SEW-Eurodrive Movidrive MDX61B User manual

Gearmotors \ Industrial Gearmotors \ Drive Electronics \ Drive Automation \ Services
MOVIDRIVE
®
MDX61B
“DriveSync via Fieldbus“ Application
M anual
FA362800
Edition 09/2005
11340819 / EN

SEW-EURODRIVE – Driving the world

Manual – MOVIDRIVE® MDX61B DriveSync via Fieldbus Application
3
1 Important notes...................................................................................................... 4
1.1 Explanation of the symbols............................................................................ 4
1.2 Safety notes and general information ............................................................ 5
2 System Description................................................................................................ 6
2.1 Areas of application ....................................................................................... 6
2.2 Application examples..................................................................................... 7
2.3 Program identification .................................................................................. 10
3 Project planning................................................................................................... 11
3.1 Prerequisites................................................................................................ 11
3.2 Functional description.................................................................................. 12
3.3 Scaling the drive .......................................................................................... 13
3.4 Limit switches, reference cams and machine zero ...................................... 14
3.5 Process data assignment............................................................................. 15
3.6 Software limit switches................................................................................. 18
3.7 Safe stop...................................................................................................... 20
4 Installation ............................................................................................................ 21
4.1 MOVITOOLS®software............................................................................... 21
4.2 Wiring diagram for connecting incremental encoder master to
MDX61B slave ............................................................................................. 22
4.3 Wiring diagram MDX61B master / MDX61B slave....................................... 23
4.4 Bus installation for MOVIDRIVE®MDX61B................................................. 24
4.5 System bus connection (SBus 1)................................................................. 31
5 Startup................................................................................................................... 32
5.1 General information ..................................................................................... 32
5.2 Preliminary work........................................................................................... 32
5.3 Starting the program "DriveSync via fieldbus" ............................................. 33
5.4 Parameters and IPOSplus®variables.......................................................... 56
5.5 Recording IPOSplus®variables................................................................... 59
6 Operation and Service......................................................................................... 60
6.1 Starting the drive.......................................................................................... 60
6.2 Monitor mode............................................................................................... 62
6.3 Jog mode ..................................................................................................... 66
6.4 Referencing mode........................................................................................ 68
6.5 Positioning mode ........................................................................................ 70
6.6 Synchronous operation................................................................................ 72
6.7 Cycle diagrams ............................................................................................ 74
6.8 Fault information .......................................................................................... 80
6.9 Fault messages............................................................................................ 81
7 Index...................................................................................................................... 84

4
Manual – MOVIDRIVE® MDX61B DriveSync via Fieldbus Application
1Explanation of the symbols
Important notes
Handbuch
1 Important notes
Always follow the safety and warning instructions contained in this section!
1.1 Explanation of the symbols
Hazard
Indicates an imminently hazardous situation which, if not avoided, WILL result in death
or serious injury.
Warning
Indicates an imminently hazardous situation caused by the product which, if not
avoided, WILL result in death or serious injury. You will also find this signal to indicate
the potential for damage to property.
Caution
Indicates a potentially hazardous situation which, if not avoided, MAY result in minor
injury or damage to products.
Note
Indicates a reference to additional information, for example on startup, or other useful
data.
Documentation reference
Indicatesareferencetoa document,suchasoperatinginstructions, catalog,data sheet.

Manual – MOVIDRIVE® MDX61B DriveSync via Fieldbus Application
5
1
Safety notes and general information
Important notes
1.2 Safety notes and general information
Risk of an electrical shock
Possible consequences: Death or serious injury.
Onlyelectricalspecialistsare allowed toinstalland start up MOVIDRIVE®driveinverters
observing the applicable accident prevention regulations and the MOVIDRIVE®
operating instructions.
Potentially hazardous situation which, if not avoided, may result in damage to
products or the surrounding area.
Possible consequences: Damage to the product
Read through this manual carefully before you commence installation and startup of
MOVIDRIVE®drive inverters with this application module. This manual does not replace
the detailed operating instructions!
A requirement of fault-free operation and the possibility of any rights to claim under guar-
antee is that you observe the information in the documentation.
Documentation reference
This manual was written assuming that the user is familiar with the MOVIDRIVE®
documentation, in particular the MOVIDRIVE®system manual.
In this manual, cross references are marked with "→". For example, (→Sec. X.X)
means: Further information can be found in section X.X of this manual.

