SEW-Eurodrive MOVIPRO PHC2 Series User manual

*26596598_1020*
Drive Technology \ Drive Automation \ System Integration \ Services
Operating Instructions
Drive and Application Controller
MOVIPRO® PHC2.A-A..M1-E45C-C5
Edition 10/2020 26596598/EN

SEW-EURODRIVE—Driving the world

Contents
Operating Instructions – MOVIPRO® PHC2.A-A..M1-E45C-C5 3
Contents
1 General information.................................................................................................................. 6
1.1 About this documentation ...............................................................................................6
1.2 Other applicable documentation .....................................................................................6
1.3 Structure of the safety notes ...........................................................................................6
1.4 Decimal separator in numerical values ...........................................................................7
1.5 Rights to claim under limited warranty ............................................................................8
1.6 Product names and trademarks......................................................................................8
1.7 Copyright notice ..............................................................................................................8
2 Safety notes .............................................................................................................................. 9
2.1 Preliminary information ...................................................................................................9
2.2 Duties of the user............................................................................................................9
2.3 Target group .................................................................................................................10
2.4 Designated use .............................................................................................................11
2.5 Functional safety technology ........................................................................................12
2.6 Transport.......................................................................................................................12
2.7 Installation/assembly.....................................................................................................13
2.8 Electrical installation .....................................................................................................14
2.9 Protective separation ....................................................................................................14
2.10 Startup/operation ..........................................................................................................15
3 Device structure ..................................................................................................................... 16
3.1 Type designation...........................................................................................................16
3.2 Scope of delivery ..........................................................................................................16
3.3 Short designations ........................................................................................................17
3.4 Device overview............................................................................................................18
3.5 Main nameplate ............................................................................................................19
3.6 Nameplate of function units ..........................................................................................20
3.7 Designation plates ........................................................................................................20
3.8 Warning signs ...............................................................................................................23
3.9 Type designations of the function units.........................................................................24
3.10 Function units................................................................................................................27
3.11 Accessories...................................................................................................................40
4 Integrated safety technology................................................................................................. 43
4.1 Prerequisites .................................................................................................................43
4.2 Safety functions ............................................................................................................43
4.3 Safety concept ..............................................................................................................43
5 Mechanical installation .......................................................................................................... 44
5.1 Requirements................................................................................................................44
5.2 Mounting position..........................................................................................................45
5.3 Minimum clearance.......................................................................................................45
5.4 Waste heat....................................................................................................................48
5.5 Assembly ......................................................................................................................49
6 Electrical installation.............................................................................................................. 55
6.1 Installation notes ...........................................................................................................55
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Contents
Operating Instructions – MOVIPRO® PHC2.A-A..M1-E45C-C5
4
6.2 Motor types ...................................................................................................................55
6.3 Low-voltage supply systems .........................................................................................55
6.4 UL-compliant installation...............................................................................................56
6.5 Electromagnetic compatibility (EMC) ............................................................................59
6.6 Cable routing.................................................................................................................60
6.7 Shielding .......................................................................................................................60
6.8 Protective measures against electrical hazards............................................................60
6.9 Using prefabricated cables ...........................................................................................64
6.10 Line components...........................................................................................................65
6.11 Connection block ..........................................................................................................66
6.12 Electrical connections ...................................................................................................71
7 Startup ................................................................................................................................... 145
7.1 For your safety ............................................................................................................145
7.2 Requirements..............................................................................................................145
7.3 Startup procedure .......................................................................................................146
7.4 Disconnecting the CAN bus ........................................................................................148
7.5 Addresses of the frequency inverters .........................................................................149
7.6 Brake control...............................................................................................................149
8 Operation............................................................................................................................... 150
8.1 For your safety ............................................................................................................150
8.2 Relative cyclic duration factor (cdf) .............................................................................150
8.3 Duty cycles..................................................................................................................151
8.4 Brake control operation...............................................................................................152
8.5 Status and error messages.........................................................................................153
8.6 Status LEDs ................................................................................................................154
8.7 Fault information .........................................................................................................157
9 Service................................................................................................................................... 159
9.1 Inspection/maintenance ..............................................................................................159
9.2 Device replacement ....................................................................................................159
9.3 Status display..............................................................................................................160
9.4 Fault information .........................................................................................................160
9.5 Reference travel after device or encoder replacement ...............................................161
9.6 Electronics Service by SEW‑EURODRIVE.................................................................161
9.7 Shutdown ....................................................................................................................162
9.8 Storage .......................................................................................................................162
9.9 Extended storage........................................................................................................162
9.10 Waste disposal............................................................................................................163
10 Technical data....................................................................................................................... 164
10.1 Marks ..........................................................................................................................164
10.2 General .......................................................................................................................165
10.3 Input data ....................................................................................................................165
10.4 DC 24 V backup voltage .............................................................................................166
10.5 Axis data .....................................................................................................................166
10.6 Braking resistor ...........................................................................................................167
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Contents
Operating Instructions – MOVIPRO® PHC2.A-A..M1-E45C-C5 5
10.7 Brake control...............................................................................................................167
10.8 DC 24 V output ...........................................................................................................167
10.9 Encoder.......................................................................................................................168
10.10 Communication and control unit .................................................................................170
10.11 Safety technology .......................................................................................................172
10.12 Dimension drawings....................................................................................................173
10.13 Hybrid cable type "D" ..................................................................................................176
10.14 Hybrid cable type "E" ..................................................................................................178
11 MAXOLUTION® Competence Center ................................................................................... 180
Index ...................................................................................................................................... 182
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1General information
About this documentation
Operating Instructions – MOVIPRO® PHC2.A-A..M1-E45C-C5
6
1 General information
1.1 About this documentation
The documentation at hand is the original.
