Technical Documentation Product manual AC servo drive LXM05A Document: 0198441113232 Edition: V1.04, 01.2006 LXM05A Important information The drive systems described here are products for general use that con- form to the state of the art in technology and are designed to prevent any dangers. However, drives and drive controllers that are not specifically designed for safety functions are not approved for applications where the functioning of the drive could endanger persons. The possibility of unexpected or unbraked movements can never be totally excluded wit- hout additional safety equipment. For this reason personnel must never be in the danger zone of the drives unless additional suitable safety equipment prevents any personal danger. This applies to operation of the machine during production and also to all service and maintenance work on drives and the machine. The machine design must ensure per- sonal safety. Suitable measures for prevention of property damage are also required. See safety section for additional critical instructions. Not all product variants are available in all countries. Please consult the current catalogue for information on the availability of product variants. We reserve the right to make changes during the course of technical de- velopments. All details provided are technical data and not promised characteristics. In general, product names must be considered to be trademarks of the respective owners, even if not specifically identified as such. 0198441113232, V1.04, 01.2006 -2 AC servo drive LXM05A Table of Contents Important information. -2 Table of Contents . -3 Writing conventions and symbols. -9 1 Introduction 1.1 Unit overview. 1-1 1.2 Components and interfaces . 1-2 1.3 Type code . 1-3 1.4 Documentation and literature references . 1-3 1.5 Directives and standards. 1-3 1.6 Declaration of conformity. 1-5 1.7 TÜV certificate for functional safety. 1-6 2 Safety 2.1 Qualification of personnel . 2-1 2.2 Intended use . 2-1 2.3 General safety instructions . 2-2 2.4 Safety functions. 2-3 2.5 Monitoring functions . 2-3 3 Technical Data 3.1 Testing agencies and certificates . 3-1 3.2 Environmental conditions . 3-1 3.2.1 Degree of protection . 3-2 3.3 Mechanical data . 3-3 3.3.1 Dimensional drawings. 3-3 3.4 Electrical Data . 3-4 3.4.1 Performance data for power amplifier. 3-4 3.4.2 24VDC controller power supply . 3-6 3.4.3 Signals . 3-6 3.4.4 Safety functions . 3-7 3.4.5 Braking resistor. 3-8 3.4.6 Internal mains filter . 3-9 3.5 Technical Data accessories. 3-10 3.5.1 External braking resistors . 3-10 3.5.2 Line reactor. 3-10 3.5.3 External mains filter . 3-10 3.5.4 Holding brake controller HBC . 3-10 3.5.5 Reference value adapter RVA. 3-11 0198441113232, V1.04, 01.2006 AC servo drive -3 LXM05A 3.5.6 Cable . 3-12 4 Basics 4.1 Safety functions . 4-1 5 Engineering 5.1 Logic type . 5-1 5.2 Specification of the control mode . 5-2 5.3 Safety function "Power Removal" . 5-2 5.3.1 Definitions . 5-2 5.3.2 Function . 5-2 5.3.3 Requirements for safe application . 5-3 5.3.4 Application examples . 5-4 6 Installation 6.1 Electromagnetic compatibility, EMC . 6-1 6.1.1 Operation in an IT mains . 6-5 6.2 Mechanical installation . 6-6 6.2.1 Mounting the device. 6-7 6.2.2 Installing mains filter, mains reactor and braking resistor . 6-9 6.3 Electrical installation . 6-11 6.3.1 Overview of procedure. 