SEW-Eurodrive MOVIFIT FC/MC User manual

*21306192_1114*
Drive Technology \ Drive Automation \ System Integration \ Services
Manual
MOVIFIT®FC/MC – Application Module Cam Positioning
Edition 11/2014 21306192/EN

SEW-EURODRIVE—Driving the world

Contents
Manual – MOVIFIT® FC/MC – Application Module Cam Positioning 3
Contents
1General information .................................................................................................................. 5
1.1 About this documentation ............................................................................................... 5
1.2 Structure of the safety notes .......................................................................................... 5
1.2.1 Meaning of signal words ................................................................................. 5
1.2.2 Structure of section-related safety notes ........................................................ 5
1.2.3 Structure of embedded safety notes ............................................................... 6
1.3 Right to claim under warranty ........................................................................................ 6
1.4 Exclusion of liability ........................................................................................................ 6
1.5 Other applicable documentation .................................................................................... 7
1.6 Product names and trademarks ..................................................................................... 7
1.7 Copyright ........................................................................................................................ 7
2Safety notes ............................................................................................................................... 8
2.1 General .......................................................................................................................... 8
2.2 Target group ................................................................................................................... 8
2.3 Designated use .............................................................................................................. 9
2.4 Bus systems ................................................................................................................... 9
2.5 Short designation ........................................................................................................... 9
3System description ................................................................................................................. 10
3.1 Area of application ....................................................................................................... 10
3.2 Properties ..................................................................................................................... 10
4Operating modes ..................................................................................................................... 11
4.1 Feed-in / feed-out ......................................................................................................... 11
4.1.1 Operating principle........................................................................................ 11
4.1.2 Operating mode "Feed-in" ............................................................................ 12
4.1.3 Operating mode "Feed-out" .......................................................................... 13
4.2 Lifting/rotating ............................................................................................................... 14
4.2.1 Operating principle........................................................................................ 14
4.2.2 Functional description ................................................................................... 15
4.3 Jog mode ..................................................................................................................... 16
4.3.1 Operating principle........................................................................................ 16
4.3.2 Functional description ................................................................................... 16
5Cycle diagrams ........................................................................................................................ 18
5.1 Feed-in/feed-out ........................................................................................................... 18
5.2 Lifting/rotating ............................................................................................................... 19
5.3 Jog mode ..................................................................................................................... 20
6 Startup ...................................................................................................................................... 21
6.1 Preparing startup .......................................................................................................... 21
6.2 Starting the application module .................................................................................... 21
6.3 Commencing startup .................................................................................................... 23
6.4 Process data configuration ........................................................................................... 24
6.5 Configuring monitoring functions .................................................................................. 25
6.6 Setting setpoints ........................................................................................................... 26
6.7 Downloading the program ............................................................................................ 28
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Contents
Manual – MOVIFIT® FC/MC – Application Module Cam Positioning
4
7Operation and diagnostics ..................................................................................................... 29
7.1 Control via fieldbus with 1 process data word .............................................................. 29
7.1.1 Monitor mode ................................................................................................ 29
7.1.2 Control mode ................................................................................................ 30
7.2 Control via fieldbus with 3 process data words ............................................................ 31
7.2.1 Monitor mode ................................................................................................ 31
7.2.2 Control mode ................................................................................................ 32
7.3 Control via fieldbus with 6 process data words ............................................................ 33
7.3.1 Monitor mode ................................................................................................ 33
7.3.2 Control mode ................................................................................................ 34
7.4 Diagnostics with the S12 safety option ........................................................................ 35
7.4.1 Safety notes .................................................................................................. 35
7.4.2 Description .................................................................................................... 35