This documentation is an integral part of the product. The documentation is intended
for all employees who perform work on the product.
Make sure this documentation is accessible and legible. Ensure that persons respon-
sible for the systems and their operation as well as persons who work on the product
independently have read through the documentation carefully and understood it. If you
are unclear about any of the information in this documentation or if you require further
information, contact SEW‑EURODRIVE.
1.2 Other applicable documentation
Observe the corresponding documentation for all further components. Observe the fol-
lowing documentation in addition to this documentation:
• "MOVIPRO® – Functional Safety" manual
• "MOVIPRO®–Accessories" addendum to operating instructions
Always use the latest edition of the documentation and the software.
The SEW‑EURODRIVE website (www.sew‑eurodrive.com) provides a wide selection
of documents for download in various languages. If required, you can also order prin-
ted and bound copies of the documentation from SEW‑EURODRIVE.
1.3 Structure of the safety notes
1.3.1 Meaning of signal words
The following table shows the grading and meaning of the signal words for safety
notes.
Signal word Meaning Consequences if disregarded
DANGER Imminent hazard Severe or fatal injuries
WARNING Possible dangerous situation Severe or fatal injuries
CAUTION Possible dangerous situation Minor injuries
NOTICE Possible damage to property Damage to the product or its envi-
ronment
INFORMATION Useful information or tip: Simplifies
handling of the product.
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1
General information
Decimal separator in numerical values
Operating Instructions – MOVIPRO® PHC2.A-A..M1-E45C-C5 7
1.3.2 Structure of section-related safety notes
Section-related safety notes do not apply to a specific action but to several actions
pertaining to one subject. The hazard symbols used either indicate a general hazard
or a specific hazard.
This is the formal structure of a safety note for a specific section:
SIGNAL WORD
Type and source of hazard.
Possible consequence(s) if disregarded.
• Measure(s) to prevent the hazard.
Meaning of the hazard symbols
The hazard symbols in the safety notes have the following meaning:
Hazard symbol Meaning
General hazard
Warning of dangerous electrical voltage
Warning of hot surfaces
Warning about suspended load
1.3.3 Structure of embedded safety notes
Embedded safety notes are directly integrated into the instructions just before the de-
scription of the dangerous action.
This is the formal structure of an embedded safety note:
SIGNAL WORD! Type and source of hazard. Possible consequence(s) if disregar-
ded. Measure(s) to prevent the hazard.
1.4 Decimal separator in numerical values
In this document, a period is used to indicate the decimal separator.
Example: 30.5kg
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1General information
Rights to claim under limited warranty
Operating Instructions – MOVIPRO® PHC2.A-A..M1-E45C-C5
8
1.5 Rights to claim under limited warranty
Read the information in this documentation. This is essential for fault-free operation
and fulfillment of any rights to claim under limited warranty. Read the documentation
before you start working with the product.
1.6 Product names and trademarks
The brands and product names in this documentation are trademarks or registered
trademarks of their respective titleholders.
1.7 Copyright notice
©2020SEW‑EURODRIVE. All rights reserved. Unauthorized reproduction, modifica-
tion, distribution or any other use of the whole or any part of this documentation is
strictly prohibited.
