SEW-Eurodrive MOVIPRO PHC11A-M1-2A-A1 Series User manual

*20278543_0914*
Drive Technology \ Drive Automation \ System Integration \ Services
Operating Instructions
Application Controller
MOVIPRO®PHC11A-..M1-..2A-A1/..
Edition 09/2014 20278543/EN

SEW-EURODRIVE—Driving the world

Contents
Operating Instructions – MOVIPRO® PHC11A-..M1-..2A-A1/.. 3
Contents
1General information .................................................................................................................. 6
1.1 About 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 Product names and trademarks ..................................................................................... 8
1.6 Copyright ........................................................................................................................ 8
2Safety notes ............................................................................................................................... 9
2.1 Preliminary information .................................................................................................. 9
2.2 General information ........................................................................................................ 9
2.3 Target group ................................................................................................................. 10
2.4 Designated use ............................................................................................................ 10
2.5 Functional safety technology ........................................................................................ 10
2.6 Transport ...................................................................................................................... 11
2.7 Installation and assembly ............................................................................................. 11
2.8 Electrical connection .................................................................................................... 12
2.9 Safe disconnection ....................................................................................................... 12
2.10 Startup/operation .......................................................................................................... 12
2.11 Inspection/maintenance ............................................................................................... 13
3Unit structure........................................................................................................................... 14
3.1 Type designation .......................................................................................................... 14
3.2 Scope of delivery .......................................................................................................... 15
3.3 Short designations ....................................................................................................... 15
3.4 Unit overview ................................................................................................................ 16
3.5 Identification ................................................................................................................. 17
3.6 Accessories .................................................................................................................. 22
3.7 Function modules ......................................................................................................... 24
4Integrated safety technology.................................................................................................. 29
4.1 Standards ..................................................................................................................... 29
4.2 Safety functions ............................................................................................................ 29
4.3 Safety concept ............................................................................................................. 29
4.4 Additional information ................................................................................................... 29
5Mechanical installation ........................................................................................................... 30
5.1 Requirements ............................................................................................................... 30
5.2 Assembly ...................................................................................................................... 34
6Electrical installation............................................................................................................... 42
6.1 Protective measures against electrical hazards ........................................................... 42
6.2 Line connection energy supply ..................................................................................... 47
6.3 MOVITRANS® energy supply ....................................................................................... 51
7Electrical connections ............................................................................................................ 52
7.1 Terminal strip ............................................................................................................... 52
7.2 Representation of connections ..................................................................................... 53
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Contents
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4
7.3 Designation key ............................................................................................................ 53
7.4 Connection cables ........................................................................................................ 54
7.5 Cable structure ............................................................................................................. 54
7.6 X1011: MOVITRANS® THM20E pick-up ...................................................................... 55
7.7 X1021: MOVITRANS® THM20C pick-up ...................................................................... 56
7.8 X1201: AC 400 V input ................................................................................................. 57
7.9 X2011: Motor with brake control .................................................................................. 59
7.10 X2292: Brake control .................................................................................................... 63
7.11 X2301: Braking resistor ................................................................................................ 64
7.12 X2311: DC 24 V output ................................................................................................ 66
7.13 X2551: DC 24 V output for 2 voltage potentials ........................................................... 67
7.14 X4001: RS485 interface – system bus ......................................................................... 69
7.15 X4011: RS485 interface – external .............................................................................. 70
7.16 X4101: CAN bus – system bus .................................................................................... 71
7.17 X4111: CAN bus – external .......................................................................................... 73
7.18 X4211: WLAN antenna (main) ..................................................................................... 75
7.19 X4223: Ethernet service interface ................................................................................ 76
7.20 X4233: Ethernet fieldbus .............................................................................................. 77
