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ACOPOS User`s Manual

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1. e L E ot 02 OF S 1 5 T 8 LO e 2 A a 5 t E E E 9 de 2 3 S M HO al Ha J o L g rO Q 9 a 08 e E oor ad roo E e tt 2 1 OL t R9 E 28 J c o z ae ME E o o ij 5 E e z Bry Chapter 3 Installation Figure 15 Dimensional diagram and installation dimensions for ACOPOS 1640 1 For proper air circulation at least 80 mm has to be left free above and below the ACOPOS servo drive Approximately 160 mm free space is required under the ACOPOS servo drive to prevent cabling problems ACOPOS User s Manual 87 Installation Dimension Diagram and Installation Dimensions 2 4 ACOPOS 128M e e o a lo o o d T ij pO o te o o Hi 3 z 2 o E 5 Ha o o 8 o 3 o thy o o 8 o 08 O E T Y e 9 L al m 28 El HE NR 3 3 9 2 J o 8 E L ZU arr Figure 16 Dimensional diagram and installation dimensions for ACOPOS 128M 1 For proper air circulation at least 80 mm has to be left free above and below the ACOPOS servo drive Approximately 160 mm free space is required under th
2. ss 141 Pin assignments for plug X4a ACOPOS 1022 1045 1090 s 141 Pin assignments for plug X4b ACOPOS 1022 1045 1090 ss 141 Activation for the external holding brake s 142 Pin assignments for plug X5 ACOPOS 1022 1045 1090 143 Protective ground conductor PE ACOPOS 1022 1045 1090 143 Pin assignments for plug X1 ACOPOS 1180 1320 sess 145 Pin assignments for plug X2 ACOPOS 1180 1320 145 Pin assignments for plug X3 ACOPOS 1180 1320 sess 146 Pin assignments for plug X4a ACOPOS 1180 1320 sss 146 Pin assignments for plug X4b ACOPOS 1180 1320 sss 146 Activation for the external holding brake see 147 Pin assignments for plug X5 ACOPOS 1180 1320 sss 148 Pin assignments for plug X6 ACOPOS 1180 1320 148 Protective ground conductor PE ACOPOS 1180 1320 sss 149 Pin assignments for plug X1 ACOPOS 1640 128M see 151 Pin assignments for X2 ACOPOS 1640 128M sse 151 Pin assignments for X8 ACOPOS 1640 128M sse 152 Pin assignments for plug X4a ACOPOS 1640 128M sseeess 152 Pin assignments for plug X4b ACOPOS 1640 128M sseseees 152 Activation for the external hold
3. 35 71 5 2 x fastening screws M5 280 Incoming air Figure 13 Dimensional diagram and installation dimensions for ACOPOS 1022 1045 1090 1 For proper air circulation at least 80 mm has to be left free above and below the ACOPOS servo drive ACOPOS User s Manual 85 Chapter 3 Installation Installation e Dimension Diagram and Installation Dimensions 2 2 ACOPOS 1180 1320 Distance to g Outgoing air next device N pee 20185 234 t LO To UN EAT fl MED D t a ol o o o o o 3 ES e D e Ir o HB e e ojo o EIE b o H T7 O e e o Ho y e n A coope amp le e VCP IJ 4x fastening screws M5 8 e Ses o L NS 200 276 fs S Incoming air l Figure 14 Dimensional diagram and installation dimensions for ACOPOS 1180 1320 1 For proper air circulation at least 80 mm has to be left free above and below the ACOPOS servo drive Approximately 100 mm free space is required under the ACOPOS servo drive to prevent cabling problems 86 ACOPOS User s Manual Installation Dimension Diagram and Installation Dimensions 2 3 ACOPOS 1640
4. Table 122 Additional environmental limits Table 123 International Certifications Table 124 Overview of stop function categories Table 125 Safety category overview essen Table 126 Parameters S F and P lead you to the safety category to be used ACOPOS User s Manual 221 Table Index Table Index 222 ACOPOS User s Manual A ACTO ettet 43 155 AGTIT2 2 0 45 156 ACT2Q nanus iniecit elm 49 157 ACTA ui outs alo rho 52 158 ACT29 uicnenespuiesie eg 55 159 AC190 ertet a a eedi 58 160 ACI T eie 62 161 Accessories for ACTO cede eee teil 43 AC T1205 ettet atii 50 AG122 ons deen etc e mee SUO 52 A eet 58 ACTII ieu Etre 62 ACOPOS 1022 1045 1090 36 ACOPOS 1180 1320 38 ACOPOS 1640 128M 40 ACOPOS 10292 7 25 A 36 139 AO uix uU RI oni 36 139 1090 unen rro 36 139 T1180 3 iio in din 38 144 128M niece ike 40 150 T2 tito eth ttes 38 144 T640 m he a tests 40 150 see Servo Drives B Braking resistor ceecee 111 Thermal Equivalent Circuit 116 C Cables Encoder Cables EnDat attese ire 71 166 Resolver inei rs 73 168 General Information 66 Motor Cable nairean 67 163 Gan Editor ion ehe 21 CAN Bus Interface AC110 43 155 Gertifications isena 2 neci vated 209 Configurations GANE E UEEEE 22 Powetrlink A
5. 169 Order Data erento recte 73 Pin Assignments seeen 168 SIIUCEtUFG ein iem 168 Technical Data oooocccncccncccncccnnconcnnnenonnn 73 Resolver Connector Order Data Idee 79 Pin Assignments secere 168 Technical Data oooonncnncincccncccnnnnnconnnnnnnn 81 Resolver Interface AC122 52 158 Restart Inhibit 126 210 Risk Evaluation eeeeesss 212 S Safety Categories sssssse 211 Safety Guidelines sssss 26 Sample project sessseesss 172 Secure restart inhibit 126 210 Security scene cients 15 16 SONICO rai eie de ees 17 Servo Drives ACOPOS 1022 1045 1090 36 ACOPOS 1022 1045 etc 139 Cables See Cables Cam Editor ccccccncncnnininininananananananononos 21 Concepts onu d E Fasti a Bee 31 Configurations GAN 22 inet roe editis ett debeo 22 Powerlink eeeeeeeer 24 Connectors see Connectors Danger Warning seeen 26 Dimensioning seeen 97 Dimensions cce 85 ACOPOS User s Manual Drive Oscilloscope 20 Function Test eeseees 19 198 General Information 15 31 Indication eres 33 Installation nasteri reio An 121 Installation Dimensions 85
6. Chapter 5 Wiring x2 Pin Description Function 1 DC2 UDC bus cum 2 DC1 U DC bus 000 00 3 Dc2 U DC bus O O O O e e e e o oO O O 4 DC1 U DC bus Te ol RI Terminal Cross Sections see table 60 Terminal cross sections for ACOPOS servo drives on page 138 Table 79 Pin assignments for X2 ACOPOS 1640 128M ACOPOS User s Manual 151 Wiring Pin Assignments ACOPOS 1640 128M 4 3 Pin Assignments X3 X3 Pin Description Function 1 L1 Power mains connection L1 2 L2 Power mains connection L2 3 L3 Power mains connection L3 4 Protective ground conductor Terminal Cross Sections see table 60 Terminal cross sections for ACOPOS servo drives on page 138 Table 80 Pin assignments for X3 ACOPOS 1640 128M 4 4 Pin Assignments for Plugs X4a X4b X4a Pin Description Function 1 2 Activation supply for the external holding brake 2 1 Activation for the external holding brake 3 S4 Activation supply for the external holding brake 4 3 Activation for the external holding brake Terminal Cross Sections see table 60 Terminal cross sections for ACOPOS servo drives on page 138 Table 81 Pin assi gnments for plug X4a ACOPOS 1640 128M X4b Pin Description Function 1 T Temperature Sensor
7. E mz EA E zz z gt i l zzi i Figure 12 Attaching the eye bolt contained in the delivery to ACOPOS 1640 and 128M drives ACOPOS User s Manual 83 Chapter 3 Installation Installation General Information ACOPOS servo drives can only be installed in an environment which corresponds to pollution degree II non conductive material When installing the device make sure that the maximum operating temperature 40 C is not exceeded and IP20 protection is provided as specified in the technical data For proper air circulation at least 80 mm has to be left free above and below the ACOPOS servo drive ACOPOS servo drives can be mounted directly next to each other the required distance between devices can be found in the respective dimensional diagram 84 ACOPOS User s Manual Installation Dimensional Diagrams and Installation Dimensions 2 Dimensional Diagrams and Installation Dimensions 2 1 ACOPOS 1022 1045 1090 Distance to y next device Outgoing air 71 ar 235 5 E H da EX fof 2 280 RA ho jo
8. ACOPOS User s Manual ACOPOS User s Manual Version 1 2 June 2003 Mod No MAACP2 E We reserve the right to change the contents of this manual without warning The information contained herein is believed to be accurate as of the date of publication however Bernecker Rainer Industrie Elektronik Ges m b H makes no warranty expressed or implied with regards to the products or the documentation contained within this book In addition Bernecker Rainer Industrie Elektronik Ges m b H shall not be liable in the event of incidental or consequential damages in connection with or arising from the furnishing performance or use of these products The software names hardware names and trademarks used in this document are registered by the respective companies ACOPOS User s Manual 1 ACOPOS User s Manual Chapter 1 General Information Chapter 2 Technical Data Chapter 3 Mounting Chapter 4 Dimensioning Chapter 5 Wiring Chapter 6 Getting Started ACOPOS User s Manual ACOPOS User s Manual Chapter 7 Standards and Certifications Figure Index Table Index Index Model Number Index ACOPOS User s Manual ACOPOS User s Manual Table of Contents Chapter 1 General Information eese 15 LACOPOS ita ades a o REB TERRIER aeu 15 T 1 Secure Operator coord dei dette este ashe cet aati ts 15 1 2 Taking it to the Limit inienn a A e vete e Pe EE de 16 1 3 Indi
9. Table 69 Pin assignments for plug X1 ACOPOS 1180 1320 3 2 Pin Assignments for Plug X2 x2 Pin Description Function 1 DC1 U DC bus le 2 DC1 U DC bus 3 DC2 U DC bus 4 DC2 U DC bus eee DC2 DC2 DC1 DC1 Terminal Cross Sections see table 60 Terminal cross sections for ACOPOS servo drives on page 138 Table 70 Pin assignments for plug X2 ACOPOS 1180 1320 ACOPOS User s Manual 145 Chapter 5 Wiring Wiring Pin Assignments ACOPOS 1180 1320 3 3 Pin Assignments for Plug X3 X3 Pin Description Function 1 L1 Power mains connection L1 le 2 L2 Power mains connection L2 3 L3 Power mains connection L3 4 PE Protective ground conductor e ee L3 L2 IL Terminal Cross Sections see table 60 Terminal cross sections for ACOPOS servo drives on page 138 Table 71 Pin assignments for plug X3 ACOPOS 1180 1320 3 4 Pin Assignments for Plugs X4a X4b X4a Pin Description Function 1 2 Activation supply for the external holding brake 2 1 Activation for the external holding brake 3 S4 Activation supply for the external holding brake 4 3 Activation for the external holding brake Termina
10. ACOPOS internal monitoring cannot be used here therefore it must be deactivated using software Table 83 Activation for the external holding brake 1 Both jumpers are already on the X4a connector delivered with the ACOPOS servo drives 2 External potential free contacts can be connected between S1 and S2 as well as between S3 and S4 This makes it possible to activate the holding brake using an external safety circuit independent of the control integrated in the ACOPOS servo drive 3 The parameters are set using ParlD 90 1 internal monitoring active 5 internal monitoring not active 4 Deactivation takes place using ParlD 90 5 internal monitoring not active ACOPOS User s Manual 153 Chapter 5 Wiring Wiring Pin Assignments ACOPOS 1640 128M 4 5 Pin Assignments X5 X5 Pin Description Function 1 PE Protective ground conductor 2 W Motor connection W 3 V Motor connection V 4 E Motor connection U Terminal Cross Sections see table 60 Terminal cross sections for ACOPOS servo drives on page 138 Table 84 Pin assignments for X5 ACOPOS 1640 128M 4 6 Pin Assignments X6 X6 Pin Description Function eve RB RB 1 PE Protective ground conductor 2 RB Brake Resistance 3 RB Brake Resistance Te
11. Table 2 General description of the ACOPOS servo drive series 1 Integrated line filter in preparation 2 External DC bus power supply 0PS320 1 24V 20A can be used 3 The braking resistor integrated in the ACOPOS servo drives 1640 and 128M is dimensioned so that it is possible to brake to a stop in a typical drive situation The ACOPOS servo drives also provide a modular fieldbus interface in addition to connection possibilities for all standard encoder systems ACOPOS servo drives are suitable for both synchronous and asynchronous servo motors and have built in line filters to meet the limit values for CISPR11 Group 2 Class A Warning ACOPOS servo drives are suitable for power mains which can provide a maximum short circuit current of 10000 Ae at a maximum of 528 V 32 ACOPOS User s Manual Technical Data e ACOPOS Servo Family 1 2 1 24 VDC Supply during Power Failures In order to be able to provide the stop function for category 1 according to IEC 60204 1 during a power failure the 24 VDC supply voltage for the servo drives as well as encoders sensors and the safety circuit must remain active during the entire stopping procedure The ACOPOS servo drives recognize a power failure and can immediately initiate active braking of the motor The brake energy that occurs when braking is returned to the DC bus and the DC bus power supply can use it to create the 24 VDC supply voltage An external DC bus power supply must
12. 2 T Temperature Sensor 3 B Brake 4 B Brake Terminal Cross Sections see table 60 Terminal cross sections for ACOPOS servo drives on page 138 Table 82 Pin assignments for plug X4b ACOPOS 1640 128M 4 4 1 Wiring the Output for the Motor Holding Brake The supply activation and monitoring of the output for the motor holding brake can take place via the the X4a connector in three different ways 152 ACOPOS User s Manual Wiring Pin Assignments ACOPOS 1640 128M Monitoring L 21 Monitoring li 21 Monitoring i 21 lt p Ref Image t 24 V t 24 V t 24 V Description Supply Internally by the ACOPOS servo drive Activation Internally by the ACOPOS servo drive Monitoring Internally by the ACOPOS servo drive A jumper must be placed between S1 and S2 as well as S3 and S4 on the X4a connector 1 Supply Internally by the ACOPOS servo drive Activation Internally by the ACOPOS servo drive and also possible externally using potential free contacts 2 Monitoring Internally by the ACOPOS servo drive Information The parameters for ACOPOS internal monitoring must be set according to the requirements of the application 3 Supply External Activation External Monitoring External Information
13. 8V1180 00 2 Servo drive 3 x 400 480V 18A 9kW line filter braking resistor DC bus power supply and electronic secure restart inhibit integrated 8V1320 00 2 Servo drive 3 x 400 480V 32A 16kW line filter braking resistor DC bus power supply and electronic secure restart inhibit integrated Accessories 8AC110 60 2 ACOPOS plug in module CAN interface 8AC112 60 1 ACOPOS plug in module ETHERNET Powerlink interface 8AC120 60 1 ACOPOS plug in module EnDat encoder interface 8AC122 60 2 ACOPOS plug in module resolver interface 8AC123 60 1 ACOPOS plug in module incremental encoder and SSI absolute encoder interface 8AC130 60 1 ACOPOS plug in module 8 digital I O configurable in pairs as 24V input or as output 400 100mA 2 digital outputs 2A Order TB712 terminal block separately A es e a E E 9 8AC131 60 1 ACOPOS plug in module 2 analog inputs 10V 2 digital I O points which can be configured as 24V input or 45mA output 0PS320 1 24VDC power supply 3 phase 20 A input 400 500 VAC 3 phases wide range DIN rail mounting Table 10 Order data for ACOPOS 1180 1320 1 5 2 Technical Data Product ID 8V1180 00 2 8V1320 00 2 General Information C UL US Listed Yes Power mains connection Mains Input Voltage 3 x 400 VAC to 480 VAC 10 Power filter according to IEC 61800 3 A11 second environment Limits from CISPR1
14. GOST R certification is available for the export of all B amp R ACOPOS servo drives in the Russian Federation Table 123 International Certifications ACOPOS User s Manual 209 Chapter 7 Standards and Certifications Standards and Certifications Standards Definitions for Safety Techniques 8 Standards Definitions for Safety Techniques Stop Functions according to IEC 60204 1 11 98 electrical equipment for machines part 1 general requirements The following three stop function categories exist Category Description 0 Stop by immediately switching off the power to the machine drive elements i e uncontrolled stop 1 A controlled stop the power to the machine drive elements remains on until the stop procedure is completed The power is switched off after the stop is complete 2 A controlled stop the power to the machine drive elements is not switched off Table 124 Overview of stop function categories The necessary stop functions must be determined based on a risk evaluation for the machine Stop functions in category O and category 1 must be able to function regardless of the operating mode A category 0 stop must have priority Stop functions must have priority over assigned start functions Resetting the stop function is not allowed to cause a dangerous state Emergency stops according to IEC 60204 1 11 98 electrical equipment for machines part 1 general requirements
15. LICSA listed 8CE025 12 1 EnDat cable length pin Intercontec socket servo connector 15 pin DSUB plug can be used in 25m 10 x 0 14mm 2 x 0 5mm EnDat connector 17 cable drag chains U L CSA listed 3 3 2 Technical Data Table 36 Order data for EnDat cables Description EnDat Cables General Information Cable Cross Section 10 x 0 14 mm 2 x 0 50 mm Durability Oil resistant according to VDE 0472 part 803 as well as standard hydraulic oil Certification UL AWM Style 20963 80 C 30 V E63216 and CSA AWM I II A B 90 C 30 V FT1 LL46064 Conductor Signal Lines 0 14 mm2 tinned Cu wire Wire Insulation Special thermoplastic material Wire Colors Blue brown yellow gray green pink red black violet white Supply Lines 0 5 mm tinned Cu wire Wire Insulation Special thermoplastic material Wire Colors White green white red Cable Structure Signal Lines Stranding No Shield No Supply Lines Stranding White red with white green and filler elements Shield No Cable Stranding With foil banding ACOPOS User s Manual Table 37 Technical data for EnDat cables 71 Chapter 2 Technical Data Technical Data Cables Description EnDat Cables Cable Shielding Cu mesh optical coverage gt 85 and wrapped in isolating fabric Outer Sheathing Material PUR Color Orange similar to RAL
16. Maximum Installation Altitude 2000 m 4 Degree of Pollution acc to IEC 60664 1 2 non conductive material Over voltage Category according to IEC 60364 4 443 1999 Protection according to IEC 60529 IP20 Storage and Transport Conditions Storage Temperature 25 to 55 C Relative Humidity during Storage 5 to 95 non condensing Transport Temperature 25 to 70 C Relative Humidity during Transport 95 at 40 C Mechanical Characteristics Dimensions Width Height Depth 276 mm 460 mm 295 mm 402 mm 460 mm 295 mm Weight 24 1 kg 33 8 kg Table 13 Technical data for ACOPOS 1640 128M cont 1 Integrated line filter in preparation 2 The current requirements depend on the configuration of the ACOPOS servo drive To determine the current requirements see section 5 Configuration of ACOPOS Servo Drives on page 117 3 The 24 VDC supply voltage for the ACOPOS servo drive is created by the integrated DC bus power supply which reduces the 24 VDC current requirements lo4ypc to 0 Mains Input Voltage 3 x 400 VAC to 480 VAC 10 4 Additional requirements are to be arranged with B amp R ACOPOS User s Manual 41 Chapter 2 Technical Data Technical Data e ACOPOS Plug in Modules 2 ACOPOS Plug in Modules 2 1 General Information The ACOPOS drives are equipped with four plug in module slots You can select the plug in m
17. N All shields connected to the plug Figure 41 Cable schematic for motor cables 8CMxxx 12 5 ACOPOS User s Manual 165 Chapter 5 Wiring Wiring Cables 6 2 EnDat Encoder Cables 6 2 1 EnDat Encoder Cable Construction Pos Amount Description Remark 1 Encoder cable 10x 0 14 mm 2x 0 50 mm 1 Circular connector 17 pin socket ASTA 035 FR 11 12 0035 000 1 DSUB housing 45 metal plated 15 pin plug lw Pp 1 Heat shrink tubing Table 96 EnDat encoder cable construction 6 2 2 Pin Assignments Circular Connector Pin Description Function Pin DSUB Plug 15 A Channel A 1 10 COM 1 3 9 11 13 15 Encoder supply 0 V 2 12 B Channel B 3 7 5V out 0 25A Encoder supply 5 V 4 14 D Data input 5 9 o 3 1 8 T Clock output 8 6 F 16 A Channel A inverted 9 o 4 Sense COM Sense input 0 V 10 15 eo 8 13 B Channel B inverted 11 1 Sense 5V Sense input 5 V 12 17 D Data inverted 13 9 T Clock output inverted 15 166 Table 97 Pin assignments for EnDat encoder cables ACOPOS User s Manual 6 2 3 Cable Schematic Wiring Cables COM 1 3 9 11 13 15 5V out 0 25A A B D T A Sense COM B Sense 5V D n Circular Plug DSUB 406 S white green 0 5 mm A m E pi white red
18. C 1 Cross talk between the Analog Inputs Min 90 dB at 1kHz Common Mode Rejection DC 50 Hz Min 73 dB Min 73 dB 64 Table 32 Technical data for AC131 cont ACOPOS User s Manual Technical Data e ACOPOS Plug in Modules Operation Product ID 8AC131 60 1 Modulation Compared to Ground Max 50 V Potential Modulation between the Analog Input Max 5 V Channels Operational Conditions Environment Temperature during 0 to 50 C Relative Humidity during Operation 5 to 95 non condensing Storage and Transport Conditions Storage Temperature 25 to 55 C Relative Humidity during Storage 5 to 95 non condensing Transport Temperature 25 to 70 C Relative Humidity during Transport 95 at 40 C 1 Refers to the measurement range 2 9 4 LEDs Table 32 Technical data for AC131 cont imit The 24V LED is lit as soon as the supply voltage for the plug in module goes above 18 VDC 2 9 5 Firmware The firmware is part of the operating system for the ACOPOS servo drives The firmware is updated by updating the ACOPOS operating system ACOPOS User s Manual 65 Chapter 2 Technical Data Technical Data Cables 3 Cables 3 1 General Information B amp R offers the cables for ACOPOS servo drives in six different lengths All cables can be used for drag chain installations 1 To prevent disturbances to encoder signals t
19. DigitalUO 7 Digital input output 7 E j 8 Digital 0 8 Digital input output 8 E 9 Digitalog Digital output 9 Pg 10 Digital O 10 Digital output 10 p 1 424v Supply 424 V Miu 12 COM 1 11 Supply 0 V pa Terminal Cross Sections mm AWG Solid Core Multiple Conductor Lines 0 5 1 5 20 14 Flexible Multiple Conductor Line without Wire Tip Sleeves 0 5 1 5 20 14 with Wire Tip Sleeves 0 5 1 5 20 14 Approbation Data UL C UL US and CSA UL C UL US 26 14 CSA 26 14 Holding Torque for the Terminal Screws Nm 0 2 0 25 Table 91 Pin assignments AC130 digital mixed module 160 ACOPOS User s Manual Wiring Plug in Module Pin Assignments 5 7 AC131 Mixed Module 5 7 1 Pin Assignments Image x1 Pin Description Function 1 Analog 1 Analog input 1 plus 2 Analog 1 Analog input 1 minus 3 COM 1 2 5 6 Analog input 0 V 4 Shield Shield 5 Analog 2 Analog input 2 plus 6 Analog 2 Analog input 2 minus 7 COM 1 2 5 6 Analog input 0 V 8 Shield Shield 9 Digital O 1 Digital input output 1 10 Digital 1 0 2 Digital input output 2 11 24V Supply 24 V 12 COM 9 11 Supply 0 V Terminal Cross Sections mm AWG Solid Core Multiple Conductor Lines 0 5 1 5 20 14 Flexible Multiple Conductor Line without Wire Tip Sleeves 0 5 1 5 20 14 with Wire Tip Sleeves 0 5 1 5 20 14 Approbation Data UL C UL US and CSA UL C
20. Table 6 Table 7 Table 8 Table 9 Table 10 Table 11 Table 12 Table 13 Table 14 Table 15 Table 16 Table 17 Table 18 Table 19 Table 20 Table 21 Table 22 Table 23 Table 24 Table 25 Table 26 Table 27 Table 28 Table 29 Table 30 Table 31 Table 32 Table 33 Table 34 Table 35 Table 36 Table 37 Table 38 Table 39 Table 40 Table 41 Table 42 Table 43 Table 44 Table 45 Table 46 Table Index Description of the safety guidelines 1 0 eee eeeeeeeeneeeeeeeeeeeneeeteeaeeereaeetenentereaaes 29 General description of the ACOPOS servo drive series sssssee 32 Status LEDs ACOPOS servo drives ooocccoccccococonnnononnnnnnnnnnonononononononnananannononnonon 33 LED Sta iii leia 34 Status changes when booting the operating system loader 34 Error status with reference to the CAN plug in module AC110 35 Error status with reference to the ETHERNET Powerlink pl g in mod le AC 112 eae ME ele tens 35 Order data for ACOPOS 1022 1045 and 1090 occncoccccccnccnnocoonnnncnnonononcnonnnannnos 36 Technical data for ACOPOS 1022 1045 and 1090 occococcnccccnnococcncconnnccnnnccnnannn 36 Order data for ACOPOS 1180 1320 ooooccccccnococonnccnoooonnnncnnnnonnnnnnnonnnnnnnncnnncnnnnnonn 38 Technical data for ACOPOS 1180 1320 ccccnncccccnnnnoccocnnnnconconnnnnonanonnnnnncnnnonnns 38 Order data for ACOPOS 1640 128
21. Tso Shield 24 V tie Lso End End o Ref ec Enable 24 V t 9c Enable ove Lito COM 8 9 1 9 0 COM 8 9 1 9 24V out 0 5A 24 V t e oc 24V Lito 24V LoG COM 5 7 13 15 HUSC COM 5 7 13 15 0 06 COM 5 7 13 15 i ACOPOS 8V1640 00 2 1640 128M 8V128M 00 2 CAN ETHERNET Powerlink 3 400 480 VAC 50 60 Hz Figure 38 Pin assignment overview ACOPOS 1640 128M 1 Starting with revision KO 150 ACOPOS User s Manual Wiring Pin Assignments ACOPOS 1640 128M 4 1 Pin Assignments for Plug X1 x1 Pin Description Function 1 Triggeri Trigger 1 2 Quickstop Trigger2 Quickstop Trigger 2 3 COM 1 2 Trigger 1 Quickstop Trigger 2 0 V 4 Shield Shield 5 End Positive HW limit 6 End Negative HW limit 7 Ref Reference switch 8 Enable Enable 9 Enable Enable 10 COM 8 9 Enable 0 V 11 COM 8 9 Enable 0 V 12 13 24V out 0 5A 24 V output 0 5 A 14 24V Supply 24 V 15 24V Supply 24 V 16 COM 5 7 13 15 Supply 0 V 17 COM 5 7 13 15 Supply 0 V 18 COM 5 7 13 15 Supply 0 V Terminal Cross Sections see table 60 Terminal cross sections for ACOPOS servo drives on page 138 Table 78 Pin assignments for plug X1 ACOPOS 1640 128M 4 2 Pin Assignments X2
22. User ROM Settings 9 ACTIO ECT stings V0472 UserROM 212 E 84C120 60 1 2 i acp10sys V047 2 UserROM 240416 3 3 i gcloader v1 31 UserROM 5816 3 4 Y ncglobal v017 UserROM 8020 9 M i acp10man V0472 UserROM 66388 i acp10par v0 47 2 UserROM 15700 CN ACP10 Real Axis E axl_par User RAM E ACP10 Error Text Module Lj acp10etx vo 00 UserROM 5469 4 13 a Dupa Find in Fies Transfers the entire project to the target Line 16 of 18 COMi CP476 V224 AUN 188 Figure 68 Click on the command to transfer the project to the target system ACOPOS User s Manual Getting Started Starting Up an ACOPOS Servo Drive If an operating system has already been transferred to the PLC a version conflict could occur In this case the operating system on the PLC is to be replaced by the operating system in the sample project e Select Replace operating system option field Operating System Mismatch 2 x The OS version used in your project is not the same as on the target Mismatch detail Project Target Version V227 V2 24 Cc Apply the current version on the target to your project 7 lgnore the mismatch between project and target ope yc Figure 69 Operating system version conflict e Acknowledge by clicking the Continue button Operating System Mismatch 2 x The OS version used in your project is not the same as on the target Mismatch detail Pr
23. 0 5 mm tl 7 TES t o4 li a it 154 green 0 14 mm Si 1 ra 0 14 mm bg i rog white 0 14 mm E 5 es E black 0 14 mm x M brown 0 14 mm 16 T rk m a T og st pin 14 mm rg di yellow 0 14 mm aA 130 H L o 11 1 bag blue 0 14 mm bag js 2 dF E 7 9 M M H 19 rd violet 0 14 mm P 17 i rt 13 nsi red 0 14 mm ae go r o 15 Ad Y 207 ne i nc o 6 304 ne no bo 7 1 i 5 O nc nc ro 14 6 O4 nc Spr CSS i Shield connected to 11 4 nc lug h usi AREA i plug housing Figure 42 Cable schematic for EnDat encoder cables ACOPOS User s Manual 167 Chapter 5 Wiring Wiring Cables 6 3 Resolver Cables 6 3 1 Resolver Cable Construction 2 Pos Amount Description Remark 1 1 Encoder cable 3x 2x24 AWG 19 2 1 Circular connector 12 pin socket ASTA 021 FR 11 10 0035 000 3 1 DSUB housing 45 metal plated 9 pin plug 4 1 Kink protection 6 3 2 Pin Assignments Table 98 Resolver cable construction Circular Connector Pin Description Function Pin DSUB Plug 1 2 3 Cos Cosine input 3 4 Sin Sine input 4 5 Ref Reference output 5 7 lola 7 Cos Cosine input inverted 7 A ola 8 Sin Sine input inverted 8 ES 9 Ref Reference output inverted 9 10 11 12 168 Table 99 Pin assignmen
24. 03 acpl manh 22476 3 4 libacpl man a 2188 c System Es 8v1048 004 fd sysconf v2 27 UserROM 752 e CLR 1 A acpl c g v0472 UserROM 212 y 84C120 60 1 2 4 acplOsys 0 47 2 UserROM 240416 J 3 gcloader v1 31 UserROM 5816 3 4 4 ncglobal v017 UserROM 8020 9 M 4 acp10man V0472 UserROM 66388 acpl par v0 47 2 UserROM 15700 THRI ACP10 Real Axis Eg nt User RAM AQ ACP10 Enor Text Module LB acpi etx v0 00 UserROM 54696 x E Output Debug Findin Fies Line 16 of 18 comi CP476 V224 RUN Figure 58 Open initial parameter module AX1 PAR ACOPOS User s Manual 183 Chapter 6 Getting Started Getting Started Starting Up an ACOPOS Servo Drive e Position the mouse pointer on dig in B amp R Automation Studio ax1_par waf Axis e Ele Edi View Open Project Object Tools Window 2 mr lel xd JDG Hgj s Beloo xa F eam 9 9 a por Ee e DRE Ue EMI cle renter if G B limit Ba controller ELBE message Output Debug Find in Fies com CP476 V224 RUN Figure 59 Place the mouse pointer on dig in Expand the view by clicking on la x B amp R Automation Studio ax1_par waf Axis lej x 6h File Edit View Open Project Object Tools Window 2 e zz Exil E d ENS El Output Debug Find in Fies COM CP476 V224 RUN 184 Figure 60 Expand the view ACOPOS User s Manual Getting Started Starting Up an A
25. 12 5 Motor cable length 7m 4 x 10mm 2 x 2 x 1 5mm Motor connector 8pin Intercontec socket can be used in cable drag chains UL CSA listed 8CM010 12 5 Motor cable length 10m 4 x 10mm 2 x 2 x 1 5mm Motor connector 8pin Intercontec socket can be used in cable drag chains UL CSA listed 8CM015 12 5 Motor cable length 15m 4 x 10mm 2 x 2 x 1 5mm Motor connector 8pin Intercontec socket can be used in cable drag chains UL CSA listed 8CM020 12 5 Motor cable length 20m 4 x 10mm 2 x 2 x 1 5mm Motor connector 8pin Intercontec socket can be used in cable drag chains UL CSA listed 8CM025 12 5 Motor cable length 25m 4 x 10mm 2 x 2 x 1 5mm Motor connector 8pin Intercontec socket can be used in cable drag chains UL CSA listed Table 33 Order data for motor cables ACOPOS User s Manual 67 Chapter 2 Technical Data Technical Data Cables Model Number Short Description Image Motor Cables 35 mm 8CM005 12 8 Motor cable drag chains U length 5m 4 x 35mm 2 x 2 x 1 5mm can be used in cable LICSA listed 8CM007 12 8 Motor cabl p drag chains U length 7m 4 x 35mm 2 x 2 x 1 5mm can be used in cable L CSA listed 8CM010 12 8 Motor cabl p drag chains U ength 10m 4 x 35mm 2 x 2 x 1 5mm can be used in cable L CSA listed 8CM015 12 8 Motor cabl p drag chains U ength 15m 4 x 35mm 2 x 2 x 1 5mm can be used in cable L
26. 2003 flat Labeling BERNECKER RAINER 10x0 14 2x0 50 FLEX Electrical Characteristics Conductor Resistance Signal Lines lt 140 O km Supply Lines lt 40 O km Insulation Resistance 200 MO per km Isolation Voltage Wire Wire 15kV Wire Shield 0 8 kV Operating Voltage Max 30 V Mechanical Characteristics Temperature Range Moving 10 C to 70 C Static 20 C to 90 C Outer Diameter 7 3 mm 0 25 mm Flex Radius 55mm Speed lt 4m s Acceleration lt 60 m s Flex Cycles gt 3 000 000 Weight 0 08 kg m Table 37 Technical data for EnDat cables cont 72 ACOPOS User s Manual 3 4 Resolver Cable 3 4 1 Order Data Technical Data Cables Model Number Short Description Image 8CR005 12 1 Resolver cabl pin In e leng ercontec socke drag chains UL CSA h 5m 3x 2 x 24 AWG 19 resolver plug 12 Servo pl isted ug 9 pin DSUB plug can be used in cable 8CR007 12 1 Resol pin In ver cable ercontec eng socke drag chains UL CSA isted h 7m 3x servo pl 2 x 24 AWG 19 resolver plug 12 ug 9 pin DSUB plug can be used in cable 8CR010 12 1 Resol pin In ver cable ercontec eng socke drag chains UL CSA h 10m serv isted 3 x 2 x 24 AWG 19 o plug 9 pin DSUB p resolver plug 12 ug can be used in cable 8CR015 12 1 Resol pin In ver cable lercontec eng socke drag chains
27. 250 VAC VDC Isolation Voltage L L 2500 V Contact Resistance lt 5mQ Mechanical Characteristics Temperature Range 20 C to 130 C Housing Material Zinc die cast brass nickel plated Gaskets FPM HNBR Mating Cycles 50 Crimp Range 4x0 5 2 5 mm 4x 0 06 1 mm 4 x 0 5 4 mm 4 x 0 06 1 mm Cable o 9 5 14 5 mm 14 17 mm Manufacturer Information Manufacturer INTERCONTEC Internet Address www intercontec biz Manufacturer s Product ID BSTA 108 FR 19 58 0036 000 BSTA 108 FR 35 59 0036 000 Table 41 Technical data for motor connectors 8PM001 00 1 and 8PM002 00 1 ACOPOS User s Manual 7T Chapter 2 Technical Data Technical Data Connectors 4 2 3 Technical Data for 8PM003 00 1 Product ID 8PM003 00 1 General Information Connector Size Size 1 5 Contacts 8 4 power and 4 signal contacts Degree of Pollution 3 Installation Altitude Up to 2 000 m Housing Insulator PA 6 6 PBT UL94 VO listed Contacts Gold plated brass Protective Ground Connection on According to VDE 0627 Protection according to DIN 40050 IP67 when connected Certifications UL CSA Electrical Characteristics Overvoltage Category 3 Power Contacts Nominal Current 75A Nominal Voltage 630 VAC VDC Isolation Voltage L L 6000 V Contact Resistance lt 1mQ Signal Contacts Nominal Current 30A Nominal Voltage 630 VAC VDC Isolation Voltage L L
28. 3 4 6 10 X4a X4b Solid core multiple conductor lines 0 2 2 5 24 12 0 2 2 5 24 12 0 2 2 5 24 12 0 2 2 5 24 12 Flexible and fine wire lines Motor without Wire Tip Sleeves 0 2 2 5 24 12 0 2 2 5 24 12 0 2 2 5 24 12 0 2 2 5 24 12 holding with Wire Tip Sleeves 0 25 2 5 23 12 0 25 2 5 23 12 0 25 25 23 12 0 25 2 5 23 12 brake Approbation Data temperature UL C UL US 30 12 30 12 30 12 30 12 sensor CSA 28 12 28 12 28 12 28 12 Holding Torque for the Terminal Screws Nm 0 5 0 6 0 5 0 6 0 5 0 6 0 5 0 6 Solid core multiple conductor lines 0 2 4 24 10 05 10 20 7 10 50 7 0 16 95 6 3 0 X5 Flexible and fine wire lines without Wire Tip Sleeves 02 4 24 10 05 6 20 9 10 35 7 2 10 70 7 2 0 Motor with Wire Tip Sleeves 025 4 28 10 0 5 6 20 9 10 35 7 2 10 70 7 2 0 power Approbation Data UL C UL US 30 10 20 8 10 2 6 2 0 CSA 28 10 20 8 12 2 _ 6 2 0 Holding Torque for the Terminal Screws Nm 0 5 0 6 12 1 5 3 4 6 10 Solid core multiple conductor lines s 0 2 4 24 10 05 10 20 7 0 5 10 20 7 X6 Flexible and fine wire lines without Wire Tip Sleeves 0 2 4 24 10 0 5 6 20 9 0 5 6 20 9 External with Wire Tip Sleeves 025 4 23 10 0 5 6 20 9 0 5 6 20 9 Brake Approbation Data Resistor UL C UL US 30 10 20 8 20 8 CSA 28 10 20 8 20 8 Holding Torque for the Terminal Screw