7.4.3 S12 diagnostics view .................................................................................... 35
7.4.4 Structure of process data.............................................................................. 36
7.5 Extended process data word ........................................................................................ 38
8Data management.................................................................................................................... 39
8.1 Safety notes ................................................................................................................. 39
8.2 Activating data management ........................................................................................ 39
8.3 Structure of process data ............................................................................................. 41
9Terminal assignment............................................................................................................... 42
9.1 MOVIFIT® FC with "Technology" function level ............................................................ 42
9.2 MOVIFIT® MC with "Technology" function level ........................................................... 42
10 Process data ............................................................................................................................ 43
10.1 Process data interface with the PLC with 1 process data word ................................... 43
10.1.1 Overview ....................................................................................................... 43
10.1.2 Process output data ...................................................................................... 43
10.1.3 Process input data ........................................................................................ 43
10.2 Process data interface with the PLC with 3 process data words ................................. 44
10.2.1 Overview ....................................................................................................... 44
10.2.2 Process output data ...................................................................................... 45
10.2.3 Process input data ........................................................................................ 46
10.3 Process data interface with the PLC with 6 process data words ................................. 46
10.3.1 Overview ....................................................................................................... 46
10.3.2 Process output data ...................................................................................... 47
10.3.3 Process input data ........................................................................................ 48
Index ......................................................................................................................................... 49
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1
General information
About this documentation
Manual – MOVIFIT® FC/MC – Application Module Cam Positioning 5
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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1General information
Right to claim under warranty
Manual – MOVIFIT® FC/MC – Application Module Cam Positioning
6
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 Right to claim under 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 at hand. There-
fore, read the documentation before you start working with the software and the con-
nected units from SEW-EURODRIVE.
Make sure that the documentation is available to persons responsible for the machi-
nery and its operation as well as to persons who work independently on the units. Also
ensure that the documentation is legible.
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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1
General information
Other applicable documentation
Manual – MOVIFIT® FC/MC – Application Module Cam Positioning 7
1.5 Other applicable documentation
This document supplements the MOVIFIT® FC/MC operating instructions and limits
the application notes according to the following information. Use this documentation
only in connection with the MOVIFIT® FC/MC operating instructions.
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
© 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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2Safety notes
General
Manual – MOVIFIT® FC/MC – Application Module Cam Positioning
8
2Safety notes
2.1 General
The following basic safety notes are intended to prevent injury to persons and damage
to property. The user must ensure that the basic safety notes are read and observed.
Ensure that persons responsible for the machinery and its operation as well as per-
sons who work independently have read through the documentation carefully and un-
derstood it. If you are unclear about any of the information in this documentation or if
you require further information, please contact SEW-EURODRIVE.
The following safety notes refer to the use of the software. Also observe the supple-
mentary safety notes in this documentation and in the documentation for the connec-
ted units from SEW-EURODRIVE.
This document does not replace the detailed documentation for the connected units.
This documentation assumes that the user has access to and is familiar with the docu-
mentation for all connected units from SEW-EURODRIVE.
Never install or operate damaged products. Report any damage to the shipping com-
pany immediately.
Depending on the degree of protection, units may have live, uninsulated, and some-
times moving or rotating parts, as well as hot surfaces during operation.
Removing required covers without authorization, improper use or incorrect installation
and operation may result in severe injury to persons, or damage to machinery. Consult
the documentation for further information.
2.2 Target group
Work with the software in this solution may only be performed by adequately qualified
personnel. Qualified personnel in this context are persons who have the following
qualifications:
• Appropriate training in their relevant field.
• Knowledge of this documentation and other applicable documentation.
• SEW‑EURODRIVE recommends additional product training for products that are
operated using this software.
All mechanical work on connected units is to be performed exclusively by adequately
qualified personnel. Qualified personnel in the context of this documentation are per-
sons familiar with the design, mechanical installation, troubleshooting and servicing of
the product, who possess the following qualifications:
• Training in mechanical engineering, e.g. as a mechanic or mechatronics technician
(final examinations must have been passed).
• Knowledge of this documentation and other applicable documentation.
All electrical work on connected units is to be performed exclusively by adequately
qualified electricians. Qualified electricians in the context of this documentation are
persons familiar with electrical installation, startup, troubleshooting and servicing of
the product, who possess 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 and other applicable documentation.
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2
Safety notes
Designated use
Manual – MOVIFIT® FC/MC – Application Module Cam Positioning 9
• Knowledge of the relevant safety regulations and laws.
• Knowledge of all other standards, directives and laws named in this documenta-
tion.
