure(s) to prevent the danger.
Signal word Meaning Consequences if disregarded
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 envi-
ronment
INFORMATION Useful information or tip: Simpli-
fies the handling of the drive
system.
SIGNAL WORD
Type and source of danger.
Possible consequence(s) if disregarded.
• Measure(s) to prevent the danger.
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Operating Instructions – MOVIPRO® ADC 7
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 limited
warranty is that you adhere to the information in the documentation. Read the documen-
tation before you start working with the unit!
1.4 Exclusion of liability
You must comply with the information contained in this documentation to ensure safe
operation of MOVIPRO®and to achieve the specified product characteristics and per-
formance features. SEW-EURODRIVE assumes no liability for injury to persons or dam-
age to equipment or property resulting from non-observance of these operating instruc-
tions. In such cases, any liability for defects is excluded.
1.5 Copyright
© 2011 – SEW-EURODRIVE. All rights reserved.
Unauthorized duplication, modification, distribution or any other use of the whole or any
part of this documentation is strictly prohibited.
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8Operating Instructions – MOVIPRO® ADC
2Preliminary information
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 ensure that the basic safety notes are read and
adhered to. Make sure that persons responsible for the system and its operation, as well
aspersonswho workindependently ontheunit, haveread throughtheoperating instruc-
tions carefully and understood them. If you are unclear about any of the information in
this documentation or if you require further information, please contact SEW-EURO-
DRIVE.
2.1 Preliminary information
The following safety notes are primarily concerned with the use of MOVIPRO®units. If
you use other SEW components, also refer to the safety notes for the respective com-
ponents in the corresponding documentation.
Please also observe the supplementary safety notes in the individual chapters of this
documentation.
2.2 General information
Removing covers without authorization, improper use as well as incorrect installation or
operation may result in severe injuries to persons or damage to property.
Refer to the documentation for more information.
WARNING
Depending on its enclosure, MOVIPRO®may have live, uninsulated as well as moving
or rotating parts and hot surfaces during operation.
Severe or fatal injuries.
• All work related to transportation, storage, setup/mounting, connection, startup,
maintenance and repair may only be carried out by qualified personnel, in strict ob-
servance of:
– The relevant detailed documentation.
– Warning and safety signs on the MOVIPRO®.
– All other relevant project planning documents, operating instructions and wiring
diagrams.
– The specific regulations and requirements for the system.
– The national/regional regulations governing safety and the prevention of acci-
dents.
• Never install damaged products.
• Submit a complaint to the shipping company immediately in the event of damage.
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Operating Instructions – MOVIPRO® ADC 9
2
Target group
Safety Notes
2.3 Target group
Any mechanical work may only be performed by adequately qualified personnel. Quali-
fied staff in the context of this documentation are persons familiar with the design, me-
chanical installation, troubleshooting and servicing of the product who possess the fol-
lowing qualifications:
• Training in mechanical engineering, e.g. as a mechanic or mechatronics technician
(final examinations must have been passed).
• They are familiar with this documentation.
Any electronic work may only be performed by adequately qualified electricians. Quali-
fied electricians in the context of this documentation are persons familiar with electrical
installation, startup, troubleshooting and servicing of the product who possess the fol-
lowing qualifications:
• Training in electrical engineering, e.g. as an electrician or mechatronics technician
(final examinations must have been passed).
• They are familiar with this documentation.
In addition to that, they must be familiar with the relevant safety regulations and laws,
especially with the requirements of the performance levels according to
DIN EN ISO 13849-1 and all other standards, directives and laws specified in this doc-
umentation. The above mentioned persons must have the authorization expressly is-
sued by the company to operate, program, configure, label and ground units, systems
and circuits in accordance with the standards of safety technology.
All work in further areas of transportation, storage, operation and waste disposal must
only be carried out by persons who are trained appropriately.
2.4 Designated use
MOVIPRO®is a component intended for installation in electrical systems or machines.
MOVIPRO®is designed for mobile and stationary use in industrial and commercial sys-
tems for the operation of AC asynchronous motors with squirrel-cage rotors or perma-
nent-field AC synchronous motors. The motors must be suitable for operation with in-
verters. Do not connect any other loads to MOVIPRO®. MOVIPRO®can take on control
and communication tasks.