6
Manual – MOVIDRIVE® MDX61B DriveSync via Fieldbus Application
2Areas of application
System Description
2 System Description
2.1 Areas of application
The "DriveSync via fieldbus" application module makes it possible to implement
conveyor systems and machinery with drives that have to move at a synchronous angle
to one another occasionally or permanently.
The program can be used for the master drive and the slave drive. The master works in
the "Jog" and "Positioning" operating modes, while the slave drives are operated in
"synchronous operation" mode.
If the "Synchronous operation" mode is deselected for the slave drives, they can be
operated with free-running in "Jog" and "Positioning" operating modes.
The "DriveSync via fieldbus" application offers the following advantages:
• One program for the master and slave drive.
• Guided startup as well as extensive diagnostic functions.
• High degree of similarity with the "Extended positioning via bus" application module.
• The selected IPOS encoder source (X13, X14, DIP) is also effective in synchronous
operation.
• The master value for the "synchronous operation" mode can be adjusted
• A mechanical vertical shaft can be replaced by transferring the virtual master value
via an S-bus connection
• Endless rotation can be implemented by the modulo function.
Features of synchronous operation mode:
• The electrical connection of the master/slave can be made using the X14 connection
or an SBus connection.
• The contents of the send object can be adjusted when the S-bus connection is used.
For example, the value of any IPOSplus® variable can be transferred instead of the
IPOSplus® variable of the master drive.
• Time or position-related sequence of motion for synchronization procedures.
• The startup cycle process can also be started with interrupt control.

Manual – MOVIDRIVE® MDX61B DriveSync via Fieldbus Application
7
2
Application examples
System Description
2.2 Application examples
The "DriceSync via fieldbus" application module offers a wide range of possible
applications. Some examples are given in this section.
Finite (linear)
movement of the
master and slave
axis
Example 1: Hoist
• Master axis: Linear axis
Operating mode: Positioning mode
• Slave axis: Linear axis
Operating mode: Synchronous operation
Example 2: Gantry crane with slip compensation through absolute encoder evaluation
• Master axis: Linear axis
Operating mode: Positioning mode using an additional absolute encoder (IPOS
encoder)
• Slave axis: Linear axis
Operating mode: Synchronous operation with additional absolute encoder
• Master value: Master position (absolute value encoder position) is transferred via
SBus
• Features:Slipbetweenmotor andabsoluteencoderis compensatedbythefirmware.
Additionalperformanceisachieved by controllingthemaster and slaveaxisusingthe
virtual encoder. Both drives are controlled in the "Synchronous operation" mode for
this purpose. The master drive is started with the master value "virtual encoder" and
57038AXX
57039AXX
Slave
Master
Slave
Master

8
Manual – MOVIDRIVE® MDX61B DriveSync via Fieldbus Application
2Application examples
System Description
transfers the setpoint position to the slave drive via SBus.
Finite (linear)
movement of the
slave axis and
endless move-
ment of the
master axis
Example 3: Belt drive with embossing punch (flying saw)
• Master axis: Belt drive [1]
Operating mode: Speed specification, i.e. jog mode
• Slave axis: Spindle drive [2]
Operating mode: Synchronous operation forward; Start cycle via interrupt event.
Once a certain actual position has been reached, the operating mode changes to
"Positioning mode."
• Features: Interrupt controlled startup cycle
Endless move-
ment with master
and slave axis
Example 4: Caterpillar drive with position reference (360°)
• Master axis: Belt drive [1]
Operating mode: Positioning mode with position specified in modulo format
• Slave axis: Belt drive [2]
Operating mode: Synchronous operation with feedback in modulo format
• Features: Retained position reference due to modulo function with infinite division
57040AXX
Slave
Master
[2]
[1]
57041AXX
Slave
Master
[1]
[2]