29. CSA listed 8CM020 12 8 Motor cabl EJ drag chains U length 20m 4 x 35mm 2 x 2 x 1 5mm can be used in cable LICSA listed 8CM025 12 8 Motor cable drag chains length 25m 4 x 35mm 2 x 2 x 1 5mm can be used in cable U LICSA listed 68 Table 33 Order data for motor cables cont 1 Standard fabrication designed for use with ACOPOS servo drives 8V1022 00 x 8V1045 00 x and 8V1090 00 x and motor sizes 2 to 7 2 Standard fabrication designed for use with ACOPOS servo drives 8V1180 00 x and 8V1320 00 x and motor sizes 2 to 7 3 Standard fabrication designed for use with ACOPOS servo drives 8V1640 00 x and 8V128M 00 x and motor size 8 ACOPOS User s Manual 3 2 2 Technical Data 1 5 and 4 mm motor cables Technical Data Cables Description Motor Cables 1 5 mm Motor Cables 4 mm General Information Cable Cross Section 4x 1 5 mm 2 x 2 x 0 75 mm 4x4mm 2x2x1 mm Wire Insulation Wire Colors Durability Oil resistant according to VDE 0472 part 803 as well as standard hydraulic oil Certification UL AWM Style 20669 90 C 600 V E63216 and CSA AWM I II A B 90 C 600 V FT1 LL46064 Conductor Power Lines 1 5 mm2 tinned Cu wire 4 mm tinned Cu wire Special thermoplastic material Black brown blue yellow green Signal Lines Wire Insulation 0 75 mm tinned Cu wire 1 mme tinned Cu wire Special thermoplastic ma
30. Count Frequency Max 800 kHz Reference Frequency Max 200 kHz Distance between Edges Min 0 6 us Counter Size 32 bit Inputs A A B B R R Differential Voltage Inputs A B R Minimum 25V Maximum 6V SSI Absolute Encoder Baud Rate 200 kBaud Word Size Max 31 bit Differential Voltage Clock Output 120 Q Minimum 25V Maximum 5V Differential Voltage Data Input Minimum 25V Maximum 6V Table 28 Technical data for AC123 56 ACOPOS User s Manual Technical Data e ACOPOS Plug in Modules Operation Product ID 8AC123 60 1 Operational Conditions Environment Temperature during 0 to 50 C Relative Humidity during Operation 5 to 95 non condensing Storage and Transport Conditions Storage Temperature 25 to 55 C Relative Humidity during Storage 5 to 95 non condensing Transport Temperature 25 to 70 C Relative Humidity during Transport 95 at 40 C Table 28 Technical data for AC123 cont 1 The AC123 is an encoder module Several encoder modules can also be inserted In this case the encoder module in the slot with the lowest number is automatically used for motor feedback 2 The power consumption of the plug in module can be approximated using the following formula Puogute W Pencoder W k 0 6 W The power consumed by the encoder Pengoder is calculated from the selected encoder supply voltage 5 V 15 V and the current required PEncoder W UEncoder IV En
31. D 3 T network D BE doin E A Units W Trace enabled EBB encoder i v pos 10000 Units s Emm Ls imit v_neg 10000 Units s al pos 50000 Units 2 ncBASIS MOVE ncINIT amp HB controller a2 pos 50000 Units neCONTROL nciNIT CBS move al neg 50000 Units ncCONTROL ncSWITCH OF EBS stop a2 neg 50000 Units s ncCONTROL neSwITCH ON LB p B ncHOMING ncSTART G25 homing ncLIMITS nclNIT EPR basis ncREL MOVE overide ncSERVICE ncREAD ncDr Be ncSERVICE ncSET ncDAT neSIMIILATIDN neSWITCH DF mi New Chart 1 axl par ax par network ax par network 0 ax parnetwork 0 UnitY For Help press F1 COM CP476 V224 RUN Figure 82 During the movement of the shaft the traverse path already completed is shown in the Watch window B amp R Automation Studio ax1_par waf Test ex 6b File Edit View Insert Open Project Test Object Tools Window 2 la x Ds ugi ea o cx TASHADI EE network BS doin Units He encoder if Units s d Be imit Units s 1 Units s ncBASIS MOVE nciNIT Ela controller Units s ncCONTROL nelNIT SB move Units s ncCONTROL ncSWITCH_OF EBS stop Units s ncCONTROL ncSWITCH ON E ncHOMING ncSTART pss homing ncLIMITS nclNIT Y parameter ncREL_MOVE EBE basis neSERVICE ncREAD ncD ncSERVICE ncSET ncDAT neSIMITLATIDN neSWITCH DF Ei a al i E
32. EN 954 1 category 3 is in preparation The limit values specified from section 3 Environmental Limits to section 6 Other Environmental Limit Values according to IEC 61800 2 are taken from product standard IEC 61800 for servo drives in industrial environments end environment Stricter test procedures and limit values are used during the type tests for ACOPOS servo drives Additional information is available from B amp R ACOPOS User s Manual 201 Chapter 7 Standards and Certifications Standards and Certifications Environmental Limits 3 Environmental Limits 3 1 Mechanical Conditions according to IEC 61800 2 3 1 1 Operation IEC 60721 3 3 class 3M1 IEC 61800 2 Vibration during operation 2 lt f lt 9Hz 9 lt f lt 200 Hz 0 3 mm amplitude 1 m s acceleration 3 1 2 Transport Table 104 Mechanical conditions during operation IEC 60721 3 2 class 2M1 IEC 61800 2 Vibration during transport 2 lt f lt 9Hz 9 lt f lt 200 Hz 200 lt f lt 500 Hz 3 5 mm amplitude 10 m s acceleration 15 m s acceleration Table 105 Mechanical conditions during transport 3 2 Climate Conditions according to IEC 61800 2 3 2 1 Operation IEC 60721 3 3 class 3K3 IEC 61800 2 Environmental temperature during operation 5 to 40 C Relative humidity during operation 5 85 non condensing 3 2 2 Storage Table 106 Climate conditions during opera
33. F nclNIT e Initialize the new values on the encoder by pressing the l button ACOPOS User s Manual 193 Chapter 6 Getting Started Getting Started Starting Up an ACOPOS Servo Drive For additional safety the traverse path can be limited using software end switches pos sw end neg sw eng The software end switches can be defined as follows e Position the mouse pointer on limit e Expand the view by clicking on e Position the mouse pointer on parameter The parameters are now shown in the right part of the window d exl par Wl par Value Uni ia network v pos 50000 Units s 25S dig in v_neg 50000 Urits s D Be encoder i al pos 500000 Units z gt a2_pos 500000 Units s TPE limit atzne 500000 Units s Lg parameter ml a2 neg 500000 Units 2 ta controller t jot 0 s die move Lin pos 0 s LB message rovc AN neg sw end 2000000000 Units ds waming 500 Urits ds stop 1000 Units Figure 78 Defining the software end switches Now the values can be adjusted to the mechanical parts used and acknowledged by pressing the ENTER key The new limit values now have to be initialized e Action window Position the mouse pointer on the action ncLIMITS ncINIT e Initialize the new limit values by pressing the button 194 ACOPOS User s Manual Getting Started Starting Up an ACOPOS Servo Drive Entering the Traverse Path e Position the mouse pointer on the action nc
34. Getting Started Starting Up an ACOPOS Servo Drive e The user memory is erased Clear Memory xj Erasing memory Please wait Figure 54 Erasing the user memory After clearing the user memory the project window will be shown again Operating System Download The first time an ACOPOS servo drive is started up the ACOPOS operating system ACP10SYS must also be transferred to the target system In the sample project transferring ACP10SYS is deactivated shown in gray in the right part of the window Transferring ACP10SYS must be activated separately in the sample project e Position the mouse pointer on ACP10SYS in the right part of the window B amp R Automation Studio 8 x EIER EG e Ml Tool Dg BHgs smg e c xmd acp10 Project lol Model no Slot Software Log book CAN 1 0 TPU Permanent Description E ACPIO Module Name Version Transferto Size bytes Description Ef 2003 _BP SE CPU ct TCPATE UT 0 Q Cyclic 1 10ms j 01 AE ate v0 00 User RAM 7676 3 02 g axtste 16265 3 03 acplOmanh 22476 3 04 libacpl man a 2188 9 1 cil System Es 8v1045 001 fd sysconf v2 27 UserROM 752 84C110 60 1 1 Y acpl0ctg V0 47 2 UserROM 212 6 8AC120 601 2 iva M 4 J 3 Qeloader lg Vi3l UserROM 5816 3 4 4 ncglobal v0 17 UserROM 8020 9 M 4 acpl man V0472 UserROM 66388 acpl par V0472 UserROM 15700 HRJ ACP10 Real Axis Tg axl par v0 00 User
35. Mounting coooccccnonccononcnonanananincnonnannnnnns NC Objects Order Data Output for Motor Holding Brake WIN Dictar iteraci n 141 146 152 Pin Assignments ssees 139 Plug in Modules 17 42 89 155 Programming eeeeeeeeee 17 Safety Guidelines 26 Sample project sesssss 172 Service iiec necne 17 SoftWare ea a 17 Stant UP ea d bees 171 Storage acarici 27 Technical Data ssessssssss 36 Tae aiiis idit caste EIS 19 198 Transport inei ee ies 27 Trigger crece ote e 20 Wiring 22 2 iii tee conecte cepa cede 121 Shield connection ssssse 123 SOflWate 4 editrice qtto 17 Software End Switches 194 SSI absolute encoder interface see AC123 E 201 Star TOPOlOGY ccoo alas 24 Status alo oni 171 Status LEDs ACOPOS conti ici 33 Storage oti du RE tereti 27 T Terminal Cross Sections 138 Terminal Screw Holding Torque 138 Thermal Equivalent Circuit 116 A n a N i 19 198 Transport ee pue 27 Tigger ute tei 20 225 Index 226 ACOPOS User s Manual 0 0AGO12 9 i toros e este cates 43 0AC913 92 5 eee deett 43 0PS320 1 nidore RO RAM 36 7 ZAGO11 9 diei heDE ES 43 AA A A 58 62 7T1B 12 91 E 58 62 7TB712 90 Q2 eee 58 62 7TB712 91 02 nae 58 62 8 SACA DO
36. Picnic 43 8AC112 60 1 idein ets 45 8AC120 60 1 dudes 50 8AC122 60 2 ssseseeeeeens 52 8A0123 60 1 ne a 55 98AC130 60 1 5 5 on iei etu 58 8AC131 60 1 tret Ere pns 62 8CE005 712 1 5 aiii nni n 71 8CE007 12 1 ee r nae nian hel 71 o uie eguenUE 71 8CE015 12 1 2 eerie eins 71 9CEO020 12 1 ces 71 AI O A ee decet 71 8CM005 12 1 AA 67 8CMOO05 12 8 cere mete s 67 8CM005 12 5 sete 67 8CMO005 12 8 essssssssee 68 8CMO00771231 acia 67 8CMO007 12 8 iaeia ia 67 8CMO007 12 5 sese 67 ACOPOS User s Manual 8CM007 12 8 8CMO010 12 1 8CMO010 12 3 8CMO010 12 5 8CMO010 12 8 8CMO015 12 1 8CM015 12 3 8CM015 12 5 8CM015 12 8 8CM020 12 1 8CMO020 12 3 8CMO020 12 5 8CM020 12 8 8CM025 12 1 8CM025 12 3 8CM025 12 5 8CM025 12 8 8CRO05 12 1 8CR007 12 1 8CR010 12 1 8CR015 12 1 8CR020 12 1 8CR025 12 1 8PE001 00 1 8PM001 00 1 8PM002 00 1 8PM003 00 1 8PR001 00 1 8V1022 00 2 8V1045 00 2 8V1090 00 2 8V1180 00 2 8V128M 00 2 8V1320 00 2 8V1640 00 2 Model Number Index 227 Model Number Index Model Number Index 228 ACOPOS User s Manual MAACP2 E
37. Pini ASSIGNMENTS X2 cat iaa ie ve cel dn 151 4 3 Pin Assignments X9 ii cun ae deter b PIED ER e ie 152 4 4 Pin Assignments for Plugs X4a X4b ssssssssseeeem meme 152 4 4 1 Wiring the Output for the Motor Holding Brake seeeeem 152 4 5 PiniAssigniments Xb unii toi AE 154 4 6 Pin Assignments XO 2 1 de Lee eateteie e tei E ee tte retenues 154 5 Pin Assignments Plug in Modules eem 155 SAAC TO CAN Iriterface ie datae nte Re decet oda acu ern 155 51 4 Pini AssigniTients 222 7 2 op rop RR ID CREBRO ire 155 5 2 AC112 ETHERNET Powerlink Interface sseeeenennnnee 156 5 2 1 Pin Assignments il rper eru cede De redeas e cde diene 156 5 3 AC120 EnDat Encoder Interface sssssssseeeneneeenen nennen 157 5 3 1 Pin Assignments cio Me ei ie ea ne 157 5 4 AC122 Resolver Interface sesssssssesssseeee enne 158 5 4 1 Pin Assignments cuac 158 5 5 AC123 Incremental Encoder and SSI Absolute Encoder Interface 159 5 91 Pin Assignments et he RE ERU EL RE Gedichte 159 5 6 AC130 Digital Mixed Module ssssseneeeeeneenenennenneee nennen 160 5 651 Pin AssighMentS 11100 et Pte nde satu oe eee 160 5 7 AC131 Mixed Module 3 1 a RERO eR ERROR 161 5 721 Pin Assignments 3 uiu aliada 161 5 8 Connecting Cables to Plug in Modules ooooococnccconccnonicoccconcnnonccancn conc conca narco ncrn
38. RAM 360 AQ ACPI0 Enor Text Module LB acpi etx v0 00 UserROM 54696 I E Oupa Find in Files Line 10 of 18 comi CP476 V224 RUN Figure 55 Place mouse pointer on ACOPOS operating system ACP10SYS 180 ACOPOS User s Manual Getting Started Starting Up an ACOPOS Servo Drive e Open the shortcut menu with the right mouse button e Position the mouse pointer on Disable e Click on Disable with the left mouse button to cancel deactivation B amp R Automation Studio File Edit View Insert Open Project Object Tools Window 2 acp10 Project 3 Efe 8v1045 00 1 8AC110 60 1 M 84C120 60 1 3 3 OSH S Selo o XE 7 24S Ea 49 9 x Brrerget Transfer to ol Software Log book CAN 1 0 TPU Permanent Description Module Name Version Transferto Size bytes _ Description v0 00 UserRAM 7676 16265 acpl manh 22476 libacpl man a 2188 c System 4 sysconf v2 27 User ROM 752 acpi0ctg V0472 UserROM 212 x M 1 goloader ien erROM 5816 neglobal begat ler ROM 8020 4 acpl man le ROM 66388 acpl par lerROM 15700 Hg ACP10 Real Axis 7 Cy axl_par Ts ler RAM 360 S ACP10 Eror Text Mod s L acp10etx jeROM 54698 oua D SSS CCA comi CP476 v224 RUN Figure 56 Enable transferring the ACOPOS operating system ACOPOS User s Manual 181 Chapter 6 Getting Started Getting Star
39. Resistor eene 114 4 3 2 Power Data for the External Braking Resistor sene 115 4 3 3 Nominal Voltage of the External Braking Resistor eeeeeeeeee 115 4 4 Setting Brake Resistor Parameters ococccincccncccocccooncnnccnoncnconncnnn crono cono cnnn cnn enne 115 4 4 1 Using the Integrated Braking Resistors ss 115 4 4 2 Using External Braking Resistors sen eme 116 5 Configuration of ACOPOS Servo Drives sssssssseeeeeeee nennen nens 117 5 1 Maximum Power Output via the Four ACOPOS Servo Drive Slots 117 5 2 24 VDC Current Requirements for the ACOPOS Servo Drive aseeseen 118 6 Formula Variables Used cceeccceseecceeseeceenseceeneeeeeeseeeeeseeeneneneeseeneeseeeseesneeeesaeeeeeseineneses 119 Chapter 5 Wiring sico 121 1 General Information acicate tad rente 121 1 1 Electromagnetic Compatibility of the Installation eene 121 1 1 1 General Information cuina i erae 121 1 3 2 Installatiori NOtes oca 122 1 2 Secure Hestart Inhibit Vic lora 126 1 2 4 General Information oie done ee p BC Re r iii 126 1 2 2 Principle Realization of the Safety Function sseeee 127 1 2 3 External WIND carried criada 128 1 3 Overview of the Terminal Cross Sections sese 138 2 Pin Assignments ACOPOS 1022 1045 1090 139 2 1 Pin As
40. SSI Encoder IF 55 159 223 Index Index Resolver interface 52 158 EnDat Cables Cable Schematic 167 Order Data iia ala 71 Pin Assignments seee 166 Structure ct eee petas 166 Technical Data oooonncncccncccncconononcnnnennnnn 71 EnDat Connector Order Data cccccccccncncncinininanananananononnonon 79 Pin Assignments seee 166 Technical Data oooccccnncincccncccnnnonnnnnennnnns 80 EnDat Encoder Interface AC120 157 ETHERNET Powerlink IF AC112 45 156 F Fault Current Protection 103 Formula Symbols ssessss 119 Function Test si ananman 19 198 G Getting Started ssssessss 171 Guidelines eene 201 Incremental SSI Encoder IF AC123 55 159 Indication ACTA xerit lon Minis 47 Installation esses 121 Installation Dimensions 85 L Line Topology esee 25 M Mixed Module AC131 62 161 Modular Servo Drive Concept 31 Motor Cable Cable Schematic 164 165 Order Data etes 67 Pin Assignments 164 165 SUCIO cavidad 163 224 Technical Data oocccccnnccnccccccconcnnnnnnnnnnnns 69 Motor Connection eese 109 Motor Conn
41. Table 75 Table 76 Table 77 Table 78 Table 79 Table 80 Table 81 Table 82 Table 83 Table 84 Table 85 Table 86 Table 87 Table 88 Table 89 Table 90 Table 91 220 Overview of the vertical offsets ACOPOS ACOPOS sse 92 Selection of the protective ground conductor cross section sssuse 98 Protective ground conditions according to ACOPOS device 98 Constant 3 2 Lire pec er De HE hee dates 100 Maximum current load for PVC insulated three phase cables or individual Wiles i iein ae e eec a 101 Discharge capacitance CD ssssssssseseeeeneneneen nennen nnns 104 Maximum current load for special insulated three phase cables 110 Braking resistors for ACOPOS Servo drives sse 111 ParlDs for setting external braking resistor parameters sssss 116 Power consumption of the ACOPOS plug in modules sss 117 Maximum current requirements and constant k see 118 NENAS A 119 Grounding the motor cable eene 125 Terminal cross sections for ACOPOS servo drives ssssssssss 138 Pin assignments for plug X1 ACOPOS 1022 1045 1090 sssss 140 Pin assignments for plug X2 ACOPOS 1022 1045 1090 140 Pin assignments for plug X3 ACOPOS 1022 1045 1090
42. The following requirements are valid for emergency stops in addition to the requirements for the stop functions e It must have priority over all other functions and operations in all operating modes The power to the machine drive elements which can cause a dangerous state must be switched off as quickly as possible without creating other dangers Resetting is not allowed to cause a restart Emergency stops must be category 0 or category 1 stop functions The necessary stop function must be determined based on a risk evaluation for the machine For emergency stop function in stop category 0 only hard wired electromechanical equipment can be used Additionally the function is not allowed to depend on electronic switching logic hardware or software or the transfer of commands via a communication network or data connection When using a category 1 stop function for the emergency stop function it must be guaranteed that the power to the machine drive elements is completely switched off These elements must be switched off using electromechanical equipment 1 In accordance to the national foreword for the valid German version of IEC 60204 1 11 98 it is determined that electronic equipment and also especially for emergency stop systems can be used regardless of the stop category if e g it provides the same safety using the standards EN 954 1 and or IEC 61508 as required by IEC 60204 1 210 ACOPOS User s Manual Standards an
43. UL CSA h 15m servi isted 3 x 2 x 24 AWG 19 o plug 9 pin DSUB p resolver plug 12 ug can be used in cable 8CR020 12 1 Resol pin In ver cable ercontec eng socke drag chains UL CSA h 20m servi isted 3 x 2 x 24 AWG 19 o plug 9 pin DSUB p resolver plug 12 ug can be used in cable 8CR025 12 1 Resol pin In ver cable lercontec eng socke drag chains UL CSA h 25m isted Servo p 3x2x24 AWG 19 ug 9 pin DSUB p resolver plug 12 ug can be used in cable 3 4 2 Technical Data Table 38 Order data for resolver cables Description Resolver Cables General Information Cable Cross Section 3x2x24 AWG 19 Durability Oil resistant according to VDE 0472 part 803 as well as standard hydraulic oil Certification UL AWM Style 20671 90 C 30 V E63216 and CSA AWM 90 C 30 V 1 11 A B FT1 LL46064 Conductor Signal Lines 24 AWG 19 tinned Cu wire Wire Insulation Special thermoplastic material Wire Colors White brown green yellow gray pink Cable Structure Signal Lines Stranding White with brown green with yellow gray with pink Shield No Cable Stranding The 3 pairs together covered by foil banding Cable Shielding Cu mesh optical coverage 90 and wrapped in isolating fabric Outer Sheathing Material PUR Color Orange similar to RAL 2003 flat Labeling BERNECKER RAINER 3x
44. UL US 26 14 CSA Es 26 14 Holding Torque for the Terminal Screws Nm 0 2 0 25 Table 92 Pin assignments AC131 digital mixed module ACOPOS User s Manual 161 Chapter 5 Wiring Wiring Plug in Module Pin Assignments 5 8 Connecting Cables to Plug in Modules Figure 39 Connecting Cables to Plug in Modules Stress relief for the cable is implemented using a cable tie The cable tie is to be run through the eye on the bottom of the plug in module Make sure that the ventilation slots on the bottom of the ACOPOS drive are not blocked 162 ACOPOS User s Manual 6 Cables 6 1 Motor Cable Wiring Cables 6 1 1 Motor Cable Construction white blue i white green white red white QO gt E yellow green Pos Amount Description Remark 1 1 Motor lines 4x 1 5 mm 2 x 2 x 0 75 mm 4x4mm 2x2x1 mm 4x10mm 2x2x 1 5 mm 4x35 mm 2 x 2 x 1 5 mm not prefabricated 2 1 Circular connector BSTA 108 FR 19 58 0036 000 for 8CMxxx 12 1 BSTA 108 FR 35 59 0036 000 for 8CMxxx 12 3 CSTA 264 FR 48 25 0001 000 for 8CMxxx 12 5 3 1 Heat shrink tubing 4 8 Wire tip sleeve ACOPOS User s Manual Table 93 Motor cable construction 163 Chapter 5 Wiring Wiring Cables 6 1 2 Pin Assignments for 8CMxxx 12 1 8CMxxx 12 3 Circular Connector Pin Description Function 1 U Motor conne
45. bec e eee ads 66 3 2 MOTOR Gables rr eet te dee eb e ede d irt i t etaed 67 3 271 Order Data x nde eee et hes A ee ake cheat eke 67 3 2 2 Technical Dala 1 iiia i eire EE e certo Rat En era LR o EIN TR PO EAE d Leda 69 3 3 EnDat Cable ou uinum ee Ee kt tok eee o coe RUSO E 71 3 3 1 Order Data cccsicccicccccshecdcsectchecdanecachactasasacpansasencsscscucceccaecetuaeavasusedinsnstaesauasasaassaqaness 71 3 3 2 Technical Data ai A e Co eno RN dd 71 3 4 ResolVer Cable cui 73 344 Order Data roe dl te 73 3 4 2 Technical Data 5 1 iia oe voe vr e ad 73 4 Gonneclols 5 ete tee eoa Eo fev Reve cadet gee ode One dee EY s devait erret date 75 4 1 General Information e eee aa xa eu A 75 4 2 Motor CONNectorS tinta nit eei te HE Eee ee per eto Pede eaten eee ete 76 42 1 Order Data ete hea ee ae 76 4 2 2 Technical Data for 8PM001 00 1 and 8PMO002 00 1 cocccooconccccccncccncccnccnoconnnnonannnnns 77 4 2 3 Technical Data for 8PMO03 00 1 c0ooocccccncccccccccnooonoccnnnnoncnnnnonononnnnnnnnnnnnononononanonennnnnnns 78 4 3 Encoder Connectors ccccccesesesessssececeececeeceeecececeesesececececeauaesaeaeeseeseaeueeeeceeeesesesereeeas 79 431 Order Dai temet ees ae ee tte ects oe 79 4 3 2 Technical Data for EnDat Connector 8PE001 00 1 occcccccccncncninininnnnacananananononononos 80 4 3 3 Technical Data for Resolver Connector 8PROO1 00 1 ooooccccccnococcccnccononcconcnononanonoss 81 Chapter 3 Installation iia 83 1
46. clearing the user memory on the PLC Inthe Project menu select Services and then Clear Memory B amp R Automation Studio Ele Edit View Inset Open Project Object Tools Window 2 Build F7 Build Al Cube Transfer To Target Ctl F5 Change OS version AN 1 0 TPU Permanent Description ENTE Version Transfer to Description Saye Scheme 10 ms Invert Scheme v0 00 User RAM 7676 Hee See m 16265 Stop Target 22476 3 Warm Restart 2188 Gifs 8 1045 00 1 m UserROM 752 8 PACTIDDA 1 Y acpi Diurostoc UserROM 212 Y 8AC120 60 1 2 Tane aa Spans i 3 3 gcloac UserROM 5816 3 4 neglot Update MEMCARD UserROM 8020 9 M Y acpl0fm UserROM 66388 acpl par v0472 UserROM 15700 THRI ACP10 Real Axis E axl_par v0 00 User RAM 360 HE ACP10 Error Text Module LE acpi etx v0 00 UserROM 54696 Ej Output Find in Files Clears memory on the target Line 16 of 18 COMI CP476 V224 RUN Figure 52 Clearing user memory on the PLC e Activate the checkbox Erase USER ROM Acknowledge the selection by clicking the OK button Clear Memory x WARNING j If the FIXRAM USER ROM MEMCARD or Permanent memory is erased the memory on the Target will be cleared j AF Erase Permanent memory DRE Cancel Figure 53 Selecting the user memory on the PLC ACOPOS User s Manual 179 Chapter 6 Getting Started
47. connector 17 pin Intercontec socket servo connector 15 pin DSUB plug can be used in cable drag chains UL CSA listed 8CM005 12 1 Motor cable length 5m 4 x 1 5mm 2 x 2 x 0 75mm motor connector 8 pin Intercontec socket can be used in cable drag chains UL CSA listed 0G0001 00 090 Cable PC lt gt PLC PW RS232 Online cable PLC CPU 7CP476 60 1 2003 CPU 750 KB SRAM 1 5 MB FlashPROM 24 VDC 12 5 W supply 1 RS232 interface 1 CAN interface CAN electrically isolated network capable 4 slots for screw in modules system bus for expansion modules max 272 digital 80 analog I O points B amp R Automation Studio 1A4000 Lx B amp R AutomationSoftware CD full version Table 100 Configuration for the start up example 1 The procedure can change slightly depending on the hardware configuration The procedure does not change using an 8V1045 00 2 172 ACOPOS User s Manual Getting Started Starting Up an ACOPOS Servo Drive The hardware configuration will be called the target system in the following sections A PC with B amp R Automation Studio installed will also be needed 2 1 1 Sample project Several sample projects are available in B amp R Automation Studio which can be used to test ACOPOS servo drives They are found in the directory BR_AS_xxx SAMPLES MOTION in the B amp R Automation Studio installation directory xxx indicates the B amp R Automation Studio version
48. during start function fails it will be recognized during up the check 3 2 Safety related parts must be designed so Caution that individual errors do not cause the safety function to fail Individual errors should if The safety function remains active when possible be recognized the next time or an error occurs Some but not all errors before the safety function is required are recognized A buildup of errors can cause the safety function to fail 4 3 Safety related parts must be designed so Information that individual errors do not cause the safety function to fail Individual errors must be The safety function remains active when recognized the next time or before the an error occurs Errors are recognized in safety function is required If this type of time to prevent the safety function from recognition is not possible a buildup of failing errors is not allowed to cause the safety function to fail Chapter 7 Standards and Certifications Table 125 Safety category overview Selecting the suitable safety category must be done separately for each ACOPOS servo drive or for each shaft based on a risk evaluation This risk evaluation is a part of the total risk evaluation for the machine 1 To prevent confusing EN 951 1 categories with IEC 60204 1 stop categories the term safety categories was used in the text shown above for EN 954 1 categories ACOPOS User s Manual 211 Standards and Certifications Sta
49. e C AE E A n a ae c e eoa een d EC ERHEBEN US 202 3 2 9 Transport ite iE RU tias 203 4 Requirements for Immunity to Disturbances EMC seseeeeenennen 204 4 1 Evaluation Criteria performance criteria see 204 4 2 Low Frequency Disturbances according to IEC 61800 3 sss 204 4 2 1 Power Mains Harmonics and Commutation Notches Voltage Distortions 204 4 2 2 Voltage Changes Deviations Dips and Short term Interruptions 204 4 2 3 Asymmetric Voltage und Frequency Changes esseeeem 205 4 3 High Frequency Disturbances according to IEC 61800 3 sss 205 4 3 1 Electrostatic Discharge 4 3 2 Electromagnetic Fields ABUSE ge HH 4 34 9UfF 6 coh eue beue ie AERARIUM 4 3 5 High Frequency Conducted Disturbances sse 206 5 Requirements for Emissions EMO ooocincccncccconccanccononcnnnanoncnannnnnnnnnnnnnnnn naar nn ran cnn anna 207 5 1 High Frequency Emissions according to IEC 61800 3 ccesscceeeeeeeseeeeesseeeeeseeeees 207 12 ACOPOS User s Manual Table of Contents 5 1 1 Emissions on the Power Connections sse 207 5 1 2 Electromagnetic Emissions oooonoccccnnnccononcccnanoncnnnrnnn nono cnn nnrn rra eem emen 207 6 Other Environmental Limit Values according to IEC 61800 2 sees 208 7 International Certifications sese nnne
50. for motor feedback 2 The EnDat encoder must be wired using a cable with a single shield 3 Noise on the encoder signal reduces the resolution that can be used by approx 4 bits factor of 16 4 The precision is actually limited by the encoder 2 5 4 LEDs The UP DN LEDs are lit depending on the rotational direction and the speed of the connected encoder UP LED lit when the encoder position changes in the positive direction DN LED lit when the encoder position changes in the negative direction The faster the encoder position changes the brighter the respective LED is lit 2 5 5 Firmware The firmware is part of the operating system for the ACOPOS servo drives The firmware is updated by updating the ACOPOS operating system ACOPOS User s Manual 51 Chapter 2 Technical Data Technical Data e ACOPOS Plug in Modules 2 6 AC122 Resolver Interface 2 6 1 General Description The AC122 plug in module can be used in an ACOPOS slot The module is equipped with a resolver interface The plug in module handles the output from resolvers which are built into B amp R servo motors or used as an encoder for external axes This resolver delivers the absolute position over one revolution Normally the movement path is longer than one revolution In this case a reference Switch must be used and a homing procedure carried out The encoder input signals are monitored In this way broken connections shorted lines and encoder
51. ground 1090 conductor with the same cross section must be connected on the designated terminal threaded bolt M5 Table 49 Protective ground conditions according to ACOPOS device 98 ACOPOS User s Manual Dimensioning Power Mains Connection ACOPOS Conditions Image 1180 In addition to the connection of the first protective ground 1320 conductor on terminal X3 PE a second protective ground conductor with the same cross section must be connected on the designated terminal threaded bolt M5 1640 The cross section of the protective ground conductor 128M connected to terminal X3 PE must be at least 10 mm Cu Table 49 Protective ground conditions according to ACOPOS device cont 1 2 Dimensioning In general dimensioning the power mains the overcurrent protection and the line contactors depend on the structure of the power mains connection The ACOPOS servo drives can be connected individually each drive has separate overcurrent protection and if necessary a separate line contactor or together in groups 1 2 1 Individual ACOPOS Power Mains Connections The structure of an individual power mains connection with line contactor and circuit breaker can be seen in the following diagram L1 3 400 480VAC L2 50 60 Hz L3 Figure 21 Circuit diagram for ACOPOS X3 individual power mains connection ACOPOS User s Manual 99 Chapter 4 Dimensioning
52. nennt 209 8 Standards Definitions for Safety Techniques oooococccioninncccnocnconnnnoncnonnnnnnccnncnnnnn cnn cnnnnnnno 210 ACOPOS User s Manual 13 Table of Contents 14 ACOPOS User s Manual General Information e ACOPOS Chapter 1 General Information Chapter 1 General Information 1 ACOPOS With the ACOPOS product line B amp R provides the basis for complete and uniform automation solutions Branch specific functions and intuitive tools allow for short development times and create more room for innovation 1 1 Secure Operation EMC was given special attention in order to guarantee proper operation in an industrial environment Field tests have been carried out under difficult conditions in addition to the tests defined in the standard The results confirm the excellent values measured by the testing laboratory and during operation The filters required to meet the CE guidelines are also integrated in the device This simplifies installation considerably Figure 1 Secure operation ACOPOS User s Manual 15 General Information e ACOPOS The embedded parameter chip on the motor is one factor used to guarantee maximum security It contains all mechanical and electronic data relevant to the functionality of the motor Parameters no longer have to be set manually and start up times are substantially reduced Secure operation also means that relevant data can be requested during service and the cause of the p
53. on the ACOPOS servo drives End Switch and Quickstop are Wired If the hardware end switches normally closed are wired to X1 End and X1 End and a quickstop switch normally closed is wired to X1 Quickstop Trigger2 according to section 2 Pin Assignments ACOPOS 1022 1045 1090 on page 139 then start up can be continued with section 2 2 4 Downloading the Project on page 188 182 ACOPOS User s Manual Getting Started Starting Up an ACOPOS Servo Drive End Switch and Quickstop are not Wired If the hardware end switches and quickstop are not wired it is possible to change the parameters so that the motor shaft can still be moved Danger When moving the motor shaft without the hardware end switches connected movements of mechanical parts mounted on the motor shaft must be considered Otherwise severe personal injury or damage to property can occur e Position the cursor on the initial parameter module AX1 PAR e Open the object by double clicking with the left mouse button B amp R Automation Studio 8 x Eie Edit View Insert Open Project Object Tools Window Dug i aen exe ASau acp10 Project ol Model no Slot Software Log book CAN 1 0 TPU Permanent Description Ege ACPIO Module Name Version Transferto Size bytes Description cht 2003 _BP e CPU Get 0P476 601 0 SQ Cyclic 1 10 ms y 01 AE atst v0 00 User RAM 7676 y 02 fg axistc 16265 9
54. power is returned to the servo drive This causes the capacitors in the DC bus to be charged to higher voltages Starting with a DC bus voltage of approx 800 V the ACOPOS servo drive links the braking resistor to the DC bus using the brake chopper and converts the braking energy to heat For ACOPOS servo drives braking resistors are integrated for this purpose or external braking resistors can be connected The equipment differences can be found in the following table Description ACOPOS 1022 1045 1090 1180 1320 1640 128M DC Bus Capacitor 235 uF 470 uF 940 uF 1645 uF 3300 uF 6600 uF Integrated Brake Chopper Yes Internal Braking Resistor Yes Yes Yes Yes Yes Continuous Power Output 130 W 200 W 400 W 200 W 240 W Maximum Power 3 5 kW 7 kW 14 kW 7 kW 8 5 kW Connection of External Braking Resistor Possible 2 No Yes Yes Continuous Power Output 8 kW 24 kW Maximum Power 40 kW 250 kW Minimum braking resistance Rgrmin ane 150 250 Rated current for the built in fuse lg 3 10 A fast acting 30 A fast acting Table 54 Braking resistors for ACOPOS servo drives 1 The braking resistor integrated in the ACOPOS servo drives 1640 and 128M is dimensioned so that it is possible to brake to a stop in a typical drive situation 2 The ACOPOS servo drives are designed so that either the integrated braking resistor or the external braking resistor can be activated Braking with both braki
55. protection with a rated fault current of gt 100 mA can be used However errors can occur e When connecting servo drives to the power mains short term single phase or two phase operation because of contact chatter on the line contactor Because of high frequency discharge currents occurring during operation when using long motor cables Because of an extreme unbalance factor for the three phase system 1 The rated fault current listed by the manufacturer are maximum values which will definitely trip the protective device Normally the protective device is tripped at approximately 60 of the rated fault current ACOPOS User s Manual 103 Chapter 4 Dimensioning Dimensioning Power Mains Connection 1 3 2 Estimating the Discharge Current Depending on the connection of the ACOPOS servo drive different discharge currents flow to ground on the protective ground conductor PE Single phase or two phase operation as intermediate state when switching on the line contactor Umainsl V 2 fmainsLHZ CalF PES Single phase operation with neutral lab or test operation Umainsl V 2 fmains HZ i CalF 25 8 The discharge capacitance Cp the various ACOPOS servo drives can be taken from the following table IATA IATA Description ACOPOS 1022 1045 1090 1180 1320 1640 128M Discharge capacitance Cp 660 nF 3 1 uF 4 Table 52 Discharge capacitance Cp 1 Integrated line fi