In case of installation in electrical systems or machines, startup of the MOVIPRO®units
(i.e. start of designated operation) is prohibited until it is determined that the machine
meets the requirements stipulated in the EC Directive 2006/42/EC (machine guideline).
Observe EN 60204-1. Startup (i.e. the start of designated use) is only permitted under
observance of the EMC (2004/108/EC) directive.
MOVIPRO®meets the requirements stipulated in the low voltage directive 2006/95/EC.
The standards given in the declaration of conformity apply to the MOVIPRO®units.
Technical data and information on the connection conditions are provided on the name-
plate and in the documentation. Always comply with the data and conditions.
2.5 Functional safety technology
MOVIPRO®may not perform safety functions without higher-level safety systems un-
less these functions are described and expressly permitted in the relevant documenta-
tion.
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10 Operating Instructions – MOVIPRO® ADC
2Transport
Safety Notes
2.6 Transport
Inspect the shipment for any damage that may have occurred in transit as soon as you
receive the delivery. Inform the shipping company immediately. It may be necessary to
preclude startup.
Observe the following instructions when transporting MOVIPRO®:
• Cover the connections with the supplied protective caps before transportation.
• Only place the unit on thecooling fins or on the side without connectors during trans-
portation.
• Make sure that the unit is not subject to mechanical impact during transport.
Use suitable, sufficiently rated handling equipment if necessary. Prior to startup, remove
the securing devices used for transportation.
Observe the information on climatic conditions as stated in chapter "Technical Data".
2.7 Installation/assembly
Ensure that the units are installed and cooled according to the regulations in the related
documentation.
Protect the MOVIPRO®unit from excessive strain. Ensure that components are not de-
formed and/or insulation spaces are maintained, particularly during transportation. Elec-
tric components must not be mechanically damaged or destroyed.
The following applications are prohibited unless the unit is explicitly designed for such
use:
• Use in potentially explosive atmospheres.
• Use in areas exposed to harmful oils, acids, gases, vapors, dust, radiation, etc.
• Use in applications that are subject to mechanical vibration and shock loads in ex-
cess of the requirements in EN61800-5-1.
Observe the notes in the "Mechanical Installation" section.
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Operating Instructions – MOVIPRO® ADC 11
2
Electrical connection
Safety Notes
2.8 Electrical connection
Observe applicable national accident prevention regulations when working on a live
MOVIPRO®.
Perform electrical installation according to the pertinent regulations (e.g. cable cross-
sections, fusing, protective conductor connection). The documentation contains addi-
tional notes.
Preventive measures and protection devices must comply with applicable regulations
(e.g. EN 60204-1 or EN 61800-5-1).
Necessary protective measures for MOVIPRO®are:
2.9 Safe disconnection
MOVIPRO®meets all of the requirements for the safe disconnection of power and elec-
tronic connections in accordance with EN 61800-5-1. To ensure safe disconnection, all
connected circuits must also satisfy the requirements for safe disconnection.
Type of power transmission Protective measure
Direct power supply • Protective grounding
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12 Operating Instructions – MOVIPRO® ADC
2Startup/operation
Safety Notes
2.10 Startup/operation
Do not deactivate monitoring and protection devices even for a test run.
When in doubt, switch off the MOVIPRO®whenever changes occur in relation to normal
mode (e.g. increased temperatures, noise, oscillation). Determine the cause of the fault
and consult SEW-EURODRIVE, if necessary.
Where required, systems with integrated MOVIPRO®units must be equipped with addi-
tional monitoring and protection devices in accordance with the respective applicable
safety regulations, e.g. the law governingtechnical equipment, accident prevention reg-
ulations, etc.
Additional protective measures may be necessary for applications with increased poten-
tial risk. You have to check the effectiveness of protection devices each time you change
the configuration.
Connections which are not being used must be covered with the supplied protection
caps during operation.
Do not touch live components or power connections immediately after disconnecting the
MOVIPRO®from the voltage supply because some capacitors may still be charged. Ad-
here to a minimum switch-off time of 10 minutes. Observe the corresponding labels on
the MOVIPRO®unit.
When the unit is switched on, dangerous voltages are present at all power connections
as well as at any connected cables and motor terminals. This also applies even when
the unit is inhibited and the motor is at standstill.
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 error.
Important – Danger of burns: During operation, the surface temperature of
MOVIPRO®and of the external options (e.g. the braking resistor) can exceed 70 °C.
2.11 Inspection/maintenance
WARNING
Exposed, live parts inside the unit.