Manual – MOVIDRIVE® MDX61B DriveSync via Fieldbus Application
9
2
Application examples
System Description
factors of the gear ratio (i gear unit).
Example 5: Electronic replacement of the mechanical vertical shaft.
• Master axis: Belt drive [1]
Operating mode: Synchronous operation with master value transfer to the
subsequent slaves via SBus object.
• Slave axis: Belt drive [2]
Operating mode: Synchronous operation
Fluctuating actual speeds of the master drive are not transferred to the subsequent
slave drives because the virtual master encoder position is transferred.
57042AXX
[A] [A]
Slave 1 Slave n
Master
[1] [2] [2]

10
Manual – MOVIDRIVE® MDX61B DriveSync via Fieldbus Application
2Program identification
System Description
2.3 Program identification
You can use the MOVITOOLS®software package to identify which application program
was last loaded into the MOVIDRIVE®MDX61B unit. Proceed as follows:
• Connect MOVIDRIVE®to the PC via the serial port.
• Start MOVITOOLS®.
• In MOVITOOLS®start the program "Shell".
• In the Shell program, choose [Display] / [IPOS Information...].
• The "IPOS-Status" window appears. The entries in this window tell you which
application software is stored in MOVIDRIVE®MDX61B.
06710BEN
Figure 1: IPOS information in Shell
11185AEN
Figure 2: Current IPOS program version displayed in MOVITOOLS®

Manual – MOVIDRIVE® MDX61B DriveSync via Fieldbus Application
11
3
Prerequisites
Project planning
3 Project planning
3.1 Prerequisites
PC and software The "DriveSync via fieldbus" application module is implemented as an IPOSplus®
program and forms part of the SEW MOVITOOLS®software package from version 4.30.
In order to use MOVITOOLS®, you must have a PC with one of the following operating
systems: Windows®95, Windows®98, Windows®NT 4.0, Windows®XP or Windows®
2000.
Inverters, motors
and encoders
•Inverters
The application module is controlled via fieldbus with 6 process data words and can
only be implemented with MOVIDRIVE®MDX61B units in application version (...0T).
•Motors and encoders
All motors with a connected motor encoder are supported.
Possible
combinations
•MOVIDRIVE
®MDX61B with the following fieldbus interfaces
Additional notes • The source of the actual position is the motor encoder. Alternatively, in systems
subject to slip an external encoder can be installed in addition or an absolute encoder
can be used in combination with the "Absolute encoder card DIP11B".
• If operated with asynchronous motors, the drive inverter must be started up in the
"CFC & IPOS" operating mode.
• If operated with synchronous motors, the drive inverter must be started up in the
"SERVO & IPOS" operating mode.
• In the "VFC n-control & IPOS" operating mode, the master and slave drives must not
be connected via SBus.
Motor shaft / load connection
Interlocking:
External encoder is not
required
Non-positive:
External encoder required
Encoder type
(external encoder) - Incremental encoder Absolute encoder
Bus type
(required option) PROFIBUS →DFP / InterBus →DFI / CAN-Bus →DFC / DeviceNet →DFD / Ethernet →DFE / System bus (SBus) →no option required
Additional
MOVIDRIVE®option
required
DEH11B or DER11B DIP11B / DEH11B /
DER11B

