SEW-Eurodrive MOVIGEAR DAC B User manual

Drive Technology \ Drive Automation \ System Integration \ Services
Operating Instructions
Mechatronic Drive System
MOVIGEAR
®
DAC B
Direct AS-Interface Communication
Edition 04/2010 16888812 / EN

SEW-EURODRIVE—Driving the world

Operating Instructions – MOVIGEAR® DAC-B 3
1 Important Information......................................................................................... 6
1.1 How to use the operating instructions......................................................... 6
1.2 Structure of the safety notes ....................................................................... 6
1.3 Rights to claim under limited warranty ........................................................ 7
1.4 Exclusion of liability..................................................................................... 7
1.5 Copyright notice .......................................................................................... 7
2 Safety Notes ........................................................................................................ 8
2.1 General ....................................................................................................... 8
2.2 Target group ............................................................................................... 8
2.3 Designated use ........................................................................................... 9
2.4 Transportation and storage......................................................................... 9
2.5 Installation................................................................................................. 10
2.6 Electrical connection ................................................................................. 10
2.7 Safe disconnection.................................................................................... 10
2.8 Operation .................................................................................................. 11
3 Unit Design ........................................................................................................ 12
3.1 MOVIGEAR®drive unit ............................................................................ 12
3.2 Shaft variants ............................................................................................ 13
3.3 Housing mounting ..................................................................................... 14
3.4 Position of the cable entry......................................................................... 15
3.5 Sample nameplate and type designation of drive unit .............................. 16
3.6 MOVIGEAR®electronics .......................................................................... 17
3.7 Sample nameplate and type designation for electronics .......................... 20
3.8 MOVIGEAR®with optional package for wet areas ................................... 22
4 Mechanical Installation..................................................................................... 23
4.1 Installation notes ....................................................................................... 23
4.2 Required tools and resources ................................................................... 23
4.3 Installation prerequisites ........................................................................... 24
4.4 Installing MOVIGEAR®............................................................................. 24
4.5 Shaft-mounted gear unit with keyway ....................................................... 27
4.6 Shaft-mounted gear unit with TorqLOC®
(customer shaft without contact shoulder) ................................................ 31
4.7 Shaft-mounted gear unit with TorqLOC®
(customer shaft with contact shoulder) ..................................................... 36
4.8 Installing the protective cover ................................................................... 41
4.9 Torque arm ............................................................................................... 42
4.10 Tightening torques .................................................................................... 43
4.11 MOVIGEAR®with optional package for wet areas ................................... 46

4Operating Instructions – MOVIGEAR® DAC-B
5 Electrical Installation ........................................................................................ 51
5.1 Installation planning considering EMC aspects ........................................ 51
5.2 Installation instructions.............................................................................. 52
5.3 Terminal assignment ................................................................................ 60
5.4 Connection of MOVIGEAR®..................................................................... 62
5.5 Cable routing and cable shielding............................................................. 63
5.6 Plug connectors ........................................................................................ 66
5.7 Plug connector assignment ...................................................................... 69
5.8 Optional plug connector assignment......................................................... 70
5.9 PC connection .......................................................................................... 78
6 Startup................................................................................................................ 79
6.1 Startup notes............................................................................................. 79
6.2 Description of the controls ........................................................................ 80
6.3 Description of the DIP switches ................................................................ 82
6.4 Startup with binary slave GLK30A in "Easy" mode................................... 84
6.5 Startup with binary slave GLK30A in "Expert" mode ................................ 88
6.6 Assigning the slave address using a hand-held programming device
(binary slave GLK30A).............................................................................. 92
6.7 Startup with double slave GLK31A ........................................................... 94
6.8 Deactivating DynaStop®for startup ........................................................ 101
7 Operation of MOVITOOLS®MotionStudio .................................................... 102
7.1 About MOVITOOLS®MotionStudio ........................................................ 102
7.2 First steps ............................................................................................... 103
7.3 Connection mode.................................................................................... 105
7.4 SBus (CAN) communication via interface adapter.................................. 107
7.5 Executing functions with the units........................................................... 111
8 Parameters....................................................................................................... 112
8.1 Overview of parameters for command pcb ............................................. 112
8.2 Overview of power section parameters .................................................. 116
8.3 Description of command pcb parameters ............................................... 123
8.4 Description of power section parameters................................................ 129
9 Communication with AS-Interface Double Slave GLK31A.......................... 144
9.1 Functional description ............................................................................. 144
9.2 Function modules.................................................................................... 146
9.3 Transmitting individual parameters via AS-Interface .............................. 152
10 Operation ......................................................................................................... 175
10.1 Manual mode with MOVITOOLS®MotionStudio .................................... 175
10.2 Local mode ............................................................................................. 179
10.3 DynaStop®.............................................................................................. 180
10.4 Deactivating DynaStop®......................................................................... 181