7.21 X4261: WLAN antenna (aux) ....................................................................................... 78
7.22 X4401: ID module ........................................................................................................ 79
7.23 X5001_1: Digital inputs/outputs ................................................................................... 80
7.24 X5001_2: Digital inputs/outputs ................................................................................... 81
7.25 X5502: Safe disconnection – input ............................................................................... 82
8 Startup...................................................................................................................................... 84
8.1 General information ...................................................................................................... 84
8.2 Prerequisites ................................................................................................................ 85
8.3 Hoist applications ......................................................................................................... 85
8.4 Device configuration ..................................................................................................... 86
8.5 Main axes ..................................................................................................................... 87
8.6 Control of the brake modules ....................................................................................... 87
9Operation.................................................................................................................................. 88
9.1 Cyclic duration factor (CDF) ......................................................................................... 89
9.2 Duty types .................................................................................................................... 89
9.3 Operating the brake control .......................................................................................... 90
9.4 Status reports ............................................................................................................... 91
10 Service...................................................................................................................................... 92
10.1 Line connection energy supply ..................................................................................... 92
10.2 MOVITRANS® energy supply ....................................................................................... 97
11 Technical data.......................................................................................................................... 98
11.1 Basic unit ...................................................................................................................... 98
11.2 Axis data ...................................................................................................................... 99
11.3 Brake control .............................................................................................................. 100
11.4 DC 24 V output ........................................................................................................... 100
11.5 Processing unit ........................................................................................................... 101
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11.6 Radio modem ............................................................................................................. 102
11.7 Safety technology ....................................................................................................... 102
11.8 Dimension drawing ..................................................................................................... 103
12 Declaration of Conformity .................................................................................................... 104
13 Address list............................................................................................................................ 105
Index ....................................................................................................................................... 115
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1General information
About this documentation
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1General information
1.1 About this documentation
This documentation is an integral part of the product. The documentation is intended
for all employees who perform assembly, installation, startup, and service work on the
product.
Make sure this documentation is accessible and legible. Ensure that persons respon-
sible for the system and its operation, as well as persons who work independently on
the unit, have read through the entire documentation and understood it. If you are un-
clear about any of the information in this documentation, or if you require further infor-
mation, 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 drive system or
its environment.
INFORMATION Useful information or tip: Sim-
plifies handling of the drive sys-
tem.
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.
Section-related safety notes are structured as follows:
SIGNAL WORD
Type and source of hazard.
Possible consequence(s) if disregarded.
• Measure(s) to prevent hazard.
Meaning of the hazard symbols
The hazard symbols in the safety notes have the following meaning:
Hazard symbol Meaning
General hazard
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1
General information
Rights to claim under limited warranty
Operating Instructions – MOVIPRO® PHC11A-..M1-..2A-A1/.. 7
Hazard symbol Meaning
Warning of dangerous electrical voltage
Warning of hot surfaces
Warning of risk of crushing
Warning of suspended load
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.
Embedded safety notes are structured as follows:
• SIGNAL WORD Type and source of hazard.
Possible consequence(s) if disregarded.
– Measure(s) to prevent hazard.
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 docu-
mentation before you start working with the product.
1.4 Exclusion of liability
You must comply with the information contained in this documentation to ensure safe
operation and to achieve the specified product characteristics and performance fea-
tures. SEW-EURODRIVE assumes no liability for injury to persons or damage to
equipment or property resulting from non-observance of these operating instructions.
In such cases, any liability for defects is excluded.
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1General information
Product names and trademarks
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1.5 Product names and trademarks
The brands and product names in this documentation are trademarks or registered
trademarks of their respective titleholders.
1.6 Copyright
© 2014 SEW‑EURODRIVE. All rights reserved.
Unauthorized reproduction, modification, distribution or any other use of the whole or
any part of this documentation is strictly prohibited.
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2
Safety notes
Preliminary information
Operating Instructions – MOVIPRO® PHC11A-..M1-..2A-A1/.. 9
2Safety notes
2.1 Preliminary information
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 observed. Ensure that persons responsible for the machinery and its opera-
tion as well as persons who work on the unit independently have read through the
documentation carefully and understood it. If you are unclear about any of the informa-
tion in this documentation, or if you require further information, please contact
SEW‑EURODRIVE.