Severe or fatal injuries.
• Never open the unit.
• Only SEW-EURODRIVE is authorized to carry out repairs.
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Operating Instructions – MOVIPRO® ADC 13
3
Type designation
Unit Structure
3 Unit Structure
3.1 Type designation
The type designation of the MOVIPRO®drive and application controller provides the fol-
lowing unit data:
P H C 2 . A - A ...M 1 - .. 1 A - 00 / ... Option:
S11 = PROFIsafe option S11
Design
Version:
A = Version 1
Unit type:
1=ADC
Bus connection:
P1 = PROFIBUS DPV1
D1 = DeviceNet
E2 = PROFINET
E3 = EtherNet/IP, Modbus/TCP
Number of power connectors:
1 = 1 axis output
Power connector:
M = Axis output
Power:
022 = 2.2 kW
040 = 4.0 kW
075 = 7.5 kW
110 = 11.0 kW
150 = 15.0 kW
Supply:
A = AC
Version
Housing height:
1 = Size 0, 1
2 = Size 2
Housing type:
C = Modular
Control type:
H = Drive control
Product range:
P = MOVIPRO®
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14 Operating Instructions – MOVIPRO® ADC
3Short designations
Unit Structure
3.2 Short designations
The following short designations are used:
3.3 Scope of delivery
The scope of delivery includes the following components:
•MOVIPRO
®PHC2.A-A...M1-..1A-00/... drive and application controller
• 2 × grounding kit
• Jumper plug (not for units with PROFIsafe option S11)
•ForMOVIPRO
®size 2, 15.0 kW:
– Mounted fan subassembly
Type designation Short designation Size Power
rating
MOVIPRO®PHC21A-A022M1-..1A-00/... drive and
application controller
MOVIPRO®
Size 0 2.2 kW
MOVIPRO®PHC21A-A040M1-..1A-00/... drive and
application controller Size 1 4.0 kW
MOVIPRO®PHC21A-A075M1-..1A-00/... drive and
application controller 7.5 kW
MOVIPRO®PHC22A-A110M1-..1A-00/... drive and
application controller Size 2 11.0 kW
MOVIPRO®PHC22A-A150M1-..1A-00/... drive and
application controller 15.0 kW
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Operating Instructions – MOVIPRO® ADC 15
3
Nameplates
Unit Structure
3.4 Nameplates
Each MOVIPRO®unit has 2 nameplates that provide important information:
• Main nameplate
• Function unit nameplate
3.4.1 Main nameplate
The main nameplate provides important information about the unit type. The following
figure shows an example of a main nameplate:
3.4.2 Function unit nameplate
This nameplate describes the internal function units of MOVIPRO®. The following figure
shows an exemplary nameplate for the function units:
2816333067
Type Type designation f Frequency
SO# Production number T Ambient temperature
Product key Product key P Output power
U Voltage IP Degree of protection
I Current UNNominal voltage
D-76646 Bruchsal
Made in Germany
MOVIPRO
Feldumrichter
Field-Inverter
Type:
SO#:
Eingang / Input
PHC2.A-A...M1-..1A-00/...
XXX.XXXXXXXX.XXX.XX
Ausgang / Output
T +5 ... +40 °C P 4,0 kW/5,5 HP IP54
U
I
f
=
=
=
U
I
f
=
=
=
3 AC 380 ... 500 V
3 AC 6,3 A
50 ... 60 Hz
3 AC 0 V ... U
N
3 AC 5 A
0 ... 600 Hz
==
Product-Key: S 0000 5AD2 1234 85
2816336907
PFH-..1A..-B..-I1..-00/.../000 Communication and control unit
PFA-MD...B-G..-BG..-../C../000 Power section
PFE-AC...A-...-000A-00/000/000 Energy supply
MOVIPRO
Feldumrichter
Field-Inverter
Type:
SO#:
Funktionsbaugruppen/function unit
PHC2.A-A...M1-..0A-00/...