Operating Instructions – MOVIGEAR® DAC-B 5
11 Service ............................................................................................................. 185
11.1 Malfunctions of the mechanical MOVIGEAR®drive ............................... 185
11.2 Evaluating error messages ..................................................................... 186
11.3 Switch-off responsess............................................................................. 187
11.4 Resetting error messages....................................................................... 187
11.5 Description of status and operating indicators ........................................ 188
11.6 AS-Interface bus monitor ........................................................................ 193
11.7 Unit replacement..................................................................................... 194
11.8 SEW-EURODRIVE Service .................................................................... 195
11.9 Extended storage.................................................................................... 196
11.10 Disposal .................................................................................................. 197
12 Inspection and Maintenance .......................................................................... 198
12.1 Determining the operating hours............................................................. 198
12.2 Inspection and maintenance intervals..................................................... 199
12.3 Lubricant change intervals ...................................................................... 200
12.4 Inspection and maintenance work on the MOVIGEAR®drive ................ 201
13 Technical Data and Dimension Sheets ......................................................... 205
13.1 Technical data of MOVIGEAR®.............................................................. 205
13.2 Integrated braking resistor BW1 ............................................................. 208
13.3 Deceleration torques DynaStop®............................................................ 209
13.4 Torque characteristics............................................................................. 210
13.5 Surface protection................................................................................... 218
13.6 Package for applications in wet areas .................................................... 220
13.7 Screw connections.................................................................................. 224
13.8 Mounting positions .................................................................................. 225
13.9 Lubricants ............................................................................................... 227
13.10 Design notes for gear units with hollow shaft and key ............................ 230
13.11 Dimension drawings................................................................................ 232
14 EC Declaration of Conformity ........................................................................ 237
15 Address List .................................................................................................... 238
Index................................................................................................................. 248

6Operating Instructions – MOVIGEAR® DAC-B
1How to use the operating instructions
Important Information
MOVIGEAR® DAC-B
1 Important Information
1.1 How to use the operating instructions
The operating instructions are an integral part of the product and contain important
information for operation and service. The operating instructions are written for all
employees who assemble, install, startup, and service this product.
The operating instructions must be legible and accessible at all times. Make sure that
staff responsible for the plant and its operation, as well as persons who work indepen-
dently on the unit, have read the operating instructions carefully and understood them.
If you are unclear about any of the information in this documentation, or if you require
further information, contact SEW-EURODRIVE.
1.2 Structure of the safety notes
The safety notes in these operating instructions are designed as follows:
Pictogram SIGNAL WORD
Type and source of danger.
Possible consequence(s) if disregarded.
• Measure(s) to prevent the danger.
Pictogram Signal word Meaning Consequences if
disregarded
Example:
General danger
Specific danger,
e.g. electric shock
DANGER Imminent danger Severe or fatal injuries
WARNING Possible dangerous situation Severe or fatal injuries
CAUTION Possible dangerous situation Minor injuries
NOTICE Possible damage to property Damage to the drive system or its
environment
INFORMA-
TION
Useful information or tip.
Simplifies the handling of the
drive system.