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2
Safety notes
Preliminary information
Operating Instructions – MOVIPRO® PHC2.A-A..M1-E45C-C5 9
2 Safety notes
2.1 Preliminary information
The following general safety notes serve the purpose of preventing injury to persons
and damage to property. They primarily apply to the use of products described in this
documentation. If you use additional components, also observe the relevant warning
and safety notes.
2.2 Duties of the user
As the user, you must ensure that the basic safety notes are observed and complied
with. Make sure that persons responsible for the machinery and its operation as well
as persons who work on the device independently have read through the documenta-
tion carefully and understood it.
As the user, you must ensure that all of the work listed in the following may be carried
out only by qualified specialists:
• Setup and installation
• Installation and connection
• Startup
• Maintenance and repairs
• Shutdown
• Disassembly
Ensure that the persons who work on the product pay attention to the following regula-
tions, conditions, documentation, and information:
• National and regional safety and accident prevention regulations
• Warning and safety signs on the product
• All other relevant project planning documents, installation and startup instructions,
and wiring diagrams
• Do not assemble, install or operate damaged products
• All system-specific specifications and conditions
Ensure that systems in which the product is installed are equipped with additional
monitoring and protection devices. Observe the applicable safety regulations and leg-
islation governing technical work equipment and accident prevention regulations.
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2Safety notes
Target group
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2.3 Target group
Specialist for me-
chanical work
Any mechanical work may be performed only by adequately qualified specialists. Spe-
cialists in the context of this documentation are persons who are familiar with the
design, mechanical installation, troubleshooting, and maintenance of the product who
possess the following qualifications:
• Qualifications in the field of mechanics in accordance with the national regulations
• Familiarity with this documentation
Specialist for elec-
trotechnical work
Any electrotechnical work may be performed only by electrically skilled persons with a
suitable education. Electrically skilled persons in the context of this documentation are
persons who are familiar with electrical installation, startup, troubleshooting, and main-
tenance of the product who possess the following qualifications:
• Qualifications in the field of electrical engineering in accordance with the national
regulations
• Familiarity with this documentation
Additional qualific-
ations
In addition to that, these persons must be familiar with the valid safety regulations and
laws, as well as with the requirements of the standards, directives, and laws specified
in this documentation.
The persons must have the express authorization of the company to operate, pro-
gram, parameterize, label, and ground devices, systems, and circuits in accordance
with the standards of safety technology.
Instructed persons All work in the areas of transportation, storage, operation and waste disposal must be
carried out by persons who are trained appropriately. The purpose of the training is to
give persons the ability to perform the required tasks and work steps in a safe and cor-
rect manner.
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2
Safety notes
Designated use
Operating Instructions – MOVIPRO® PHC2.A-A..M1-E45C-C5 11
2.4 Designated use
The product is intended for installation in electrical plants or machines.
In case of installation in electrical systems or machines, startup of the product is pro-
hibited until it is determined that the machine meets the requirements stipulated in the
local laws and directives. For Europe, Machinery Directive 2006/42/EC as well as the
EMC Directive 2014/30/EU apply. Observe EN60204-1 (Safety of machinery - elec-
trical equipment of machines). The product meets the requirements stipulated in the
Low Voltage Directive 2014/35/EU.
The standards given in the declaration of conformity apply to the product.
The systems can be mobile or stationary.
The motors must be suitable for operation with inverters.
Do not connect any other loads to the product. Never connect capacitive loads to the
product.
The product can be used to operate the following motors in industrial and commercial
systems:
• AC asynchronous motors with squirrel-cage rotor
• Permanent-field AC synchronous motors
Technical data and information on the connection conditions are provided on the
nameplate and in chapter "Technical data" in the documentation. Always comply with
the data and conditions.
Unintended or improper use of the product may result in severe injury to persons and
damage to property.
2.4.1 Restrictions under the European WEEE Directive 2012/19/EU
You may use options and accessories from SEW-EURODRIVE exclusively in connec-
tion with products from SEW-EURODRIVE.
2.4.2 Hoist applications
To avoid danger of fatal injury by falling hoists, observe the following points when us-
ing the product in lifting applications:
• The product is not designed for use as a safety device in lifting applications.
• Use additional monitoring systems or mechanical protection devices.
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2Safety notes
Functional safety technology
Operating Instructions – MOVIPRO® PHC2.A-A..M1-E45C-C5
12
2.5 Functional safety technology
The product must not perform any safety functions without a higher-level safety sys-
tem unless explicitly allowed by the documentation.