XXX.XXXXXXXX.XXX.XX
PFH-..1A..-B..-I1..-00/.../000
PFA-MD...B-G..-BG..-../C../000
PFE-AC...A-...-000A-00/000/000
Product-Key: S 0000 5AD2 1234 85
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16 Operating Instructions – MOVIPRO® ADC
3Function units
Unit Structure
3.5 Function units
3.5.1 Power section
PFA-MD...B-G. .-B...-../C../000 Version of option 1:
01 = Standard without fan
subassembly
02 = Standard with fan subassembly
Type of option 1:
C = Cooling
Axis interface:
11 = 2 × M12 plug connector for
4 digital axis inputs
15 = 2 × M12 plug connectors for
2 digital axis inputs and 1 analog
axis input
Brake control voltage:
02 = DC 24 V
23 = AC 230 V
40 = AC 400 V
46 = AC 460 V
Brake control
BG = Standard brake control
BS = With safety-related brake
module
Distance encoder type:
0 = Without distance encoder
1 = CANopen
2 = SSI, HIPERFACE®, sin/cos,
HTL, TTL, RS422
Motor encoder type:
0 = Without motor encoder
1 = Resolver
2 = HIPERFACE®, Sin/Cos, HTL,
TTL, RS422
G=Encoder
Frequency inverter power rating:
022 = 2.2 kW
040 = 4.0 kW
075 = 7.5 kW
110 = 11.0 kW
150 = 15.0 kW
Frequency inverter type:
MD = MOVIDRIVE®platform
Subassembly:
A = Internal axis
F = Internal function
Product range:
P = MOVIPRO®
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Operating Instructions – MOVIPRO® ADC 17
3
Function units
Unit Structure
3.5.2 Communication and control unit
P F H - .. 1 A . . - B .. - I 1 0 . -00 / ... / 000 Option 1:
000 = Without option 1
S11 = PROFIsafe option S11
Design
Communication packages
0= Without
1 = With SBUSplus, CAN and
RS485 interface
2 = With SBUSplus, CAN and
RS485 interface (with
DC 24 V)
3 = With SBUSplus, CAN (with
DC 24 V) and RS485
interface (with DC 24 V)
4 = With SBUSplus, CAN (with
DC 24 V) and RS485
interface
1= 12 digital inputs and 4
digital inputs/outputs
I = Local interface
Bus connection type:
11 = DIP module PROFIBUS,
2×M12
12 = DIP module DeviceNet,
2×M12
53 = 2 × M12, D-coded,
Ethernet, copper
63 = 2 × push-pull RJ45,
Ethernet, copper
64 = 2 × push-pull SCRJ
B = Fieldbus connection
Memory card
0= OM._T0
1= OM._T1
2= OM._T2
Memory card type
C = Parameterizable
H = Programmable
A = Version 1
Unit type:
1= ADC
Communication type:
P1 = PROFIBUS DPV1
D1 = DeviceNet
E2 = PROFINET IO
E3 = EtherNet/IP / Modbus/TCP
Subassembly:
H = Control / communication
F = Internal function
Product range:
P = MOVIPRO®
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18 Operating Instructions – MOVIPRO® ADC
3Function units
Unit Structure
3.5.3 Energy supply
P F E - AC ... A - ... - 000A- 00 / ... / 000 Type of option 2:
000 = Without option 2
Type of option 1:
000 = Without option 1
R15 = Regenerative power supply for
MOVIPRO®with a power
rating of at least 11.0 kW
Supply system connection:
001 = Connection for plug
connectors, size 0,1
002 = Connection for plug
connectors, size 2
101 = Connectionforpowerinterface,
sizes 0 and 1
102 = Connectionforpowerinterface,
size 2
A = Version A
Power rating of supply system
rectifier
AC = Power supply
Subassembly:
E = Energy
F = Internal function
Product range:
P = MOVIPRO®
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Operating Instructions – MOVIPRO® ADC 19
3
Basic unit
Unit Structure
3.6 Basic unit
3.6.1 Size 0
The following figure shows the unit structure of size 0:
2648537483
[1] Unit cover [5] Connecting block (connections depend on the unit variant)
[2] Service cover plate [6] Cooling fins
[3] Service unit [7] T-slot profile
[4] Power interface (optional)
[1] [3][2]
[4]
[7]
[5] [6]
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20 Operating Instructions – MOVIPRO® ADC
3Basic unit
Unit Structure
3.6.2 Size 1
The following figure shows the unit structure of size 1:
2660814987
[1] Unit cover [5] Connecting block (connections depend on the unit variant)
[2] Service cover plate [6] Cooling fins
[3] Service unit [7] T-slot profile
[4] Power interface (optional)
[1] [3][2]
[4]
[7][5] [6]
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