Operating Instructions – MOVIGEAR® DAC-B 7
1
Rights to claim under limited warranty
Important Information
1.3 Rights to claim under limited warranty
A requirement of fault-free operation and fulfillment of any rights to claim under limited
warranty is that you adhere to the information in the operating instructions. Therefore,
read the operating instructions before you start working with the unit.
Make sure that the operating instructions are available to persons responsible for the
plant and its operation, as well as to person who work independently on the unit. You
must also ensure that the documentation is legible.
1.4 Exclusion of liability
You must comply with the information contained in the operating instructions to ensure
safe operation of MOVIGEAR®and to achieve the specified product and performance
features. SEW-EURODRIVE does not assume 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.
1.5 Copyright notice
© 2010 – SEW-EURODRIVE. All rights reserved.
Copyright law prohibits the unauthorized duplication, modification, distribution, and use
of this document, in whole or in part.

8Operating Instructions – MOVIGEAR® DAC-B
2General
Safety Notes
2 Safety Notes
The following basic safety notes must be read carefully to prevent injury to persons and
damage to property. The operator must ensure that the basic safety notes are read and
observed. Ensure that persons responsible for the system and its operation, as well as
persons who work independently on the unit, have read through the operating instruc-
tions carefully and understood them. If you are unclear about any of the information in
this documentation, please contact SEW-EURODRIVE.
2.1 General
Never install or start up damaged products. Submit a complaint to the shipping company
immediately in the event of damage.
During operation, MOVIGEAR®drive units can have live, bare and movable or rotating
parts as well as hot surfaces, depending on their enclosure.
Removing covers without authorization, improper use as well as incorrect installation or
operation may result in severe injuries to persons or damage to property.
Refer to the documentation for additional information.
2.2 Target group
Only qualified electricians are authorized to install, startup or service the units or
correct unit faults (observing IEC 60364 or CENELEC HD 384 or DIN VDE 0100 and
IEC 60664 or DIN VDE 0110 as well as national accident prevention guidelines).
Qualified personnel in the context of these basic safety notes are: All persons familiar
with installation, assembly, startup and operation of the product who possess the
necessary qualifications.
Any activities regarding transportation, storage, operation, and disposal must be carried
out by persons who have been instructed appropriately.

Operating Instructions – MOVIGEAR® DAC-B 9
2
Designated use
Safety Notes
2.3 Designated use
MOVIGEAR®drive units are components intended for installation in electrical systems
or machines.
In case of installation in machines, startup of the MOVIGEAR®drive units (i.e. start of
designated operation) is prohibited until it is determined that the machine meets the
requirements stipulated in the EC Directive 2006/42/EC (machine directive).
Startup (i.e. the start of designated use) is only permitted under observance of the
EMC (2004/108/EC) directive.
MOVIGEAR®drive units comply with the regulations of the Low Voltage Directive 2006/
95/EC. The standards given in the declaration of conformity are applied to the
MOVIGEAR®drive units.
You must observe the technical data and information on the connection requirements
as provided on the nameplate and in the documentation.
2.3.1 Safety functions
The MOVIGEAR®drive units may not perform safety functions unless these functions
are described and expressly permitted.
2.3.2 Hoist applications
MOVIGEAR®drive units must not be used for hoist applications.
MOVIGEAR®drive units may only be used for inclining tracks after the operator has
performed a risk assessment. For further information, consult the information in the
documentation.
2.4 Transportation and storage
You must observe the notes in the documentation regarding transportation, storage and
proper handling. Use suitable, sufficiently rated handling equipment (e.g. rope guides)
if required. Do not attach any additional loads. Observe climatic conditions in accor-
dance with the documentation.
The following figure shows the eyebolt of MOVIGEAR®:
2770620811