The above-mentioned persons must have the express authorization of the company to
operate, program, configure, label and ground units, systems and circuits in accord-
ance with the standards of safety technology.
All work in the areas of transportation, storage, operation and waste disposal must be
carried out by persons who are trained appropriately.
2.3 Designated use
The application module cam positioning is used to control cam positioning systems
with MOVIFIT®.
The cam positioning application module can be implemented with the following
MOVIFIT® units:
• MOVIFIT® FC with "Technology" function level
• MOVIFIT® MC with "Technology" function level
2.4 Bus systems
A bus system makes it possible to adapt frequency inverters and/or motor starters to
the particulars of the machinery within wide limits. This results in the risk that a change
of parameters that cannot be detected externally can result in unexpected, though not
uncontrolled, system behavior.
2.5 Short designation
The following short designations are used in this documentation.
Type designation Short designation
Application module cam positioning Application module
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3System description
Area of application
Manual – MOVIFIT® FC/MC – Application Module Cam Positioning
10
3System description
3.1 Area of application
The application module is based on the "rapid/creep speed positioning" principle and
can be used in the following applications:
• Roller and chain conveyors
• Lifting table applications
• Rotary table applications
The following operating modes are supported:
• Feed-in
• Feed-out
• Lifting/rotating
• Jog mode
3.2 Properties
This application module has the following characteristics:
• Bidirectional rapid/creep speed positioning to one limit switch pair at each end
• Jog mode or positioning mode
• Control via fieldbus
• 3 run time monitoring functions for positioning
• Monitoring of the creep speed when the stop sensor is reached
• Data management
• Diagnostics with the S12 safety option
• User-guided startup and diagnostics
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4
Operating modes
Feed-in / feed-out
Manual – MOVIFIT® FC/MC – Application Module Cam Positioning 11
4Operating modes
4.1 Feed-in / feed-out
4.1.1 Operating principle
The following figure shows a typical application example of the "rapid/creep speed po-
sitioning" principle.
9007199704202507
In this roller conveyor, longer track sections are subdivided into segments.
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4Operating modes
Feed-in / feed-out
Manual – MOVIFIT® FC/MC – Application Module Cam Positioning
12
Decentralization of positioning takes load off the central controller. The independence
of bus runtimes allows for a high degree of positioning accuracy. This ensures a quick,
segment-wise transfer of the conveyed material.
Stop
[A]
[1] [2]
[3]
[4]
[B]
9007199704348043
[1] Sensor "Stop CCW" / item control CW [A] Rapid movement
[2] Sensor "F/S1) CCW" [B] Slow movement
[3] Sensor "F/S1) CW"
[4] Sensor "Stop CW" / item control CCW
1) F/S = Rapid/creep speed
4.1.2 Operating mode "Feed-in"
Functional description
Mode selection Mode 2
Prerequisite Drive enabled.
Functional descrip-
tion
After setting the start bit, the drive accelerates along the set ac-
celeration ramp until it reaches rapid speed.
Upon contacting the "F/S"1) sensor, the drive brakes along the
deceleration ramp until it reaches creep speed.
After the "Stop" sensor trips, the drive brakes along the stop
ramp to a standstill.
1) F/S = rapid/creep speed
The following table shows the correlation between the setpoints and their sources (see
chapter "Monitor mode" and "Setting setpoints").
Setpoint selec-
tion
Setpoint source
Rapid speed • Fieldbus 1PD Set during startup.
• Fieldbus 3PD Read from "PO2 rapid speed".
• Fieldbus 6PD Read from "PO2 rapid speed".
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4
Operating modes
Feed-in / feed-out
Manual – MOVIFIT® FC/MC – Application Module Cam Positioning 13
Setpoint selec-
tion
Setpoint source
Creep speed • Fieldbus 1PD Set during startup.
• Fieldbus 3PD Set during startup.
• Fieldbus 6PD Set via "PO3 creep speed".
Acceleration ramp • Fieldbus 1PD Set during startup.
• Fieldbus 3PD Read from "PO3 ramp".