12
Manual – MOVIDRIVE® MDX61B DriveSync via Fieldbus Application
3Functional description
Project planning
3.2 Functional description
Functional
characteristics
The "DriveSync via fieldbus" application offers the following functional characteristics:
•Jog mode
The drive is moved clockwise or counterclockwise using two bits for direction
selection. The speed and the ramp can be varied using the fieldbus.
•Referencing mode
Reference travel is started with the start signal. Reference travel establishes the
reference point (machine zero) for absolute positioning operations. The axis must be
referenced in order for "positioning mode" to be selected.
•Positioning mode
The machine control specifies the target position via process output data words PO2
and PO3. The speed and the ramp can be varied using the fieldbus. The current
actual position is reported back via the process input data words PI2 and PI3.
The program cyclically queries the target position so that position changes are
possible during the positioning procedure. The positioning procedure is only
performed when the axis has been referenced.
•Synchronous operation
"Synchronous mode" is a motion control based on the technology function "Internal
synchronous operation" (ISYNC).
After "synchronous mode" has been selected, the startup cycle process is started by
a startup cycle event that is defined during the startup procedure. Once the slave
drive has been synchronized with the master, the slave moves synchronously with
the master.
Synchronous operation is terminated by resetting the "start bit" or deselecting
"synchronous operation".
The "synchronous operation" mode can be started without prior reference travel.
In addition, a bus offset value (PO6) can be specified in synchronous mode to shift
the reference to the master axis without having to exit the operating mode.
Additional
startup functions
You can choose the following additional functions at startup:
•Encoder in positioning mode (IPOS encoder source)
– With interlocking connection:
The incremental encoder, sin/cos encoder or Hiperface®encoder can be
connected to terminal X15 of the DEH11B / DER11B option.
– With non-positive connection:
An encoder for slip compensation can be connected to terminal X14 of the
DEH11B / DER11B option in addition to the motor encoder. Alternatively, slip can
be compensated via the evaluation of an SSI absolute encoder (requires absolute
encoder card DIP11B option).

Manual – MOVIDRIVE® MDX61B DriveSync via Fieldbus Application
13
3
Scaling the drive
Project planning
•Selecting the master drive source in "synchronous operation mode"
– Incremental encoder input X14 of the DEH11B / DER11B option for reading in the
master encoder value (is not allowed to be used if the input is already being used
as an IPOS encoder source).
– Simulation with the virtual master encoder. Variable specification of the position,
speed as well as acceleration via process output data words PO2 to PO5.
– Received "SBus data object" with read-in master encoder actual value of the
master drive. For example, each application module can operate as master and
transfer the specified IPOS encoder source via SBus.
•Control via fieldbus
– Fieldbuses with communication via 6 process data words (PROFIBUS, INTER-
BUS, DeviceNet, CANopen, Ethernet, SBus 2) are supported.
•Special function "positioning in modulo format" for endless movements
– Positioning can be in modulo format for endless movements (e.g. conveyor belts).
As a result, it is possible to achieve endless movements without losing the
position reference to the reference position.
3.3 Scaling the drive
The controller must be able to detect the number of encoder pulses (increments) per
travel unit to position the drive. The scaling function is used to set a user unit suitable to
the application.
Drive without
external encoder
(interlocking
connection)
In drives without an external encoder, the system can calculate the scaling automatically
during startup of the application module. Enter the following data:
• Diameter of the drive wheel (ddrive wheel) or slope of the spindle (sspindle)
• Gear ratio of the gear unit (igear unit, speed-reduction)
• Gear ratio of the additional gear (igear unit, speed-reduction)
The following scaling factors are calculated:
• Pulses / distance scaling factor [inc/mm] using the formula:
Pulses = 4096 ×igear unit ×iadditional gear
Distance = Π×ddrive wheel or Π×sspindle
• Speed scaling factor
Numerator factor in [1/min] and denominator value in "speed unit".
You can also enter the distance and speed scaling factors directly. If you enter a unit
other than [mm] or [1/10 mm] as the travel unit, this user defined unit will also be used
for the position of the software limit switches, the reference offset and the maximum
travel distances.