10 Operating Instructions – MOVIGEAR® DAC-B
2Installation
Safety Notes
2.5 Installation
The units must be installed and cooled according to the regulations and specifications
in the corresponding documentation.
Protect the MOVIGEAR®drive units from improper strain.
The following applications are prohibited unless the unit is explicitly designed for such
use:
• Use in potentially explosive atmospheres.
• Use in areas exposed to harmful oils, acids, gases, vapors, dust, radiation, etc.
• Use in non-stationary applications that are subject to mechanical vibration and shock
loads as stated in the documentation for MOVIGEAR®drive units.
Important: MOVIGEAR®drive units and corresponding mount-on parts must not
protrude into footways.
2.6 Electrical connection
Working on live parts of MOVIGEAR®drive units is not permitted.
The drive is operated as a generator due to the kinetic energy of the plant/machine.
Secure the output shaft against rotation before you open the wiring compartment.
Electrical installation is to be carried out in compliance with pertinent regulations (e.g.
cable cross sections, fusing, protective conductor connection). For any additional
information, refer to the applicable documentation.
You will find notes on EMC-compliant installation, such as shielding, grounding,
arrangement of filters and routing of lines, in the documentation of the MOVIGEAR®
drive units. The manufacturer of the system or machine is responsible for maintaining
the limits established by EMC legislation.
Protective measures and protection devices must comply with the regulations in force
(e.g. EN 60204-1 or EN 61800-5-1).
2.7 Safe disconnection
MOVIGEAR®drive units meet all requirements for safe disconnection of power and
electronic connections in accordance with EN 61800-5-1. All connected circuits must
satisfy the requirements for safe disconnection as well.

Operating Instructions – MOVIGEAR® DAC-B 11
2
Operation
Safety Notes
2.8 Operation
Systems with integrated MOVIGEAR®drive units must be equipped with additional
monitoring and protection devices according to the applicable safety guidelines, such as
the law governing technical equipment, accident prevention regulations, etc. Additional
protective measures may be necessary for applications with increased potential risk.
Changes to the MOVIGEAR®drive units using the operating software are permitted.
Do not touch live components and power connections immediately after separation of
the MOVIGEAR®drive units from the supply voltage because some capacitors might
still be charged. Wait at least 10 minutes after the supply voltage has been switched off.
The connection boxes must be closed and screwed on before the supply voltages are
connected to MOVIGEAR®.
The unit may still be live and connected to the supply, even if the operation LEDs and
other display elements are no longer illuminated.
Mechanical blocking or internal safety functions of the unit can cause a motor standstill.
Eliminating the cause of the problem or performing a reset may result in the drive re-
starting automatically. If, for safety reasons, this is not permitted for the driven machine,
disconnect the unit from the supply system before correcting the error.
Caution: Danger of burns: The surface temperatures of the MOVIGEAR®drive units can
be more than 60 °C during operation.

12 Operating Instructions – MOVIGEAR® DAC-B
3MOVIGEAR®drive unit
Unit Design
3 Unit Design
3.1 MOVIGEAR®drive unit
MOVIGEAR®drive units are made up of 3 core components: gear unit, motor and drive
electronics. These 3 core components are included in one cast aluminum housing (see
following figure).
2364012555
[1] MOVIGEAR®electronics cover
[2] Connection ring for cable glands
[3] Gear unit cover
[4] Output shaft version (pictured here: hollow shaft with keyway)
[5] Grounding screws
[6] AS-Interface connection
MGF..2
[1]
[2]
[4]
[3]
[5]
MGF..4/ET
[1]
[2]
[4]
[3]
[5]
[6]
[6]
[1]
[2]
[4]
[3]
[5]
[6]
MGF..4

Operating Instructions – MOVIGEAR® DAC-B 13
3
Shaft variants
Unit Design
3.2 Shaft variants
MOVIGEAR®is available with the following shaft variants:
3.2.1 MOVIGEAR®with hollow shaft and keyway (MGFA..)
The following figure shows a MOVIGEAR®unit with hollow shaft and keyway:
3.2.2 MOVIGEAR®with TorqLOC®hollow-shaft mounting system (MGFT..)
The following figure shows a MOVIGEAR®unit with TorqLOC®hollow shaft mounting
system
2690820619
2690822539

14 Operating Instructions – MOVIGEAR® DAC-B
3Housing mounting
Unit Design
3.3 Housing mounting
3.3.1 Torque arm (MGF.T)
The following figure shows the torque arm for MGF.T:
3.3.2 Housing with threads (MGF.S)
The following figure shows the housing type with threads for mounting a torque arm.
This type does not include a centering shoulder, which means it is not suitable for direct
installation to the machine:
2690826379
2690824459