• Fieldbus 6PD Read from "PO4 ramp".
Deceleration ramp • Fieldbus 1PD Set during startup.
• Fieldbus 3PD Read from "PO3 ramp".
• Fieldbus 6PD Read from "PO5 ramp down".
Stop ramp • Fieldbus 1PD Set during startup.
• Fieldbus 3PD Set during startup.
• Fieldbus 6PD Read from "PO6 ramp stop".
4.1.3 Operating mode "Feed-out"
Functional description
Mode selection Mode 3
Prerequisite Drive enabled.
Functional descrip-
tion
After setting the start bit, the drive accelerates along the set ac-
celeration ramp until it reaches rapid speed.
After the start bit is reset, the drive brakes along the decelera-
tion ramp to a standstill.
The following table shows the correlation between the setpoints and their sources (see
chapter "Monitor mode" and "Setting setpoints").
Setpoint selec-
tion
Setpoint source
Rapid speed • Fieldbus 1PD Set during startup.
• Fieldbus 3PD Read from "PO2 rapid speed".
• Fieldbus 6PD Read from "PO2 rapid speed".
Acceleration ramp • Fieldbus 1PD Set during startup.
• Fieldbus 3PD Read from "PO3 ramp".
• Fieldbus 6PD Read from "PO4 ramp".
Deceleration ramp • Fieldbus 1PD Set during startup.
• Fieldbus 3PD Read from "PO3 ramp".
• Fieldbus 6PD Read from "PO5 ramp down".
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4Operating modes
Lifting/rotating
Manual – MOVIFIT® FC/MC – Application Module Cam Positioning
14
4.2 Lifting/rotating
4.2.1 Operating principle
The following figure shows a typical application example of a lifting station.
9007199704825483
For rotating and lifting, positioning is performed according to the same principle as for
inward conveyance.
Once positioning in one direction has been performed, however, the drive cannot be
started in the same direction again. Starting in the same direction is inhibited by the "In
position" message. This prevents unintentional travel against the mechanical stop.
DANGER
Risk of crushing if the load falls.
Severe or fatal injuries.
• Do not stand under the load.
• Secure the danger zone.
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4
Operating modes
Lifting/rotating
Manual – MOVIFIT® FC/MC – Application Module Cam Positioning 15
Stop
[A]
[B]
[3]
[4]
[2]
[1]
9007199704833547
[1] Sensor "Stop CCW" / item control CW [A] Rapid movement
[2] Sensor "F/S1) CCW" [B] Slow movement
[3] Sensor "F/S1) CW"
[4] Sensor "Stop CW" / item control CCW
1) F/S = Rapid/creep speed
4.2.2 Functional description
Functional description
Mode selection Mode 4
Prerequisite Drive enabled.
Functional descrip-
tion
After setting the start bit, the drive accelerates along the set ac-
celeration ramp until it reaches rapid speed.
Upon contacting the "F/S"1) sensor, the drive brakes along the
set deceleration ramp until it reaches creep speed.
After the "Stop" sensor trips, the drive brakes along the set stop
ramp to a standstill.
Re-start in the same direction is blocked.
1) F/S = Rapid/creep speed
The following table shows the correlation between the setpoints and their sources (see
chapter "Monitor mode" and "Setting setpoints").
Setpoint selec-
tion
Setpoint source
Rapid speed • Fieldbus 1PD Set during startup.
• Fieldbus 3PD Read from "PO2 rapid speed".
• Fieldbus 6PD Read from "PO2 rapid speed".
Creep speed • Fieldbus 1PD Set during startup.
• Fieldbus 3PD Set during startup.
• Fieldbus 6PD Set via "PO3 creep speed".
Acceleration ramp • Fieldbus 1PD Set during startup.
• Fieldbus 3PD Read from "PO3 ramp".
• Fieldbus 6PD Read from "PO4 ramp".
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4Operating modes
Jog mode
Manual – MOVIFIT® FC/MC – Application Module Cam Positioning
16
Setpoint selec-
tion
Setpoint source
Deceleration ramp • Fieldbus 1PD Set during startup.
• Fieldbus 3PD Read from "PO3 ramp".