56. the node number becomes active the next time the ACOPOS servo drive is switched on There must be a terminating resistor 120 O 0 25 W between CAN_H and CAN L at the beginning and end of the CAN bus 2 3 5 LEDs The status LEDs show if data is being received RXD or sent TXD 2 3 6 Firmware The firmware is part of the operating system for the ACOPOS servo drives The firmware is updated by updating the ACOPOS operating system 1 Changing the node number using software is not possible Basis CAN ID can be changed The ACOPOS Manager only supports node numbers from 1 32 When using the NC157 positioning module only node numbers from 1 8 are possible 44 ACOPOS User s Manual Technical Data e ACOPOS Plug in Modules 2 4 AC112 ETHERNET Powerlink Interface 2 4 1 General Description The AC112 plug in module can be used in an ACOPOS slot The module is equipped with an ETHERNET Powerlink interface This fieldbus interface is used for communication and setting parameters on the ACOPOS servo drive for complex and time critical applications The plug in module is set up as a 2x hub This makes it easy to establish a device to device connection line topology 2 4 2 Order Data Model Number Short Description Image Plug in Module 8AC112 60 1 ACOPOS plug in module ETHERNET Powerlink interface Table 18 Order data for AC112 2 4 3 Technical Data Product ID 8AC112 60 1 Gen
57. to evaluate simple incremental encoders with sine formed output signal This module can be used to evaluate encoders which are built into B amp R servo motors and also encoders for external axes encoders that evaluate any machine movement The input signals are monitored In this way broken connections shorted lines and encoder supply failure can be recognized EnDat Encoder EnDat is a standard developed by Johannes Heidenhain GmbH www heidenhain de incorporating the advantages of absolute and incremental position measurement and also offers a read write parameter memory in the encoder With absolute position measurement absolute position is read in serially the homing procedure is usually not required When necessary a multi turn encoder 4096 revolutions should be installed To save costs a single turn encoder and a reference switch can also be used In this case a homing procedure must be carried out The incremental process allows the short delay times necessary for position measurement on drives with exceptional dynamic properties With the sinusoidal incremental signal and the fine resolution in the EnDat module a very high positioning resolution is achieved in spite of the moderate signal frequencies used The parameter memory in the EnDat encoder is used by B amp R to store motor data among other things In this way the ACOPOS servo drives are always automatically provided the correct motor parameters and limit value
58. 0 14 0 5 1 5 20 14 0 5 1 5 20 14 0 5 1 5 20 14 Flexible and fine wire lines without Wire Tip Sleeves 0 5 1 5 20 14 05 15 20 14 05 15 20 14 0 5 1 5 20 14 x1 with Wire Tip Sleeves 0 5 1 5 20 14 0 5 1 5 20 14 0 5 1 5 20 14 0 5 1 5 20 14 Approbation Data UL C UL US 26 14 26 14 _ 26 14 26 14 CSA 26 14 26 14 26 14 26 14 Holding Torque for the Terminal Screws Nm 0 2 0 25 0 2 0 25 0 2 0 25 0 2 0 25 Solid core multiple conductor lines 0 2 4 24 10 0 5 10 20 7 10 50 7 0 16 95 6 3 0 Flexible and fine wire lines x2 without Wire Tip Sleeves 02 4 24 10 05 6 20 9 10 35 7 2 10 70 7 2 0 with Wire Tip Sleeves 025 4 28 10 05 6 20 9 10 35 7 2 10 70 7 2 0 DCBus Approbation Data UL C UL US 30 10 20 8 10 2 6 2 0 CSA 28 10 20 8 12 2 6 2 0 Holding Torque for the Terminal Screws Nm 0 5 0 6 12 1 5 3 4 6 10 Solid core multiple conductorlines 0 2 4 24 10 0 5 10 20 7 10 50 7 0 16 95 6 3 0 Flexible and fine wire lines X3 without Wire Tip Sleeves 02 4 24 10 05 6 20 9 10 35 7 2 10 70 7 2 0 with Wire Tip Sleeves 0 25 4 28 10 0 5 6 20 9 10 35 7 2 10 70 7 2 0 Power mains Approbation Data UL C UL US 30 10 20 8 10 2 6 2 0 CSA 28 10 20 8 _ 12 2 6 2 0 Holding Torque for the Terminal Screws Nm 0 5 0 6 12 1 5
59. 1 Group 2 Class A Frequency 50 60Hz 4 Installed Load Max 17 kVA Max 30 kVA Starting Current at 400 VAC 13A Switch on Interval gt 10s Power Loss at Max Device Power without Approx 500 W Approx 800 W Brake Resistor Table 11 Technical data for ACOPOS 1180 1320 38 ACOPOS User s Manual Technical Data e ACOPOS Servo Family Product ID 8V1180 00 2 8V1320 00 2 24 VDC Supply Input Voltage 24 VDC 25 20 Input Capacitance 40000 uF Current Requirements 1 Mains Input Voltage Applied Mains Input Voltage not Applied 2 Max 2 8 A current for the motor holding brake current on the 24 VDC output Motor Connection Maximum Switching Frequency 10 kHz Continuous Current at 400 VAC 19 Ag 34 Aer Continuous Current at 480 VAC 14 Aeg 25 Aer Peak Current 50 Aer 80 Aeff Maximum Motor Line Length 25m Protective Measures Short circuit and ground fault protection Motor Holding Brake Connection Maximum Output Current 15A Protective Measures Short circuit and ground fault protection Braking resistor Peak Power Int Ext 14 40 kW Continuous Power Int Ext 0 4 8 kW Operational Conditions Environment Temp during Operation 0 to 40 C Relative Humidity during Operation 5 to 95 non condensing Reduction of the Continuous Current at 10 per 1000 m Installation Altitudes over 500 m above S
60. 12 1 Resolver cable length 20m 3 x 2 x 24 AWG 19 resolver connector 12 pin Intercontec socket servo plug 9 pin DSUB plug can be used in cable drag chains UL CSA listed 8CR025 12 1 Resolver cable length 25m 3 x 2 x 24 AWG 19 resolver connector 12 pin Intercontec socket servo plug 9 pin DSUB plug can be used in cable drag chains UL CSA listed Table 25 Order data for AC122 52 ACOPOS User s Manual 2 6 3 Technical Data Technical Data e ACOPOS Plug in Modules Product ID 8AC122 60 2 General Information C UL US Listed Yes Max El Angular Error Module Type ACOPOS plug in module Slot Slots 2 3 and 4 Power Consumption Max 1 2 W Resolver Input 2 Resolver Type BRX I Number of Poles 2 pin Nominal Voltage Ratio 0 5 5 6 Input Frequency 10 kHz Input Voltage 310 7 Vims Max Phase Shift 3 10 angular minutes Connection Module Side 9 pin DSUB socket LEDs UP DN LEDs Electrical Isolation No Resolver ACOPOS Encoder Monitoring Yes Resolution Depends on the maximum speed 14 bits rev for n lt 3900 min 12 bits rev for n lt 15600 min Bandwidth 1 7 kHz for n lt 3900 min 2 5 kHz for n lt 15600 min Precision x 8 angular minutes Reference Output Signal Transfer Differential Voltage Output Current Frequency Differential signals Typically 3 4 Ver Max 50 MA of 10 kHz Sin
61. 179 Figure 53 Selecting the user memory on the PLC ssssseeneenene 179 Figure 54 Erasing the user memory eeesssesseeseieenee nennen nnne nnne nenne 180 Figure 55 Place mouse pointer on ACOPOS operating system ACP10SYS 180 Figure 56 Enable transferring the ACOPOS operating system 181 Figure 57 The operating system is also transferred the next time the project E A ente ie n ei erint aiaa 182 Figure 58 Open initial parameter module AX1 PAR sssseeenne 183 Figure 59 Place the mouse pointer on dig in 184 Figure 60 Expand the View leitete eei aa Aa Ea AEE a AEAEE SA 184 Figure 61 Displaying the level parameters seenee 185 Figure 62 Place mouse pointer on level NCACTIV_LO sessssseseeeeee 185 Figure 63 Change the level for the positive hardware end switch 186 Figure 64 Acknowledge level change sseeeeeeneneenmnnn 186 Figure 65 Levels after all changes are made sssseeeene 186 Figure 66 Closing the object window seesseeeeeeeeeenenen eene 187 Figure 67 Acknowledge level changes sseeeememem n 187 Figure 68 Click on the command to transfer the project to the target system 188 Figure 69 Operating system version conflict sese Figure 70 Acknowledge selection of con
62. 2 Trigger 1 Quickstop Trigger 2 0 V 4 Shield Shield 5 End Positive HW limit 6 End Negative HW limit 7 Ref Reference switch 8 Enable Enable 9 Enable Enable 10 COM 8 9 Enable 0 V 11 COM 8 9 Enable 0 V 12 13 14 24V Supply 24 V 15 24V Supply 24 V 16 COM 5 7 14 15 Supply 0 V 17 COM 5 7 14 15 Supply 0 V 18 COM 5 7 14 15 Supply 0 V Terminal Cross Sections see table 60 Terminal cross sections for ACOPOS servo drives on page 138 Table 61 Pin assignments for plug X1 ACOPOS 1022 1045 1090 2 2 Pin Assignments for Plug X2 x2 Pin Description Function 1 DC1 U DC bus 2 4Dc1 UDC bus 3 DC2 U DC bus e O e 4 DC2 U DC bus 002 002 7001 001 Terminal t Sections see table 60 Terminal cross sections for ACOPOS servo drives on page Table 62 Pin assignments for plug X2 ACOPOS 1022 1045 1090 140 ACOPOS User s Manual Wiring Pin Assignments ACOPOS 1022 1045 1090 2 3 Pin Assignments for Plug X3 L3 L1 X3 Pin Description Function 1 L1 Power mains connection L1 2 L2 Power mains connection L2 3 L3 Power mains connection L3 4 PE Protective ground conductor Terminal Cross Sections see table 60 Terminal cross sections for ACOPOS servo drives on page 138 Table 63 Pin assignments for p
63. 2 lel x Dengi renc XAAS 1 00f por 0 571489 pos 0 701021 0 571483 0 700021 0 571489 71 204399 0 571489 Gradient 1 0331050 0 078433 1 47373 18 561135 1 0 000000 0 000000 0 172037 0 000000 0 2 0 668950 0 321567 1 47973 18 61135 2 0 490064 0 470536 0 509936 0 529404 369933 125000 3 0 827963 1 000000 1 000000 1 000000 For Help press F1 COM CP476 V224 RUN Figure 6 Cam profiles for everyone ACOPOS User s Manual 21 Chapter 1 General Information General Information e ACOPOS Configurations 2 ACOPOS Configurations 2 1 General Information The ACOPOS servo drives can be used in various configurations depending on the network type CAN Powerlink and the requirements of the application The following ACOPOS functions are possible with all ACOPOS configurations e Point to point Electronic gears e Electronic compensation gears e Cross cutter Electronic cam profiles Flying saw Line shaft e CNC 2 2 CAN 2 2 1 Configuration 1 B amp R SYSTEM 2003 All CPUs for B amp R SYSTEMS 2003 2005 2010 and LS251 with CAN Bus CAN Bus B amp R SYSTEM 2003 max 8 nodes For CNC applications I O nodes on the same CAN line are not possible ALUFUS 1022 a ALUPDS 1022 AUUFUS 1022 Figure 7 CAN configuration 1 22 ACOPOS User s Manual General Information e ACOPOS Configurations 2 2 2 Con
64. 2x24 AWG FLEX ACOPOS User s Manual Table 39 Technical data for resolver cables 73 Chapter 2 Technical Data Technical Data Cables Description Resolver Cables Electrical Characteristics Conductor Resistance 24 AWG lt 86 O km Insulation Resistance 200 MO per km Isolation Voltage Wire Wire 15kV Wire Shield 0 8 kV Operating Voltage Max 30 V Mechanical Characteristics Temperature Range Moving 10 C to 80 C Static 40 C to 90 C Outer Diameter 6 5 mm 0 2 mm Flex Radius gt 50 mm Speed lt 4 m s Acceleration lt 60 m s Flex Cycles gt 3 000 000 Weight 0 07 kg m Table 39 Technical data for resolver cables cont 74 ACOPOS User s Manual Technical Data Connectors 4 Connectors 4 1 General Information B amp R offers five different motor encoder connectors for AC servo motors All connectors have IP67 protection The metallic housing provides a protective ground connection on the housing according to VDE 0627 All plastic used in the connector is UL94 VO listed High quality gold plated cage connector contacts guarantee a high level of contact security even when reinserted many times Using B amp R connectors guarantees that the EMC limits for the connection are not exceeded Make sure that connectors are put together correctly including a proper shield connection ACOPOS User s Manual 75 Chapter 2 Technical Data Techni
65. 4000 V Contact Resistance lt 3mQ Mechanical Characteristics Temperature Range 20 C to 130 C Housing Material Magnesium die cast aluminum nickel plated Gaskets FPM HNBR Mating Cycles gt 50 Crimp Range 4x1 5 10 mm 4x 0 5 2 5 mm Cable o 17 26 mm Manufacturer Information Manufacturer INTERCONTEC Internet Address www intercontec biz Manufacturer s Product ID CSTA 264 FR 48 25 0001 000 Table 42 Technical data for motor connector 8PM003 00 1 78 ACOPOS User s Manual Technical Data Connectors 4 3 Encoder Connectors 4 3 1 Order Data 0 06 1 0mm for cable 5 5 10 5mm IP67 UL CSA listed Model Number Short Description Image EnDat Connector 8PE001 00 1 EnDat Connector 17 pin Intercontec socket crimp range 17 x 0 06 1 0mm for cable o 9 12mm IP67 UL CSA listed Resolver Connector 8PR001 00 1 Resolver connector 12 pin Intercontec socket crimp range 12 x Table 43 Order data for encoder connectors ACOPOS User s Manual 79 Chapter 2 Technical Data Technical Data Connectors 4 3 2 Technical Data for EnDat Connector 8PE001 00 1 Product ID 8PE001 00 1 General Information Connector Size Size 1 Contacts 17 signal contacts Degree of Pollution 3 Installation Altitude Up to 2 000 m Insulator PA 6 6 PBT UL94 VO listed Contacts Gold plated brass Protective Ground Connectio
66. 45 and 1090 1 4 1 Order Data Model Number Short Description Image Servo Drives 8V1022 00 2 Servo drive 3 x 400 480V 2 2A 1kW line filter braking resistor and electronic secure restart inhibit integrated 8V1045 00 2 Servo drive 3 x 400 480V 4 4A 2kW line filter braking resistor and electronic secure restart inhibit integrated 8V1090 00 2 Servo drive 3 x 400 480V 8 8A 4kW line filter braking resistor and electronic secure restart inhibit integrated Accessories 8AC110 60 2 ACOPOS plug in module CAN interface 8AC112 60 1 ACOPOS plug in module ETHERNET Powerlink interface 8AC120 60 1 ACOPOS plug in module EnDat encoder interface 8AC122 60 2 ACOPOS plug in module resolver interface 8AC123 60 1 ACOPOS plug in module incremental encoder and SSI absolute encoder interface 8AC130 60 1 ACOPOS plug in module 8 digital I O configurable in pairs as 24V input or as output 400 100mA 2 digital outputs 2A Order TB712 terminal block separately 8AC131 60 1 ACOPOS plug in module 2 analog inputs 10V 2 digital I O points which can be configured as 24V input or 45mA output 0PS320 1 24VDC power supply 3 phase 20 A input 400 500 VAC 3 phases wide range DIN rail mounting Table 8 Order data for ACOPOS 1022 1045 and 1090 1 4 2 Technical Data Product ID 8V1022 00 2 8V1045 00 2 8V1090 00 2 General Information C UL US Listed Y
67. 5mQ Mechanical Characteristics Temperature Range 20 C to 130 C Housing Material Zinc die cast brass nickel plated Gaskets FPM HNBR Mating Cycles 50 Crimp Range 12x0 06 1 mm Cable o 5 5 10 5 mm Manufacturer Information Manufacturer INTERCONTEC Internet Address www intercontec biz Manufacturer s Product ID ASTA 021 FR 11 10 0035 000 Table 45 Technical data for resolver connector 8PRO01 00 1 ACOPOS User s Manual 81 Chapter 2 Technical Data Technical Data Connectors 82 ACOPOS User s Manual Installation General Information Chapter 3 Installation 1 General Information Make sure that installation takes place on a flat surface which is correctly dimensioned The dimensional diagram lists the number and type of mounting screws to be used The eye bolt contained in the delivery can be attached to the device to lift ACOPOS 1640 and ACOPOS 128M drives ACOPOS O S 3 ES o ACOPOS 1640 PA
68. 6 Figure 17 Figure 18 Figure 19 Figure 20 Figure 21 Figure 22 Figure 23 Figure 24 Figure 25 Figure 26 Figure 27 Figure 28 Figure 29 Figure 30 Figure 31 Figure 32 Figure 33 Figure 34 Figure 35 Figure 36 Figure 37 Figure 38 Figure 39 Figure 40 ACOPOS User s Manual Figure Index Secure operaliOFis 3 cedro t do peed 15 Individual l O configurations esseeeeenenennneneeneennenn 17 Software and hardware as a unit ssssssssseeeee 18 Simple function test vna a 19 Control trigget us oe alain tere 20 Cam profiles for everyone nene 21 CAN configuration 1 ERU UI RM DR RR RM NN RNEE 22 CAN configuration 2 2 intel etr tbe dua ridad 23 Powerlink configuration 1 star topology 24 Powerlink configuration 2 line topology 25 Status LEDS AGT 12 rnt oen UE IO be ar 47 Attaching the eye bolt contained in the delivery to ACOPOS 1640 and 128M drives sss 83 Dimensional diagram and installation dimensions for ACOPOS 1022 1045 1090 iinei e nnne 85 Dimensional diagram and installation dimensions for AGOPOS 1180 1920 chin enter ci oe e eee 86 Dimensional diagram and installation dimensions for ACOPOS 1640 87 Dimensional diagram and installation dimensions for ACOPOS 128M 88 Installing ACOPOS plug in modules en 90 Installing various ACOPOS se
69. 676 g axtste 16265 acpl manh 22476 libacplOman 2188 c System Elf 8v1045 001 3 sysconf v224 UserROM 752 84C110 60 1 Y acpi0ctg v0472 UserROM 212 6 8AC120 60 1 i acplOsys v0472 UserROM 240416 gcloader v1 30 UserROM 5828 neglobal v0 17 UserROM 8020 4 acpl man V0472 UserROM 66388 acpl par v0472 UserROM 15700 THRI ACP10 Real Axis Cex m HE ACP10 Error Text Module LB acpi etx v0 00 UserROM 54696 Transferring ax tst ok 4 gt Oupa Find in Fies Open the NC Object test Line 16 of 18 COMI CP476 v2 24 RUN Figure 75 Command to open the test window The test window is shown Action area B amp R Automation Studio ox1_par waf Test File Edit View Insert jDc Hg e d uen m E A A NC object parameter area j Units Units s Units s Subject ncBASIS MOVE nclNIT lunas ncCONTROL nelNIT Units e ncCONTROL ncSWITCH OF 1 Units e ncCONTROL ncSWITCH ON i ncHOMING ncSTART E ncLIMITS nclNIT E parameter ncREL MOVE EEN basis ncSERVICE ncREAD ncD Lo override EH asD Trace enabled Mew Chart 1 aw par network axl_par network 0 axl_par network 0 axl_par monitor s D Units axl_par monitor v 0 Unis p el x Ej Oupa Find in Files For Help press F1 COMi CP476 V224 RUN Watch window Trace window Figure 76 Test window for ACOPOS servo drives 192 ACOPOS U
70. 9 override New Chart 1 i he 50 0 aw par network 3 axl_par network 0 Ei ns E O NO er er axl_par network 0 For Help press F1 COM CP476 V224 RUN Figure 83 The defined traverse path was completed and the Trace data is loaded 198 ACOPOS User s Manual Getting Started Starting Up an ACOPOS Servo Drive B amp R Automation Studio ax1_par waf Test 8 x Ele Edit View Insert Open Project Test Object Tools Window 2 zi xl JD Hs se eE A Tet s Ae 100 100 ES network Alm 9 9 BS dig in B00 Unis 4B encoder i v pos 10000 Units s Be imt v neg 10000 Units s L al pos 50000 Units s ncBASIS_MOVE nclNIT pas controller Units ncCONTROL nciNIT B Units s ncCONTROL ncSWITCH DF Units s ncCONTROL ncSWITCH ON ncHOMING ncSTART neLIMITS nclNIT ncREL MOVE ncSERVICE ncREAD ncD ncSERVICE ncSET ncDAT neSIMI I STINK ne SWITCH AF x n B al el gi ax par network axl_par network 0 axl_parnetwork 0 axT_par monitor s 5000 nits axl_par monitor y 0 Units s x Transferring ax tst ok JE B Output Find in Files For Help press F1 COMi CP476 V224 RUN Figure 84 The data recorded is shown in the Trace window The current position of the motor shaft is shown in the Watch window Display of
71. 98 kVA Starting Current at 400 VAC 26A Switch on Interval 10s Power Loss at Max Device Power without Brake Resistor Approx 1600 W Approx 3200 W 40 Table 13 Technical data for ACOPOS 1640 128M ACOPOS User s Manual Technical Data e ACOPOS Servo Family Product ID 8V1640 00 2 8V128M 00 2 24 VDC Supply Input Voltage 24 VDC 25 20 Input Capacitance 32800 uF Current requirements at 24 VDC 2 Mains Input Voltage Applied Mains Input Voltage not Applied 3 Max 6 A 1 4 current for the motor holding brake current on the 24 VDC output Motor Connection Maximum Switching Frequency 10 kHz 5 kHz Continuous Current at 400 VAC 64 Act 128 Aer Continuous Current at 480 VAC 48 Ack 96 Act Peak Current 200 Ac 300 Aer Maximum Motor Line Length 25m Protective Measures Short circuit and ground fault protection Motor Holding Brake Connection Maximum Output Current 3A Protective Measures Short circuit and ground fault protection Braking resistor Peak Power Int Ext 7 250 kW 8 5 250 kW Continuous Power Int Ext 0 2 24 kW 0 24 24 kW Operational Conditions Environment Temp during Operation 0 to 40 C Relative Humidity during Operation 5 to 95 non condensing Reduction of the Continuous Current at Installation Altitudes over 500 m above Sea Level 10 per 1000 m
72. C to 3 x 480 VAC x10 Respective intermediate transformers must be used for other supply voltages With grounded power mains autotransformers can also be used to adjust the voltage Neutral does not have to be connected for this type of transformer ACOPOS User s Manual 97 Chapter 4 Dimensioning Dimensioning Power Mains Connection 1 1 3 Protective Ground Connection PE The following information concerning the protective ground connection corresponds to IEC 61800 5 draft Item 3 2 5 3 Connection elements for the protective ground conductor and must be followed Wire Cross Section The wire cross section for the protective ground conductor is oriented to the external conductors and must be selected according to the following table Wire Cross Section for External Line A Minimum Wire Cross Section for Protective Ground Connection Ape mm mm A lt 16 A 16 lt A lt 35 16 35 lt A A 2 Table 48 Selection of the protective ground conductor cross section Increased Discharge Current ACOPOS servo drives are devices with increased discharge current larger than 3 5 mA AC or 10 mA DO Therefore a fixed immobile protective ground connection is required on the servo drives The following conditions must be met depending on the ACOPOS device being used ACOPOS Conditions Image 1022 In addition to the connection of the first protective ground 1045 conductor on terminal X3 PE a second protective
73. COPOS Servo Drive Position the mouse pointer on level The parameters are now shown in the right part of the window B amp R Automation Studio ax1_par waf Axis l File Edit View Open Project Object Tools Window 2 la x Daeh s Selo cx 5 emm e wl par dig in reference ncACTIV HI L r pos hw end neACTIN LO neg hw end ncACTIV LO encoder if trigger ncACTIV HI trigger ncACTIV LO ncQUICKSTOP controller se 5 BES limit Be Be qe message El Output Debus Find in Files COMI CP476 V224 RUN Figure 61 Displaying the level parameters To allow movement of the motor shaft the following parameters must be changed to the value ncACTIV HI pos_hw_end neg_hw_end trigger2 quickstop ncACTIV_HI means that the inputs for both hardware end switches and the quickstop are activated logical 1 This allows the motor shaft to be moved without wiring the hardware end switches and a quickstop The procedure is shown here in an example for pos hw end Inthe right part of the window position the mouse pointer on level ncACTIV LO for the shaft parameter pos hw end ax par Value Unit reference ncACTIV HI pos hw end neg hw end ncACTIV LO trigger ncACTIV HI trigger ncACTIV_LO ncQUICKSTOP Figure 62 Place mouse pointer on level ncACTIV_LO ACOPOS User s Manual 185 Chapter 6 Getting Started Getting Start
74. Data rente tere ari 53 AID AMZDISM T UE 54 2 Bi5 EImWaless S o ERAI DM A E AAA UTE LEM 54 2 7 AC123 Incremental Encoder and SSI Absolute Encoder Interface 55 2 71 General Descriptior i ec trice en tec ere ieee ae tentes 55 IEZRIGABPLICEREEIIT RECTORI 55 2 23 rechnical Data ike bett AE A I alta cette tesa itte Petits atus 56 PETA MEDS 2 ubi NAO 57 227 Firmware oce ete e i haee ces nee ct dieere tdt dede ode Secs epesaceasecdatie begun eve ida 57 2 8 AC130 Digital Mixed Module sese 58 2 8 1 General Descriptiori ca ceder mci ete t ne recte p idee rei ees 58 2 8 2 Order Data i neki ae Se Siena e E edere ce el eis 58 2 8 3 Technical Data vna ina eo et hones e HO Ee e LO r EP evn Ree 59 2 8 AI bEDS 5 sr RA ce e e eve eec re Pe eee SS 61 2 8 5 FIFITIWALe iiia ce rte tiene p ap esa ORE Pe fases Sheet eode d La io o PES P RR es AR aq 61 2 9 AG 1931 Mixed Modu le 1 n rere dianas a 62 2 9 1 GeneraliDescriplion eie de EDD REUNIR 62 2 9 2 O0rder Data adesse eem mee el mul M n et Pe Ll LU 62 2 9 3 Technical Data seeeseesesssssssssseeeene nnne nennen nennen nnn en senes nsa naar rnnt nennen nn 63 DIME EMT 65 8 ACOPOS User s Manual Table of Contents ARO Firmware siio o Se cay eats rect eyes dai 65 ICAO ELM 66 3 T General InfotmatiOn 2 etre ta ite dee heed 66 3 11 PrefabricatediCables coil er
75. Dimensioning Power Mains Connection Dimensioning the Power Mains and Overcurrent Protection The cross section of the power mains and the rated current for overcurrent protection should be dimensioned for the average current load to be expected The power mains are to be equipped with overcurrent protection in the form of a circuit breaker or a fuse Circuit breakers time lag with type C tripping characteristics according to IEC 60898 or fuses time lag with type gM tripping characteristics according to IEC 60269 1 are to be used The average current load to be expected can be calculated as follows S VA lozin A mainsLA B Urani The apparent power S can be calculated as follows 2 in 1 T NaverlMIN 2 S VA M d Nm k 20 The constant k for each of the various ACOPOS servo drives can be taken from the following table Description ACOPOS 1022 1045 1090 1180 1320 1640 128M Constant k 2 8 24 2 1 1 9 1 7 1 5 Table 50 Constant k 1 Circuit breakers are available on the market with rated currents from 6 A to 63 A Outside of this range fuses must be used 2 If information concerning load torque inertia and friction are available the effective torque is calculated using the following formula the nominal torque of the motor can also be used here if the motor is dimensioned correctly Mer NmM dues M Nm t s To calculate Nave informatio
76. E E EO DEO A EE 24 ACOPOS User s Manual Index Connectors Encoder Connectors EN Dat cierre bnt verd ce 79 166 Resolver anneren nnee 79 168 General Information 75 Motor Connectors 76 164 Correctly installing cooling aggregates 93 D Danger Warning eene 26 DO BUS A E eiu 105 Digital Mixed Module AC130 58 160 Dimension diagram and installation dimensions ACOPOS 1022 1045 1090 85 ACOPOS 1180 1320 ss 86 ACOPOS 128M eee 88 ACOPOS 1640 sss 87 Dimensioning Braking resistor sssess 111 Configuration of ACOPOS Servo Drives 117 DG B Sszisoiobeieeel ream 105 Formula Symbols sss 119 Motor Connection sussss 109 Power mains connection 97 Drive Oscilloscope esess 20 Drives see Servo Drives E Electromagnetic Compatibility of the Installation eeeesss 121 Embedded Parameter Chip 16 Encoder Cables EnDat xz oe itn nd 71 166 Resolver cooooonocccccnccnnncnoncononcncnnnnnnnnn 73 168 Encoder Connectors EnDat a eme eie Resolver Encoder Resolution 193 Encoder Systems EnDat Encoder Interface 49 157 Incremental
77. E sc cOM 1 2 i O Shield 24 V ty Les t End 8G En 9 Ref Enable 24 V t i29 Enable ove L Sc COM 8 9 ss COM 8 9 S c n c 1 OG 24V out 0 5A 24V t LOG 24V H5sc 24V L 4 5S c COM 5 7 13 15 LiZ9G COM 5 7 13 15 ove H9G COM 5 7 13 15 1 ACOPOS 8V1180 00 2 1 1180 1320 8V1320 00 2 CAN ETHERNET Powerlink DC 12 EnDat 6 Resolver RB RB Sc PE MESES 29 Loe 4 ET Figure 37 Pin assignment overview ACOPOS 1180 1320 1 Starting with revision FO 144 ACOPOS User s Manual 3 1 Pin Assignments for Plug X1 Wiring Pin Assignments ACOPOS 1180 1320 x1 Pin Description Function 1 Triggeri Trigger 1 2 Quickstop Trigger2 Quickstop Trigger 2 3 COM 1 2 Trigger 1 Quickstop Trigger 2 0 V 4 Shield Shield 5 End Positive HW limit 6 End Negative HW limit 7 Ref Reference switch 8 Enable Enable 9 Enable Enable 10 COM 8 9 Enable 0 V 11 COM 8 9 Enable 0 V 12 13 24V out 0 5A 24 V output 0 5 A 14 24V Supply 24 V 15 24V Supply 24 V 16 COM 5 7 13 15 Supply 0 V 17 COM 5 7 13 15 Supply 0 V 18 COM 5 7 13 15 Supply 0 V Terminal Cross Sections see table 60 Terminal cross sections for ACOPOS servo drives on page 138
78. EDs 24 V LED Supply Voltage Power Supply Minimum 18 VDC Nominal 24 VDC Maximum 30 VDC Reverse Polarity Protection Yes Voltage Monitoring 24 V LED Yes supply voltage 18 V Digital Inputs Number of Inputs Max 8 Wiring Sink Electrical Isolation Input ACOPOS Yes Input Input No Input Voltage Nominal 24 VDC Maximum 30 VDC Switching Threshold LOW 5V HIGH gt 15V Input Current at Nominal Voltage nputs 1 4 Approx 10 mA nputs 5 8 Approx 5 5 mA Switching Delay nputs 1 4 Max 5 us nputs 5 8 Max 35 us Event Counter Signal Form Square wave pulse Input Frequency Max 100 kHz Counter Size 16 bit Inputs Input 1 Counter 1 Input 2 Counter 2 ACOPOS User s Manual Table 30 Technical data for AC130 59 Chapter 2 Technical Data Technical Data e ACOPOS Plug in Modules Product ID 8AC130 60 1 Incremental encoder Signal Form Square wave pulse Evaluation 4 fold Encoder Monitoring No Input Frequency Max 62 5 kHz Count Frequency Max 250 kHz Reference Frequency Max 62 5 kHz Distance between Edges Min 2 5 us Counter Size 16 bit Inputs Input 1 Channel A Input 2 Channel B Input 3 Reference pulse R Outputs Number of Outputs Max 10 Type Transistor outputs Outputs 1 4 Push pull Outputs 5 10 High side Electrical Isolation Output ACOPOS Yes Output Outp
79. Electrostatic Discharge Tests according to IEC 61000 4 2 IEC 61800 3 Performance Criteria Contact discharge to powder coated and bare metal housing parts 6kV Discharge through the air to plastic housing parts 8kV 2 Table 115 Limits for electrical discharge 4 3 2 Electromagnetic Fields Tests according to IEC 61000 4 3 IEC 61800 3 Performance Criteria Housing completely wired 80 MHz 1 GHz 10 V m A 80 amplitude modulation at 1 kHz Table 116 Limits for electromagnetic fields 4 3 3 Burst Tests according to IEC 61000 4 4 IEC 61800 3 Performance Criteria Power connection 2 kV 1 min direct coupling Lines for measurement and control functions in the process 2 kV 1 min B environment Signal interfaces other lines 1 kV 1 min Table 117 Limits for burst ACOPOS User s Manual 205 Chapter 7 Standards and Certifications Standards and Certifications Requirements for Immunity to Disturbances EMC 4 3 4 Surge Tests according to IEC 61000 4 5 IEC 61800 3 Performance Criteria Power connection 1 kV 2 Q DM symmetrical 2 kV 12 O 1 CM unsymmetrical B Table 118 Limits for surge 1 The impedance was added from IEC 61000 4 5 because it is not defined in IEC 61800 3 4 3 5 High Frequency Conducted Disturbances Tests according to IEC 61000 4 6 IEC 61800 3 Performance Criteria Po
80. General Information ra aa a nennen nennen nennen nnn rna nnns nnn nana nananinnns 83 2 Dimensional Diagrams and Installation Dimensions ee 85 2 1 ACOPOS 1022 1045 1090 occonccocccnncnocococanoncnononononcnnonnncnncnnnnnonnnnnnnnnnnnnnnnnnennnnncnnncnnnnnnos 85 22 AGOPOS 1180 1920 a 86 2 3 ACOPOS 1040 div Det reete A verae dee ee ubique 87 2 4 AGOPOS 128M inde tete ee e e iced iret dee ze dece 88 3 Installation and Removal of Plug in Modules eee 89 3 TGeneral Infotrmation 2 rct ret dei ied 89 3 2 Installation 2 2 vo reete er e iia v VV 89 3 9 RemoVval ssh iuste satis ione avec aas ck Pct d ED dis 90 4 Installing Various ACOPOS Series Devices Directly Next to Each Other 91 5 Using Cooling Aggregates in Switching Cabinets essseeene 93 SREE EIIE MNAO daat a g e E E te eed lacio 93 5 2 Cooling Aggregate on Top of the Switching Cabinet sse 94 5 3 Placing a Cooling Aggregate on the Front of the Switching Cabinet 95 Chapter 4 Dimensioning eeeeeeeeeeeee nennen 97 1 Power Mains Connection ccccccccnnnnninnnananananoncnononononnnnnnnnnnnnonananannnnn nono nnrnnnonnnnnnn nana nnnnnnnnnnnns 97 11 General Information ta dit 97 TAA System Configuration node POCHE ai a aiaia a a 97 1 1 2 Supply Voltage Range oap eese eae a nnne nennen enne 97 AC
81. M ssssseeeeeeenn enne 40 Technical data for ACOPOS 1640 128M cccnnococccccccnoooncnnncnononcnnncnononanoncnonanona 40 Order data for plug in modules ooooncconicccnccncccnonnoncnnncnnn rc nano rorcnnn crac 42 Order data for AC 110 cit dd bir ltda 43 Technical Data fo ACT O iii ci is 43 Setting the CAN node number with the two HEX code switches 44 Order data for AC 112 oe a ad 45 Technical data for AC112 seen menn nora nnn nnns 45 Setting the Powerlink node number with the two HEX code switches 46 Indication diagram for the AC112 status LEDS seeee 47 System stop eiror codes ciencias 48 Order data for ACTO ica att rt estre REI doce eee oreet 50 Technical data tor ACTO cuina te eee torii ee eee edd 50 Order data for AC 122 Rte eR d ete oa eee 52 Technical data tor AG 122 otc cct ettet tcs 53 Order data for ACT iii ERO eee eise 55 Technical data tor ACT citan eoe ete teneo eene deis 56 Order data for ACTIO an ce ek aa NS a ed 58 Technical data for AC130 cccccsesssssssceceeeeeeeecececeeeceeceseseeseseseessseueaeeeeeaeeeeeaess 59 Order data for ACT Muni ti oes ee 62 Technical data for AC131 cccccccesssssssssseceeeeceeeeececeeeceeseseseesesesesessnaeaeeeeeeeeeeeeess 63 Order data for motor cables ccccccccccccconininananananananoncnonononononononononn non on nnanannnnns 67 Technical data for motor cables 1 5 and 4 m
82. Manual 5 5 AC123 Incremental Encoder and SSI Absolute Encoder Interface 5 5 1 Pin Assignments Wiring Plug in Module Pin Assignments Image xi Pin Description Function in Function in Incremental mode SSI mode 1 A Channel A 2 A Channel A inverted 3 B Channel B 4 B Channel B inverted 5 RD Reference Pulse Data input 6 RD Reference pulse Data input inverted inverted 15 7 T Clock output 8 T Clock output inverted 9 9 5V out 0 35A Encoder supply 5 V 10 Sense 5V Sense 5 V 11 Sense COM Sense 0 V 12 COM 7 9 13 Encoder supply 0 V 13 15V out 0 35A Encoder supply 15 V 14 M Activate encoder supply 15 A2 Activate encoder supply Table 90 Pin assignments AC 123 incremental encoder and SSI absolute encoder interface 1 To activate the encoder supply pins 14 and 15 must be connected in the encoder cable plug ACOPOS User s Manual 159 Chapter 5 Wiring Wiring Plug in Module Pin Assignments 5 6 AC130 Digital Mixed Module 5 6 1 Pin Assignments Image x1 Pin Description Function 1 Digital O 1 Digital input output 1 2 Digital I O 2 Digital input output 2 3 Digital 1 0 3 Digital input output 3 4 Digital 1 0 4 Digital input output 4 5 Digital I O 5 Digital input output 5 Si 6 Digital 1 O 6 Digital input output 6 HER 7