Operating Instructions – MOVIGEAR® DAC-B 15
3
Position of the cable entry
Unit Design
3.4 Position of the cable entry
The following cable entries are possible for MOVIGEAR®:
• Position X + 2
– X: 2 x M25 x 1.5 + 1 x M16 x 1.5 + 1 x M16 x 1.5 1)
– 2: 2 x M25 x 1.5 + 1 x M16 x 1.5 + 1 x M16 x 1.5 1)
• Position X + 2 + 3
– X: 2 x M25 x 1.5 + 1 x M16 x 1.5 + 1 x M16 x 1.5 1)
– 2: 2 x M25 x 1.5 + 1 x M16 x 1.5 + 1 x M16 x 1.5 1)
– 3: 2 x M25 x 1.5 + 2 x M16 x 1.5
• Position X + 3
– X: 2 x M25 x 1.5 + 1 x M16 x 1.5 + 1 x M16 x 1.5 1)
– 3: 2 x M25 x 1.5 + 2 x M16 x 1.5
• Position 2 + 3
– 2: 2 x M25 x 1.5 + 1 x M16 x 1.5 + 1 x M16 x 1.5 1)
– 3: 2 x M25 x 1.5 + 2 x M16 x 1.5
3.4.1 Overview
The following figure shows the possible cable entries:
1) 1 x M16 x 1.5 reserved for pressure compensation fitting in connection with the package for wet areas
2690896779
3
3
3
X
X
X
2
2
2

16 Operating Instructions – MOVIGEAR® DAC-B
3Sample nameplate and type designation of drive unit
Unit Design
3.5 Sample nameplate and type designation of drive unit
3.5.1 Nameplate
The following figure gives an example of a MOVIGEAR®nameplate. For the structure
of the type designation, refer to chapter "Type designation".
Bar code:
The bar code on the nameplate (code 39) according to ISO/IEC 16388 represents the
unique serial number (with period as separator).
3.5.2 Type designation
The following table shows the type designation of MOVIGEAR®:
2368152331
[1] Unique serial number
76646 Bruchsal/Germany
Nm
°C
n
R
U
N
f
N
Nm
n
A
A
M
A
M
a pk
i
Made in Germany
IM
kg
cos
IP
r/min
Hz
V
13356887
MGFAT2-DSM-DAC-B/DSP
01.1233697403.0001.08
5,4...53,7
37,24
M1,M2,M5,M6 50...60
380...500
65
0,99
1,52
1/10
16.000
CLP HC 220 Synth.Öl/0,55l
-25 ... +40
[1]
3~ EN61800 TENV M.L.
143
220
MGFAS2–DSM–DAC–B/DSP
MOVIGEAR®option
DSP = Electrodynamic
deceleration function DynaStop®
ECR = Extended control range
ET = Extended torque
IV = Plug connector
MOVIGEAR®version
MOVIGEAR®installation technology
DAC = Direct AS-Interface Communication
Motor type
Size
2 = Torque class 200 Nm
4 = Torque class 400 Nm
Housing mounting
T = Drive with torque arm
S = Housing with threads for
mounting a torque arm
Shaft variant
A = Shaft-mounted gear unit
(hollow shaft with keyway)
T = TorqLOC®hollow shaft mounting system
Gear unit type
F = Parallel-shaft helical gear unit
Product series
MG = MOVIGEAR®