• Fieldbus 6PD Read from "PO5 ramp down".
Stop ramp • Fieldbus 1PD Set during startup.
• Fieldbus 3PD Set during startup.
• Fieldbus 6PD Read from "PO6 ramp stop".
4.3 Jog mode
4.3.1 Operating principle
In jog mode, you can move the drive independently of the other operating modes of
the system.
In jog mode, you can set the control bits "Jog+" or "Jog-" to move the drive clockwise
or counterclockwise. It is not necessary to set the start bit.
Speed and ramps are specified dynamically via the corresponding process data
words.
4.3.2 Functional description
Functional description
Mode selection Mode 1
Prerequisite Drive enabled.
Functional descrip-
tion
As long as the "positive" (jog+) signal is set, the drive rotates
clockwise. As long as the "negative" (jog-) signal is set, the drive
rotates counterclockwise. The drive stops if none or both signals
are set.
Acceleration and deceleration depend on the set acceleration
and deceleration ramp time.
The following table shows the correlation between the setpoints and their sources (see
chapter "Monitor mode" and "Setting setpoints").
Setpoint selec-
tion
Setpoint source
Rapid speed • Fieldbus 1PD Set during startup.
• Fieldbus 3PD Read from "PO2 rapid speed".
• Fieldbus 6PD Read from "PO2 rapid speed".
Acceleration ramp • Fieldbus 1PD Set during startup.
• Fieldbus 3PD Read from "PO3 ramp".
• Fieldbus 6PD Read from "PO4 ramp".
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4
Operating modes
Jog mode
Manual – MOVIFIT® FC/MC – Application Module Cam Positioning 17
Setpoint selec-
tion
Setpoint source
Deceleration ramp • Fieldbus 1PD Set during startup.
• Fieldbus 3PD Read from "PO3 ramp".
• Fieldbus 6PD Read from "PO5 ramp down".
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5Cycle diagrams
Feed-in/feed-out
Manual – MOVIFIT® FC/MC – Application Module Cam Positioning
18
5Cycle diagrams
5.1 Feed-in/feed-out
The following figure shows the actual speed of the drive against the status of the input
and output signals during feed-in or feed-out conveying.
n
[1]
[2]
[3]
[4]
[5]
[6]
[7]
[8]
[9]
1
2
3
4
9007199704374795
n Actual speed
[1] "Mode" input signal
[2] "Start" input signal
[3] "Positive" input signal
[4] "Start detected" output signal
[5] "Sensor "F/S1) CW" input signal
[6] "Sensor stop CW" input signal
[7] "Rapid speed active" output signal
[8] "Creep speed active" output signal
[9] "In position CW" output signal/top
1) F/S = Rapid/creep speed
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5
Cycle diagrams
Lifting/rotating
Manual – MOVIFIT® FC/MC – Application Module Cam Positioning 19
5.2 Lifting/rotating
The following figure shows the actual speed of the drive against the status of the input
and output signals during lifting or rotating.
1
2
3
4
n
[1]
[2]
[3]
[4]
[5]
[6]
[7]
[8]
[9]
[10]
[11]
[12]
[13]
450530955
n Actual speed [7] "Sensor stop CW" input signal
[1] "Mode" input signal [8] "Sensor F/S CCW" input signal
[2] "Start" input signal [9] "Sensor stop CCW" input signal
[3] "Positive" input signal [10] "Rapid speed active" output signal
[4] "Negative" input signal [11] "Creep speed active" output signal
[5] "Start detected" output signal [12] "In position CW" output signal/top
[6] "Sensor F/S CW" input signal [13] "In position CCW" output signal/bottom
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5Cycle diagrams
Jog mode
Manual – MOVIFIT® FC/MC – Application Module Cam Positioning
20
5.3 Jog mode
The following figure shows the actual speed of the drive against the status of the input
and output signals in jog mode.
1
2
3
4
[1]
n
[2]
[3]
[4]
450541579
n Actual speed
[1] "Mode" input signal
[2] "Positive" input signal
[3] "Negative" input signal
[4] "Rapid speed active" output signal
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