2.6 Transport
Inspect the shipment for damage as soon as you receive the delivery. Inform the ship-
ping company immediately about any damage. If the product is damaged, it must not
be assembled, installed or started up.
Observe the following notes when transporting the device:
• Ensure that the product is not subject to mechanical impact.
• Before transportation, cover the connections with the supplied protection caps.
• Only place the product on the cooling fins or on the side without connectors during
transportation.
• Always use all attachment points if available. The attachment points are designed
to carry only the mass of the product. Severe or fatal injuries. Do not apply any ad-
ditional loads.
If necessary, use suitable, sufficiently dimensioned handling equipment.
Observe the information on climatic conditions in chapter "Technical data"(→2164)
of the documentation.
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2
Safety notes
Installation/assembly
Operating Instructions – MOVIPRO® PHC2.A-A..M1-E45C-C5 13
2.7 Installation/assembly
Ensure that the product is installed and cooled in accordance with the regulations in
the documentation.
Protect the product from excessive mechanical strain. The product and its mounted
components must not protrude into the path of persons or vehicles. Ensure that no
components are deformed or no insulation spaces are modified, particularly during
transportation. Electrical components must not be mechanically damaged or de-
stroyed.
Observe the notes in chapter "Mechanical installation" (→ 2 44) in the documenta-
tion.
2.7.1 Restrictions of use
The following applications are prohibited unless the device is explicitly designed for
such use:
• Use in potentially explosive atmospheres
• Use in areas exposed to harmful oils, acids, gases, vapors, dust, and radiation
• Operation in applications with impermissibly high mechanical vibration and shock
loads in excess of the regulations stipulated in EN61800-5-1
• Use at an elevation of more than 4000m above sea level
The product can be used at altitudes above 1000 m above sea level up to 4000 m
above sea level under the following conditions:
• The reduction of the nominal output current and/or the line voltage is considered
according to the data in chapter "Technical data"(→2164) in the documentation.
• Above 2000m above sea level, the air and creeping distances are only sufficient
for overvoltage class II according to EN60664. At altitudes above 2000m above
sea level, limiting measures must be taken which reduce the line side overvoltage
from category III to category II for the entire system.
• If a protective electrical separation (in accordance with EN 61800‑5‑1 and
EN 60204‑1) is required, then implement this outside the product at altitudes of
more than 2000m above sea level.
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2Safety notes
Electrical installation
Operating Instructions – MOVIPRO® PHC2.A-A..M1-E45C-C5
14
2.8 Electrical installation
Ensure that all of the required covers are correctly attached after carrying out the elec-
trical installation.
Make sure that preventive measures and protection devices comply with the applica-
ble regulations (e.g. EN60204-1 or EN61800-5-1).
2.8.1 Required preventive measure
Make sure that the product is correctly attached to the ground connection.
2.9 Protective separation
The product meets all requirements for protective separation of power and electronics
connections in accordance with EN 61800-5-1. The connected signal circuits must
meet requirements according to SELV (Safety Extra Low Voltage) or PELV (Protective
Extra Low Voltage) to ensure protective separation. The installation must meet the re-
quirements for protective separation.
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2
Safety notes
Startup/operation
Operating Instructions – MOVIPRO® PHC2.A-A..M1-E45C-C5 15
2.10 Startup/operation
Observe the safety notes in chapters "Startup"(→2145) and "Operation"(→2150)
in this documentation.
Make sure that any existing transport protection is removed.
Do not deactivate monitoring and protection devices of the machine or system, even
for a test run.
Depending on the degree of protection, products may have live, uninsulated, and
sometimes moving or rotating parts as well as hot surfaces during operation.
Additional preventive measures may be required for applications with increased haz-
ard potential. Be sure to check the effectiveness of the protection devices after every
modification.
In the event of deviations from normal operation, switch the product off. Possible devi-
ations are increased temperatures, noise, or vibration, for example. Determine the
cause. Contact SEW‑EURODRIVE if necessary.
When the device is switched on, dangerous voltages are present at all power connec-
tions as well as at any connected cables and terminals. This also applies even when
the product is inhibited and the motor is at standstill.
Do not separate the connection to the product during operation. This may result in
dangerous electric arcs damaging the product.
If you disconnect the product from the voltage supply, do not touch any live compo-
nents or power connections because capacitors might still be charged. Observe the
following minimum switch-off time:
10 minutes.