Operating Instructions – MOVIGEAR® DAC-B 17
3
MOVIGEAR®electronics
Unit Design
3.6 MOVIGEAR®electronics
3.6.1 MOVIGEAR®electronics cover (inside) and connection box
The following figure shows the connection box and the bottom side of the MOVIGEAR®
electronics cover:
2366107275
[1] AS-Interface connection
[2] Nameplate of drive unit, see following detailed view
2584957963
[3] AS-Interface terminals (wired to plug connector)
[4] Connection ring
[5] AS-Interface sensors
[6] Plug connector connection unit for MOVIGEAR®electronics cover
[7] MOVIGEAR®electronics cover
[8] Electronics cover nameplate
[9] DIP switches S1/1 – S1/4
[10] DIP switches S2/1 – S2/4
[11] Cable glands
[12] Screw for PE connection 
[13] Supply system connection L1, L2, L3
[14] Electronics terminal strips
[15] Switch t1 for integrator ramp (green)
[16] Diagnostic interface (below screw fitting)
[17] Setpoint switch f2 (white)
[18] Setpoint potentiometer f1 with screw plug
34567 34567
ON ADE04SA
1234
ON ADE04SA
1234
t1
S1 S2
f2 f1
12 34 12 3 4
[3] [4][2]
[1] [5]
[12]
[11] [12] [12][12] [11]
[14]
[13]
[10][9]
[6] [7] [8]
[15] [16] [17] [18]
[2]

18 Operating Instructions – MOVIGEAR® DAC-B
3MOVIGEAR®electronics
Unit Design
3.6.2 AS-Interface option
The AS-Interface option is located on the connection board in the connection box.
MOVIGEAR®DAC is available with the following AS-Interface variants:
• GLK30A binary slave
• GLK31A double slave for drive with several speed setpoints and ramps
The following figure shows the topology and the travel diagrams of the MOVIGEAR®
DAC drive unit with the AS-Interface slaves GLK30A [A] and GLK31A [B]:
GLK30A binary
slave
Connected to AS-Interface, the GLK30A slave works like a module with 4 inputs and 4
outputs.
The cyclic output bits control the MOVIGEAR®DAC inverter.
The input bits transmit the status of the drive and 2 additional sensor signals to the
AS-Interface master.
The acyclic parameter bits are used to select speed scaling factors.
2588627467
[A] MOVIGEAR®DAC with binary slave GLK30A
[B] MOVIGEAR®DAC with double slave GLK31A
Drive with several speed setpoints and ramps
[1] Power supply
[2] Sensors
B
v
t
v
t
A
MOVIGEAR
®
MOVIGEAR
®
[1]
[2] [2]
GLK30A GLK31A

Operating Instructions – MOVIGEAR® DAC-B 19
3
MOVIGEAR®electronics
Unit Design
GLK31A double
slave
The GLK31A option works as a double slave on AS-Interface according to AS-Interface
specification 3.0.
The serial AS-Interface data transmission (analog profile) allows for MOVIGEAR®DAC
parameters and display values to be written and read.
The MOVIGEAR®DAC inverter is controlled via the cyclic output bits. The coding of the
data bits is specified in different function modules. The MOVIGEAR®DAC inverter
interprets these bits as different control and status codes. With the acyclic parameter
bits, you can switch between the function modules.
The input bits transmit the status of the drive and 2 additional sensor signals to the
AS-Interface master.
3.6.3 MOVIGEAR®electronics cover (outside)
The following figure shows the outside of the MOVIGEAR®electronics cover:
2367868555
[1] Setpoint potentiometer f1 (underneath the gland)
[2] Diagnostic interface (underneath the gland)
[3] Status LEDs
[1] [2] [3]
MOVIGEAR
®
DRIVE
RUN
NET

20 Operating Instructions – MOVIGEAR® DAC-B
3Sample nameplate and type designation for electronics
Unit Design
3.7 Sample nameplate and type designation for electronics
3.7.1 Nameplate of electronics cover
The following figure gives an example of a MOVIGEAR®nameplate. For the structure
of the type designation, refer to chapter "Type designation".
3.7.2 Type designation of electronics cover
The following table shows the type designation of the electronics cover:
2585095947
[1] Nameplate of connection unit
[2] Electronics cover nameplate
[1]
[2]
MGx4–503–DAC–B–00/ET
Electronics cover option
ET = Extended torque
Variant
00 = Standard
MOVIGEAR®
Version
MOVIGEAR®installation technology
DAC =
Direct AS-Interface Communication
Connection type
3 = 3-phase
Supply voltage
50 = AC 380 – 500 V
Size
2 = Torque class 200 Nm
4 = Torque class 400 Nm
Product series
MG = MOVIGEAR®