83. OPOS User s Manual 9 Table of Contents 1 1 3 Protective Ground Connection PE cesceesceeeeeeeeeeeeeeeeneeeeeeeneeeseeseeeeeeaeseeeeeeees 98 122 DIMENSIONING 2366 hae oe A oe 99 1 2 1 Individual ACOPOS Power Mains Connections eene 99 1 2 2 Implementing ACOPOS Power Mains Connections for Drive Groups 102 T 3 Fault Current Protection 3 ois et eed A tie eder tg ened 103 1 3 1 Rated Fault Current cepe e tete ped neering ds 103 1 3 2 Estimating the Discharge Current occcinccinccnocccnocnnoccnnoncnnnc conc cnn cc nnnc ran 104 13 3 Manufacturer Used retire tende iran 104 24DC BUS pita 105 2 1 Generallrformationi 2 25 5 eee tien tad Er ern edi RC ea 105 2 2 Ing OOO 106 2 3 Equal Distribution of the Applied Power via the Power Rectifiers 107 2 4 Equal Distribution of the Brake Power on the Braking Resistors 107 2 5 Connection of External DC Bus Power Supplies seene 108 3 Motor Connection ta ded auc eit bcr ee ee e imc e ce dee PONE a a 109 4 Braking Resistor coelo eite arr e i cena dq e eet i diee sue dee dre e 111 4 1 General Information sisirin eicere ete id tc dee e ac Adee ido s 111 4 2 External Braking Resistor Connection essen 112 4 3 Dimensioning the Braking Resistor ssem eee 113 4 3 1 Resistance of the External Braking
84. OS User s Manual General Information ACOPOS Configurations 2 3 3 Configuration 2 B amp R SYSTEM 2005 HUB TH B amp R SYSTEM 2005 with CP260 CP360 IF260 Powerlink Module 1F686 1F786 1F787 0 Manager l Powerlink 1 O nodes in B amp R SYSTEM LS251 network Powerlink Module LS187 B amp R SYSTEM 2003 ACOPOS 1022 ALUFUS 1022 Not allowed L omma ILS 1022 le DES E ACOPOS We e ACOPOS 102 max 253 nodes ALOPOS We ACUPOS 1022 E ACOPOS 1022 Ses 0105102 Figure 10 Powerlink configuration 2 line topology The advantage compared to configuration 1 is the low cabling expenditure for the same functionality ACOPOS User s Manual 25 Chapter 1 General Information General Information Safety Guidelines 3 Safety Guidelines 3 1 General Information Danger Servo drives and servo motors can have bare parts with voltages applied e g terminals or hot surfaces Additional sources of danger result from moving machine parts Improperly removing the required covers inappropriate use incorrect installation or incorrect operation can result in severe personal injury or damage to property All tasks such as transport installation commissioning and service are only allowed to be carried out by qualified personnel Qualified personnel are persons familiar with transport mounting installation commissioning and operation of th
85. POS servo drives 1 WARNING In some applications there is not enough brake energy provided to guarantee that the 24 VDC supply voltage remains active until the system is stopped 108 ACOPOS User s Manual Dimensioning Motor Connection 3 Motor Connection On B amp R motors the power connections the connections for the holding brake and the connections for the motor temperature sensor are all made using the same motor plug On the servo drive the motor connection is made using terminals X5 U V W and PE as well as terminals X4b B B T and T The motor connection must be shieled correctly see section 1 1 Electromagnetic Compatibility of the Installation on page 121 The structure of the motor connection can be seen in the following diagram Slot 1 12 EnDat r 6 Resolver Figure 25 ACOPOS X4 X5 circuit diagram motor connection The cross section of the motor cable must be dimensioned for the thermal equivalent effective value of the motor current 1 The cross section of the motor cable is chosen for B amp R motor cables according to the following table so that the maximum current load for the cable cross section selected is greater than or equal to the thermal equivalent effective value of the motor current Iz 2l 1 If information concerning load torque inertia and friction are available the thermal equivalent effective value for the motor current of the motor used
86. START for the subject ncREL_MOVE in the action window B amp R Automation Studio ax1_par waf Test lej x b Ele Edt View Insert Open Project Test Object Tools Window 2 la x era T ee oo EESE EA pu n Ex Sy A aa fioo 100 T Trace enabled amp 3 ncBASIS MOVE nclNIT ncCONTROL nelNIT ncCONTROL ncSWITCH OF ncCONTROL ncSWITCH ON ncHOMING ncSTART ncLIMITS nelNIT ncREL MOVE ncSERVICE ncREAD ncD ncSERVICE ncSET ncDAT neSIMIILATIDN neSWITCH DF El ee al e y aw par network axl_par network 0 axl_par network 0 axl_par monitor s 0 Units axl_par monitor v 0 luris x Transferring ax tst ok 7 gt al Lj Dupa Findin Fies For Help press F1 comi CP476 V224 RUN BER network I f B dan Ha encoder if v pos Units s y_neg Units s al_pos Units s controller A UPN al_neg Units s a2 neg Units s Figure 79 Place mouse pointer on the action ncSTART Enter the value e g 5000 for s target position or relative traverse path in the parameter object value column e Acknowledge by pressing the ENTER key The value is entered in the axis data structure ACOPOS User s Manual 195 Chapter 6 Getting Started Getting Started Starting Up an ACOPOS Servo Drive Enabling the Trace Function Position the mouse pointer on the Trace enabled checkbox in the action window e Activate the checkbox by
87. Standards and Certifications Valid European Guidelines Chapter 7 Standards and Certifications 1 Valid European Guidelines e EMC guidelines 89 336 EWG Low voltage guidelines 73 23 EWG Machine guidelines 98 37 EG 2 Valid Standards Standard Description IEC EN 61800 2 Adjustable speed electrical power drive systems Part 2 General requirements Rating specifications for low voltage adjustable frequency AC power drive systems IEC EN 61800 3 Adjustable speed electrical power drive systems Part 3 EMC product standard including specific test methods IEC 61800 5 draft Adjustable speed electrical power drive systems Part5 Electrical thermal and functional safety aspects drive systems with electrically adjustable speed IEC 22G CD 1998 IEC EN 61131 2 Programmable logic controllers Part 2 Equipment requirements and tests IEC 60204 1 Safety of machinery electrical equipment on machines Part 1 General requirements EN 1037 Safety of machinery prevention of unexpected start up IEC 61508 Functional safety of electrical electronic programmable electronic systems EN 954 1 Safety of machinery safety related parts of control systems Part 1 General design principles 1 UL 508 C Industrial control equipment e Part 6 Solid state AC Motor Controllers Table 103 Valid Standards for ACOPOS Servo Drives 1 T V Sample test for secure restart inhibit according to
88. adapter CAN 2 CAN interfaces including 30 cm connection A c Co 2 ES fo 2 3 3 Technical Data Table 15 Order data for AC110 CAN ACOPOS Product ID 8AC110 60 2 General Information C UL US Listed Yes Module Type ACOPOS plug in module Slot Slot 1 Power Consumption Max 0 7 W CAN Interface Connection Module Side 9 pin DSUB plug LEDs RXD TXD LEDs Electrical isolation Yes ACOPOS User s Manual Table 16 Technical Data for AC110 43 Chapter 2 Technical Data Technical Data e ACOPOS Plug in Modules Product ID 8AC110 60 2 Maximum Distance 60m Baud Rate 500 kBit s Network Capable Yes Bus Termination Resistor Externally wired Operational Conditions Environment Temperature during 0 to 50 C Operation Relative Humidity during Operation 5 to 95 non condensing Storage and Transport Conditions Storage Temperature 25 to 55 C Relative Humidity during Storage 5 to 95 non condensing Transport Temperature 25 to 70 C Relative Humidity during Transport 95 at 40 C Table 16 Technical Data for AC110 cont 2 3 4 CAN Node Number Seitings The CAN node number can be set using two HEX code switches 1 Code Switch CAN Node Number Top 16s position high Bottom 1s position low Table 17 Setting the CAN node number with the two HEX code switches Changing
89. ake power curve Pg t from the drive power curve The power must be set to zero in areas where it is positive P t gt 0 This results in the following maximum brake power Pg W abs max P t W max ACOPOS User s Manual 113 Chapter 4 Dimensioning Dimensioning Braking Resistor Then the average brake power is calculated over the given cycle Par IW j X Pa O00 ui aver Tools In order to use an external braking resistor 1 the following parameters must be calculated e the resistance Rgp e the maximum power Permax e the nominal power Pag 4 3 1 Resistance of the External Braking Resistor The resistance of the external braking resistor Rg can be calculated as follows UnclVI eoo Vj Re Q eee an pay IW Pg W max The selected resistance is not allowed to be less than the minimum resistance for the respective ACOPOS servo drive see table 54 Braking resistors for ACOPOS servo drives on page 111 Rg 0 gt Rpy 2 If this condition is not met the maximum brake power required cannot be reached Typical resistances are between 4 and 50 O depending on the size of the ACOPOS device Caution If a resistance less than the minimum resistance is used the brake chopper built into the ACOPOS device could be destroyed Then the following calculation Pg WIS Rgi Q Mg A must be made to check if the average continuous power for the brake can be reached with the selected bra
90. all angle of rotation between 5 and 15 For applications where this can be dangerous the goal for protection cannot be obtained 1 T V Sample test for secure restart inhibit according to EN 954 1 category 3 is in preparation 2 A detailed explanation of the standards and categories can be found in chapter 7 Standards and Certifications 126 ACOPOS User s Manual Wiring Secure Restart Inhibit 1 2 2 Principle Realization of the Safety Function Secure restart inhibit is obtained by removing the IGBT driver supply Terminals X1 Enable and X1 COM 8 9 are used to supply an integrated DC DC converter with 24 VDC The converter creates the supply voltage for the IGBT driver from this voltage N KH M Dh gt gt IGBT driver x1 l Enable 5 amp ig Enable 12901 J4 T VA Supply for COM 8 9 94 COM 8 9 9q IGBT driver Figure 31 Block diagram of secure restart inhibit If the 24 VDC voltage supply for the DC DC converter is interrupted the IGBT driver is also no longer supplied Then it is no longer possible to transfer the modulation pattern needed to generate the rotating field on the IGBT output stage ACOPOS User s Manual 127 Chapter 5 Wiring Wiring Secure Restart Inhibit Additional Function The availability of the DC DC converter output voltage can be requested from the microproc
91. an also be inserted In this case the encoder module in the slot with the lowest number is automatically used for motor feedback 2 Shielded cables must be used for inputs 1 4 2 8 4 LEDs The 24V LED is lit as soon as the supply voltage for the plug in module goes above 18 VDC 2 8 5 Firmware The firmware is part of the operating system for the ACOPOS servo drives The firmware is updated by updating the ACOPOS operating system ACOPOS User s Manual 61 Chapter 2 Technical Data Technical Data e ACOPOS Plug in Modules 2 9 AC131 Mixed Module 2 9 1 General Description The AC131 plug in module can be used in an ACOPOS slot A maximum of 2 analog inputs 10 V differential inputs or single ended inputs and 2 digital inputs or digital outputs are available The analog inputs have a resolution of 12 bits and are scanned synchronously using the 50 us clock for the ACOPOS servo drive The analog inputs have a 10 kHz analog input filter low pass 3rd order The digital inputs and outputs can be configured individually as input or output The digital inputs are equipped with a counter function The digital outputs push pull can be read 2 9 2 Order Data Model Number Short Description Image Plug in Module 8AC131 60 1 ACOPOS plug in module 2 analog inputs 10V 2 digital I O points which can be configured as 24V input or 45mA output Accessories 7TB712 9 Terminal block 12 pin scre
92. ange that can be used with the power mains terminals see table 60 Terminal cross sections for ACOPOS servo drives on page 138 102 ACOPOS User s Manual Dimensioning Power Mains Connection Dimensioning the Line Contactor The rated current of a common line contactor is oriented to the overcurrent protection for the power mains connection The line contactor is set up so that nominal operating current specified by the manufacturer of the line contactor for category AC 1 is approximately 1 3 times the rated current of the overcurrent protection 1 3 Fault Current Protection Fault current protection RCD residual current operated protective device can be used with ACOPOS servo drives However the following points must be noted ACOPOS servo drives have a power rectifier If a short circuit to the frame occurs a flat DC fault current can be created which prevents an AC current or pulse current sensitive RCD Type A or AC from being activated therefore canceling the protective function for all connected devices Danger If used for protection during direct or indirect contact of the fault current protection RCD only a Type B RCD AC DC sensitive according to IEC 60755 can be used for the ACOPOS power mains connection Otherwise additional protective measures must be used such as neutralization or isolation from the power mains using an isolation transformer 1 3 1 Rated Fault Current On ACOPOS servo drives fault current
93. angerous Movements Danger Incorrect control of motors can cause unwanted and dangerous movements Such incorrect behavior can have various causes Incorrect installation or an error when handling the components Incorrect or incomplete wiring Defective devices servo drive motor position encoder cable brake Incorrect control e g caused by software error Some of these causes can be recognized and prevented by the servo drive using internal monitoring However it is generally possible for the motor shaft to move every time the device is switched on Therefore protection of personnel and the machine can only be guaranteed using higher level safety precautions The movement area of machines must be protected to prevent accidental access This type of protection can be obtained by using stabile mechanical protection such as protective covers protective fences protective gates or photocells Removing bridging or bypassing these safety features and entering the movement area is prohibited A sufficient number of emergency stop switches are to be installed directly next to the machine The emergency stop equipment must be checked before commissioning the machine 28 ACOPOS User s Manual General Information Safety Guidelines Remove shaft keys on free running motors or prevent them from being catapulted The holding brake built into the motors cannot prevent hoists from allowing the load to sink 3 6 Safety Guidel
94. ar waf Test BEE Gm File Edit View Insert Open Project Test Object Tools Window 218 x Dm H5 elo xi eam 9 eurem mr d ev o v Trace enabled Dl 3 ncBASIS MOVE nclNIT ncCONTROL nelNIT ncCONTROL ncSWITCH OF ncCONTROL ncSWITCH ON ncHOMING ncSTART ncLIMITS nelNIT ncREL_MOVE num ncSERVICE ncREAD ncD ncSERVICE ncSET ncDAT neSIMI I STINK ne SWITCH DF 100 100 EE network Be dan sl Ba encoder_if v pos 10000 Units s v neg 10000 Units s al_pos 50000 Units s controller a2_pos 50000 Units 2 al neg 50000 Units s a2 neg 50000 Units e awl par network axl_par network 0 axl_par network 0 wl parmonitors 0 nis axl par monitor v 0 Units s CTE x Transferring ax tst ok i 4 i E ouo Findin Fles For Help press F1 COMI CP476 V224 RUN Figure 81 Place mouse pointer on the action ncSTART Click on the button on the toolbar ACOPOS User s Manual The motor shaft now moves according to the traverse path s defined and the Trace function starts 197 Chapter 6 Getting Started Getting Started Starting Up an ACOPOS Servo Drive Display and Evaluation of the Trace Function B amp R Automation Studio ax1_par waf Test lej x Ele Edt View Inset Open Project Test Object Tools Window 2 la x AT ATEREA RFEA AU Saa ooz 100 7
95. at cable length 10m connector 17 pin Intercon plug can be used 10 x 0 14mm 2 x 0 5mm EnDa lec socke in cable drag chains UL CSA servo connector 15 pin DSUB isted 8CE015 12 1 EnDat cable length 15m connector 17 pin Intercon plug can be used 10 x 0 14mm 2 x 0 5mm EnDa lec socke in cable drag chains UL CSA Servo connector 15 pin DSUB isted 8CE020 12 1 EnDat cable length 20m connector 17 pin Intercon plug can be used 10 x 0 14mm 2 x 0 5mm EnDa lec socke in cable drag chains UL CSA servo connector 15 pin DSUB isted 8CE025 12 1 EnDat cable length 25m connector 17 pin Intercon 10 x 0 14mm 2 x 0 5mm EnDa lec socke plug can be used in cable drag chains UL CSA servo connector 15 pin DSUB isted 2 5 3 Technical Data Table 23 Order data for AC120 Product ID 8AC120 60 1 General Information C UL US Listed Yes Module Type ACOPOS plug in module Slot Slots 2 3 and 4 Power Consumption EO EnDat single turn 512 lines Max 1 8 W E1 EnDat multi turn 512 lines Max 2 5 W E2 EnDat single turn 32 lines inductive Max 2 2 W E3 EnDat multi turn 32 lines inductive Max 1 9 W E4 EnDat single turn 512 lines Max 1 7 W E5 EnDat multi turn 512 lines Max 2 2 W Encoder Input 2 Connection Module Side 15 pin DSUB socket LEDs UP DN LEDs Electr
96. be made as illustrated in the following diagram L1 3 400 480VAC L2 50 60 Hz L3 Quickstop T rigger2 COM 1 2 Shield 24 V ten 9 End Poi End og Ref gt SS Enable 24 V t Ho Enable 0 rr COM 8 9 x1 1SE COM 8 9 1 8 n c LIS 424V out 0 5A 24 V t ei 424V L894 24V H5sd COM 5 7 13 15 bins L COM 5 7 13 15 L6 COM 5 7 13 15 OV ACOPOS 12 EnDat 6 Resolver CAN ETHERNET Powerlink Figure 29 Connection diagram for ground and shield connections ACOPOS User s Manual 123 Chapter 5 Wiring Wiring General Information O The protective ground conductors PE for the power mains the motor lines and external braking resistor connection are internally connected with the housing of the ACOPOS servo drive The second protective ground conductor connection is required because of the increased discharge current 3 5 mA on ACOPOS servo drives 1022 1045 1090 1180 and 1320 The same cross section as the power mains protective ground conductor must be used Both trigger inputs are only filtered internally with approx 50 us Make sure the cable shield is grounded properly O The cable shield must be attached to the shield connector On all plug in modules the two screws used to fasten the module must be tightened so that the mounting bracket is connected to ground Using a DSUB connecto
97. be used for ACOPOS servo drives 8V1022 to 8V1090 A DC bus power supply is integrated in ACOPOS servo drives 8V1180 to 8V128M The ACOPOS servo drives with an integrated DC bus power supply provide the 24 VDC supply for the servo drive and also a 24 VDC output to supply encoders sensors and the safety circuit In may cases it is not necessary to use an uninterruptible power supply UPS which is otherwise needed 1 3 LEDs The ACOPOS servo drives are equipped with three LEDs for direct diagnosis Image LED Description Color 1 Ready Green 2 Run Orange 3 Error Red Table 3 Status LEDs ACOPOS servo drives If no LEDs are lit the ACOPOS servo drive is not being supplied with 24 VDC Danger After switching off the device wait until the DC bus discharge time of at least five minutes has passed The voltage currently on the DC bus must be measured with a suitable measuring device before beginning work This voltage must be less than 42 VDC to rule out danger The Run LED going out does not indicate that voltage is not present on the device 1 WARNING In some applications there is not enough brake energy provided to guarantee that the 24 VDC supply voltage remains active until the system is stopped ACOPOS User s Manual 33 Chapter 2 Technical Data Technical Data e ACOPOS Servo Family Signal LED Description Ready Green Lit when the ACOPOS servo drive is read
98. ble 75 Pin assignments for plug X5 ACOPOS 1180 1320 3 6 Pin Assignments for Plug X6 X6 Pin Description Function 1 PE Protective ground conductor 2 RB Brake Resistance 3 RB Brake Resistance e eo AB RB QD Terminal Cross Sections see table 60 Terminal cross sections for ACOPOS servo drives on page 138 148 Table 76 Pin assignments for plug X6 ACOPOS 1180 1320 ACOPOS User s Manual Wiring Pin Assignments ACOPOS 1180 1320 3 7 Protective Ground Connection PE The protective ground conductor is connected to the threaded bolt M5 provided using a cable lug For information concerning dimensioning see section 1 1 3 Protective Ground Connection PE on page 98 Image Pin Description Function PE Protective ground conductor Terminal Cross Sections mm AWG Cable lug for threaded bolt M5 0 25 16 23 5 Table 77 Protective ground conductor PE ACOPOS 1180 1320 Danger Before turning on the servo drive make sure that the housing is properly connected to ground PE rail The ground connection must be made even when testing the servo drive or when operating it for a short time ACOPOS User s Manual 149 Chapter 5 Wiring Wiring Pin Assignments ACOPOS 1640 128M 4 Pin Assignments ACOPOS 1640 128M ex Ho Trigger e D 7 Quickstop Trigger2 OVE pet 9 COM 1 2
99. c socket can be used in cable drag chains UL CSA listed 8CM020 12 1 Motor cable length 20m 4 x 1 5mm 2 x 2 x 0 75mm Motor connector 8pin Intercontec socket can be used in cable drag chains UL CSA listed 8CM025 12 1 Motor cable length 25m 4 x 1 5mm 2 x 2 x 0 75mm Motor connector 8pin Intercontec socket can be used in cable drag chains UL CSA listed Motor Cables 4 mm 2 8CM005 12 3 Motor cable length 5m 4 x 4mm 2 x 2 x 1mm Motor connector 8pin Intercontec socket can be used in cable drag chains UL CSA listed 8CM007 12 3 Motor cable length 7m 4 x 4mm 2 x 2 x 1mm Motor connector 8pin Intercontec socket can be used in cable drag chains UL CSA listed 8CM010 12 3 Motor cable length 10m 4 x 4mm 2 x 2 x 1mm Motor connector 8pin Intercontec socket can be used in cable drag chains UL CSA listed 8CM015 12 3 Motor cable length 15m 4 x 4mm 2 x 2 x 1mm Motor connector 8pin Intercontec socket can be used in cable drag chains UL CSA listed 8CMO020 12 3 Motor cable length 20m 4 x 4mm 2 x 2 x 1mm Motor connector 8pin Intercontec socket can be used in cable drag chains UL CSA listed 8CM025 12 3 Motor cable length 25m 4 x 4mm 2 x 2 x 1mm Motor connector 8pin Intercontec socket can be used in cable drag chains UL CSA listed Motor Cables 10 mm 9 8CM005 12 5 Motor cable length 5m 4 x 10mm 2 x 2 x 1 5mm Motor connector 8pin Intercontec socket can be used in cable drag chains UL CSA listed 8CM007
100. cal Data Connectors 4 2 Motor Connectors 4 2 1 Order Data Model Number Short Description Image Cable Diameter 9 17 mm 8PM001 00 1 Motor plug 8 pin Intercontec socket crimp range 4 x 0 5 2 5mm 4 x 0 06 1 0mm for cable 9 14mm IP67 UL CSA listed 8PM002 00 1 Motor plug 8 pin Intercontec socket crimp range 4 x 2 5 4 0mm 4 x 0 06 1 0mm for cable 14 17mm IP67 UL CSA listed x Cable Diameter 17 26 mm 8PM003 00 1 Motor plug 8 pin Intercontec socket crimp range 4 x 1 5 10mm 4 x 0 5 2 5mm for cable o 17 26mm IP67 UL CSA listed 4 x 4 x Table 40 Order data for motor connectors 76 ACOPOS User s Manual Technical Data Connectors 4 2 2 Technical Data for 8PM001 00 1 and 8PM002 00 1 Product ID 8PM001 00 1 8PM002 00 1 General Information Connector Size Size 1 Contacts 8 4 power and 4 signal contacts Degree of Pollution 3 Installation Altitude Up to 2 000 m Insulator PA 6 6 PBT UL94 VO listed Contacts Gold plated brass Protective Ground Connection on Housing According to VDE 0627 Protection according to DIN 40050 IP67 when connected Certifications UL CSA Electrical Characteristics Overvoltage Category 3 Power Contacts Nominal Current 30A Nominal Voltage 630 VAC VDC Isolation Voltage L L 6000 V Contact Resistance lt 3mQ Signal Contacts Nominal Current 10A Nominal Voltage
101. category 2 reliable switching devices must be used in the e stop chain To obtain safety category 3 according to EN 954 1 the e stop function must be checked once a day For applications where this is not possible the goal for protection cannot be obtained 128 ACOPOS User s Manual Wiring Secure Restart Inhibit Stop Function for Category 0 Safety Category 3 L1 3 400 480VAC L2 50 60 Hz L3 PE eI A 2142 ee Emergency 1 WwW f Stop ir Stop Function S Trigger 1 Cat 0 Quickstop Trigger 2 Se COM 1 2 Stop szioy litec Shield Stop Function l E po Endt Cat 0 a is End 1 Sc Ref O6 Enable Enable X1 COM 8 9 COM 8 9 n c 24V out 0 54 qv L 424V ce 5 7 13 15 H7 i ov ts 490 COM 5 7 13 15 i ACOPOS 4 COM 5 7 13 15 FE yep uem em 2 MN SEES LE EN A NE 1 2 3 3 3 o lo o o CAN ETHERNET Powerlink Figure 32 External wiring for the stop function in category 0 safety category 3 1 The network connection is used for diagnosis and setting parameters 2 For servo drives which have no 24 VDC output ACOPOS 1022 1045 1090 the control voltage must be provided externally ACOPOS User s Manual 129 Chapter 5 Wiring Wiring Secure Restart Inhibit Description By pressing the e stop switch S1 cat O stop function or the stop switch S2 cat O stop function the drive has no
102. clicking on it with the left mouse button B amp R Automation Studio ax1_par waf Test gt File Edit View Inset Open Project Test Object Tools Window 2 8 x 181x Dus E gie Selo co m SE pu n Ex Sy DE y 100 100 GB network BE dig in pa encoder_if v_pos v ne es limit EET neBASIS_MOVE ncINIT HBE controller ad pos neCONTROL nclNIT z al neg ncCONTROL ncSWITCH DF E a2 neg ncCONTROL ncSWITCH ON rd x ncHOMING ncSTART ncLIMITS nelNIT ncREL MOVE neSTART 1 ncSERVICE neREAD ncb SERVICE aeSET em DATI et ee ncSET ncDAT zl Units 10000 Units s 10000 Units s 50000 Units s 50000 Units s 50000 Units s 50000 Units s 4 al E oupa Findin Fles neSIMIILATIOA neSWiTCH AF zi Mew Chart 1 Uniex 100 0 80 0 b 50 0 a par netwc 3 ax par network r P axl_par network 0 p i axl_par network 0 26 4 4 axl_par monitor s 0 Units axl_par monitor y 0 Urits s e 9 0 eer 0 0 20 0 40 0 60 0 0 0 100 0 x Transferring ax tst ok i For Help press F1 COM CP476 V224 RUN Figure 80 Enable trace function 196 ACOPOS User s Manual Getting Started Starting Up an ACOPOS Servo Drive Start the Motor Movement Position the mouse pointer on the action ncSTART for the subject ncREL_MOVE in the action window B amp R Automation Studio ax1_p
103. cnnnn 162 6 Cables iot eee tec pue quate qa qute ite e e atit fec deed eres bte md 163 6 1 Motor Cable iia i eee e ite e e dr eru dece dine 163 6 1 1 Motor Cable Construction ooocccnnccnccccocccnnccnnoncnonnnanc nono n cnn nnnn nn rnn nc non crac rca 163 6 1 2 Pin Assignments for 8CMxxx 12 1 BCMXXX 12 3 cocoooocccococccoooonoconnnnnconnnnnonannnnnnnos 164 6 1 3 Cable Schematic for 8CMxxx 12 1 8CMXxxx 12 9 coooocccccccccccccncccccnnanananananananonononos 164 6 1 4 Pin Assignments for 8CMXXX 12 5 coccocccococccconcnonnnnnnnnnncnnnn cnn nn nn anno nana n nn nnnn nn nnnccns 165 6 1 5 Cable Schematic for BCMXXX 12 5 sse 165 6 2 EnDat Encoder Gables cimil rai eet eut 166 6 2 1 EnDat Encoder Cable Construction oooconnccciccciocacaccnoncnnonnnnncnrnnncnna cnn cr nnn nn nccnnnn 166 6 2 2 Pin Assignirients iiu pe eR Rex Roche EAR ERE e o eL ate 166 6 2 3 Cable Schematics it riera 167 6 3 Resolver Cables uote la ed e re ec opor egeat 168 ACOPOS User s Manual 11 Table of Contents 6 3 1 Resolver Cable Construction ssssssssseeeeeeneeeennee nennen 168 6 3 2 Pini Assignments i e RE er e tiet eue ere o Uude Ue eh ie 168 6 3 3 Cable Schemat anisini irre epe tese epe c depo de erede 169 Chapter 6 Getting Started eeeeeeesseeeeees 171 d Preparation ii ee has 171 1 1 Unpacking the ACOPOS Servo Drive sssssssseeeeeeeeneeneen eene 171 1 2 Installing and Connec
104. coder A The following values must be used for k k 1 2 with 15 V encoder supply k 1 75 with 5 V encoder supply 3 The encoder must be wired using a cable with a single shield and twisted pair signal lines e g 4 x 2 x 0 14 mm 2 x 0 5 mm 4 Acable with at least 4 x 2 x 0 14 mm 2 x 0 5 mm is required for the maximum cable length The sense lines must be used 5 Incremental encoders can be used as motor feedback only for asynchronous motors but can only provide limited control quality for this purpose An encoder with at least 1000 lines must be used for motor feedback 2 7 4 LEDs The UP DN LEDs are lit depending on the rotational direction and the speed of the connected encoder UP LED lit when the encoder position changes in the positive direction DN LED lit when the encoder position changes in the negative direction The faster the encoder position changes the brighter the respective LED is lit 2 7 5 Firmware The firmware is part of the operating system for the ACOPOS servo drives The firmware is updated by updating the ACOPOS operating system ACOPOS User s Manual 57 Chapter 2 Technical Data Technical Data e ACOPOS Plug in Modules 2 8 AC130 Digital Mixed Module 2 8 1 General Description The AC130 plug in module can be used in an ACOPOS slot A maximum of 8 digital inputs or 10 digital outputs are available I O points can be configured in pairs as inputs or outputs The first three i
105. connection should then also be selected as described in table 60 Terminal cross sections for ACOPOS servo drives on page 138 so that the maximum current load of the cable cross section is greater than or equal to the thermal equivalent effective value of the compensation current Iz gt Iq ACOPOS User s Manual 107 Chapter 4 Dimensioning Dimensioning DC Bus 2 5 Connection of External DC Bus Power Supplies The ACOPOS servo drives recognize a power failure and can immediately initiate active braking of the motor The brake energy that occurs when braking is returned to the DC bus and the DC bus power supply can use it to create the 24 VDC supply voltage In this way the ACOPOS servo drives as well as encoders sensors and possible safety circuit can be supplied with 24 VDC while braking 1 An external DC bus power supply must be used for ACOPOS servo drives 8V1022 to 8V1090 A DC bus power supply is integrated in ACOPOS servo drives 8V1180 to 8V128M I o I f ps CODE S45 Of i i MTS Input i i al 1 i i _3AC400 500v 389 i 1 7 1 5A Phase TFF i x2 i l i i OPS320 1 i 88 i l i i I i i i i ACOPOS i Output i i 1022 1045 1090 DC24V 20A i i l I i 00 i i i i ov i X1 i L is u 424V 7 SGi 24V I I Hsc COM 5 7 14 15 1 90 COM 5 7 14 15 ovis COM 5 7 14 15 Figure 24 B amp R power supply 0PS320 1 as DC bus power supply for ACO
106. cted from excessive stress mechanical load temperature humidity aggressive atmosphere Servo drives contain components sensitive to electrostatic charges which can be damaged by inappropriate handling During installation removal of servo drives provide the necessary safety precautions against electrostatic discharges 3 4 Installation The installation must take place according to the documentation using suitable equipment and tools The devices are only allowed to be installed without voltage applied and by qualified personnel Voltage to the switching cabinet should be switched off and prevented from being switched on again The general safety regulations and national accident prevention guidelines e g VBG 4 must be observed when working with high voltage systems The electrical installation must be carried out according to the relevant guidelines e g line cross section fuse protective ground connection also see chapter 4 Dimensioning 3 5 Operation 3 5 1 Protection against Touching Electrical Parts Danger To operate servo drives it is necessary that certain parts are carrying voltages over 42 VDC A life threatening electrical shock could occur if you touch these parts This could result in death severe injury or material damage Before turning on the servo drive make sure that the housing is properly connected to protective ground PE rail The ground connection must be made even when testing the servo d
107. ction U 4 V Motor connection V 3 Ww Motor connection W 2 PE Protective ground conductor A T Temperature B T Temperature C B Brake D B Brake Table 94 Pin assignments for motor cable 8CMxxx 12 1 8CMxxx 12 3 6 1 3 Cable Schematic for 8CMxxx 12 1 8CMxxx 12 3 Motor Plug Wire Tip Sleeves blue 1 5 4 mm m oU ex brown 1 5 4 mm A i 40 Ho V black 1 5 4 mm i 3 ow ellow green 1 5 4 mm y g PE pod 0 75 1 mm Py A T T T white red 0 75 1 mm PUN ap NE ils whiteblue 075 1 mm a HH B rey ud white green 0 75 1 mm vr Alle shields connected to the plug Figure 40 Cable schematic for motor cable 8CMxxx 12 1 8CMxxx 12 3 164 ACOPOS User s Manual Wiring Cables 6 1 4 Pin Assignments for 8CMxxx 12 5 Circular Connector Pin Description Function U U Motor connection U V V Motor connection V W Ww Motor connection W PE Protective ground conductor 1 T Temperature 2 T Temperature B Brake B Brake Table 95 Pin assignments for motor cables 8CMxxx 12 5 6 1 5 Cable Schematic for 8CMxxx 12 5 Motor Plug Wire Tip Sleeves 2 zs blue 10 mm oU brown 10 mm Vo oV black 10 mm yellow green 10 mm white 1 5 mm white red 1 5 mm white blue 1 5 mm a JE white green 1 5 mm
108. d Certifications Standards Definitions for Safety Techniques Safety category according to EN 954 1 03 97 safety of machines safety related parts of control systems part 1 general design principles 1 The safety related parts of control systems must meet one or more of the requirements for five defined safety categories The safety categories define the required behavior of safety related controller parts regarding their resistance to errors Safety Category Safety Integrity Short Description System Behavior according to EN 954 Level SIL 1 according to IEC 61508 2 B Safety related parts must be designed and Caution built so that they can meet the expected operational requirements An error can cause the safety function to fail No specific safety measures are implemented 1 1 Safety related parts must be designed and Caution built so that only reliable components and safety principles are used An error can cause the safety function to fail e g preventing short circuits by using sufficient distances reducing the probability of errors by over dimensioning components defining the failure route closed circuit current principle etc 2 1 Safety related parts must be designed so Caution that their safety functions are checked in suitable intervals by the machine controller An error between checks can cause the safety function to fail If the safety e g automatic or manual check