The following safety notes are primarily concerned with the use of the unit described in
these operating instructions. If you use other components from SEW‑EURODRIVE, al-
so refer to the safety notes for these particular components in the corresponding docu-
mentation.
Also observe the additional safety notes provided in the individual chapters of this
document.
2.2 General information
WARNING
Depending on its degree of protection, the unit 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, installation, assembly, connection,
startup, maintenance and repair may only be carried out by qualified personnel,
in strict observance of
– The relevant detailed documentation,
– The warning and safety signs on the unit,
– All other relevant project planning documents, operating instructions and wir-
ing diagrams
– The specific regulations and requirements for the system, and
– 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.
Unauthorized removal of covers, improper use, or incorrect installation and operation
may result in severe injury to persons, or damage to machinery.
Refer to the following chapters for more information.
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2Safety notes
Target group
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10
2.3 Target group
Mechanical work of any kind may be carried out only by trained specialists. Qualified
personnel in the context of this documentation are persons who are familiar with the
design, mechanical installation, troubleshooting and maintenance of the product and
have the following qualifications:
• Training in mechanical engineering, e.g. as a machinist or mechatronics technician
(final examinations must have been passed).
• Knowledge of this documentation.
Electrical work of any kind may be carried out only by skilled persons. In the context of
this documentation, skilled persons are persons who are familiar with the electrical in-
stallation, startup, troubleshooting and maintenance of the product and who have the
following qualifications:
• Training in electrical engineering, e.g. as an electrician or mechatronics technician
(final examinations must have been passed).
• Knowledge of 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 express authorization of the
company to operate, program, parameterize, identify and ground units, systems and
circuits in accordance with safety technology standards.
All work in the areas of transportation, storage, operation and waste disposal must be
performed by suitably trained personnel.
2.4 Designated use
The device is intended for installation in electrical plants or machines. The device can
be used in mobile and stationary operation in industrial and commercial plants for the
operation of AC asynchronous motors with squirrel cage rotor or permanent-field AC
synchronous motors. The motors must be suitable for operation with frequency inver-
ters. Do not connect any other loads to the device. The device can take on control and
communication tasks.
In case of installation in electrical systems or machines, startup of the device (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 (Machinery Directive). Ob-
serve standard EN 60204-1. Startup (i.e. the start of designated use) is only permitted
under observance of the EMC Directive (2004/108/EC).
The device meets the requirements stipulated in the low voltage directive 2006/95/EC.
The standards included in the declaration of conformity are used for the unit.
Technical data and information on the connection conditions are provided on the
nameplate and in the documentation. Always comply with the data and conditions.
2.5 Functional safety technology
The unit may not perform safety functions without higher-level safety systems unless
these functions are described and expressly permitted in the relevant documentation.
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2
Safety notes
Transport
Operating Instructions – MOVIPRO® PHC11A-..M1-..2A-A1/.. 11
2.6 Transport
Immediately upon delivery, inspect the shipment for any damage that may have occur-
red in transit. Inform the shipping company immediately about any damage. You may
need to suspend startup.
Observe the following notes when transporting the unit:
• Before transportation, cover the connections with the supplied protection caps.
• Place the unit only on the cooling fins or on the side without connectors during
transportation.
• Ensure that the unit is not subject to mechanical impact during transportation.
If necessary, use suitable, sufficiently dimensioned handling equipment. Remove the
securing devices used for transportation prior to startup.
Observe the information on climatic conditions as stated in chapter "Technical data".
2.7 Installation and assembly
Ensure that the unit is installed and cooled according to the regulations in this docu-
mentation.
Protect the unit from excessive strain. Ensure that components are not deformed and
that insulation spaces are maintained, particularly during transportation. Electric com-
ponents must not be mechanically damaged or destroyed.
The following applications are prohibited unless explicitly permitted:
• 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 EN 61800-5-1.
Observe the notes in the chapter "Mechanical installation".
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2Safety notes
Electrical connection
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12
2.8 Electrical connection
Observe applicable national accident prevention regulations when working on a live
unit.