6-13 6.3.2 Overview of all connections . 6-14 6.3.3 Reference value signals and limits. 6-16 6.3.4 Motor phase connections. 6-16 6.3.5 Connection of braking resistor . 6-20 6.3.6 Connection of power amplifier supply voltage . 6-26 6.3.7 Connection for parallel operation . 6-28 6.3.8 Connection of motor encoder (CN2) . 6-28 6.3.9 Connection of holding brake controller (HBC) . 6-31 6.3.10 Connection of controller supply voltage (24V at CN3) . 6-33 6.3.11 Connecting encoder signals A, B, I (CN5) . 6-35 6.3.12 PULSE (CN5) connection . 6-36 6.3.13 Connection of encoder simulation (CN5) . 6-39 6.3.14 CANopen connection (CN1 or CN4) . 6-41 6.3.15 Modbus connection (CN4) . 6-43 6.3.16 Connection of analogue inputs (CN1) . 6-43 6.3.17 Connection of digital inputs/outputs (CN1) . 6-45 6.3.18 Connection to PC or remote terminal (CN4) . 6-47 6.3.19 Reference value adapter . 6-49 6.4 Checking installation. 6-52 7 Commissioning 7.1 General safety instructions . 7-1 7.2 Overview. 7-4 0198441113232, V1.04, 01.2006 -4 AC servo drive LXM05A 7.3 Tools for commissioning . 7-5 7.3.1 Overview. 7-5 7.3.2 HMI: Human-Machine Interface . 7-6 7.3.3 Commissioning software (PowerSuite) . 7-11 7.4 Commissioning procedure. 7-13 7.4.1 "First Setup" . 7-13 7.4.2 Operating status (state diagram) . 7-18 7.4.3 Setting basic parameters and limit values . 7-19 7.4.4 Analogue inputs . 7-21 7.4.5 Digital inputs/outputs . 7-24 7.4.6 Testing limit switches signals in fieldbus devices . 7-26 7.4.7 Testing safety functions . 7-27 7.4.8 Checking holding brake . 7-28 7.4.9 Check direction of rotation . 7-29 7.4.10 Setting parameters for encoder simulation . 7-30 7.4.11 Setting parameters for encoder . 7-31 7.4.12 Setting parameters for braking resistor. 7-33 7.4.13 Run autotuning . 7-35 7.4.14 Extended settings for autotuning . 7-37 7.5 Controller optimisation with step response . 7-39 7.5.1 Controller structure . 7-39 7.5.2 Optimisation . 7-40 7.5.3 Optimising the speed controller . 7-41 7.5.4 Checking and optimising default settings . 7-45 7.5.5 Optimising the position controller . 7-47 8Operation 8.1 Control mode and operating mode management . 8-1 8.2 Access monitor . 8-2 8.2.1 via HMI . 8-2 8.2.2 via fieldbus . 8-3 8.2.3 via commissioning software . 8-3 8.2.4 via hardware input signals . 8-3 8.3 Operating states . 8-4 8.3.1 Status diagram . 8-4 8.3.2 Changing operating states . 8-8 8.3.3 Displaying the operating states. 8-10 8.4 Starting and changing operating modes . 8-12 8.4.1 Start operating mode . 8-12 8.4.2 Change operating mode . 8-13 8.5 Operating modes. 8-15 8.5.1 Jog operation mode . 8-15 8.5.2 Current control operating mode . 8-17 8.5.3 Speed control operating mode . 8-19 8.5.4 Electronic gear operation mode . 8-21 8.5.5 Profile position operating mode . 8-25 8.5.6 Operation mode Profile velocity . 8-29 8.5.7 Operation mode Homing. 8-31 0198441113232, V1.04, 01.2006 AC servo drive -5 LXM05A 8.6 Functions . 8-45 8.6.1 Monitoring functions. 8-45 8.6.2 Scaling . 8-57 8.6.3 Movement profile . 8-60 8.6.4 Quick Stop . 8-63 8.6.5 Halt. 8-64 8.6.6 Fast position capture . 8-65 8.6.7 Standstill window . 8-68 8.6.8 Braking function with HBC . 8-69 8.6.9 Reversal of direction of rotation . 8-71 8.6.10 Restoring default values. 8-73 9 Examples 9.1 Wiring of local control mode . 9-1 9.2 Wiring of fieldbus control mode . ..