109. damental knowledge in many positioning application areas This knowledge can be passed on to our customers in the form of clear and easy to use function blocks Industry specific functionality can be quickly and easily implemented in an application program 1 5 Easy Service All necessary data is placed in application memory on the controller so that service is limited to simply exchanging the device The program does not have to be changed After the system is started again the controller installs the operating system that is used automatically or when requested by the user After this procedure is complete the parameters are sent to the servo drive again Problems resulting from different software versions or parameters can be ruled out ACOPOS User s Manual 17 Chapter 1 General Information General Information e ACOPOS 1 6 Software and Hardware as a Unit B amp R integrates all relevant technologies in one tool B amp R Automation Studio Adding a B amp R ACOPOS servo drive is done in a Windows Look amp Feel environment which becomes routine after using the program a few times Wizards and selection boxes ease configuration of servo axis parameters The target system is shown in a clear tree structure Detailed information concerning the target system with integrated hardware documentation ranging from software to terminal assignments reduces project development times considerably B amp R Automation Studio lala Pro
110. e Red T Green 4 Network communication active Orange Table 5 Status changes when booting the operating system loader 34 ACOPOS User s Manual Technical Data e ACOPOS Servo Family Error status with reference to the CAN plug in module AC110 Status LED Display Green Boot error on CAN basic hardware Orange ea N N T NNNN Green Bus Off Orange ret INIM NNI Green CAN node number is 0 Orange Chapter 2 ea WM Mi El Technical Data Table 6 Error status with reference to the CAN plug in module AC110 Error status with reference to the ETHERNET Powerlink plug in module AC112 Status LED Display Green Boot error on Powerlink basic hardware Orange N N T NNNN Green Error when booting the AC112 ARM Orange ea WINIM NHNN Green Powerlink node number is 0 Orange WIN NN Table 7 Error status with reference to the ETHERNET Powerlink plug in module AC112 ACOPOS User s Manual Technical Data e ACOPOS Servo Family 1 4 ACOPOS 1022 10
111. e ACOPOS servo drive to prevent cabling problems 88 ACOPOS User s Manual Installation Installation and Removal of Plug in Modules 3 Installation and Removal of Plug in Modules 3 1 General Information All ACOPOS servo drives are equipped with four slots for plug in modules At present the following module arrangements must be used Image Plug in module Operation possible in Slot 1 Slot 2 Slot 3 Slot 4 8AC110 60 2 Yes No No No 8AC112 60 1 Yes No No No 8AC120 60 1 No Yes Yes Yes 8AC122 60 2 No Yes Yes Yes 8AC123 60 1 No Yes Yes Yes 8AC130 60 1 No Yes Yes Yes 8AC131 60 1 No Yes Yes Yes 1 2 3 4 Table 46 Slot overview for ACOPOS plug in modules Caution Keep the plug in modules in the original packaging and only take them out immediately before installation e Avoid touching the plug in modules anywhere but on the front cover Take the necessary steps to protect against electrostatic discharges 3 2 Installation 1 Disconnect the ACOPOS servo drive from the power mains and prevent reconnection 2 Switch off 24 VDC supply voltage 3 Remove screw from the bottom of the slot cover 4 Loosen screw on the front side ACOPOS User s Manual 89 Chapter 3 Installation Installation Installation and Removal of Plug in Modules 5 Remove slot cover 6 7 8 9 Figure 17 Installing ACOPOS plug in modules Insert plug in module
112. e Cosine Inputs Signal Transfer Input Impedance at 10 kHz per pin Electrical Isolation Encoder ACOPOS Differential signals 10 4 KQ j 11 1 KQ No common mode voltage on the sine cosine inputs max 20 V Operational Conditions Environment Temperature during Operation 0 to 50 C Relative Humidity during Operation 5 to 95 non condensing Storage and Transport Conditions Storage Temperature 25 to 55 C Relative Humidity during Storage 5 to 95 non condensing Transport Temperature 25 to 70 C Relative Humidity during Transport 95 at 40 C Table 26 Technical data for AC122 1 The AC122 is an encoder module Several encoder modules can also be inserted In this case the encoder module in the slot with the lowest number is automatically used for motor feedback 2 The resolver must be wired using a cable with a single shield and twisted pair signal lines 3 BRX resolvers are fed with a sine signal reference signal from the module and provide two sine signals with a 90 phase shift as a result The amplitudes of these signals change with the angular position of the resolver Unlike BRX resolvers BRT resolvers can be fed with two sine signals which are offset by 90 A single sine signal with constant amplitude is returned The phase position of this signal changes with the angular position of the resolver ACOPOS User s Manual 53 Chapter 2 Technical Data Technica
113. e external braking resistor Pan Ww Nominal power of the external braking resistor Phak Ww Maximum power P module W Power consumption of the plug in modules p Pi 8 1415 Rer Ww Braking resistor ar Ww Minimum braking resistance Rar C W Thermal resistance between braking resistor and the environment S VA Apparent power t S Time general tar S Braking time To ax C Maximum over temperature of the resistor Toycle s Cycle time Upc V DC bus voltage Umains V Supply voltage phase to phase Table 58 Formula variables used ACOPOS User s Manual 119 Dimensioning Formula Variables Used 120 ACOPOS User s Manual Wiring General Information Chapter 5 Wiring 1 General Information 1 1 Electromagnetic Compatibility of the Installation 1 1 1 General Information If the guidelines for elecromagnetic compatibility of the installation are followed ACOPOS servo drives meet EMC guidelines 89 336 EWG and low voltage guidelines 73 23 EWG They meet the requirements for harmonized EMC product standard IEC 61800 3 1996 A11 2000 for industry second environment Additional EMC measures must be implemented by the manufacturer of machines or systems if the product standards for the machine has lower limits or if the machine should conform to generic standard IEC 61000 6 4 Additional EMC measures may also be needed for machines with a large number of ACOPOS servo drives The installation of a central line filter is mostly su
114. e placed between S1 and S2 as well as S3 and S4 on the X4a connector 1 Monitoring ET 1 24 V i Supply E i q Internally by the ACOPOS servo drive Activation Internally by the ACOPOS servo drive and also possible externally using potential free contacts 2 Monitoring Internally by the ACOPOS servo drive Information The parameters for ACOPOS internal monitoring must be set according to the requirements of the application 3 Monitoring E 1 24 V l m 0 Supply External Activation External Monitoring External Information ACOPOS internal monitoring cannot be used here therefore it must be deactivated using software Table 66 Activation for the external holding brake 1 Both jumpers are already on the X4a connector delivered with the ACOPOS servo drives 2 External potential free contacts can be connected between S1 and S2 as well as between S3 and S4 This makes it possible to activate the holding brake using an external safety circuit independent of the control integrated in the ACOPOS servo drive 3 The parameters are set using ParlD 90 1 internal monitoring active 5 internal monitoring not active 4 Deactivation takes place using ParlD 90 5 internal monitoring not active 142 ACOPOS User s Manual Wiring Pin Assignments ACOPOS 1022 1045 1090 2 5 Pin Assign
115. e product and have the respective qualifications e g IEC 60364 National accident prevention guidelines must be followed The safety guidelines connection descriptions type plate and documentation and limit values listed in the technical data are to be read carefully before installation and commissioning and must be observed Danger Handling servo drives incorrectly can cause severe personal injury or damage to property 3 2 Intended Use Servo drives are components designed to be installed in electrical systems or machines They are not being used as intended unless the machine meets EG regulation 98 37 EG machine regulation as well as regulation 89 336 EWG EMC regulation The servo drives are only allowed to be operated directly on grounded three phase industrial mains TN TT power mains When using the servo drives in living areas shops and small businesses additional filtering measures must be implemented by the user The technical data as well as the values for connection and environmental guidelines can be found on the type plate and in the documentation The connection and environmental guidelines must be met Electronic devices are generally not fail safe If the servo drive fails the user is responsible for making sure that the motor is placed in a secure state 26 ACOPOS User s Manual General Information Safety Guidelines 3 3 Transport and Storage During transport and storage the devices must be prote
116. e treed ties eaten 43 2 3 1 General Descriptioni 5 3 disp en cdo 43 2 3 2 Order Data EPEAT AE nnn non rrr nns asa sa sese s e essen seen ener enn nnn 43 2 3 3 Technical Data is 43 2 3 4 CAN Node Number Settings ssssssseeneeneeneen eene 44 2G DI E a D ME 44 2 316 EIIIWATO cili noroeste S Hen den tei mta amt ih Ee M n 44 2 4 AC112 ETHERNET Powerlink Interface eeeee n 45 2 4 1 General Description essessssssssseseseeeseeeeee nennen nnne enne nnns 45 24 2 Order Data ido id ii eme eee qutd eeu Rete Drei 45 2443 Technical Data er e YE v e 45 2 4 4 Powerlink Node Number Setting sesssssseeeeeenneneeeeeneennnnns 46 24 E SNIPPETS 47 2 4 6 FIIWaIe dad 48 2 5 AC120 EnDat Encoder Interface occccccccccccncnnnnnnnnananananoncnnnnonononononnnnnononannnnnnananos 49 2 5 1 Gerieral Descriplion sci idet O REA eNA E HU EUR OD AE 49 2 52 Order Data edet O eeepc ithe 50 253 Technical Data iio ice reo corto rat Fee a dencia san YR Fe kE XE KERN BAR TA decada 50 PA HII SM MuR 51 25 5 Firfwalte cicer eve ce dua cae vw ru Tua eas rra voasccvedacuies Eae a seas ava P don TEE Ra v TE VUN RE 51 2 8 AC 122 Resolver Interface e dcr tee eine ooo ct tec cte cere deed cede qal 52 2 6 1 General Description viii E a e EL Eod 52 2 6 2 Order Data eei etre ec a dentes 52 216 3 Technical
117. e wired correctly no short circuits ground faults or reverse polarity A suitable measure to ensure that the wiring is secure against short circuits and ground faults 1 is the use of corresponding cabling Special rubber insulated wires with increased resistance to heat 90 C of types e NSGAOU e NSGAFOU e NSGAFCMOU with a nominal voltage U U of at least 1 7 3 kV are considered to be secure against short circuits and ground faults in switchgear and distribution systems up to 1000 V 2 1 Cabling e g according to DIN VDE 0100 part 200 Electrical systems for buildings terms item A 7 6 2 See e g DIN VDE 0298 part 3 Use of cables and insulated wires for high voltage systems item 9 2 8 106 ACOPOS User s Manual Dimensioning DC Bus 2 3 Equal Distribution of the Applied Power via the Power Rectifiers When creating a DC bus connection between several servo drives it is possible that the parallel connection of the power rectifiers causes incorrect distribution of the applied power To prevent this undesired effect appropriately dimensioned shunt resistors are integrated in the ACOPOS servo drives The following rules must be observed so that the effect of these shunt resistors is not cancelled out The length of the DC bus wiring is not allowed to exceed a total length of 3 m and must be within a single switching cabinet Dimensioning the cross section of the ACOPOS servo drive power mains must be done acco
118. ea Level Maximum Installation Altitude 2000 m 9 Degree of Pollution acc to IEC 60664 1 2 non conductive material Over voltage Category according to IEC 60364 4 443 1999 Protection according to IEC 60529 IP20 Storage and Transport Conditions Storage Temperature 25 to 55 C Relative Humidity during Storage 5 to 95 non condensing Transport Temperature 25 to 70 C Relative Humidity during Transport 95 at 40 C Mechanical Characteristics Dimensions Width 200 mm Height 375 mm Depth 234 mm Weight 10 7 kg 11 3 kg Table 11 Technical data for ACOPOS 1180 1320 cont 1 The current requirements depend on the configuration of the ACOPOS servo drive To determine the current requirements see section 5 Configuration of ACOPOS Servo Drives on page 117 2 The 24 VDC supply voltage for the ACOPOS servo drive is created by the integrated DC bus power supply which reduces the 24 VDC current requirements lo4ypc to 0 Mains Input Voltage 3 x 400 VAC to 480 VAC 10 3 Additional requirements are to be arranged with B amp R ACOPOS User s Manual 39 Chapter 2 Technical Data Technical Data e ACOPOS Servo Family 1 6 ACOPOS 1640 128M 1 6 1 Order Data Model Number Short Description Image Servo Drives 8V1640 00 2 Servo drive 3 x 400 480V 64A 32kW line filter braking resistor DC bus power s
119. ectors Order Data laico 76 Pin Assignments 164 165 Technical Data 77 78 Motors Configurations esee 22 Embedded Parameter Chip 16 General Information 15 Mounting IMPR 27 83 N NC Objects isinin te 18 Node Number Setting GAN settee ra Hee Ae 44 ETHERNET Powerlink 46 O Order Data Servo Drives 8V1022 00 2 conocccccccnncncnnnnnanananannanononnns 36 8V1045 00 2 ni i api iae nono non 36 8V1090 00 2 conccccccnncccccncninnnananananononnnos 36 8V1180 00 2 v aaae 38 8V128M 00 2 cocccccccccnnnnnnanananananononnnnnnns 40 8V1320 00 2 ninnan nA ants 38 8V1640 00 2 inann apanan as 40 P Pin Assignments ACOPOS Servo Drives 139 Cable and Plug eeeeses 163 Plug in Modules sese 155 Plug in Modules AC110 iier 43 155 O ttt ee ee teks 45 156 ACTO ati e 49 157 ACI dada 52 158 AGQT29 ii it 55 159 ACIDO ura a 58 160 ACTO 62 161 General Information 17 42 ACOPOS User s Manual Installation and Removal 89 Order Data eee cetus 42 Power mains connection 97 Programming eee 17 Protective Ground Connection PE Sas cen and 98 143 149 R Resolver Cables Cable Schematic
120. ed Starting Up an ACOPOS Servo Drive Open the selection list by clicking with the left mouse button Select ncACTIV HI by clicking with the left mouse button axi par Value Unit reference nc CTIV HI ps end ncACTIV LO o aii neACTIV_LO 99 ncACTIV LO ncFORCE trigger2 neACTIV_HI ncFORCE ncACTIV HI ncQUICKSTOP ncACTIV HI ncFORCE ncQU ncACTIV LO ncQUICKSTOP ncACTIV LO ncFORCE nc Figure 63 Change the level for the positive hardware end switch e Acknowledge the selection by pressing the ENTER key al par Value Unit reference ncACTIV HI pos hw end neg hw end ncACTIV LO trigger ncACTIV HI trigger ncACTIV LO ncQUICKSTOP Figure 64 Acknowledge level change Use the same procedure for the other two parameters neg hw end and trigger2 quickstop When all changes are made the value list looks like this ax par Value Unit reference ncACTIV HI pos hw end ncACTIV HI neg hw end ncACTIV HI WH trigger WH trigger Figure 65 Levels after all changes are made 186 ACOPOS User s Manual Getting Started Starting Up an ACOPOS Servo Drive Now the object window can be closed Inthe File menu click on Close B amp R Automation Studio ax1_par waf Axis 6 File Edt View Open Project Object Tools Window 2 la xl New Project CuleN Am amp OE s i it Open Project CuO Sie E Ca IES SI E refer
121. ence ncACTIV_HI 1 pos hw end ncACTIV HI neg hw end nc CTIV HI trigger ncACTIV_HI trigger Close Project Save Cul S Save Project As Export Project As Save All Page Setup Print Ctd Export Import 1acp10 2C BR_AS_210 acp10 Exit 1 l Output Find in Files Closes the active document ls COMI CP476 V224 RUN Figure 66 Closing the object window e Acknowledge the changes by clicking the Yes button B amp R Automation Studio x Save changes to Le C BR_AS_210 Samples Motion English C acp1 0 pgp pam ACP10 CPU ax1_par waf Figure 67 Acknowledge level changes The project window will be shown again ACOPOS User s Manual 187 Chapter 6 Getting Started Getting Started Starting Up an ACOPOS Servo Drive 2 2 4 Downloading the Project After making the preparations the project can now be transferred to the target system In the Project menu click on Transfer To Target B amp R Automation Studio acp10 Project lej x J Eie Edt View Insert Open Project Object Tools Window 2 0000 2181 x os Ea Build ES Baste Build All CUE H Transfer To Target CuisF5 ERN ACPIO E a p Description Cot 2003 D cJ un CMM 7CP476 60 7 10 pen Scheme y Saye Scheme User RAM y t Invert Scheme 3 Reset Scheme 3 1 Services Es 8v1045 004 PECIA Ra gt
122. eral Information C UL US Listed Yes Module Type ACOPOS plug in module Slot Slot 1 Power Consumption Max 25W Table 19 Technical data for AC112 ACOPOS User s Manual 45 Chapter 2 Technical Data Technical Data e ACOPOS Plug in Modules Product ID 8AC112 60 1 Powerlink Interface Connection Module Side 2 x RJ45 socket LEDs Status LEDs Electrical isolation Yes ETHERNET ACOPOS Maximum Distance per Segment 100 m Baud Rate 100 Mbit s Network Capable Yes Hub 2x Yes Maximum Number of Hub Levels 10 see section 2 ACOPOS Configurations on page 22 Cabling Topology Star or tree with level 2 hubs Possible Station Operating Modes Synchronous to Powerlink cycle Watchdog Function Hardware Software Yes via ACOPOS servo drive Yes via ACOPOS servo drive Operational Conditions Environment Temperature during Operation 0 to 50 C Relative Humidity during Operation 5 to 95 non condensing Storage and Transport Conditions Storage Temperature 25 to 55 C Relative Humidity during Storage 5 to 95 non condensing Transport Temperature 25 to 70 C Relative Humidity during Transport 95 at 40 C Table 19 Technical data for AC112 cont 1 With a cycle time of 400 us and 10 ACOPOS servo drives the maximum total cable length is 200 m 2 4 4 Powerlink Node Number Setting The Power
123. es Power mains connection Mains Input Voltage 3 x 400 VAC to 480 VAC 10 Power filter according to IEC 61800 3 A11 second environment Limits from CISPR11 Group 2 Class A Frequency 50 60 Hz x 4 Installed Load Max 3 kVA Max 5 kVA Max 10 kVA Starting Current at 400 VAC 4A 7A 7A Switch on Interval gt 10s Power Loss at Max Device Power Approx 120 W without Brake Resistor Approx 180 W Approx 200 W Table 9 Technical data for ACOPOS 1022 1045 and 1090 36 ACOPOS User s Manual Technical Data e ACOPOS Servo Family Product ID 8V1022 00 2 8V1045 00 2 8V1090 00 2 24 VDC Supply Input Voltage 24 VDC 25 20 Input Capacitance 8200 uF Current Requirements 2 Max 2 5 A current for motor holding brake Motor Connection Maximum Switching Frequency 20 kHz 20 kHz 10 kHz Continuous Current at 400 VAC 2 2 Aeff 44 Ag 8 8 Aeff Continuous Current at 480 VAC 1 7 Agr 3 3 Aer 6 6 Aer Peak Current 14 Aer 24 Aeff 24 Aer Maximum Motor Line Length 25m Protective Measures Short circuit and ground fault protection Motor Holding Brake Connection Maximum Output Current 1A Protective Measures Short circuit and ground fault protection Braking resistor Peak Power Output 3 5 kW 7 kW 7 kW Continuous Power Output 130 W 200 W 200 W Operational Conditions Enviro
124. essor If a voltage is not present the generation of the modulation pattern is suppressed by the microprocessor Danger After activating the secure restart inhibit using terminals X1 Enable and X1 COM 8 9 the motor is de energized and therefore torque free If the motor was moving before activation of the secure restart inhibit it is only stopped by an operational brake which is sometimes available or from the friction of the entire system Therefore the motor is not able to hold hanging loads Holding brakes must be used for this purpose For applications where this can be dangerous the goal for protection cannot be obtained 1 2 3 External Wiring The following section contains four wiring suggestions for the external wiring of the secure restart inhibit They are divided corresponding to the three stop functions categories O 1 and 2 according to IEC 60204 1 With the wiring shown you can obtain safety category 3 according to EN 954 1 for the emergency stop function for regular checks of the emergency stop function and for secure restart inhibit In order for the wiring to meet the requirements of the respective application and the listed safety category according to EN 954 1 suitable switching devices one or two pin e stop switching devices from safety category 2 reliable switching devices and cabling concepts must be used Danger To set up the e stop function one or two pin switching devices from safety
125. f the respective brake current If information concerning the flow of the brake current is available calculate the thermal equivalent effective value of the brake current using 1 WIA a LIAJ t5 The cross section of the braking resistor connection should then be selected as described in table 51 Maximum current load for PVC insulated three phase cables or individual wires on page 101 so that the maximum current load of the cable cross section is greater than or equal to the thermal equivalent effective value of the brake current Iz gt lq 112 ACOPOS User s Manual Dimensioning Braking Resistor 4 3 Dimensioning the Braking Resistor Like other drive components the externally connected braking resistors must be dimensioned according to the requirements of the application To determine the required braking power Permax and Pprave the mechanical values M t ot and Toycle must be known The following formulas are used to determine the drive power curve P t W M t Nm o t rad s71 n min s 1 2 o t rad s 2 2 1 60 s min M t o t Pelt Figure 27 Diagram of a typical movement with the brake power curve Pg t 1 1 If as shown a typical triangular brake power curve occurs then the average brake power can be calculated directly with the following formula 1 Persa Em Perel T s 2 The calculation is continued by deriving the br
126. fficient in such cases Proof of conformity to the necessary limits must be provided according to the documentation for use of the EMC guidelines from the manufacturer or distributor of the machine or system Additional EMC measures are needed when operating ACOPOS servo drives in living area or when connecting ACOPOS servo drives to a low voltage system which supplies buildings in living areas without an intermediate transformer first environment ACOPOS User s Manual 121 Chapter 5 Wiring Wiring General Information 1 1 2 Installation Notes 1 The switching cabinet or the system must be constructed appropriately 2 To prevent the effects of disturbances the following lines must be properly shielded motor lines e encoder cables control lines data cables 3 Inductive switching elements such as contactors or relays are to be equipped with corresponding suppressor elements such as varistors RC elements or damping diodes 4 All electrical connections are to be kept as short as possible 5 Cable shields are to be attached to the designated shield terminals and the plug housing 6 Shielded cables with copper mesh or tinned copper mesh are to be used Twisting or extending the protective mesh using single conductors is not allowed 7 Unused cable conductors are to be grounded on both sides if possible 122 ACOPOS User s Manual Wiring General Information The ground connections and shield connections have to
127. figuration 2 B amp R SYSTEM 2005 m s B amp R SYSTEM 2005 with CP260 IF260 and NC157 CAN Bus ommmm ACOFOS 1645 gt mm accros 1645 o mm aceros 1645 ommmm coros 1045 1 2 3 4 max 4 shafts Figure 8 CAN configuration 2 ACOPOS User s Manual 23 Chapter 1 General Information General Information e ACOPOS Configurations 2 3 Powerlink 2 3 1 Recommended Topology In the Powerlink network seen from the manager the tree structure should always come first followed then by the line structure Otherwise the line structure delay affects the entire tree beneath it Information It should be noted that the longest path is allowed a maximum of 10 hubs by the manager Further Literature Unless otherwise stated these recommendations apply to the following documents e Industrial Ethernet Planning and Installation Guide X Draft 2 0 IAONA www iaona eu com Guide to Understanding and Obtaining High Quality Generic Cabling 3P Third Party Testing www 3ptest dk 2 3 2 Configuration 1 B amp R SYSTEM 2005 B amp R SYSTEM 2005 with CP260 CP360 IF260 Powerlink modules 1F686 1F786 1F787 AA Powerlink module LS187 e is B amp R SYSTEM LS251 0 Manager Powerlink acuros mwee E max 253 nodes mes 400705 1022 B amp R SYSTEM 2003 VO nodes in network Figure 9 Powerlink configuration 1 star topology 24 ACOP
128. flict resolution Figure 71 Acknowledge message from B amp R Automation Studio with Yes 190 Figure 72 The project is transferred 190 Figure 73 The project was transferred successtfully eese 190 Figure 74 Select initial parameter module AX1 PAR coooooocococcconoconcoooncnononcnnnnncnnnnnnnnnns 191 Figure 75 Command to open the test window seen 192 Figure 76 Test window for ACOPOS servo drives 192 Figure 77 Setting the encoder resolution see 193 Figure 78 Defining the software end switches ooonnociocnnincnnocanicnninnncnacanananarnn nana nrn na 194 Figure 79 Place mouse pointer on the action NCSSTART ssssssseseee 195 Figure 80 Enable trace fUriction ctione conte siue rete et 196 Figure 81 Place mouse pointer on the action NCSTART ssssssssseesee 197 Figure 82 During the movement of the shaft the traverse path already completed is shown in the Watch window eeee 198 Figure 83 The defined traverse path was completed and the Trace data is loaded ego dede te Duvet dui giis 198 216 ACOPOS User s Manual Figure 84 The data recorded is shown in the Trace window Figure 85 Risk graph according to EN 954 1 Appendix B ACOPOS User s Manual Figure Index 217 Figure Index Figure Index 218 ACOPOS User s Manual Table 1 Table 2 Table 3 Table 4 Table 5
129. going air Chapter 3 Installation Figure 20 Placing a cooling aggregate on the front of the switching cabinet ACOPOS User s Manual Installation Using Cooling Aggregates in Switching Cabinets 96 ACOPOS User s Manual Dimensioning Power Mains Connection Chapter 4 Dimensioning 1 Power Mains Connection 1 1 General Information 1 1 1 System Configuration The power mains connection is made using terminals X3 L1 L2 L3 and PE The ACOPOS servo drives can be directly connected to TT and TN systems these are three phase systems with grounded neutral When using ungrounded IT systems three phase systems without grounded neutral isolation transformers must be used The secondary neutral must be grounded and connected to the ACOPOS protective ground conductor In this way it is possible to prevent overvoltages between external conductors and the ACOPOS housing Three phase isolation transformers with the corresponding input and output voltages and a vector group with secondary neutral can be used e g 3 x 400 V 3 x 400 V Dyn3 Danger The ACOPOS servo drives are only allowed to be operated directly on grounded three phase industrial mains TN TT systems When using the servo drives in living areas shops and small businesses additional filtering measures must be implemented by the user 1 1 2 Supply Voltage Range The permissible supply voltage range for ACOPOS servo drives is 3x400 VA
130. he ACOPOS servo drive Information The parameters for ACOPOS internal monitoring must be set according to the requirements of the application 3 Supply External Activation External Monitoring External Information ACOPOS internal monitoring cannot be used here therefore it must be deactivated using software Table 74 Activation for the external holding brake 1 Both jumpers are already on the X4a connector delivered with the ACOPOS servo drives 2 External potential free contacts can be connected between S1 and S2 as well as between S3 and S4 This makes it possible to activate the holding brake using an external safety circuit independent of the control integrated in the ACOPOS servo drive 3 The parameters are set using ParlD 90 1 internal monitoring active 5 internal monitoring not active 4 Deactivation takes place using ParlD 90 5 internal monitoring not active ACOPOS User s Manual 147 Chapter 5 Wiring Wiring Pin Assignments ACOPOS 1180 1320 3 5 Pin Assignments for Plug X5 X5 Pin Description Function 1 PE Protective ground conductor a le 2 W Motor connection W 3 V Motor connection V 4 E Motor connection U e eee U V W Terminal Cross Sections see table 60 Terminal cross sections for ACOPOS servo drives on page 138 Ta
131. he holding brake and temperature sensor wires are in the motor cable and not in the EnDat or resolver cable 3 1 1 Prefabricated Cables Using B amp R cables guarantees that the EMC limits are not exceeded The cables are prefabricated in the EU and are therefore subject to the strictest quality standards Information If other cables are used make sure that they have the same wave parameters If deviations exist additional measures are necessary to ensure that EMC guidelines are met 1 Custom fabrication of motor cables is available on request For custom fabrication of motor cables the plug size must be matched to the motor used 66 ACOPOS User s Manual 3 2 Motor Cables 3 2 1 Order Data Technical Data Cables Model Number Short Description Image Motor Cables 1 5 mm 1 8CM005 12 1 Motor cable length 5m 4 x 1 5mm 2 x 2 x 0 75mm Motor connector 8pin Intercontec socket can be used in cable drag chains UL CSA listed 8CM007 12 1 Motor cable length 7m 4 x 1 5mm 2 x 2 x 0 75mm Motor connector 8pin Intercontec socket can be used in cable drag chains UL CSA listed 8CM010 12 1 Motor cable length 10m 4 x 1 5mm 2 x 2 x 0 75mm Motor connector 8pin Intercontec socket can be used in cable drag chains UL CSA listed 8CM015 12 1 Motor cable length 15m 4 x 1 5mm 2 x 2 x 0 75mm Motor connector 8pin Interconte
132. ical isolation No Encoder ACOPOS Encoder Monitoring Yes 50 Table 24 Technical data for AC120 ACOPOS User s Manual Technical Data ACOPOS Plug in Modules Product ID 8AC120 60 1 Encoder Supply Output Voltage Typ 5V Load 200 mA Sense Lines 2 compensation of max 2 x 0 7 V Sine Cosine Inputs Signal Transfer Differential signal symmetric Differential Voltage 0 5 1 25 Vs Common Mode Voltage Max 7 V Terminating Resistance 1200 Signal Frequency DC 400 kHz Resolution 9 16384 number of encoder lines Precision Reference Input Signal Transfer Differential signal symmetric Differencial Voltage for High 2402V Differencial Voltage for Low lt 0 2 V Common mode Voltage Max 7 V Terminating Resistance 1200 Serial Interface Synchronous Signal Transfer RS485 Baud Rate 625 kBaud Operational Conditions Environment Temperature during Operation 0 to 50 C Relative Humidity during Operation 5 to 95 non condensing Storage and Transport Conditions Storage Temperature 25 to 55 C Relative Humidity during Storage 5 to 95 non condensing Transport Temperature 25 to 70 C Relative Humidity during Transport 95 at 40 C Table 24 Technical data for AC120 cont 1 The AC120 is an encoder module Several encoder modules can also be inserted In this case the encoder module in the slot with the lowest number is automatically used
133. in the free slot see figure shown above Fasten the plug in module with the two screws Switch on 24 VDC supply voltage Connect ACOPOS servo drive to the power mains 3 3 Removal 1 2 3 4 5 6 7 8 9 90 Disconnect the ACOPOS servo drive from the power mains and prevent reconnection Switch off 24 VDC supply voltage Remove screw from the bottom of the plug in module Loosen screw on the front side Remove plug in module Insert slot cover in free slot Fasten the slot cover with the two screws Switch on 24 VDC supply voltage Connect ACOPOS servo drive to the power mains ACOPOS User s Manual Installation Installing Various ACOPOS Series Devices Directly Next to Each Other 4 Installing Various ACOPOS Series Devices Directly Next to Each Other When installing various ACOPOS series devices directly next to each other we recommend aligning the vertical position so that the LED displays of the respective devices are lined up ACOPOS ACOPOS ACOPOS ACOPOS 1022 1180 1640 128M 1045 1320 o O Vertical displacement of the position of the upper mounting holes Figure 18 Installing various ACOPOS series devices directly next to each other You can see from the image above that the vertical offset of the upper mounting holes is 10 mm The distances for the lower mounting holes and the number and size of the sc
134. ines The safety guidelines are handled as follows Safety Guidelines Description Danger Disregarding the safety regulations and guidelines can be life threatening Warning Disregarding the safety regulations and guidelines can result in severe injury or major damage to material Caution Disregarding the safety regulations and guidelines can result in injury or damage to material Information Important information for preventing errors ACOPOS User s Manual Table 1 Description of the safety guidelines 29 Chapter 1 General Information General Information Safety Guidelines 30 ACOPOS User s Manual Chapter 2 Technical Data Technical Data e ACOPOS Servo Family 1 ACOPOS Servo Family 1 1 Modular Servo Drive Concept Controlling your power transmission system with B amp R ACOPOS servo drives allows you to fully use the advantages of an optimized system architecture Applications that require additional positioning tasks such as torque limitation or torque control can be created quickly and elegantly The flexible system concept for B amp R servo drives is achieved using matched hardware and software components You can select the optimal system configuration for your application and increase your competitiveness Perfect integration in the B amp R 2000 product family Object oriented axis programming minimizes development time and increases reusability Integrated technology functions fo