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 meet the applicable regulations
(e.g. EN 60204-1 or EN 61800-5-1).
Necessary preventive measures for mobile use:
Type of energy transfer Protective measure
Direct power supply • Ground connection
MOVITRANS® Contactless Energy Trans-
fer System
• Protective separation
DIN VDE 0100-410 / IEC 60364-4-41
• ESD protection
Necessary preventive measures for stationary use:
Type of energy transfer Protective measure
Direct power supply • Ground connection
MOVITRANS® Contactless Energy Trans-
fer System
2.9 Safe disconnection
The unit meets all requirements for reliable isolation of power and electronics connec-
tions in accordance with EN 61800-5-1. All connected circuits must also meet the re-
quirements for reliable isolation.
2.10 Startup/operation
CAUTION
Danger of burns due to hot surfaces of the unit or connected options, e.g. braking
resistors.
Injury.
• Provide for covers to secure hot surfaces.
• Install the protection devices according to the regulations.
• Check the protection devices on a regular basis.
• Let the unit and the connected options cool down before you start working on
them.
Do not deactivate monitoring and protection devices even for a test run.
When in doubt, switch off the unit 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.
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2
Safety notes
Inspection/maintenance
Operating Instructions – MOVIPRO® PHC11A-..M1-..2A-A1/.. 13
Where required, systems in which such units are installed must be equipped with addi-
tional monitoring and protection devices in accordance with the respective applicable
safety regulations, e.g. the law governing technical equipment, accident prevention
regulations, etc.
Additional protective measures may be necessary for applications with increased po-
tential 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 unit 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 unit.
When the unit is switched on, dangerous voltages are present at all power connec-
tions 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 operation 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 stand-
still. Eliminating the cause of the problem or performing a reset may result in the drive
re-starting automatically. If this is not permitted for the driven machine for safety rea-
sons, disconnect the unit from the supply system before correcting the fault.
2.11 Inspection/maintenance
WARNING
Danger of electric shock due to exposed, live parts in the unit.
Severe or fatal injuries.
• Never open the unit.
• Only SEW-EURODRIVE is authorized to carry out repairs.
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3Unit structure
Type designation
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14
3Unit structure
3.1 Type designation
The type designation comprises the following characteristic data:
PProduct range:
P = MOVIPRO®
HControl type:
H = Application controller
CHousing type:
C = Modular
1Housing depth:
1 = 70 mm
1Housing height:
1 = 300 mm
AVersion
-
.Supply:
A = AC three-phase current
T = MOVITRANS®
.. Rated input power:
016 = 1.6 kW
020 = 2.0 kW
022 = 2.2 kW
040 = 4.0 kW
M1 Number of internal power sections:
1 = 1 power section
-
.. Bus connection:
E4 = LAN, TCP + UDP
W4 = WLAN, TCP + UDP
2Function level:
2 = System
AGeneration:
A = 1. Version
-
A1 Design:
A1 = Skillet
/
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3
Unit structure
Scope of delivery
Operating Instructions – MOVIPRO® PHC11A-..M1-..2A-A1/.. 15
001 Option:
001 = Operating switch
3.2 Scope of delivery
The following components are included in the delivery:
• MOVIPRO® PHC11A-..M1-..2A-A1/..
• Grounding kit
3.3 Short designations
The following short designations are used:
Type designation Supply Short designa-
tion
Power
PHC11A-A022M1-..2A-A1/.. AC 400 V
Unit
2.2 kW
PHC11A-A040M1-..2A-A1/.. 4.0 kW
PHC11A-T016M1-..2A-A1/..
MOVITRANS®
1.6 kW
PHC11A-T020M1-..2A-A1/.. 2.0 kW
PHC11A-T022M1-..2A-A1/.. 2.2 kW
PHC11A-T022M1-..2A-A1/.. 4.0 kW
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3Unit structure
Unit overview
Operating Instructions – MOVIPRO® PHC11A-..M1-..2A-A1/..