14
Manual – MOVIDRIVE® MDX61B DriveSync via Fieldbus Application
3Limit switches, reference cams and machine zero
Project planning
Drive with
external encoder
(non-positive
connection)
In this case, you must have activated and scaled the external encoder before starting
up the "DriveSync via fieldbus" application module. To do so, make the following
settings in the Shell program before starting the "DriveSync via fieldbus" application
module (→following figure).
• P941 Source actual position
If an incremental encoder or an absolute encoder (DIP11) is connected, set P941 to
"EXTERN. ENCODER (X14)". You can also make this setting during the startup
procedure of the application module.
• P942 Encoder factor numerator / P943 Encoder factor denominator / P944 Encoder
scaling ext. encoder
Calculation of the scaling is blocked during startup of the application module.
3.4 Limit switches, reference cams and machine zero
Note the following points during project planning:
• The softwarelimitswitches must be located within the travel distance of the hardware
limit switches.
• When defining the reference position (position of the reference cam) and the soft-
ware limit switches, make sure they do not overlap. Fault message F78 "IPOS SW
limit switch" is generated in the event of an overlap during referencing.
• You can enter a reference offset during startup if you do not want the machine zero
to be located on the reference cam. The following formula applies: Machine zero =
Reference position + Reference offset This way, you can alter the machine zero
without having to move the reference cam.
10091AEN
• For more information about scaling an external encoder, refer to the "IPOSplus®
Positioning and Sequence Control System" manual.
• When using an absolute encoder, note the startup instructions in the "MOVIDRIVE®
MDX61B0 Absolute Encoder Card DIP11B" manual.
Please also refer to the information in Sec. "Software limit switches."

Manual – MOVIDRIVE® MDX61B DriveSync via Fieldbus Application
15
3
Process data assignment
Project planning
3.5 Process data assignment
The PLC sends six process output data words (PA1 ... PA6) to the inverter and receives
six process input data words (PE1 ... PE6) from the inverter.
56163AXX
Figure 3: Data exchange via 6 process data
PA = Process output data
PA1 = Control word 2
PA2 = Target position high
PA3 = Target position low
PA4 = Setpoint speed (IPOS PO data)
PA5 = Setpoint speed and deceleration ramp (IPOS PO data)
PA6 = Offset (IPOS PO data)
PE = Process input data
PE1 = Status word (IPOS PI data)
PE2 = Actual position high (IPOS PI data)
PE3 = Actual position low (IPOS PI data)
PE4 = Actual speed (IPOS PO data)
PE5 = Master/slave position difference (IPOS PI data)
PE6 = Active current (IPOS PI data)
PE
PA
PA1
PE1
PA2
PE2
PA3 P A4 PA5 P A6
PE3 PE4 PE5 PE6

16
Manual – MOVIDRIVE® MDX61B DriveSync via Fieldbus Application
3Process data assignment
Project planning
Process output
data
Assignment of the process output data words:
• PA1: Control word 2
• PA2 + PA3: Target position
• PA4: Setpoint speed
• PA5: Ramp up and down
• PA6: Offset
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
/SWLS off Controller
inhibit/Enable
Offset Enable/Rapid stop
Set zero point Enable/stop
Mode high /Hold control
Mode low Ramp switchover
Jog – Parameter set switcho-
ver
Jog + Error reset
Start Reserved
PA2 Target position high PA3 Target position low
31302928272625242322212019181716 1514131211109876543210
Target position [user-defined unit]
1514131211109876543210
Setpoint speed [User-defined unit]
1514131211109876543210
Ramp up and down [ms]
1514131211109876543210
Bus offset [User-defined units]

Manual – MOVIDRIVE® MDX61B DriveSync via Fieldbus Application
17
3
Process data assignment
Project planning
Process input
data
The process input data words are assigned as follows:
• PE1: Status word
• PE2 + PE3: Actual position
• PE4: Actual speed
• PE5: Master/slave position difference
• PE6: Active current
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
Inverter status/fault code Drive synchronous
Inverter ready
IPOS reference (= drive referenced)
Target position reached
Brake released
Fault/warning
CW limit switch
CCW limit switch
The fault code is displayed in the high byte (bits 8 to 15) of the status word if bit 5
"Fault/warning" is set. If there is no fault, the current unit status is displayed in the high
byte of the status word.
PE2 Actual position high PE3 Actual position low
31302928272625242322212019181716 1514131211109876543210
1514131211109876543210
Speed [User-defined units]
1514131211109876543210
Lag distance [User-defined units]
1514131211109876543210
Active current [% IN]