135. ing Wiring Secure Restart Inhibit 1 2 Secure Restart Inhibit 1 2 1 General Information ACOPOS servo drives have a built in secure restart inhibit to guarantee that the device is stopped securely and to prevent it from restarting unexpectedly It is designed to correspond to safety category 3 according to EN 954 1 1 In addition to preventing the device from restarting unexpectedly according to EN 1037 this safety function also meets the requirements of EN 60204 1 regarding the stop function for categories 0 and 1 Both stop functions require the supply to the machine drives to be switched off immediately for category 0 and after stopping for category 1 The secure restart inhibit interrupts the supply to the motor by preventing the pulses to the IGBTs In this way a rotating field can no longer be creating in synchronous and asynchronous motors controlled by the ACOPOS servo drives This fulfills the requirements of EN 1037 regarding preventing the device from starting unexpectedly and IEC 60204 1 regarding the stop function for categories 0 and 1 2 Danger Take note that multiple errors in the IGBT bridge can cause a short advancing movement The maximum rotary angle of the advancing movement q on the motor shaft depends on the motor used For permanently excited synchronous motors o 360 2p for B amp R standard motors p 3 and the angle is therefore 60 For three phase current asynchronous motors there is a relatively sm
136. ing brake sse 153 Pin assignments for X5 ACOPOS 1640 128M sse 154 Pin assignments for X6 ACOPOS 1640 128M sss 154 Pin assignments for AC110 CAN Interface 155 Pin assignments for AC112 ETHERNET Powerlink Interface 156 Pin assignments for AC120 EnDat encoder interface sss 157 Pin assignments for AC122 resolver interface sesssssssss 158 Pin assignments AC123 incremental encoder and SSI absolute encoder interface E T eoi ege PP ODORE CB UHR ME 159 Pin assignments AC130 digital mixed module sss 160 ACOPOS User s Manual Table Index Table 92 Pin assignments AC131 digital mixed module essesess Table 93 Motor cable construction seeee Table 94 Pin assignments for motor cable 8CMxxx 12 1 8CMxxx 12 3 Table 95 Pin assignments for motor cables 8CMxxx 12 5 sss Table 96 EnDat encoder cable construction sess e Table 97 Pin assignments for EnDat encoder cables Table 98 Resolver cable construction Table 99 Pin assignments for resolver cable oooooconccocccccccnococcccnconananccnncnnnnnn cnn nnnnnnnncnnnnos Table 100 Configuration for the start up example sse Table 101 Display of the current position of the motor shaft in
137. ions shorted lines and encoder supply failure can be recognized With incremental encoders the count frequency and distance between edges is also monitored With absolute encoders the parity bit is evaluated and a plausibility check carried out 2 7 2 Order Data Model Number Short Description Image Plug in Module 8AC123 60 1 ACOPOS plug in module incremental encoder and SSI absolute encoder interface Table 27 Order data for AC123 ACOPOS User s Manual 55 Chapter 2 Technical Data Technical Data e ACOPOS Plug in Modules 2 7 3 Technical Data Product ID 8AC123 60 1 General Information C UL US Listed Yes Module Type ACOPOS plug in module Slot 1 Slots 2 3 and 4 Power Consumption Max 7 5 W Depends on the current requirements for the encoder connected 2 Encoder Input Connection Module Side 15 pin DSUB socket Protection LEDs UP DN LEDs Electrical Isolation Yes Encoder ACOPOS Encoder Monitoring Yes Signal Transfer Differential signal transfer Cable Length 4 Max 50 m Encoder Supply Supply Voltages Internal select between 5 V 15 V Sense Lines for 5 V Yes 2 compensation of max 2 V for 15 V No Load 5V 350 mA 15V 350 mA Short Circuit Protection Overload Yes Incremental encoder Signal Form Square wave pulse Evaluation 4 fold Input Frequency Max 200 kHz
138. is calculated as follows 1 A deep LAT amp s ACOPOS User s Manual 109 Chapter 4 Dimensioning Dimensioning Motor Connection The following table shows the maximum current load for special insulated three phase cables according to IEC 60364 5 523 at 40 C environmental temperature and 90 C maximum cable temperature Line cross section mm Maximum current load on the line I7 A depending on type of installation Three phase cable in insulating Three phase cable on walls Three phase cable in a cable conduit or cable duct tray B2 C E 1 5 17 8 20 20 9 4 31 9 36 4 38 2 10 54 6 64 6 68 3 35 116 5 133 8 143 8 Table 53 Maximum current load for special insulated three phase cables When determining the cross section for the motor cable make sure that the cross section selected is within the range that can be used with motor connection terminal X5 see table 60 Terminal cross sections for ACOPOS servo drives on page 138 1 The entry for the maximum current load in IEC 60364 5 523 is for an environmental temperature of 30 C The values in table 53 Maximum current load for special insulated three phase cables on page 110 are calculated with the factor ktemp 0 91 given in the standard for use at 40 C environmental temperature 110 ACOPOS User s Manual Dimensioning Braking Resistor 4 Braking Resistor 4 1 General Information When braking servo motors
139. ject J Fie Edt View Inset Open Project Obiect Tools Window 2 D e ugs Belo EA AECE EAT Model no 2 Software Log book CAN 170 TPU Permanent Description A T LA Version Transfer to Descriptio 4 U clic 1 10 ms ax tstl User ROM 3160 HC ax tst2 User ROM 3160 19 User ROM 3160 acplOcig UserROM 32968 syscont User ROM 752 Pe GACTI0 601 sys ib UserROM 23684 Gx 84C120 60 1 burtrap User ROM 12164 3 neglobal User ROM 8020 gcloader User ROM 5828 Lg SMSA3LEO 30 acpl par UserROM 15500 8V1090 00 1 acp10man User ROM 66116 gk 8AC110 60 1 ata modules HEZ 8AC120 60 1 paral UserROM 224 HEZ 85C1235601 para2 UserROM 224 MA 8MSA3L EO 30 81090 001 Lg sAcTI0504 L Z BACT20 504 parad User ROM 224 Lia acpl sys User ROM 240512 UserROM 360 rJ 3 UserROM 360 r3 Lf SMSA3LEO 32 EM 8v1090 00 1 User ROM 360 Line 55 0f58 COMI OFFLINE Figure 3 Software and hardware as a unit 1 7 Plain Text for Functions NC Objects that can be accessed by the application program are also stored on the CPU like the application program Creating NC Objects for axes a CNC system or a cam profile takes place using dialog boxes and special data module editors The individual hardware and software channels are assigned symbolic names This eases use and increases clarity The initial parameters are set in a separate editor in plain text 18 ACOPOS User
140. king resistor on the ACOPOS servo drive The brake power which can be continually output by the ACOPOS device is limited by the built in fuse rated current of the built in fuse see table 54 Braking resistors for ACOPOS servo drives on page 111 1 Reliable braking resistors are available from Danotherm www danotherm com 114 ACOPOS User s Manual Dimensioning Braking Resistor 4 3 2 Power Data for the External Braking Resistor The maximum power that the external braking resistor must be able to dissipate is calculated as follows Pra W gt Pg LW The nominal power the power which can be continually dissipated for the external braking resistor is calculated using the following formulas Pa LW 2 Pg aver The second condition depends on ACOPOS internal relationships 4 3 3 Nominal Voltage of the External Braking Resistor The external braking resistor must be selected so that it can handle the maximum voltage that can occur during operation During braking voltages up to 900 VDC can occur Danger During braking voltages up to 900 VDC can occur on the external braking resistor The external braking resistor must be able to handle these voltages 4 4 Setting Brake Resistor Parameters The braking resistors integrated in the ACOPOS servo drives as well as braking resistors which can be connected externally are controlled using a specially developed procedure This guarantees that the brake power is optimall
141. l Cross Sections see table 60 Terminal cross sections for ACOPOS servo drives on page 138 Table 72 Pin ass ignments for plug X4a ACOPOS 1180 1320 X4b Pin Description Function 1 T Temperature Sensor 2 T Temperature Sensor 3 B Brake 4 B Brake 4 Terminal Cross Sections see table 60 Terminal cross sections for ACOPOS servo drives on page 138 3 4 1 Wiring the Output for the Motor Holding Brake Table 73 Pin assignments for plug X4b ACOPOS 1180 1320 The supply activation and monitoring of the output for the motor holding brake can take place via the the X4a connector in three different ways 146 ACOPOS User s Manual Wiring Pin Assignments ACOPOS 1180 1320 Monitoring L 21 Monitoring li 21 Monitoring i 21 lt p Ref Image t 24 V t 24 V t 24 V Description Supply Internally by the ACOPOS servo drive Activation Internally by the ACOPOS servo drive Monitoring Internally by the ACOPOS servo drive A jumper must be placed between S1 and S2 as well as S3 and S4 on the X4a connector 1 Supply Internally by the ACOPOS servo drive Activation Internally by the ACOPOS servo drive and also possible externally using potential free contacts 2 Monitoring Internally by t
142. l Data e ACOPOS Plug in Modules 2 6 4 LEDs The UP DN LEDs are lit depending on the rotational direction and the speed of the connected encoder UP LED lit when the encoder position changes in the positive direction DN LED lit when the encoder position changes in the negative direction The faster the encoder position changes the brighter the respective LED is lit 2 6 5 Firmware The firmware is part of the operating system for the ACOPOS servo drives The firmware is updated by updating the ACOPOS operating system 54 ACOPOS User s Manual Technical Data e ACOPOS Plug in Modules 2 7 AC123 Incremental Encoder and SSI Absolute Encoder Interface 2 7 1 General Description The ACOPOS plug in module AC123 is used to connect standard industrial incremental or absolute encoders with a synchronous serial interface SSI to ACOPOS servo drives For example this allows electronic gears to be configured which read master movements using external encoders If the encoder resolution is high enough motor feedback for asynchronous motors is also possible With incremental encoders the maximum counter frequency is 200 kHz Single and multi turn encoders with a maximum of 31 bits at 200 kBaud can be read as absolute SSI encoders The position is determined cyclically initiated by the module and is exactly synchronized with the ACOPOS controller clock The input signals are monitored for both encoder types In this way broken connect
143. link node number can be set using two HEX code switches Code Switch Powerlink Node Number Top 16s position high Bottom 1s position low Table 20 Setting the Powerlink node number with the two HEX code switches Changing the node number becomes active the next time the ACOPOS servo drive is switched on 46 ACOPOS User s Manual 2 4 5 LEDs Technical Data e ACOPOS Plug in Modules green red Figure 11 Status LEDs AC112 The status is indicated on the AC112 using one green and one red LED LED Test Immediately after resetting the module both LEDs are switched off for 0 5 s then switched on for 1 5 s Then the green LED is cleared for one second and the following boot procedure After proper initialization the red LED is switched off and the green LED is switched on Status of the LEDs The following timing is used for the indication diagram Block size 150 ms Status LED Display Green Error free operation Red Green Fatal system error 1 Red Green Master has dropped out v POURRA Green System stop Red See System Stop Error Codes Table 21 Indication diagram for the AC112 status LEDs 1 This is a problem which cannot be repaired the system can no longer carry out tasks correctly This status can only be cha
144. lter in preparation 1 3 3 Manufacturer Used For example the AC DC sensitive 4 pole fault current protective device F 804 from ABB fault current 300 mA nominal current 63 A can be used Using this fault current protective device approximately 5 ACOPOS 1022 or 1045 1090 can be connected in parallel 104 ACOPOS User s Manual Dimensioning DC Bus 2 DC Bus 2 1 General Information With ACOPOS servo drives it is possible to connect several servo drives via the DC bus This connection allows compensation of braking and drive energy of several axes or the distribution of braking energy to several braking resistors The connection is made using terminals X2 DC and DC The structure of the DC bus connections can be seen in the following diagram ds i DC2 DC1 DC1 DC2 X N t DC DC Figure 23 ACOPOS X2 circuit diagram DC bus connections Caution To prevent excessively high discharge currents from flowing over the individual servo drives make sure that smaller servo drives are not connected between two larger servo drives ACOPOS User s Manual 105 Chapter 4 Dimensioning Dimensioning DC Bus 2 2 Wiring The DC bus connections on the ACOPOS servo drives do not have short circuit and ground fault protection and are not protected against reverse polarity Therefore the DC bus connections must be wired correctly Caution The DC bus connections must b
145. lug X3 ACOPOS 1022 1045 1090 2 4 Pin assignments for plugs X4a X4b X4a Pin Description Function 1 2 Activation supply for the external holding brake 2 1 Activation for the external holding brake 3 S4 Activation supply for the external holding brake 4 3 Activation for the external holding brake Terminal Cross Sections see table 60 Terminal cross sections for ACOPOS servo drives on page 138 Table 64 Pin assignments for plug X4a ACOPOS 1022 1045 1090 X4b Pin Description Function 1 T Temperature Sensor 2 T Temperature Sensor 3 B Brake 4 B Brake Terminal Cross Sections see table 60 Terminal cross sections for ACOPOS servo drives on page 138 Table 65 Pin assignments for plug X4b ACOPOS 1022 1045 1090 2 4 1 Wiring the Output for the Motor Holding Brake The supply activation and monitoring of the output for the motor holding brake can take place via the the X4a connector in three different ways ACOPOS User s Manual 141 Chapter 5 Wiring Wiring Pin Assignments ACOPOS 1022 1045 1090 Image Description Monitoring 1 24 V zr 1 Supply A Internally by the ACOPOS servo drive zH Ref Activation Internally by the ACOPOS servo drive 1 Leer 0 Pl 5 gt totg Monitoring A E a aT Internally by the ACOPOS servo drive 2 X4b A jumper must b
146. me 69 Technical data for motor cables 10 and 35 MM ccccsssscsssssccceeeeeeeeeeeeeeeseeess 70 Order data for EnDat cables c eee ute ce erre eene eos 71 Technical data for EnDat cables ooncccccccccncconnoonnoncnnnnnnnncnnononanronnnnnnnnnnonononarans 71 Order data for resolver cables sssssssseseeeeenn nennen 73 Technical data for resolver cables ooocccccccccccoocooonnnnonnnnnnnononononanconcnnnnnnnnnnnonanons 73 Order data for motor connectors cccccccccnnnninananananononnnnncnonononononononononononnnnnnanananos 76 Technical data for motor connectors 8PM001 00 1 and 8PMO002 00 1 77 Technical data for motor connector 8PMO003 00 1 sssssssssseeesseeeeeeeeeeeees 78 Order data for encoder connectors ccccccessseeecessssseeeeceeseeeceeeeseseteeeeeeeeseaees 79 Technical data for EnDat connector 8PEO001 00 1 oocccccnnccccccconnncnnnnnnncnnnnnononoroos 80 Technical data for resolver connector 8PRO01 00 1 eees 81 Slot overview for ACOPOS plug in modules see 89 ACOPOS User s Manual 219 Table Index Table Index Table 47 Table 48 Table 49 Table 50 Table 51 Table 52 Table 53 Table 54 Table 55 Table 56 Table 57 Table 58 Table 59 Table 60 Table 61 Table 62 Table 63 Table 64 Table 65 Table 66 Table 67 Table 68 Table 69 Table 70 Table 71 Table 72 Table 73 Table 74
147. ments for Plug X5 O 1 Crs X5 Pin Description Function 1 PE Protective ground conductor 2 wW Motor connection W 3 V Motor connection V 4 E Motor connection U O e Terminal Cross Sections see table 60 Terminal cross sections for ACOPOS servo drives on page 138 Table 67 Pin assignments for plug X5 ACOPOS 1022 1045 1090 2 6 Protective Ground Connection PE The protective ground conductor is connected to the threaded bolt M5 provided using a cable lug For information concerning dimensioning see section 1 1 3 Protective Ground Connection PE on page 98 Image Pin Description Function PE Protective ground conductor Terminal Cross Sections mm AWG Cable lug for threaded bolt M5 0 25 16 23 5 Table 68 Protective ground conductor PE ACOPOS 1022 1045 1090 Danger Before turning on the servo drive make sure that the housing is properly connected to ground PE rail The ground connection must be made even when testing the servo drive or when operating it for a short time ACOPOS User s Manual 143 Chapter 5 Wiring Wiring Pin Assignments ACOPOS 1180 1320 3 Pin Assignments ACOPOS 1180 1320 3 400 480VAC L2 50 60 Hz L3 Q L1 A aa it gt lt N x oo O 9 E 24 V to apes plo Trigger1 L 3 26 Quickstop Trigger2 OVE igi
148. mperature Range Moving 10 C to 70 C Static 20 C to 90 C Outer Diameter 20 1 mm 0 7 mm 32 5 mm 1 mm Flex Radius gt 150 8 mm gt 243 8 mm Speed lt 4m s Acceleration lt 60 m s Flex Cycles gt 3 000 000 Weight 0 77 kg m 2 2 kg m 70 Table 35 Technical data for motor cables 10 and 35 mm ACOPOS User s Manual 3 3 EnDat Cable 3 3 1 Order Data Technical Data Cables Model Number Short Description Image 8CE005 12 1 EnDat cable length cable drag chains U pin Intercontec socket servo connector 15 pin DSUB plug can be used in 5m 10 x 0 14mm 2 x 0 5mm EnDat connector 17 L CSA listed 8CE007 12 1 EnDat cable length cable drag chains U pin Intercontec socket servo connector 15 pin DSUB plug can be used in 7m 10 x 0 14mm2 2 x 0 5mm EnDat connector 17 L CSA listed 8CE010 12 1 EnDat cable length cable drag chains U pin Intercontec socket servo connector 15 pin DSUB plug can be used in 10m 10 x 0 14mm 2 x 0 5mm EnDat connector 17 L CSA listed 8CE015 12 1 EnDat cable length cable drag chains U pin Intercontec socket servo connector 15 pin DSUB plug can be used in 15m 10 x 0 14mm 2 x 0 5mm EnDat connector 17 L CSA listed 8CE020 12 1 EnDat cable length cable drag chains U pin Intercontec socket servo connector 15 pin DSUB plug can be used in 20m 10 x 0 14mm 2 x 0 5mm EnDat connector 17
149. n The K3 auxiliary relay with drop out time lag is a part of the safety function Therefore K3 must meet safety category 3 2 The network connection is used to transfer the interruption command for active braking for diagnosis and setting parameters 3 For servo drives which have no 24 VDC output ACOPOS 1022 1045 1090 the control voltage must be provided externally 136 ACOPOS User s Manual Wiring Secure Restart Inhibit Description When the e stop switch S1 cat 1 stop function is pressed the EmergencyStop control input on the controller triggers active braking see Example Code on page 132 If the controller the network the drive etc is faulty then auxiliary relay K3 is released after a defined delay and causes the energy feed to the motor to be cut off Pressing stop switch S2 cat 2 stop function basically triggers the same procedure but is handled differently by the software separate digital input Stop However the energy feed to the motor is not switched off after stopping If you open and lock e stop switch S1 restart is inhibited ACOPOS User s Manual 137 Chapter 5 Wiring Wiring Overview of the Terminal Cross Sections 1 3 Overview of the Terminal Cross Sections Terminal Cross Sections 8V1022 00 2 8V1180 00 2 8V1640 00 2 8V128M 00 2 8V1045 00 2 8V1320 00 2 8V1090 00 2 mm AWG mm AWG mm AWG mm AWG Solid core multiple conductor lines 0 5 1 5 2
150. n Studio B amp R Automation Studio Ele View Tools 2 lela Rs e sere oa ano gE Loans For Help press F1 I E F Figure 45 B amp R Automation Studio Start up Screen 174 ACOPOS User s Manual Getting Started Starting Up an ACOPOS Servo Drive Open the project recommended make a copy of sample project ACP10 GDM in the respective project path Click Open Project in the File menu B amp R Automation Studio lej x File View Tools BEL AES Ele Ea ao 0 a Gose Project SAVE Gaye Al 1CABR AS 210 NacplO 2C BR_AS_210 acp10 Exit Figure 46 Open project e Select ACP10 PGP ACP10 GDM e Load the project by clicking on the Open button Open Look in S ecpt0 pap al ex DBK Library pam EE meme e Bom Files of type Project Files gdm Cancel vA Figure 47 Selecting the project E Oo ot 5 Bo D mE E O 5 o ACOPOS User s Manual 175 Getting Started Starting Up an ACOPOS Servo Drive The selected project is then opened in the project window B amp R Automation Studio File Edit View Insert Open Project Object Tools Window 2 Os EX Salo c acp10 Project xm 47S El A o 9 2 lol Model no Slot Software Log book CAN 1 0 TPU Permanent Description S3 EC ME Lm Version Transfer
151. n concerning the positioning cycle must be available Nave is calculated using the following formula 1 TeycielS l L nayg min7 ni min ts 100 ACOPOS User s Manual Dimensioning Power Mains Connection The cross section of the power mains and the rated current of the overcurrent protection used are chosen according to table 51 Maximum current load for PVC insulated three phase cables or individual wires on page 101 so that the maximum current load for the cable cross section selected is greater than or equal to the calculated mains current I72 Imains The rated current of the overcurrent protection must be less than or equal to the maximum current load for the cable cross section selected see table 51 Maximum current load for PVC insulated three phase cables or individual wires on page 101 lg lt lz The following table shows the maximum current load of PVC insulated three phase cables or three current carrying wires according to IEC 60204 1 at 40 C environmental temperature y and 70 C maximum conductor temperature maximum current load for installation type F and cross sections greater than 35 mm IEC 60364 5 523 is used for installation types B1 and B2 Line cross section Maximum current load for the cable cross section rated current for the overcurrent protection Ip A depending mm4 on the type of installation Three individual Three phase cable Th
152. n on Housing According to VDE 0627 Protection according to DIN 40050 IP67 when connected Certifications UL CSA Electrical Characteristics Overvoltage Category 3 Signal Contacts Nominal Current 9A Nominal Voltage 125V Isolation Voltage L L 2500 V Contact Resistance lt 5mQ Mechanical Characteristics Temperature Range 20 C to 130 C Housing Material Zinc die cast brass nickel plated Gaskets FPM HNBR Mating Cycles 50 Crimp Range 17x0 06 1 mm Cable o 9 12 mm Manufacturer Information Manufacturer INTERCONTEC Internet Address www intercontec biz Manufacturer s Product ID ASTA 035 FR 11 12 0035 000 Table 44 Technical data for EnDat connector 8PE001 00 1 80 ACOPOS User s Manual Technical Data Connectors 4 3 3 Technical Data for Resolver Connector 8PR001 00 1 Product ID 8PR001 00 1 General Information Connector Size Size 1 Contacts 12 signal contacts Degree of Pollution 3 Installation Altitude Up to 2 000 m Insulator PA 6 6 PBT UL94 VO listed Contacts Gold plated brass Protective Ground Connection on Housing According to VDE 0627 Protection according to DIN 40050 IP67 when connected Certifications UL CSA Electrical Characteristics Overvoltage Category 3 Signal Contacts Nominal Current 9A Nominal Voltage 160 V Isolation Voltage L L 2500 V Contact Resistance lt
153. ndards Definitions for Safety Techniques The following risk graph according to EN 954 1 Appendix B provides a simplified procedure for risk evaluation Safety Category according to IEC 954 1 Safety Integrity Level SIL according to IEC 61508 2 Starting point for the risk evaluation of the safety related parts of the controller B 1to4 Safety categories for safety related parts of controllers e Preferred categories e Possible categories which require extra measures O Measure which may be over dimensioned with regard to the actual risk Figure 85 Risk graph according to EN 954 1 Appendix B Begin at the starting point shown and follow the parameters S F and P to the safety category to be used Parameter S Seriousness of injury 1 Light usually reversible injury S2 Serious usually irreversible injury Parameter F Frequency and or duration of the danger exposure F1 Seldom to slightly more frequent and or short exposure duration F2 Frequent to continuous and or long exposure duration Parameter P Possibility to prevent danger P1 Possible under some conditions P2 Nearly impossible Table 126 Parameters S F and P lead you to the safety category to be used 212 ACOPOS User s Manual Standards and Certifications Standards Definitions for Safety Techniques Restart inhibit according to EN 1037 04 96 Safety of machinery prevention
154. ng resistors at the same time is not possible Switching takes place using the software and is only possible during the ACOPOS servo drive initialization phase ParlD 398 Setting for an internal external braking resistor 0 Internal default 1 External 3 The fuses used must be fast acting fuses 10 x 38 mm for 600 VAC VDC For example type KLKDOxx xx is the rated current of the fuse in amperes e g KLKD030 from Littelfuse www littelfuse com can be used 4 The braking resistors integrated in ACOPOS servo drives 1022 1045 and 1090 are optimally dimensioned for the respective sizes ACOPOS User s Manual 111 Chapter 4 Dimensioning Dimensioning Braking Resistor 4 2 External Braking Resistor Connection The external braking resistors are connected using terminals X6 RB RB and PE The structure of the external braking resistor connection can be seen in the following diagram e DC Figure 26 Circuit diagram for ACOPOS X6 external braking resistor on ACOPOS 1180 1320 1640 128M When determining the cross section 1 for wiring the external braking resistor make sure that the cross section selected is within the range that can be used with braking resistor connection terminal X6 see table 60 Terminal cross sections for ACOPOS servo drives on page 138 1 The cross section of the braking resistor cable must be dimensioned for the thermal equivalent effective value o
155. nged by resetting the module 2 The red LED blinks an error code the output of the error code occurs in 4 short 150 ms or long 600 ms phases ACOPOS User s Manual 47 Chapter 2 Technical Data Technical Data e ACOPOS Plug in Modules System stop error codes The following timing is used for the indication diagram Block size 150 ms Pause 2000 ms Error Stack overflow RAM error Undefined address 1 Instruction fetch memory abort 2 Data access memory abort Assertion failed Programming failed 9 Table 22 System stop error codes Display 1 Access of non existent address 2 Invalid memory access during instruction fetch e g WORD access of add numbered address 3 Invalid memory access during data access e g WORD access of add numbered address 4 This system stop code only occurs in debug mode The condition for a software assertion was not fulfilled 5 Error during programming 2 4 6 Firmware The firmware is part of the operating system for the ACOPOS servo drives The firmware is updated by updating the ACOPOS operating system 48 ACOPOS User s Manual Technical Data ACOPOS Plug in Modules 2 5 AC120 EnDat Encoder Interface 2 5 1 General Description The AC120 plug in module can be used in an ACOPOS slot The module has an EnDat encoder interface but can also be used
156. nk AC112 interface which can be used to connect to a B amp R PLC The connection is made using a a CAN cable AC110 or an Ethernet cable AC112 pin assignments can be found in chapter 5 Wiring and in the User s Manual for the PLC 1 Caution In general crossover Ethernet cables must be used for ETHERNET Powerlink connections ACOPOS User s Manual 171 Chapter 6 Getting Started Getting Started Starting Up an ACOPOS Servo Drive 2 Starting Up an ACOPOS Servo Drive The goal of the following example is move the shaft of a motor connected to an ACOPOS servo drive 5000 units In order to emphasize the important points of starting up the hardware this will be done using an sample project contained in B amp R Automation Studio Danger Incorrect control of motors or mechanical parts connected to the motor shaft can cause unwanted and dangerous movements 2 1 General Information The start up procedure described here is based on the following configuration Model number Short description Servo Drives 8V1045 00 1 Servo drive 3 x 400 480V 4 4A 2KW line filter and braking resistor integrated Plug in Modules 8AC110 60 1 ACOPOS plug in module CAN interface 8AC120 60 1 ACOPOS plug in module EnDat encoder interface Motor 8MSA4L E0 B4 Motor MSA4 series with EnDat encoder Accessories 7AC911 9 Bus connector CAN 2 pcs 8CE005 12 1 EnDat cable length 5m 10 x 0 14mm 2 x 0 5mm EnDat
157. nment Temperature during 0 to 40 C Operation Relative Humidity during Operation 5 to 95 non condensing Reduction of the Continuous Current 10 per 1000 m at Installation Altitudes over 500 m above Sea Level Maximum Installation Altitude 2000 m 9 Degree of Pollution according to 2 non conductive material IEC 60664 1 Over voltage Category according to ll IEC 60364 4 443 1999 Protection according to IEC 60529 IP20 Storage and Transport Conditions Storage Temperature 25 to 55 C Relative Humidity during Storage 5 to 95 non condensing Transport Temperature 25 to 70 C Relative Humidity during Transport 95 at 40 C Mechanical Characteristics Dimensions Width 70 5 mm Height 375 mm Depth 235 5 mm Weight 4 0 kg 4 1 kg 44 kg Table 9 Technical data for ACOPOS 1022 1045 and 1090 cont 1 When using motor holding brakes the valid input voltage range is reduced The input voltage range should be selected so that the proper supply voltage for the brake can be maintained 2 The current requirements depend on the configuration of the ACOPOS servo drive To determine the current requirements see section 5 Configuration of ACOPOS Servo Drives on page 117 3 Additional requirements are to be arranged with B amp R ACOPOS User s Manual 37 Chapter 2 Technical Data Technical Data e ACOPOS Servo Family 1 5 ACOPOS 1180 1320 1 5 1 Order Data Model Number Short Description Servo Drives
158. nput 2 Counter 2 ACOPOS User s Manual Table 32 Technical data for AC131 63 Chapter 2 Technical Data Technical Data e ACOPOS Plug in Modules Product ID 8AC131 60 1 Digital Outputs Number of Outputs Max 2 Type Transistor outputs push pull Electrical Isolation Output ACOPOS Yes Output Output No Switching Voltage Minimum 18 VDC Nominal 24 VDC Maximum 30 VDC Continuous Current Max 45 mA Switching Delay 0 gt 1 and 1 gt 0 Max 5 us Switching Frequency resistive load Max 100 kHz Protection Short Circuit Protection Yes Overload Protection Yes Short Circuit Current at 24 V until cut off Approx 0 3 A Readable Outputs Yes Analog Inputs Number of Inputs Max 2 Design Differential input or single ended input Electrical Isolation Input ACOPOS Yes Input Input No Input Signal Nominal 10 V to 10 V Maximum 15 V to 15 V Operating mode Cyclic measurement synchronous to 50 us ACOPOS clock Digital Converter Resolution 12 bit Non Linearity 1 LSB Output Format INT16 8000 7FF01 LSB 0010 4 883 mV Conversion Procedure Successive approximation Conversion Time for both Inputs lt 50 us Differential Input Impedance gt 10 MQ Input Filter Analog low pass 3rd order cut off frequency 10 kHz Basic Accuracy at 25 C 0 05 1 Offset Drift Max 0 0005 C 1 Gain Drift Max 0 006
159. nputs have incremental encoder functionality A B R The first two outputs can be operated in pulse width modulation PWM mode The inputs are divided into 4 standard max 10 kHz and 4 high speed max 100 kHz inputs The outputs include 4 high speed push pull outputs with a maximum current of 100 mA 4 standard high side outputs with a maximum current of 400 mA and 2 low speed high side outputs with a maximum current of 2 A All outputs can be read 2 8 2 Order Data Model Number Short Description Image Plug in Module 8AC130 60 1 ACOPOS plug in module 8 digital I O configurable in pairs as 24V input or as output 400 100mA 2 digital outputs 2A Order TB712 terminal block separately Accessories 7TB712 9 Terminal block 12 pin screw clamps 7TB712 91 Terminal block 12 pin cage clamps 7TB712 90 02 Terminal block 12 pin 20 pcs screw clamps 7TB712 91 02 Terminal block 12 pin 20 pcs cage clamps Table 29 Order data for AC130 58 ACOPOS User s Manual 2 8 3 Technical Data Technical Data e ACOPOS Plug in Modules Product ID 8AC130 60 1 General Information C UL US Listed Yes Module Type ACOPOS plug in module Slot 1 Slots 2 3 and 4 Power Consumption Max 0 8 W Inputs Outputs Connection Module Side 12 conductor pin connector Configuration of the Inputs Outputs Can be configured in pairs as input or output L
160. ntinuous level B Table 110 Limits for power mains harmonics IEC 60146 1 1 class 3 IEC 61800 3 Performance Criteria Commutation notches Depth 40 total area 250 x degree A Table 111 Limit values for commutation notches voltage distortions 4 2 2 Voltage Changes Deviations Dips and Short term Interruptions IEC 61000 2 4 class 3 IEC 61800 3 Performance Criteria Voltage changes and deviations 10 Voltage changes and deviations lt 1 min 10 to 15 A Table 112 Limit values for voltage changes and deviations IEC 61000 2 1 IEC 61800 3 Performance Criteria Voltage dips and short term interruptions 10 to 100 C Table 113 Limit values for voltage dips and short term interruptions 204 ACOPOS User s Manual Standards and Certifications Requirements for Immunity to Disturbances EMC 4 2 3 Asymmetric Voltage und Frequency Changes IEC 61000 2 4 class 3 IEC 61800 3 Performance Criteria Asymmetric voltages 3 negative component Frequency change and change rate 42 1 s A 4 2 s if the power supply is isolated from general power mains Table 114 Limit values for asymmetric voltages and frequency changes 4 3 High Frequency Disturbances according to IEC 61800 3 These immunity tests are valid for industrial environments ond environment 4 3 1