16
3.4 Unit overview
The following figure gives an overview of the main parts of the unit and the location of
the identifiers:
[3]
[2]
[4]
[5]
[6]
[7]
[8]
[1]
9007202514559883
[1] Main nameplate
[2] Function unit nameplate
[3] Status display
[4] Cooling fins
[5] T-slot profile
[6] Terminal strip
[7] Service interface
[8] Connection block label
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3
Unit structure
Identification
Operating Instructions – MOVIPRO® PHC11A-..M1-..2A-A1/.. 17
3.5 Identification
3.5.1 Main nameplate
The following figure shows an example of a nameplate:
D-76646 Bruchsal
Made in Germany
MOVIPRO
Type:
SO#:
Eingang / Input
PH..
XXX.XXXXXXXX.XXX.XX
Ausgang / Output
U
I
f
T
=
=
=
=
U
I
f
P
=
=
=
=IPXX
Product-Key:
Part#:
36028798225065995
The main nameplate lists the following information:
• Type designation (Type)
• Production number (SO#)
• Voltage (U)
• Current (I)
• Frequency (f)
• Ambient temperature (T)
• Rated output power (P)
• Degree of protection (IP)
• Product key
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3Unit structure
Identification
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18
3.5.2 Function modules nameplate
This nameplate describes the unit's internal function modules. The following figure
shows an example of a nameplate for the function modules:
Product-Key:
Funktionsbaugruppen/function units
XXX.XXXXXXXX.XXX.XX
PFF-..
PFS-..
PFZ-..
PFH-..
PFA-..
PFE-..
18014401506207371
Designation Function
PFA-.. Internal axis
PFE-.. Power supply
PFH-.. Communication and control unit
PFS-.. Safety device
PFZ-.. Actuator module
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3
Unit structure
Identification
Operating Instructions – MOVIPRO® PHC11A-..M1-..2A-A1/.. 19
Power section
PMOVIPRO® product range
FInternal function
AInternal axis
-
MD Frequency inverter on MOVIDRIVE® basis
.. Frequency inverter power rating:
022 = 2.2 kW
040 = 4.0 kW
BGeneration B
-
GEncoder evaluation
0 Motor encoder type:
0 = Without motor encoder
0 Distance encoder type:
0 = Without distance encoder
-
BBrake control
.. Brake control type:
S23 = Safety-related brake module (230 V)
S40 = Safety-related brake module (400 V)
S46 = Safety-related brake module (460 V)
-
.. Axis interfaces:
10 = 1 motor connection + STO
30 = 1 motor connection + STO + 1 digital output
/
.. Option 1:
C01 = Without fan subassembly
C11 = Smaller heat sink without fan
/
.. Option 2:
000 = Motor connections dependent on the power rating (BG0 = HANQ8, BG1 = HAN6B,
BG2 = HAN10B)
010 = Motor connections dependent on the power rating (HANQ8)
INFORMATION
Option 1 design: C11 is the nominal output power in S1 operation, thermally reduced
to the value specified in the technical data.
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3Unit structure
Identification
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Communication and control unit
PMOVIPRO® product range
FInternal function
HControl and communication
-
.. E4 = LAN, TCP + UDP
W4 = WLAN, TCP + UDP
2SEWOS function level
AVersion 1
IID module storage medium
0Standard ID module with M12 connector
-
BFieldbus interface
.. 00 = No bus connection
83 = 1 x Ethernet M12, copper
-
ILocal interfaces
33 = 6 digital inputs, 2 digital outputs, 8 digital inputs/outputs
.. 7 = Interfaces for SBus, CAN bus and RS485, each with a DC 24 V supply
8 = Interfaces for RS485 system bus, CAN bus and RS485, each with a DC 24 V supply
-
21 Micro DLC control card
/
000 Without option 1
/
.. 000 = Without option 2
W = With WLAN
1Single-client modem, 2.4 / 5.0 GHz, 2 coupler connections
.WLAN region:
1 = Europa
2 = China
3 = U.S. / Canada
4 = Brazil
5 = Mexico
6 = India
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