Observe the corresponding information signs on the product.
The fact that the operation LED and other display elements are no longer illuminated
does not indicate that the product has been disconnected from the supply system and
no longer carries any voltage.
Mechanical blocking or internal protective functions of the product can cause a motor
standstill. Eliminating the cause of the problem or performing a reset may result in the
drive restarting automatically. If, for safety reasons, this is not permitted for the drive-
controlled machine, first disconnect the product from the supply system and then start
troubleshooting.
Cover unused connections with the supplied protection caps during operation.
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3Device structure
Type designation
Operating Instructions – MOVIPRO® PHC2.A-A..M1-E45C-C5
16
3 Device structure
3.1 Type designation
PHC2.A MOVIPRO® drive and application controller
Size:
1=Size1
2=Size2
–
APower supply: Three-phase current
.. Rated input power:
022=2.2kW
040=4kW
075=7.5kW
110=11kW
150=15kW
220=22kW
M1 1 integrated power section
–
E4 Fieldbus: Ethernet
5C Control type: MNC45A
–
C5 Device design: for EMS for heavy loads
3.2 Scope of delivery
The scope of delivery includes the following components:
Component Part number
Drive and Application Controller
MOVIPRO® PHC2.A-A..M1-E45C-C5
–
Protective covers for all plug connectors –
Grounding kit 12704628
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3
Device structure
Short designations
Operating Instructions – MOVIPRO® PHC2.A-A..M1-E45C-C5 17
3.3 Short designations
The following short designations are used in this documentation:
Type designation Short designa-
tion
Size Power rating
PHC21A-A022M1-E45C-C5
Device
Size1
2.2kW
PHC21A-A040M1-E45C-C5 4kW
PHC21A-A075M1-E45C-C5 7.5kW
PHC22A-A110M1-E45C-C5
Size2
11kW
PHC22A-A150M1-E45C-C5 15kW
PHC22A-A220M1-E45C-C5 22kW
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3Device structure
Device overview
Operating Instructions – MOVIPRO® PHC2.A-A..M1-E45C-C5
18
3.4 Device overview
The following figure provides an example of an overview of the most important device
components and the position of the labels on the device:
[1] [2]
[4]
[5]
[7]
[3]
[8]
[9]
[6]
33336936971
[1] Main nameplate [6] Status display
[2] Function unit nameplate [7] Ethernet service interfaces
[3] MAC address label [8] Connection block
[4] Cooling fins [9] Connection block label
[5] T-slot profile
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3
Device structure
Main nameplate
Operating Instructions – MOVIPRO® PHC2.A-A..M1-E45C-C5 19
3.5 Main nameplate
The main nameplate lists information about the device type. The following figure
shows an example of a main nameplate:
D-76646 Bruchsal
Made in Germany
Eingang / Input Ausgang / Output
U =
I =
f =
T =
XXXXX
P = IP
U =
I =
f =
Product-Key:
Type:
SO#:
ML
[2]
[1]
[6]
[3] [4]
[5]
32532916235
[1] Product name
[2] CE mark
[3] RCM mark
[4] China RoHS-2 mark
[5] Mark for WEEE Directive
[6] EAC mark
Depending on the device design, the following information is listed on the main name-
plate:
Value Specification
Type Type designation
SO# Production number
U Voltage
I Electricity
f Frequency
T Ambient temperature
P Rated output power
IP Degree of protection
Product-Key Product key
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3Device structure
Nameplate of function units
Operating Instructions – MOVIPRO® PHC2.A-A..M1-E45C-C5
20
3.6 Nameplate of function units
The nameplate contains information on the device's function units. For more informa-
tion on function units, refer to chapters "Type designations of the function
units" (→ 2 24) and "Function units" (→ 2 27). The following figure shows an ex-
ample of a nameplate of function units:
Product-Key:
Funktionsbaugruppen/function units
PFX-..
PFX-..
PFX-..
PFX-..
PFX-..
PFX-..
XXX.XXXXXXXX.XXX.XX
27021600760948363
Depending on the device design, the following information is listed on the nameplate
of function units:
Value Specification
Product-Key Product key
PFX-.. Type designation of the function unit
3.7 Designation plates
3.7.1 Connection block label
The designations of the individual connections of the device are given on the connec-
tion block label. The following figure shows an example of a connection block label:
Type: XXXXXX-XXXXXX-XXXX-XX
X.. X.. X..X.. X.. X.. X..
X..X..X..X..X..X..X..X..
72057598865108747
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