161. number BR_AS_xxx GAMPLES MOTION DEUTSCH ACP10 CAN M68K C ACP10 PGP ACP10 GDM is the sample project referred to in this section starting with ACOPOS operating system version V 0 472 xxx indicates the B amp R Automation Studio version number Open Lookin E acp10 peo Y amp Al es DBK 7 Library pgm omm File name acp10 Files of type Project Files gdm Cancel Figure 44 Open sample project Information During start up changes will be made to the sample project We recommend that you make a copy of the sample project entire ACP10 PGP directory see figure 44 Open sample project in a different project directory and use it for the start up 2 1 2 Preparing the Hardware for Sample Project acp10 gdm e Check the wiring of the ACOPOS servo drive connections also see chapter 5 Wiring Set node number 1 on the AC110 plug in module see chapter 2 Technical Data e Connect the PC with the PLC using the online cable see user s manual for the PLC for information concerning the online cable connection to the PLC Apply power to the PLC and the ACOPOS servo drive 24 VDC 400 VAC You can make sure the ACOPOS servo drive boots correctly by watching the blink code see chapter 2 Technical Data ACOPOS User s Manual 173 Chapter 6 Getting Started Getting Started Starting Up an ACOPOS Servo Drive 2 2 Start Up 2 2 1 Load Sample Project Start B amp R Automatio
162. odules required for your application and insert them into the ACOPOS servo drive 2 2 Order Data Model Number Short Description 8AC110 60 2 ACOPOS plug in module CAN interface 8AC112 60 1 ACOPOS plug in module ETHERNET Powerlink interface 8AC120 60 1 ACOPOS plug in module EnDat encoder interface 8AC122 60 2 ACOPOS plug in module resolver interface 8AC123 60 1 ACOPOS plug in module incremental encoder and SSI absolute encoder interface 8AC130 60 1 ACOPOS plug in module 8 digital 1 O configurable in pairs as 24V input or as output 400 100mA 2 digital outputs 2A Order TB712 terminal block separately 8AC131 60 1 ACOPOS plug in module 2 analog inputs 10V 2 digital I O points which can be configured as 24V input or 45mA output 42 Table 14 Order data for plug in modules ACOPOS User s Manual Technical Data e ACOPOS Plug in Modules 2 3 AC110 CAN Interface 2 3 1 General Description The AC110 plug in module can be used in an ACOPOS slot The module is equipped with a CAN interface This fieldbus interface is used for communication and setting parameters on the ACOPOS servo drive for standard applications 2 3 2 Order Data cable Model Number Short Description Image Plug in Module 8AC110 60 2 ACOPOS plug in module CAN interface Accessories 7AC911 9 Bus connector CAN RXD TXD 0AC912 9 Bus adapter CAN 1 CAN interface OQ AM he 0AC913 92 Bus
163. of unexpected start up Keeping a machine in an idle state when people are working in the danger zone is one of the most important requirements for safe operation of machines Starting refers to the transition of a machine or its parts from an idle state to moving state Any start is unexpected if it is caused by e Astart command sent because of a controller failure or because of external influences on the controller A start command sent because of incorrect operation of a start element or another part of the machine e Restoration of power supply after an interruption e External internal influences on parts of the machine To prevent unexpected starting of machines or parts of machines power should be removed and dissipated If this is not practical e g frequent short work in danger zone other measures must be taken Measures to prevent random start commands Measures to prevent that random start commands cause unexpected starting Measures to automatically stop dangerous parts of the machine before a dangerous situation can be caused by unexpected starting ACOPOS User s Manual 213 Chapter 7 Standards and Certifications Standards and Certifications Standards Definitions for Safety Techniques 214 ACOPOS User s Manual Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15 Figure 1
164. oject Target Version V227 V224 Mismatch handling E target to r Apply the your project Ignore the mismatch between project and target Exe oce Figure 70 Acknowledge selection of conflict resolution Le oO ot SS 28 D aa ot 5 ACOPOS User s Manual 189 Getting Started Starting Up an ACOPOS Servo Drive Amessage will be displayed by B amp R Automation Studio Acknowledge this message by clicking Yes B amp R Automation Studio During transfer of the application to the target 2 cold restart s Sl 1 warm restart s will be LI required resulting in possible data loss Do you want to continue Figure 71 Acknowledge message from B amp R Automation Studio with Yes The project is transferred Project Transfer 2 x Object neglobal PY Procesor CPU KS Aj se 8020 PITT TT Figure 72 The project is transferred The following message is given after the project has been successfully transferred Transfer Project x Lig onde project or eqs aget v non up to date Figure 73 The project was transferred successfully e Acknowledge the message by clicking the OK button 190 ACOPOS User s Manual Getting Started Starting Up an ACOPOS Servo Drive 2 2 5 Test Function Now control of the motor shaft can be taken over using the test function ACP10 real axis Position the cursor on the initial paramete
165. ooling aggregate must remain in operation even when the system is switched off Cooling aggregates must be installed in a way that prevents condensation from dripping into the ACOPOS servo drives This should be considered when selecting the switching cabinet special construction for use of cooling aggregates on top of the switching cabinet Also make sure that condensed water which forms in the cooling aggregate fan when it is switched off cannot sprinkle into the ACOPOS servo drives Make sure the temperature setting of the cooling aggregates is correct ACOPOS User s Manual 93 Chapter 3 Installation Installation Using Cooling Aggregates in Switching Cabinets 5 2 Cooling Aggregate on Top of the Switching Cabinet Cooling aggregate LE E E E E a Abdo ooo D Switching cabinet Cooling aggregate Switching cabinet Figure 19 Cooling aggregate on top of the switching cabinet 94 ACOPOS User s Manual Installation Using Cooling Aggregates in Switching Cabinets 5 3 Placing a Cooling Aggregate on the Front of the Switching Cabinet Ns am EEE e 5 Incoming air Outgoing air Cooling a E S aggregate K a AS R EEE Switching cabinet Re CHERECHECEEGECECHCUECE HN Incoming air t t Switching cabinet t Air duct Cooling aggregate Out
166. or the stop function in category 2 safety category 3 136 Pin assignment overview ACOPOS 1022 1045 1090 139 Pin assignment overview ACOPOS 1180 1320 sss 144 Pin assignment overview ACOPOS 1640 128M cccsscccesseeeeesreeeeeees 150 Connecting Cables to Plug in Modules eeeene 162 Cable schematic for motor cable 8CMxxx 12 1 8CMxxx 12 3 164 Figure Index Figure Index Figure 41 Cable schematic for motor cables 8CMxxx 12 5 sss 165 Figure 42 Cable schematic for EnDat encoder cables sssssssssss 167 Figure 43 Cable schematic for resolver cables 169 Figure 44 Open sample project 2 cce trade 173 Figure 45 B amp R Automation Studio Start up Screen essssss 174 Figure 46 Open projec EE 175 Figure 47 Selecting the project ceeeeesceceseeeseeeeeeeeeeseaeeseeeeeaeeeaeteaeeeaeeetaeeteaeeeaeeeed 175 Figure 48 Project window with representation of the hardware and software configuration cloacas HERO EROR ERE GR RPM DUNS 176 Figure 49 Select the CPU in the left part of the window eeeeees 177 Figure 50 Select the command used to replace the CPU from the shortcut menu 178 Figure 51 Acknowledge the change of the CPU ssssseeeeeee 178 Figure 52 Clearing user memory on the PLC ssssssseseeeeeenennene
167. otection against Touching Electrical Parts ss 27 3 5 2 Protection from Dangerous Movements seem 28 3 6 Safety Guidelines cocti eene e te M eee Ue an ee 29 Chapter 2 Technical Data ecce eee mnnn 31 1 AGOPOS Servo Fkamlily cascara n idc dt ne 31 1 1 Modular Servo Drive Concept c ccoccccoccccocanoccconcconnncancnononnnncnnnnn rana nan ocn nennen rennen nnne 31 1 2 General Description 2 ute atic detenti dedo ete rae ge wien deed 32 1 2 1 24 VDC Supply during Power Failures eseeeneneneeee 33 TS LEDS ete nne dne eosdem ee ete idet a ie 33 131 LED Status aite whee dee Mn ded is rice deus i DES es 34 1 4 ACOPOS 1022 1045 and 1090 ea e aaia a nnne nennen nnne 36 1 441 Order Data E tee Pe E PERSE MS 36 14 2 Tectinical Data o ente nai dE HEREIN RI CREE iii 36 1 5 ACOPOS 1180 1920 00 ades a o Poit e Beets 38 1 51 Order D ta i o ouai omite noB piat ditat 38 1 5 2 Technical Dala est ete ate eM ette p ee ee HERES 38 1 6 ACOPOS 1640 128M siii ee re de eoe De Cue E ede codon 40 1 6 1 Order Data iecit ice 40 ACOPOS User s Manual 7 Table of Contents 1 6 2 Technical Dita ee eter ce issue e et E a te v tend 40 2 ACOPOS Plug in Modules inesse cia aa 42 2 1 Generali Information ini reete Deo etc ctio eet Fa ert t err dee cbe eod 42 2 2 Order Data 2 2 C m ee 42 2 39 AC4A10 CAN IBterface citet crt ecd cet
168. p_active 0 ACOPOS User s Manual switch step case MOV_STOP Wiring Secure Restart Inhibit Call NC action for movement stop p_ax_dat gt move stop index command stop_index action_status ncaction ax_obj ncMOVE ncSTOP if action_status ncOK step break W_MOVE_STOP case W_MOVE_STOP Wait for completion of movement stop if p_ax_dat gt move mode ncOFF Movement stop completed step break ACOPOS User s Manual lt NEXT_STEP gt 133 Chapter 5 Wiring Wiring Secure Restart Inhibit Type 2 Starting active braking using the Quickstop input on the ACOPOS L1 3 400 480VAC L2 50 60 Hz L3 aot 1 M K3 Stop Function Cat 1 Stop S210v7 Stop Function Cat 1 K207 3 L 9E COM 5 7 13 15 OG COM 5 7 13 15 pe Lov o Vc Hs COM 5 7 13 15 Figure 34 Type 2 Starting active braking using the Quickstop input on the ACOPOS 1 The drop out time lag corresponds to the requirements of the application The K3 auxiliary relay with drop out time lag is a part of the safety function Therefore K3 must meet safety category 3 2 The network connection is used for diagnosis and setting parameters 3 For servo drives which have no 24 VDC output ACOPOS 1022 1045 1090 the control voltage must be provided externally 134 ACOPOS User
169. r The cable shield must be connected to the designated clamp in the metallic or metal plated plug housing The fastening screws must be tightened Cable connection via terminals The cable shield must be attached to the shield connection terminal Cable connection via RJ45 plug Also grounding the cable shield provides an improvement in EMC properties Grounding should take place on both sides extensively and near to the connector Figure 30 Cable shield grounding for the ETHERNET Powerlink cable 124 ACOPOS User s Manual Wiring General Information The cable shield for the motor line or the connection cable for the external braking resistor is connected with the housing of the ACOPOS servo drive via the grounding plate using the grounding clamp provided Shield connection for the motor cable using grounding clamps 1022 1045 1090 1180 1320 1640 128M Table 59 Grounding the motor cable On the motor side the cable shield for the motor line is connected to the motor housing using the motor plug and connected to ground via the machine The cable shield on the connection cable for the external braking resistor must be connected with the housing of the braking resistor O On the motor side the encoder cable shield is connected to the motor housing using the encoder plug and connected to ground via the machine ACOPOS User s Manual 125 Chapter 5 Wir
170. r branch specific tasks Operation of synchronous and asynchronous motors possible Current controller scan time up to 50 us Reduced commissioning and service times using embedded motor parameter chip CAN and Powerlink network connection Input voltage range from 400 480 VAC 10 for use worldwide Connection possibilities for all standard encoder systems 2 free slots for optional technology modules Electronic secure restart inhibit integrated ACOPOS User s Manual 31 Chapter 2 Technical Data Technical Data e ACOPOS Servo Family 1 2 General Description The ACOPOS servo drive series covers a current range from 2 2 128 A and a power range from 1 64 kW with 7 devices in 3 groups The devices in a group are designed using the same basic concept Group 8V1022 00 2 8V1180 00 2 8V1640 00 2 8V1045 00 2 8V1320 00 2 8V128M 00 2 8V1090 00 2 Power Connections Plug connection Plug connection Fixed Integrated Line Filter Yes Yes zen Mains Failure Monitoring Yes Yes Yes DC Bus Connection Yes Yes Yes 24 VDC Supply External 2 External or internal via DC bus External or internal via DC bus 24 VDC Output No 24V 0 5A 24V 0 5A Integrated Brake Chopper Yes Yes Yes Internal Braking Resistor Yes Yes Yes 3 Connection of External Braking No Yes Yes Resistor Possible Monitored Output for Motor Yes Yes Yes Holding Brake Monitored Input for Motor Yes Yes Yes Temperature Sensor
171. r module AX1_PAR amp B amp R Automation Studio Ele Edit View Insert Open Project Object Tools Window 2 JOsug xce ec xmi zGs aj m eoe acp10 Project Software Log book CAN 1 0 TPU Permanent Description a y aS Module Name Version Transfer to Size bytes Description T Sg CPU il O Cycic tt 10 ma n 5E att v0 00 UserRAM 7676 3 02 fe artiste 16265 3 03 acplOmanh 20476 J 04 libacp10man a 2188 9 1 cl System Gifs 8v1045 00 1 a sysconf v2 24 UserROM 752 y PACTIDEDA 1 Y acpi0ctg v0472 UserROM 212 y saco 2 4 acpl0sys v0472 UserROM 240416 3 3 gcloader v1 30 UserROM 5828 3 4 M ncolobal v017 UserROM 8020 9 M Y acpl man V0472 UserROM 66388 acpl par 0 47 2 UserROM 15700 THRI ACP10 Real Axis Cy axl_par User RAM ACPIO Error Text Module L acpi etx v0 00 UserROM 54696 x Transferring ax tst ok x gt a E Output Find in Files Line 16 of 18 COMI CP476 V224 RUN Figure 74 Select initial parameter module AX1 PAR ACOPOS User s Manual 191 Chapter 6 Getting Started Getting Started Starting Up an ACOPOS Servo Drive Inthe Open menu click on Test B amp R Automation Studio Eile Edit Miew Insert Open Project Object Tools Ds Data Types ug Library Manager acp10 Project Object Window 2 Size bytes Cyclic 1 10 ms E ax tst v0 00 User RAM 7
172. rding to section Dimensioning the Power Mains and Overcurrent Protection on page 100 The cross section of the DC bus wiring on the respective ACOPOS servo drives must be less than or equal to the cross section of the servo drive power mains e The selected cross section must be within the range possible for the DC bus connection terminal X2 see table 60 Terminal cross sections for ACOPOS servo drives on page 138 2 4 Equal Distribution of the Brake Power on the Braking Resistors The braking resistors integrated in the ACOPOS servo drives as well as braking resistors which can be connected externally are controlled using a specially developed procedure This guarantees that the brake power is optimally and equally distributed on the braking resistors when a DC bus connection is made between several units When using the integrated braking resistors additional configuration is not required When using external braking resistors the corresponding parameters must be defined see section 4 4 Setting Brake Resistor Parameters on page 115 1 The cross section of the individual segments of the DC bus wiring must be dimensioned for the thermal equivalent effective value of the respective compensation current If information concerning the flow of the compensation current is available calculate the thermal equivalent effective value of the compensation current using Toycle s WAL f Y MAR as The cross section of the DC bus
173. ree phase cable Three phase cable Three individual wires in insulating in insulating on walls in a cable tray wires in a cable tray conduit or cable conduit or cable duct duct B1 B2 c E F 1 5 13 5 13 12 2 10 15 2 13 16 1 16 2 5 18 3 16 16 5 16 21 20 22120 4 25 25 23 16 28 25 30 25 6 32 32 29 25 36 32 37 32 10 44 32 40 32 50 50 52 50 16 60 50 53 63 66 63 70 63 25 77163 67 63 84 80 88 80 96 80 35 97 80 83 80 104 100 114 100 119 100 50 117 100 103 100 123 100 123 100 145 125 70 149 125 130 125 155 125 155 125 188 160 95 180 160 156 125 192 160 192 160 230 200 Table 51 Maximum current load for PVC insulated three phase cables or individual wires When determining the cross section for the power mains make sure that the cross section selected is within the range that can be used with power mains terminal X3 see table 60 Terminal cross sections for ACOPOS servo drives on page 138 1 The maximum current load value in IEC 60204 1 is for an environmental temperature of 40 C In IEC 60364 5 523 this reference temperature is 30 C The values in table 51 Maximum current load for PVC insulated three phase cables or individual wires on page 101 from IEC 60364 5 523 are calculated with the factor ktemp 0 87 given in the standard and also at 40 C ACOPOS User s Manual 101 Chapter 4 Dimensioning Dimensioning Power Mains Connection Dimensioning the Line Contactor The rated current of the line contactor i
174. rews required can be taken from the dimensional diagrams for the respective ACOPOS servo drives ACOPOS User s Manual 91 Chapter 3 Installation Installation Installing Various ACOPOS Series Devices Directly Next to Each Other Overview of the vertical offsets Installed next to ACOPOS 1022 1045 1090 1180 1320 1640 128M 1022 1045 1090 No offset 10 mm ACOPOS 1180 1320 1640 128M 10 mm No offset Table 47 Overview of the vertical offsets ACOPOS ACOPOS 92 ACOPOS User s Manual Installation Using Cooling Aggregates in Switching Cabinets 5 Using Cooling Aggregates in Switching Cabinets 5 1 General Information To prevent exceeding the required environmental temperatures it may be necessary to cool the air inside of a switching cabinet Caution Incorrect installation of cooling aggregates may cause condensation which can damage the ACOPOS servo drives installed there Condensation can enter the ACOPOS servo drives with the cooled air stream Make sure that only well sealed switching cabinets are used condensation caused by outside air entering the switching cabinet During operation with the switching cabinet doors open e g service the ACOPOS servo drives are not allowed to be cooler than the air in the switching cabinet at any time after the doors are closed To keep the temperature of the ACOPOS servo drives and the switching cabinet at the same level the c
175. ries devices directly next to each other 91 Cooling aggregate on top of the switching cabinet ssssssss 94 Placing a cooling aggregate on the front of the switching cabinet 95 Circuit diagram for ACOPOS X3 individual power mains connection 99 Circuit diagram for ACOPOS X3 power mains connection fora dre OU iii 102 ACOPOS X2 circuit diagram DC bus connections usssssess 105 B amp R power supply 0PS320 1 as DC bus power supply for ATAN 108 ACOPOS X4 X5 circuit diagram motor CONNEeCtION oooooconocccnnoccccnancnnnonnos 109 Circuit diagram for ACOPOS X6 external braking resistor on ACOPOS 1180 1320 1640 128M sese 112 Diagram of a typical movement with the brake power curve PBr t 113 Thermal equivalent circuit for the external braking resistor 116 Connection diagram for ground and shield connections 123 Cable shield grounding for the ETHERNET Powerlink cable 124 Block diagram of secure restart iMhibit ooooocccnnnncccnoniccnnncccnnnanonanannnnancnnnnos 127 External wiring for the stop function in category 0 safety category 3 129 Type 1 Starting active braking over the network sssss 131 Type 2 Starting active braking using the Quickstop input on the ACOPOS cene nee dede ie dta e diene ny 134 External wiring f
176. rive or when operating it for a short time Before turning the device on make sure that all voltage carrying parts are securely covered During operation all covers and switching cabinet doors must remain closed Control and high power contacts can have voltage applied even when the motor is not turning Touching the contacts when the device is switched on is not permitted ACOPOS User s Manual 27 Chapter 1 General Information General Information Safety Guidelines Before working on servo drives they must be disconnected from the power mains and prevented from being switched on again Danger After switching off the device wait until the DC bus discharge time of at least five minutes has passed The voltage currently on the DC bus must be measured with a suitable measuring device before beginning work This voltage must be less than 42 V DC to rule out danger The Run LED going out does not indicate that voltage is not present on the device The connections for the signal voltages 5 to 30 V found on the servo drives are isolated circuits Therefore the signal voltage connections and interfaces are only allowed to be connected to devices or electrical components with sufficient isolation according to IEC 60364 4 41 or EN 50178 Never remove the electrical connections from the servo drive with voltage applied In unfavorable conditions arcs can occur causing personal injury and damage to contacts 3 5 2 Protection from D
177. rminal Cross Sections see table 60 Terminal cross sections for ACOPOS servo drives on page 138 Table 85 Pin assignments for X6 ACOPOS 1640 128M 154 ACOPOS User s Manual Wiring Pin Assignments Plug in Modules 5 Pin Assignments Plug in Modules 5 1 AC110 CAN Interface 5 1 1 Pin Assignments Image x1 Pin Description Function 1 2 CAN_L CAN Low 3 COM 2 7 CANO V 4 5 6 E 7 CAN H CAN High o o 3 8 s o o 9 Table 86 Pin assignments for AC110 CAN Interface ACOPOS User s Manual 155 Chapter 5 Wiring Wiring Plug in Module Pin Assignments 5 2 AC112 ETHERNET Powerlink Interface 5 2 1 Pin Assignments Image xi Pin Description Function 1 RXD Receive Signal 2 RXD Receive Signal Inverted 3 TXD Transmit Signal 4 Shield Shield 5 Shield Shield 6 TXD Transmit Signal Inverted 7 Shield Shield 8 Shield Shield X2 Pin Description Function 1 RXD Receive Signal 2 RXD Receive Signal Inverted 3 TXD Transmit Signal 50 4 Shield Shield P pA 5 Shield Shield sal Sent 6 TXD Transmit Signal Inverted E 7 Shield Shield 8 Shield Shield Table 87 Pin assignments for AC112 ETHERNET Powerlink Interface Information In general crossover Ethernet cables must be used for ETHERNET Powerlink connections Take care when plugging the cable in and out becau
178. roblem can be determined 1 2 Taking it to the Limit Operational security is also improved by monitoring high temperature components IGBT modules brake resistor motor windings Computer based simulation allows component temperatures which cannot be measured directly to be calculated One example is the junction temperature This is a decisive value for the maximum load of a semiconductor Using these models a sufficiently precise value can be determined for each IGBT Hot spots can be ruled out and the full dynamic properties of the device can be used at low rpm values and when stalled The brake resistor and motor windings are monitored in the same way This form of monitoring allows better use of absolute limits on the drive and provides the user with the advantages of higher performance at lower costs 16 ACOPOS User s Manual General Information e ACOPOS 1 3 Individual I O Configurations The I O points needed to operate a servo axis are part of the standard equipment for ACOPOS drives The user is provided two trigger inputs for tasks requiring precise measurements or print mark control Sensor and actuator configurations are made using modular plug in modules This modular concept allows the optimum configuration to be selected to meet the requirements of the application Figure 2 Individual I O configurations 1 4 Configuring instead of Programming Long term cooperation with our customers has provided us with fun
179. rtifications Standards and Certifications Other Environmental Limit Values according to 6 Other Environmental Limit Values according to IEC 61800 2 IEC 61800 2 Degree of pollution according to IEC 61800 2 4 1 2 1 2 Over voltage category according to ll IEC 60364 4 443 1999 Protection according to IEC 60529 IP20 Reduction of the continuous current at installation 10 per 1000 m altitudes over 500 m above sea level Maximum Installation Altitude 2000 m Table 122 Additional environmental limits 1 Additional requirements are to be arranged with B amp R 208 ACOPOS User s Manual Standards and Certifications International Certifications 7 International Certifications B amp R products and services comply with the applicable standards They are international standards from organizations such as ISO IEC and CENELEC as well as national standards from organizations such as UL CSA FCC VDE OVE etc We give special consideration to the reliability of our products in an industrial environment Certifications USA and Canada All important B amp R products are tested and listed by Underwriters Laboratories and are checked quarterly by a UL inspector This mark is valid for the USA and Canada and eases certification of your machines and systems in these areas t US Europe All harmonized EN standards for the valid guidelines are met Kk x x kk Russian Federation
180. s Nm 0 5 0 6 12 1 5 12 1 5 Table 60 Terminal cross sections for ACOPOS servo drives 1 ACOPOS 1022 1045 1090 revision I0 and up ACOPOS 1180 1320 revision FO and up ACOPOS 1640 128M revision KO and up 138 ACOPOS User s Manual Wiring Pin Assignments ACOPOS 1022 1045 1090 2 Pin Assignments ACOPOS 1022 1045 1090 x w L1 3 400 480 VAC L2 50 60 Hz L3 PEs oir E IM eid QC BA I 420 J X N k l l l l Ho Trigger I 1 95 Quickstop Trigger2 OVI hy 8G COM 1 2 I 49 Shield Ho End l l l l l l l l X1 1 Lo 7 End Hoc Ref i89 Enable 24 V t diss Enable X1 0 Vl 28 COM 8 9 i SG COM 8 9 USC COM 5 7 14 15 ove 894 COM 5 7 14 15 ACOPOS 8V1022 00 2 1022 1045 1090 8V1045 00 2 8V1090 00 2 CAN ETHERNET Powerlink 1 42 EnDat 7 6 Resolver Figure 36 Pin assignment overview ACOPOS 1022 1045 1090 1 Starting with revision 10 ACOPOS User s Manual 139 Chapter 5 Wiring Wiring Pin Assignments ACOPOS 1022 1045 1090 2 1 Pin Assignments for Plug X1 x1 Pin Description Function 1 Triggeri Trigger 1 2 Quickstop Trigger2 Quickstop Trigger 2 3 COM 1
181. s This is referred to as the embedded parameter chip During start up the module is automatically identified configured and its parameters set by the ACOPOS servo drive operating system Incremental encoder with sine formed output signal When using the AC120 plug in module to evaluate simple incremental encoders with sine formed output signal only the incremental transfer channel is now used The embedded parameter chip it not available in this case because this encoder does not have parameter memory The absolute position is also not available immediately after switching the device on In this situation a homing procedure normally has to be carried out The module is equipped with a reference pulse input for this purpose 1 Starting with revision FO ACOPOS User s Manual 49 Chapter 2 Technical Data Technical Data e ACOPOS Plug in Modules 2 5 2 Order Data Model Number Short Description Image Plug in Module 8AC120 60 1 ACOPOS plug in module EnDat encoder interface Accessories 8CE005 12 1 EnDat cable leng connector 17 pin Intercon plug can be used h 5m 10 x 0 14mm 2 x 0 5mm EnDat lec socke in cable drag chains UL CSA servo connector 15 pin DSUB isted 8CE007 12 1 EnDat cable leng connector 17 pin Intercon plug can be used h 7m 10 x 0 14mm 2 x 0 5mm EnDat lec socke in cable drag chains UL CSA servo connector 15 pin DSUB isted 8CE010 12 1 EnD
182. s Manual General Information e ACOPOS 1 8 Simple Function Test The built in NC test allows an axis to be used without a line of program code being written As seen in the picture several editors are grouped together as a single window All movements ranging from point to point movements to gear functions can be carried out using an NC Action The reaction of the axis can be seen online in the monitor window If the trace function is turned on relevant data from position to motor temperature is recorded on the drive The multiple curve display in the trace window allows simple evaluation of the movement results B amp R Automation Studio ax4 waf ees bse NE Gs iow dl Inserts E Dec UU Locke PHONE NN _ lel xd osagt Selo o xe F 493m 9 t SU Go ec Se be p 100 100 EBs basis override 4 Units Units s ncHOMING ncSTART ncCONTROL ncSWITCH ON ncREL MOVE neSTART ncSIMULATION ncSWITCH ON neBASIS_MOVE ncINIT ncLIMITS nclNIT ncPOS MOVE ncSTART ncCONTROL ncSWITCH OFF ncCONTROL nclNIT neSERVICE ncREAD ncDATA T Y ax4 Current controller Set stator current quadrature component S monttor s ax monitor v 0 ax4 network service data_text axd network service requestpar id 0 axd network service response par_id 0 X AA Jer tne IIa Ear y ae cn P AND I COM CP260 V224 RUN Fig
183. s Manual Wiring Secure Restart Inhibit Description Pressing e stop switch S1 cat 1 stop function causes relay K2 to be released In this way the ACOPOS input Quickstop triggers active braking If the drive etc is faulty then auxiliary relay K3 is released after a defined delay and causes the energy feed to the motor to be cut off Pressing stop switch S2 cat 1 stop function starts the same procedure as for type 1 This guarantees that the energy feed to the motor is definitely switched off afterwards If you open and lock stop switch S2 restart is inhibited ACOPOS User s Manual 135 Chapter 5 Wiring Wiring Secure Restart Inhibit Stop Function for Category 2 Safety Category 3 L1 3 400 480VAC L2 50 60 Hz L3 Emergency i S1k ly Stop Function ef is Trigger 1 Cat 1 l i aS 7 Quickstop Tri rigger 2 iS0 COM 1 2 Stop S2w7 K3 Lo Shield i ii SS End Stop Functi a 19 End T To Ref OF Enable p5sc Enable X1 ov is COM 8 9 SE COM 8 9 E 29 n c L ot 24V out 0 54 3 1ASG 24V 9 SQ 24V 8 K3 E 11 L COM 5 7 13 15 g SE COM 5 7 13 15 co E Lu al Lov o V c Lissii COM 5 7 13 15 ACOPOS CAN ETHERNET Powerlink Figure 35 External wiring for the stop function in category 2 safety category 3 1 The drop out time lag corresponds to the requirements of the applicatio
184. s Section 4x10 mm 2 x 2x 1 5 mm 4x35 mm 2 x 2 x 1 5 mm Durability Oil resistant according to VDE 0472 part 803 as well as standard hydraulic oil Certification UL AWM Style 20669 90 C 600 V E63216 and CSA AWM I II A B 90 C 600 V FT1 LL46064 Conductor Power Lines 10 mm tinned Cu wire 35 mm tinned Cu wire Wire Insulation Special thermoplastic material Wire Colors Black brown blue yellow green Signal Lines 1 5 mm tinned Cu wire Wire Insulation Special thermoplastic material Wire Colors White white red white blue white green Cable Structure Power Lines Stranding No Shield No Signal Lines Stranding White with white red and white blue with white green Shield Separate shielding for pairs tinned Cu mesh optical coverage gt 85 and foil banding Cable Stranding With filler elements and foil banding Cable Shielding Tinned Cu mesh optical coverage gt 85 and wrapped in isolating fabric Outer Sheathing Material PUR Color Orange similar to RAL 2003 flat Labeling BERNECKER RAINER 4x10 0 2x2x1 5 FLEX BERNECKER RAINER 4x35 0 2x2x1 5 FLEX Electrical Characteristics Conductor Resistance Power Lines lt 2 4 O km lt 0 6 O km Signal Lines lt 14 O km lt 14 O km Insulation Resistance 200 MO per km Isolation Voltage Wire Wire 3kV Wire Shield 1kV Operating Voltage Max 600 V Mechanical Characteristics Te
185. s oriented to the overcurrent protection for the power mains connection The line contactor is set up so that nominal operating current specified by the manufacturer of the line contactor for category AC 1 is approximately 1 3 times the rated current of the overcurrent protection 1 2 2 Implementing ACOPOS Power Mains Connections for Drive Groups The structure of the power mains connection for a drive group with line contactor and circuit breaker can be seen in the following diagram L1 3 400 480VAC L2 50 60 Hz L3 Figure 22 Circuit diagram for ACOPOS X3 power mains connection for a drive group Dimensioning the Power Mains and Overcurrent Protection The cross section of the distribution point and all power mains connections are chosen according to table 51 Maximum current load for PVC insulated three phase cables or individual wires on page 101 sothat the maximum current load for the cable cross section selected 1 is greater than or equal to the sum of the calculated mains current Iz 2 X Imains The rated current of the overcurrent protection must be less than or equal to the maximum current load for the cable cross section selected see table 51 Maximum current load for PVC insulated three phase cables or individual wires on page 101 1 When determining a common cross section for several drives especially with different sized ACOPOS modules make sure that the cross section selected is within the r
186. se otherwise the shield connection could break between the RJ45 plug and the cable shield which could then cause connection disturbances Information ETHERNET Powerlink cables must have crossover pin assignments Unassigned wires cannot be omitted 156 ACOPOS User s Manual 5 3 AC120 EnDat Encoder Interface 5 3 1 Pin Assignments Wiring Plug in Module Pin Assignments Image xi Pin Description Function in Function in EnDat mode Incremental mode 1 A Channel A 2 COM 1 3 9 11 13 15 Encoder supply 0 V 3 B Channel B 4 5V out 0 254 Encoder supply 5 V 5 D Data input 6 15 7 R Reference pulse inverted 8 T Clock output 9 A Channel A inverted i 10 Sense COM Sense input 0 V 11 B Channel B inverted 12 Sense 5V Sense input 5 V 13 D Data inverted 14 R Reference Pulse 15 T Clock output inverted Table 88 Pin assignments for AC120 EnDat encoder interface ACOPOS User s Manual 157 Chapter 5 Wiring Wiring Plug in Module Pin Assignments 5 4 AC122 Resolver Interface 5 4 1 Pin Assignments Image x1 Pin Description Function 1 2 3 Cos Cosine input 4 Sin Sine input 5 Ref Reference output 6 9 5 7 Cos Cosine input inverted 8 Sin Sine input inverted 6 1 9 Ref Reference output inverted Table 89 Pin assignments for AC122 resolver interface 158 ACOPOS User s