18
Manual – MOVIDRIVE® MDX61B DriveSync via Fieldbus Application
3Software limit switches
Project planning
3.6 Software limit switches
General
information
The "software limit switch" monitoring function is used to check that the target position
is set to appropriate values. During this process, it is not important where the drive is
positioned. In contrast to the monitoring of the hardware limit switch, the monitoring
function for the software limit switch makes it possible to detect whether there is an error
in the target specifications before the axis starts to move. The software limit switches
are active when the axis is referenced; that is, when the bit "IPOS reference" is set in
PI1.
Moving clear of
the software limit
switch
When using an absolute encoder or Multiturn Hiperface®encoder it may be necessary
for the drive to be moved within the range of the software limit switches (for example,
after an encoder has been replaced). For this purpose, bit 15 in the process output data
word 1 (PO1) is set to "/SWLS" (= Moving clear of the software limit switch).
Bit 15 "/SWLS" is only available in "jog mode" and "referencing mode." If bit 15 is set,
the drive can be moved out of the valid positioning range into the area of the software
limit switches (→Example 3).
Example 1 It is necessary to differentiate between the following three examples:
• Prerequisites:
– Bit 15 "/SWLS" in the process output data word 1 (PO1) is not set.
– Drive is within valid positioning area
– Software limit switch monitoring function is active.
In jog mode, the drive runs until it is three positioning windows (P922) before the
software limit switch and then stays there.
In positioning mode, the drive can be positioned up to the software limit switches
but not beyond.
In referencing mode, the software limit switches are not active, which means the
drive can move past the software limit switches during reference travel.
The "software limit switch" monitoring function is disabled in synchronous mode.
11119AEN

Manual – MOVIDRIVE® MDX61B DriveSync via Fieldbus Application
19
3
Software limit switches
Project planning
Example 2 • Prerequisites:
– Bit 15 "/SWLS" in the process output data word 1 (PO1) is not set.
– The drive is outside the software limit switches.
The following error message appears once the drive is enabled:
Click <Reset> to acknowledge the error message. The monitoring function is
deactivated. For example, if the drive is right to the software limit switch (→above
figure), the drive can be moved at two different velocities depending on the specified
direction of the motor rotation:
– Closer toward the travel range of the software limit switch at reference speed 2
(P902).
– Away from the travel range of the software limit switches at maximum speed.
The monitoring function is reactivated when:
– The actual position of the drive set using P941 enters the permitted positioning
range again.
– A positioning job is issued via the opposite software limit switch.
– The unit is switched off and on again.
11120AEN
10983AEN

20
Manual – MOVIDRIVE® MDX61B DriveSync via Fieldbus Application
3Safe stop
Project planning
Example 3 • Prerequisite:
– Bit 15 "/SWLS" in the process output data word 1 (PO1) is set.
The monitoring function is deactivated in the "Jog mode" and "Referencing mode"
operating modes. The drive can be moved within the travel area of the software limit
switches and from the valid positioning range into the area of the software limit
switches without an error message being generated. The speed can be varied.
3.7 Safe stop
A "Safe stop" can only be achieved by safe disconnection of the jumpers at terminal X17
(with safety switch or safety PLC).
The "Safe stop active" state is indicated by a "U" in the 7-segment display. In the
application module, this state is treated in the same way as the "CONTROLLER
INHIBIT" state.
11121AEN
Changing the monitoring function of the software limit switches during operation!
Possible consequences: Risk of injury.
You must not change the monitoring function of the software limit switches (PO1, Bit 15
"/SWLS") during operation (i.e. when the axis is in motion).
For more information on the "Safe stop" function, refer to the following publications:
•MOVIDRIVE
®MDX60B / 61B Safe Disconnection - Conditions
•MOVIDRIVE
®MDX60B/61B Safe Disconnection - Applications