187. ser s Manual Getting Started Starting Up an ACOPOS Servo Drive 2 2 6 Starting the Motor Movement Danger The traverse path must be adjusted for the conditions present installed mechanical parts etc Incorrect control of motors or mechanical parts connected to the motor shaft can cause unwanted and dangerous movements This can cause severe personal injury or damage to property If mechanical parts are mounted on the motor the number of encoder units per motor revolution must be adjusted to the mechanical characteristics possible traverse path etc The number of encoder units per motor revolution units rev motor can be set as follows Position the mouse pointer on encoder if e Expand the view by clicking on e Position the mouse pointer on parameter e Expand the view by clicking on e Position the mouse pointer on scaling e Expand the view by clicking on e Position the mouse pointer on load The parameters are now shown in the right part of the window b axl_par 1 E och BS dia in rev motor CHES encoder if CABS parameter SHEN scaling Ug load BS limit te controller move BE message Figure 77 Setting the encoder resolution Now the values can be adjusted to the mechanical parts used and acknowledged by pressing the ENTER key The new encoder parameters now have to be initialized e Action window Position the mouse pointer on the action ncENCODER
188. signments for Pl g XI sterre ied te ed eder negent ty 140 2 2 Pin Assignments for Plug X2 nenetsien aa a e e a 140 2 3 P In Assignments tor Plug X3 ettet iii a beoe ees 141 2 4 Pin assignments for plugs X4a X4b seems 141 2 4 1 Wiring the Output for the Motor Holding Brake seen 141 10 ACOPOS User s Manual Table of Contents 2 5 Pin Assignments for Pl g XS 22ers vane telecine cite ek ee ae tetas 143 2 6 Protective Ground Connection PE ceccceeceseeeeeeeeseeeeeeecneeeeeeeeeaeeeeeseeeseaeeseeeeneenias 143 3 Pin Assignments ACOPOS 1180 1820 sse nennen 144 3 1 Pin Assignments for Plug X1 cooonoccconncconnncccnnorccnnnncccnnnnnnn rn 145 3 2 Pin Assignments for Plug X2 i apsari Araona e ati orbata e teeth 145 3 3 Pin Assignments for Plug X3 seeesssssseseseeseeee nennen nnne nennen 146 3 4 Pin Assignments for Plugs X4a X4b coooooccconocccconocccononcnnonnnonnononononn corno eee 146 3 4 1 Wiring the Output for the Motor Holding Brake seem 146 3 5 Pin Assignments for Plug Xb 2 etri et p be Rod p HERI dran ds 148 3 6 Pin Assignments for Plug X6 oooooocconoccccnoocccononccnannncnnnnnn non nn nro nn rnr a eene 148 3 7 Protective Ground Connection PE essssssseeeeenennee nennen 149 4 Pin Assignments ACOPOS 1640 128M sse eene 150 4 1 Pin Assignments for Plug X1 neneiia tiiin conan nana a a 151 4 2
189. st be provided externally ACOPOS User s Manual 131 Chapter 5 Wiring Wiring Secure Restart Inhibit Description When the e stop switch S1 cat 1 stop function is pressed the EmergencyStop control input on the controller triggers active braking see following example code If the controller the network the drive etc is faulty then auxiliary relay K3 is released after a defined delay and causes the energy feed to the motor to be cut off Pressing stop switch S2 cat 1 stop function basically triggers the same procedure but is handled differently by the software separate digital input Stop This guarantees that the energy feed to the motor is definitely switched off afterwards If you open and lock stop switch S2 restart is inhibited Example Code Trigger the stop command via CAN bus or ETHERNET Powerlink if stop active Movement stop not active Test stop inputs else if EmergencyStop ncLOW Movement stop with parameter set for emergency stop activated stop_index E_STOP_INDEX step MOV_STOP stop_active 1 else if Stop ncLOW Movement stop with parameter set for stop activated stop_index STOP_INDEX step MOV_STOP stop_active 1 Movement stop was activated 132 if EmergencyStop ncHIGH amp amp Stop ncHIGH amp amp step W_MOV_STOP Movement stop completed sto
190. supply failure reference signal can be recognized During start up the AC122 module is automatically identified by the ACOPOS operating system Making automatic adjustments to the motor resolution parameter and reading the motor parameters and limit values is not possible because the resolver does not have parameter memory like the EnDat encoder If the precision resolution bandwidth or ease of setting parameters is not sufficient with the resolver the EnDat system should be used see section 2 5 AC120 EnDat Encoder Interface on page 49 2 6 2 Order Data Model Number Short Description Image Plug in Module 8AC122 60 2 ACOPOS plug in module resolver interface Accessories 8CR005 12 1 Resolver cable length 5m 3 x 2 x 24 AWG 19 resolver connector 12 pin Intercontec socket servo plug 9 pin DSUB plug can be used in cable drag chains UL CSA listed 8CR007 12 1 Resolver cable length 7m 3 x 2 x 24 AWG 19 resolver connector 12 pin Intercontec socket servo plug 9 pin DSUB plug can be used in cable drag chains UL CSA listed 8CR010 12 1 Resolver cable length 10m 3 x 2 x 24 AWG 19 resolver connector 12 pin Intercontec socket servo plug 9 pin DSUB plug can be used in cable drag chains UL CSA listed 8CR015 12 1 Resolver cable length 15m 3 x 2 x 24 AWG 19 resolver connector 12 pin Intercontec socket servo plug 9 pin DSUB plug can be used in cable drag chains UL CSA listed 8CR020
191. ted Starting Up an ACOPOS Servo Drive ACP10SYS is now enabled shown in black instead of gray and is also transferred the next time the project is downloaded B amp R Automation Studio File Edit View Insert Open Project Object Tools Window 2 OSH aloe xs Ea 49 9 2 acp10 Project lol Model no Software Log book CAN 1 0 TPU Permanent Description Ele ACPIO Module Name Version Transfer to E 2009 BP CPU NITCPA EB 710 2S Cycle tt 10 ms 3 01 AE a tot v0 00 User RAM 7676 J 02 fd axtste 16265 3 03 acplOmanh 22476 9 04 libacpl man a 2188 9 1 c System Ede giis 001 3 syscont v227 UserROM 752 ek 7i acpl clg V0472 UserROM 212 Ge SACT20 601 2 y User ROM J 3 w gcloader vi3l UserROM 5816 3 4 ncglobal v017 UserROM 8020 3 M acpl man v0472 UserROM 66388 4 acpl par v0472 UserROM 15700 RO ACP10 Real Axis Tu aw par V0 00 UserRAM 360 H ACPIO Error Text Module LiB acp10etx v0 00 UserROM 54698 R x eee ee el Output Debug Find in Fies Line 10 of 18 Comi CP476 V224 RUN Figure 57 The operating system is also transferred the next time the project is downloaded Information After successfully downloading the operating system the first time Disable can be set again which shortens the download time for projects 2 2 3 Preset Values Concerning Wiring The further procedure depends on the wiring of the digital control inputs
192. terial Wire Colors White white red white blue white green Cable Structure Power Lines Stranding No Shield No Signal Lines Stranding White with white red and white blue with white green Shield Separate shielding for pairs tinned Cu mesh optical coverage 85 6 and foil banding Cable Stranding With filler elements and foil banding Cable Shielding Tinned Cu mesh optical coverage gt 85 and wrapped in isolating fabric Outer Sheathing Material PUR Color Orange similar to RAL 2003 flat Labeling BERNECKER RAINER 4x1 5 2x2x0 75 FLEX BERNECKER RAINER 4x4 0 2x2x1 5 FLEX Electrical Characteristics Conductor Resistance Power Lines lt 14 Q km lt 52 O km Signal Lines lt 29 O km lt 14 O km Insulation Resistance 200 MO per km Isolation Voltage Wire Wire 3kV Wire Shield 1kV Operating Voltage Max 600 V Mechanical Characteristics Temperature Range Moving 10 C to 70 C Static 20 C to 90 C Outer Diameter 12 8 mm 0 4 mm 15 8 mm 0 5 mm Flex Radius 96 mm 118 5 mm Speed lt 4m s Acceleration 60 m s Flex Cycles 3 000 000 Weight 0 26 kg m 0 45 kg m ACOPOS User s Manual Table 34 Technical data for motor cables 1 5 and 4 mm 69 Chapter 2 Technical Data Technical Data Cables 10 and 35 mm motor cables Description Motor Cables 10 mm Motor Cables 35 mm General Information Cable Cros
193. the Watch window Table 102 Output of the recorded data in the Trace window Table 103 Valid Standards for ACOPOS Servo Drives Table 104 Mechanical conditions during operation ese Table 105 Mechanical conditions during transport Table 106 Climate conditions during operation Table 107 Climate conditions temperature during storage Table 108 Climate conditions humidity during storage Table 109 Climate conditions during transport Table 110 Limits for power mains NarmMonics ccccccceeeeeeneeeeeeeeeeeeeeeeeeeseneeeeeeseeeneeeees Table 111 Limit values for commutation notches voltage distortions Table 112 Limit values for voltage changes and deviations sesseeeessss Table 113 Limit values for voltage dips and short term interruptions Table 114 Limit values for asymmetric voltages and frequency changes Table 115 Limits for electrical discharge em naar Table 116 Limits for electromagnetic fields Table T17 Limits for Urs oe eee baee e N ete dnt Table 118 Limits TOI Surge oii etn repito treu iter er eee Table 119 Limits for conducted disturbances radio frequency Table 120 Limits for emissions on the power connections Table 121 Limits for electromagnetic emissions
194. the current position of the motor shaft Before the shaft movement During the shaft movement After the shaft movement ax par netwotk axl_par network 0 le se El axl par netwotk axl_par network 0 ax par network axl_par network 0 Units Units s M Units s iv EY ta ES Units s Table 101 Display of the current position of the motor shaft in the Watch window ACOPOS User s Manual 199 Chapter 6 Getting Started Getting Started Starting Up an ACOPOS Servo Drive The following data concerning shaft movement is displayed in the Trace window Set Speed The acceleration phase the constant speed phase and the braking phase of the shaft movement can be evaluated here Lag Error Units the lag error increases in the acceleration phase of the motor axis thelag error remains constant at a constant speed thelag error decreases in the braking phase Actual stator current quadrature component ul par Current controller Actual stator current quadratu mponent 01 03 02 13 15 08 The various movement phases are represented here inthe acceleration phase of the motor axis high current atconstant speed current is reduced inthe braking phase negative current Table 102 Output of the recorded data in the Trace window 200 ACOPOS User s Manual
195. the mouse pointer on Replace with 7CP476 60 1 e Select this menu item with the left mouse button B amp R Automation Studio File Edit View Insert Open Project Object Tools Window 2 Deng sgpgooxmitcesiamoosot acp10 Project ol Software Log book CAN 1 0 TPU_ Permanent Description SES Module Name Version Transferto Size bytes Description Cj 2003 BP esee em oe Tenues Dent A awe 7CP474 60 1 a 10 ms gt v0 00 User RAM 7676 Ntc 16265 p10manh 22476 3 cpl man a 2188 Efe 81045001 v2 27 UserROM 752 84C110 60 1 beto 0 47 2 UserROM 212 Y 84C120 60 1 i i i 3 T acloader vit UserROM 5816 3 4 Y noglobal v0 17 UserROM 8020 y M M acplOman v0472 UserROM 66388 4 acpl par v047 2 UserROM 15700 THRI ACP10 Real Axis Cy axl_par v0 00 User RAM 360 HE ACP10 Enor Text Module LE acpi 0etx v0 00 UserROM 54696 El Output Debug Find in Fies COMi CP476 V224 RUN Figure 50 Select the command used to replace the CPU from the shortcut menu Acknowledge the change of the CPU by clicking on the OK button Replace module x Replacing a module is potentially dangerous l All data which cannot be adopted will be lost Figure 51 Acknowledge the change of the CPU 178 ACOPOS User s Manual Getting Started Starting Up an ACOPOS Servo Drive User Memory Before downloading the sample project we recommend
196. ti turn 32 lines inductive Max 1 9W E4 EnDat single turn 512 lines Max 1 7 W E5 EnDat multi turn 512 lines Max 2 2 W 8AC122 60 2 Max 1 2 W 8AC123 60 1 Max 7 5 W Depends on the current requirements for the encoder connected 1 8AC130 60 1 Max 0 8 W 8AC131 60 1 Max 1W Table 56 Power consumption of the ACOPOS plug in modules 1 The power consumption of the plug in module can be approximated using the following formula Pmodule W Pencoder W k 0 6 W The power consumed by the encoder Pencoder is calculated from the selected encoder supply voltage 5 V 15 V and the current required PEncoder W Ugncoger V lEncoder A The following values must be used for k k 1 2 with 15 V encoder supply k 1 75 with 5 V encoder supply ACOPOS User s Manual 117 Chapter 4 Dimensioning Dimensioning Configuration of ACOPOS Servo Drives 5 2 24 VDC Current Requirements for the ACOPOS Servo Drive The 24 VDC current requirements has to be regarded differently depending on the size of the ACOPOS servo drive The following estimation can always be used for the ACOPOS 1022 1045 and 1090 1 1 loavoclA loavpo A 24 7 22W 7 9 Pmoauiel WI This estimation can also be used for the ACOPOS 1180 1320 1640 and 128M as long as a mains input voltage is not applied As soon as a mains input voltage is applied to these servo drives the 24 VDC supply voltage is created via the integrated DC bus po
197. ting the ACOPOS Servo Drive sseseeeeeee 171 1 3 Connecting the ACOPOS Servo Drive with a B amp R PLC esee 171 2 Starting Up an ACOPOS Servo Drive sse nennen 172 2 1 General Informaltioh rette Le eibi te etae ede e b te Pe er dd 172 21 1 5ample project eee pena da 173 2 1 2 Preparing the Hardware for Sample Project acp10 gdm sssssss 173 2 2 Start Up veneer tata 174 2 2 1 Load Sample Project etg de e RR De Ute Reed 174 2 2 2 Preset Values for the Sample Project sssee 177 2 2 3 Preset Values Concerning Wiring ssssseeeeneeneeeemen 182 2 2 4 Downloading the Project ssseeeeeneenm emere 188 2 2 5 Test FUNCION iei ee Er hti pede Ev HS voe cL ie ne e eee 191 2 2 6 Starting the Motor Movement ssssseseeeeeeneeennennee nennen 193 Chapter 7 Standards and Certifications 201 1 Valid European Guidelines siisii iaar aaaea ea aE Ea Ta EEEE aE piedete 201 2 XAalid Standards 5 5 rice rna td dde idu dnde decet 201 3 Environmental Limits vio eee d Ud fe e ce t C N 202 3 1 Mechanical Conditions according to IEC 61800 2 see 202 34 T Operation oe n a aci 202 8 1 2 Trans porin oco onere ete o ite oa istae e d ec tcc 202 3 2 Climate Conditions according to IEC 61800 2 sss 202 3 21 Op ration cia 202 EESO
198. tion IEC 60721 3 1 class 1K4 IEC 61800 2 Storage temperature 25 to 55 C Table 107 Climate conditions temperature during storage IEC 60721 3 1 class 1K3 IEC 61800 2 Relative humidity during storage 5 95 non condensing 202 Table 108 Climate conditions humidity during storage ACOPOS User s Manual 3 2 3 Transport Standards and Certifications Environmental Limits IEC 60721 3 2 class 2K3 IEC 61800 2 Transport temperature 25 to 70 C Humidity during transport 95 at 40 C ACOPOS User s Manual Table 109 Climate conditions during transport 203 Chapter 7 Standards and Certifications Standards and Certifications Requirements for Immunity to Disturbances EMC 4 Requirements for Immunity to Disturbances EMC 4 1 Evaluation Criteria performance criteria Criteria A Test object not influenced during test Criteria B Test object only temporarily influenced during test Criteria C The system does not reboot automatically reset required 4 2 Low Frequency Disturbances according to IEC 61800 3 The following limits are valid for industry and environment 4 2 1 Power Mains Harmonics and Commutation Notches Voltage Distortions IEC 61000 2 4 class 3 IEC 61800 3 Performance Criteria Harmonics THD 10 A Short harmonics lt 15 s 1 5x co
199. to Description k CPU dee FHP 7CP474 60 1 0 e Cyclic 1 10 ms 2 SHE axis v0 00 UserRAM 7676 3 02 F axtste 16265 03 E Omanh 22476 J 04 libacpl man a 2188 3 L c System Elf 841045001 syscont v227 UserROM 752 8AC110 60 1 1 3 acpT0ctg v0472 UserROM 212 GF GcI20601 2 it 3 3 gcloader vi3t UserROM 5816 3 4 ncglobal v0 17 UserROM 8020 M acpl man v0472 UserROM 66388 acpl par v0472 UserROM 15700 ra ACPO ue v0 00 User RAM 360 le ym Enor Tex Mode LB acpi0etx vo 00 UserROM 54696 R x li Output Debus Find in Files Software module check Ok Line 16 of 18 Com1 CP476 V224 RUN Figure 48 Project window with representation of the hardware and software configuration The left part of the window contains the hardware configuration for the project and the right part of the window contains the software configuration for the hardware component selected in the left part of the window Information When loading the project a connection is automatically established between the PC and the PLC If the connection is active the CPU type and RUN are shown to the right below the status bar see figure 48 Project window with representation of the hardware and software configuration 176 ACOPOS User s Manual Getting Started Starting Up an ACOPOS Servo Drive 2 2 2 Preset Values for the Sample Project A few preset values must be defined on the target s
200. torque and spins out This guarantees that the energy feed to the motor is immediately switched off If you open and lock stop switch S2 restart is inhibited 130 ACOPOS User s Manual Stop Function for Category 1 Safety Category 3 Type 1 Starting active braking over the network Wiring Secure Restart Inhibit Stop Function Cat 1 Stop Stop Function Cat 1 Emergency Stop Sth7 3 400 480 VAC 50 60 Hz S2bOV 7 1 K3 CI Ll0V EmergencyStop Stop T El Pe A A o g CAN ETHERNET Powerlink a 4 Trigger 1 12 vs Quickstop Trigger 2 e0 COM 1 2 I S Shield End M End T e Ref i ec Enable pis gt Enable X1 0 VI COM 8 9 SF COM 8 9 S n c Lg 24 out 0 54 l MG 24V edt 24V 1890 COM 5 7 13 15 li 1 S0 COM 5 7 13 15 ove COM 5 7 13 15 ACOPOS i F pes mc Slot 2 Slot 3 Slot 4 Figure 33 Type 1 Starting active braking over the network 1 The drop out time lag corresponds to the requirements of the application The K3 auxiliary relay with drop out time lag is a part of the safety function Therefore K3 must meet safety category 3 2 The network connection is used to transfer the interruption command for active braking for diagnosis and setting parameters 3 For servo drives which have no 24 VDC output ACOPOS 1022 1045 1090 the control voltage mu
201. ts for resolver cable ACOPOS User s Manual 6 3 3 Cable Schematic Wiring Cables Circular Plug PSU ink AWG 24 E Ref 9o f i a P nn ray AWG 24 Ref 504 i gray MS n ellow AWG 24 1 Cos 704 A y E ze EA reen AWG 24 rdg Cos 3o 1 g ES i E white AWG 24 E en 5i E 73 tt o4 E b AWG 24 H Sim 8o rown E a o pi i ne o 1 aie par ee ne to 6 i aies 11 4 nc 10 e4 nc 12 94 nc Shield connected to ERE plug housing ACOPOS User s Manual Figure 43 Cable schematic for resolver cables 169 Chapter 5 Wiring Wiring Cables 170 ACOPOS User s Manual Getting Started Preparation Chapter 6 Getting Started 1 Preparation 1 1 Unpacking the ACOPOS Servo Drive Remove the protective packaging from the ACOPOS servo drive Check the ACOPOS servo drive for obvious mechanical damage Danger Do not operate the ACOPOS servo drive if it is damaged This can cause severe personal injury or damage to property 1 2 Installing and Connecting the ACOPOS Servo Drive The guidelines and specifications for installing and wiring the respective ACOPOS servo drive can be found in chapter 3 Installation chapter 4 Dimensioning and chapter 5 Wiring 1 3 Connecting the ACOPOS Servo Drive with a B amp R PLC Depending on the configuration ACOPOS servo drives are equipped with a CAN AC110 or ETHERNET Powerli
202. upply and electronic secure restart inhibit integrated 1 8V128M 00 2 Servo drive 3 x 400 480V 128A 64kW line filter braking resistor DC bus power supply and electronic secure restart inhibit integrated 1 Accessories 8AC110 60 2 ACOPOS plug in module CAN interface 8AC112 60 1 ACOPOS plug in module ETHERNET Powerlink interface 8AC120 60 1 ACOPOS plug in module EnDat encoder interface 8AC122 60 2 ACOPOS plug in module resolver interface 8AC123 60 1 ACOPOS plug in module incremental encoder and SSI absolute encoder interface 8AC130 60 1 ACOPOS plug in module 8 digital I O configurable in pairs as 24V input or as output 400 100mA 2 digital outputs 2A Order TB712 terminal block separately 8AC131 60 1 ACOPOS plug in module 2 analog inputs 10V 2 digital I O points which can be configured as 24V input or 45mA output 0PS320 1 24VDC power supply 3 phase 20 A input 400 500 VAC 3 phases wide range DIN rail mounting a qa en um ACOPOS 1640 Table 12 Order data for ACOPOS 1640 128M 1 Integrated line filter in preparation 1 6 2 Technical Data Product ID 8V1640 00 2 8V128M 00 2 General Information C UL US Listed Yes Power mains connection Mains Input Voltage 3 x 400 VAC to 480 VAC 10 Power filter according to IEC 61800 3 A11 second environment Limits from CISPR11 Group 2 Class A 1 Frequency 50 60 Hz 4 Installed Load Max 54 kVA Max
203. ure 4 Simple function test ACOPOS User s Manual 19 Chapter 1 General Information General Information e ACOPOS 1 9 Control Trigger The oscilloscope in the drive allows movements to be monitored in real time Many trigger possibilities allow data required for analysis to be easily obtained The graphic display of diagnosis data supports the user when making fine adjustments and when optimizing the movement Measurement cursor and reference points allow us precision 8 B amp R Automation Studio lala ax4 waf Trace lej x TI File Edi View Open Project Trace Object Tools Window 2 zie x EES ES SCA 18 100 100 Current controller Current quadrature component x pos 0 980400 y pes 2 537068 yorms 1 776940 Ks sante hgn o orra E Srta A asco on of motor chai iee i ag i c Me For Help press F1 COM OFFLINE Figure 5 Control trigger 20 ACOPOS User s Manual General Information e ACOPOS 1 10 Cam Profiles for Everyone Modular technology plug ins allow homogenous integration of high performance tools such as the Cam Editor The mouse is used to define fixed points synchronous sections or interpolations Effects of positioning behavior on speed acceleration and jolt for the slaves axes connected can be monitored directly B amp R Automation Studio cam_vor2 waf Cam ex File Edit View Insert Open Project Object Tools Window
204. ut No Switching Voltage Minimum 18 VDC Nominal 24 VDC Maximum 30 VDC Continuous Current Outputs 1 4 Max 100 mA Outputs 5 8 Max 400 mA Outputs 9 10 Max 2 A Switching Delay 0 gt 1 and 1 gt 0 Outputs 1 4 Max 5 us Outputs 5 8 Max 50 us Outputs 9 10 Max 500 ys Switching Frequency resistive load Outputs 1 2 Max 10 kHz max 20 kHz in PWM mode Outputs 3 4 Max 10 kHz Outputs 5 8 Max 5 kHz Outputs 9 10 Max 100 Hz PWM Outputs 1 2 Resolution of the Pulse Width 13 bit Period Duration 50 us 400 us Protection Short Circuit Protection Yes Overload Protection Yes Table 30 Technical data for AC130 cont 60 ACOPOS User s Manual Technical Data e ACOPOS Plug in Modules Operation Product ID 8AC130 60 1 Short Circuit Current at 24 V until cut off Outputs 1 4 Approx 1 A Outputs 5 8 Approx 1 2A Outputs 9 10 Approx 24 A Readable Outputs Yes Operational Conditions Environment Temperature during 0 to 50 C Relative Humidity during Operation 5 to 95 non condensing Storage and Transport Conditions Storage Temperature 25 to 55 C Relative Humidity during Storage 5 to 95 non condensing Transport Temperature 25 to 70 C Relative Humidity during Transport 95 at 40 C Table 30 Technical data for AC130 cont 1 The AC130 can also be used as an encoder module Several encoder modules c
205. value for the maximum over temperature of the external braking resistor is not given it can be determined using the following formula Termo P Rs Par 1 An example of reliable braking resistors are SIGMA type braking resistors from Danotherm www danotherm com Dimensioning Configuration of ACOPOS Servo Drives 5 Configuration of ACOPOS Servo Drives The plug in modules for ACOPOS servo drives allow each servo drive to be individually configured according to the requirements of the application When putting together plug in module combinations the power consumption must be checked This then results in the current requirements of the ACOPOS servo drive configuration 5 1 Maximum Power Output via the Four ACOPOS Servo Drive Slots The maximum power output for all four slots is 22 W The total power consumption for all plug in modules must be less than or equal to the maximum power output Pmax 22W2 y Pmoduiel W The power consumption of the individual modules can be found in table 56 Power consumption of the ACOPOS plug in modules or the technical data for the modules see chapter 2 Technical Data Plug in module Power Consumption 8AC110 60 2 Max 0 7 W 8AC112 60 1 Max 2 5 W 8AC120 60 1 Depends on the EnDat encoder connected EO EnDat single turn 512 lines Max 1 8 W E1 EnDat multi turn 512 lines Max 2 5 W E2 EnDat single turn 32 lines inductive Max 2 2 W E3 EnDat mul
206. vidual I O Configurations sssssseeseeeeeeenenennen nennen nennen neni 17 1 4 Configuring instead of Programming oooconccconccnnccnnncnnncnnnnncnona non cnn nn n rn cinc 17 1 5 EdSy SONICO uta dde 17 1 6 Software and Hardware as a Unit nennen 18 1 7 Plain Text for Functlons e Re ROO Rt e ee EUR ERR 18 1 8 Simple F nction Test nih e ree tie oS e Eg UR Ser redd ii 19 1 9 Control TAJO ica ROI PUE DD UP BEER e 20 1 10 Cam Profiles for Everyone sss nennen nnne enne reni 21 2 ACOPOS Configurations n tere HR ER CERE RE RU aAa aR iE a 22 2 1 General Information snis aeara aaa aaa cnn entren nne enne eterne nnn reni 22 2 2 CAN iii A E M 22 2 21 Configuration Morada ne eidem eee YER cd ree pdt ede gk eue tu sca 22 2 2 2 Config ratiori 2 x 5 etate Date E Ald ER Ce D has eh evn 23 2 3 POWSMIN acre 3 tco eph teret aca te tes dle rtf ette res tut e tete 24 2 3 1 Recommended Topology ccooccccoccccnonacinnnnconnonnco nono nnnnonnnnnnn o rr nn eem ener nennen 24 2 3 2 Configuration T i citi ce i e i Pee e ERR did 24 2 39 39 Config rationa cat ii RR Ru Ne acetals 25 3 Safety Guidelines iu etie Din doe ERROR COUR ERR UR OMA 26 3 1 General Information 1 uc a ada Sa lobe C Cement 26 3 2 Intended Use cinc EC RP dea 26 3 3 Transport and Storage 2 1 e a etes ted tue Die evi meos 27 3 4 Installation i rt HEREIN ERO UD UI PR He RR ARS 27 3 5 Operational 27 3 5 1 Pr
207. w clamps 7TB712 91 Terminal block 12 pin cage clamps 7TB712 90 02 Terminal block 12 pin 20 pcs screw clamps 7TB712 91 02 Terminal block 12 pin 20 pcs cage clamps 62 Table 31 Order data for AC131 ACOPOS User s Manual 2 9 3 Technical Data Technical Data e ACOPOS Plug in Modules Product ID 8AC131 60 1 General Information C UL US Listed Yes Module Type ACOPOS plug in module Slot Slots 2 3 and 4 Power Consumption Max 1 W Inputs Outputs Connection Module Side 12 conductor pin connector Configuration of the Digital Inputs Outputs Can be configured individually as digital input or output LEDs 24 V LED Supply Voltage Power Supply Minimum 18 VDC Nominal 24 VDC Maximum 30 VDC Reverse Polarity Protection Yes Voltage Monitoring 24 V LED Yes supply voltage gt 18 V Digital Inputs Potential Number of Inputs Max 2 Wiring Sink Electrical isolation Input ACOPOS Yes Input Input No Input Voltage Minimum 18 VDC Nominal 24 VDC Maximum 30 VDC Switching Threshold LOW lt 5V HIGH gt 15V Input Current at Nominal Voltage Approx 8 mA Switching Delay Counters Max 5 us Digital Input Max 55 ys digitally filtered Modulation Compared to Ground Max x50 V Event Counter Signal Form Square wave pulse Input Frequency Max 100 kHz Counter Size 16 bit Inputs Input 1 Counter 1 I
208. wer supply the 24 VDC current requirements lo4ypc is then reduced to O The 24 VDC maximum current requirements for the ACOPOS servo drives can be found in table 57 Maximum current requirements and constant k or the technical data for the ACOPOS servo drives see chapter 2 Technical Data Description ACOPOS 1022 1045 1090 1180 1320 1640 128M l2avDO 0 25 28 k 0 64 0 63 a 1 Table 57 Maximum current requirements and constant k 1 In preparation Dimensioning Formula Variables Used 6 Formula Variables Used Chapter 4 Dimensioning Symbol Unit Description Cp F Discharge capacitance Car Ws C Heat capacitance of the filament k General constants frang Hz Mains frequency loaavoc A 24 VDC current requirements 124VDC mo A 24 VDC maximum current requirements la A Discharge current via protective ground conductor PE lg A Rated current for overcurrent protection lmains A Mains current phase current la A Thermal equivalent current effective value lz A Maximum current load on a cable M Nm Torque general Mag Nm Effective load torque for a cycle n min Speed general Naver min Average speed for a cycle 0 rad s Rotational Speed P Ww Power or true power general Par Ww Brake power Pp ax Ww Maximum brake power Braver W Average brake power PR s Ww Maximum load on th
209. wer connection Lines for measurement and control functions in the process environment Signal interfaces other lines 0 15 80 MHz 10 V 80 amplitude modulation at 1 kHz Table 119 Limits for conducted disturbances radio frequency 206 ACOPOS User s Manual Standards and Certifications Requirements for Emissions EMC 5 Requirements for Emissions EMC 5 1 High Frequency Emissions according to IEC 61800 3 These emissions tests are valid for industrial environments 2 environment 5 1 1 Emissions on the Power Connections Tests according to IEC 55011 Continuous Current on Frequency Range MHz Quasi peak Value Average Motor 0 15 f 0 5 100 dB V 90 dB uV 1x 100A 05xf 5 86 dB uV 76 dB uV 5 lt f lt 30 90 dB uV 80 dB uV 0 15 f 0 5 130 dB V 120 dB V 100A 1 05xf 5 125 dB uV 115 dB V 5 lt f lt 30 115 dB uV 105 dB uV Table 120 Limits for emissions on the power connections 5 1 2 Electromagnetic Emissions Tests according to IEC 55011 Frequency Range MHz Quasi peak Value 30x f lt 230 40 dB V m measured at distance of 30 m 1 230 lt f lt 1000 50 dB V m measured at distance of 30 m 1 Table 121 Limits for electromagnetic emissions 1 The limit values were increased by 10 dB uV m when measuring from distances of 10 m ACOPOS User s Manual 207 Chapter 7 Standards and Ce
210. y and equally distributed on the braking resistors when a DC bus connection is made between several units 4 4 1 Using the Integrated Braking Resistors No settings or configuration is required by the user ACOPOS User s Manual 115 Chapter 4 Dimensioning Dimensioning Braking Resistor 4 4 2 Using External Braking Resistors When using external braking resistors the following parameters must be set on the ACOPOS servo drive using B amp R Automation Studio ParlD Formula Symbols Description Unit 10 Rer Ohmic resistance 9 11 Tor x Maximum over temperature on the external braking resistor C 12 Rar Thermal resistance between braking resistor and the environment 1 CM 13 Car Heat capacitance of the filament 2 Ws C Table 55 ParlDs for setting external braking resistor parameters 1 Total thermal resistance for series or parallel connections of several ngr of the same braking resistors Par Br Total Dp 2 Total heat capacitance of the filament for series or parallel connections of several ngr of the same braking resistors n Brr otal Cary Br The parameters can normally be found on the data sheet from the manufacturer p The parameters are based on the following thermal equivalent circuit for the external braking resistor Eu URS cet ios Figure 28 Thermal equivalent circuit for the external braking resistor If a
211. y for operation and the power level can be enabled operating system present and booted no permanent or temporary errors Run Orange Lit as soon as the power level is enabled for the ACOPOS servo drive Error Red Lit when a permanent or temporary error exists on the ACOPOS servo drive After correcting the error the LED is automatically switched off Examples of permanent errors Motor feedback not connected or defective Low level on the enable input Motor temperature sensor not connected or defective Internal error on the device e g IGBT heat sink temperature sensor defective Examples of temporary errors 24 VDC supply voltage exceeds the tolerance range DC bus voltage exceeds the tolerance range Internal 15 VDC control voltage exceeds the tolerance range IGBT current limit reached Over temperature on the motor temperature sensor Over temperature on the servo drive IGBT junction heat sink conductive tracks Over temperature on braking resistor CAN or Powerlink network faulty Table 4 LED status 1 3 1 LED Status The following timing is used for the indication diagrams Block size 125 ms Repeats after 3000 ms Status changes when booting the operating system loader Status LED Display Green 1 Boot procedure for basic hardware active Orange Red Green 2 Configuration of network plug in module active Orange Red Green 3 Waiting for network telegram Orang
212. ystem before downloading the project CPU The sample project was originally created for a different PLC CPU 7CP474 60 1 This must be changed to the CPU used on the target system shown to the right under the status bar In the left part of the window position the mouse pointer on the CPU 7CP474 60 1 Software Log book CAN 1 0 TPU_ Permanent Description B amp R Automation Studio 2 x File Edi View Insert Open Project Object Tools Window 2 Dc Hg roo xP FSE ao 9 2 acp10 Project n Module Name gl CPU ax stc acplOmanh libacpl man Fe Syst Efe 8v1045 001 El BACI10 601 1 Suo M BACI0801 2 3 4 M Y acpl0ctg gcloader Y ncolobal 4 acpl man acpl par FHR ACP10 Real Axis 8 al par HD ACP10 Error Text Module LB acpi etx v0 00 V2 27 0 47 2 v1 31 V0 17 V0 47 2 V0 47 2 v0 00 v0 00 Transfer to User RAM User ROM User ROM M User ROM User ROM User ROM User ROM User RAM User ROM Size bytes 7676 16265 22476 2188 752 212 5816 8020 66388 15700 360 54696 Description E _Dupu Debug Fndin Fies COMI CP476 V224 IRUN Figure 49 Select the CPU in the left part of the window ACOPOS User s Manual 177 Chapter 6 Getting Started Getting Started Starting Up an ACOPOS Servo Drive Open the shortcut menu with the right mouse button Position

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