Schneider Electric Network Router 17S Series User Guide

Modicon

Lexium 17S Series SERCOS Servo Drive

User Guide

890 USE 121 00 Eng

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Preface

The data and illustrations found in this book are not binding. We reserve the right to

modify our products in line with our policy of continuous product development. The

information in this document is subject to change without notice and should not be

construed as a commitment by Schneider Electric.

Schneider Electric assumes no responsibility for any errors that may appear in this

document. If you have any suggestions for improvements or amendments or have

found errors in this publication, please notify us.

No part of this document may be reproduced in any form or by any means,

electronic or mechanical, including photocopying, without express written

permission of the Publisher, Schneider Electric.

CAUTION!

All pertinent state, regional, and local safety regulations must be observed when

installing and using this product. For reasons of safety and to assure compliance

with documented system data, repairs to components should be performed only by

the manufacturer.

Failure to observe this precaution can result in injury or equipment damage.

MODSOFT® is a registered trademark of Schneider Electric.

(SERCOS interface is a trademark of SERCOS Interface, Inc., promotion society.)

The following are trademarks of Schneider Electric:

Modbus Modbus Plus

Modicon Quantum 984 Concept

IBM® and IBM AT® are registered trademarks of International Business Machines

Corporation.

Microsoft®, MS-DOS®, Windows®, Windows 95®, Windows 98® and

Windows NT® are registered trademarks of Microsoft Corporation.

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Preface

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Contents

Chapter 1 Introduction

At a Glance......................................................................................................

Document Scope .......................................................................................

What’s in this Chapter ...............................................................................

About this User Guide ....................................................................................

Who Should Use this User Guide .............................................................

How this User Guide Is Organized ............................................................

Related System Components .........................................................................

SERCOS Multi-Axis Motion Control System .............................................

UniLink Commissioning Software for 17S .................................................

Related Documentation ..................................................................................

Documents.................................................................................................

Hazards, Warnings and Guidelines.................................................................

Hazards and Warnings .............................................................................

Additional Safety Guidelines......................................................................

Qualified Personnel ...................................................................................

Standards and Compliances .......................................................................... 10

European Directives and Standards ......................................................... 10

EC Directive Compliance .......................................................................... 10

SERCOS Standard ...................................................................................

UL and cUL Compliance ...........................................................................

Conventions ....................................................................................................

Acronyms and Abbreviations .................................................................... 12

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Contents

Chapter 2 Product Overview

At a Glance......................................................................................................

Introduction ...............................................................................................

What’s in this Chapter ...............................................................................

The 17S Series SERCOS Drive Family .........................................................

Introducing the 17S SERCOS Drive Family .............................................

Drives Available ........................................................................................

Implementing the Drives ...........................................................................

Applicable Servo Motor Types ..................................................................

Electrical Considerations ..........................................................................

17S Drive Family Portrait ..........................................................................

17S Drives Front View ..............................................................................

Equipment Supplied ..................................................................................

Equipment Available .................................................................................

17S System Configuration Diagram .........................................................

Modicon Multi-Axis Motion SERCOS Network Configuration .........................

Overview ...................................................................................................

Which Motion Controllers run a SERCOS Network ..................................

SERCOS Fiber- Optic Transmit and Receive Connectors ........................

Example of a Typical SERCOS Network Ring Configuration ...................

Benefits of Fiber-Optic Communication ....................................................

Two Types of Fiber-Optic Communication ...............................................

Digital Control ...........................................................................................

Usability Enhancements ...........................................................................

Overview of 17S Internal Electronics .............................................................

17S Internal Electronics Block Diagram ...................................................

General Characteristics ............................................................................

Primary Power ..........................................................................................

Bias Power ................................................................................................

EMI Suppression ......................................................................................

Internal Power Section ..............................................................................

DC Link Capacitor Reconditioning ............................................................

Integrated Safe Electrical Separation .......................................................

Keypad ......................................................................................................

LED Display and Discrete Indicators ........................................................

Overview of System Software ........................................................................

Setup ........................................................................................................

Setting Parameters ...................................................................................

Default Settings ........................................................................................

UniLink Commissioning Software .............................................................

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Contents

Chapter 3 Mounting and Physical Dimensions

At a Glance...................................................................................................... 33

What’s in this Chapter ............................................................................... 33

Installation Safety Precautions .......................................................................

Power Supply Overcurrent Protection .......................................................

Earth Connections .................................................................................... 36

Cable Separation ...................................................................................... 36

Air Flow ..................................................................................................... 36

Drive Mounting and Physical Dimensions ......................................................

17S Height, Width and Depth Dimensions ................................................

17S Drive and Mounting Area Dimensions ...............................................

Optional External Regen Resistor Assembly Dimensions .........................

Optional Motor Choke Assembly Dimensions ...........................................

Chapter 4 Wiring and I/O

At a Glance...................................................................................................... 41

Introduction ............................................................................................... 41

What’s in this Chapter ............................................................................... 42

Wiring and I/O Initial Considerations .............................................................. 43

Initial Considerations .................................................................................

Grounding .................................................................................................

Wiring Overview .............................................................................................

Overview of 17S Wiring Connections ........................................................ 44

Cable Shield Connections .............................................................................. 47

Connecting Cable Shields to the Front Panel ...........................................

Cable Shield Connection Diagram ............................................................

Power Wiring ..................................................................................................

AC Mains Power Supply Connection ........................................................ 49

Bias Supply Connection ............................................................................ 49

Serial Power Connections ......................................................................... 50

Optional External Regen Resistor Connection ......................................... 51

Regen Circuit Functional Description......................................................... 51

Lexium BPH Servo Motor Connection (excluded BPH055) ...................... 52

Lexium BPH 055 Servo Motor Connection................................................

Servo Motor (with Optional Dynamic Brake...............................................

Resistors and Contactor) Connection .......................................................

Servo Motor Holding-Brake Control Functional Description ...................... 55

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Contents

Signal Wiring ..................................................................................................

Lexium BPH Resolver Connection (excluded BPH055) ...........................

Lexium BPH055 Resolver Connection .....................................................

Encoder Input Connection ........................................................................

Auxiliary Encoder Interface .......................................................................

Analog Input Connection ................................................................................

Analog Inputs ............................................................................................

Fault Relay and Digital I/O Connection ..........................................................

Digital Inputs and Outputs ........................................................................

Using Functions Pre-programmed into the Drive ......................................

Serial Communications Connection ...............................................................

RS-232 Null Modem Type Communication Connection Diagram .............

Chapter 5 System Operation

At a Glance......................................................................................................

What’s in this Chapter ...............................................................................

Powering Up and Powering Down the System ...............................................

Power-on and Power-off Characteristics ..................................................

Stop Function ............................................................................................

Emergency Stop strategies .......................................................................

Wiring example .........................................................................................

Procedure for Verifying System Operation .....................................................

Overview ...................................................................................................

Quick Tuning Procedure ...........................................................................

Front Panel Controls and Indicators ...............................................................

Keypad Operation .....................................................................................

LED Display ..............................................................................................

SERCOS Communication LED Indicators ................................................

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Contents

Chapter 6 Troubleshooting

At a Glance...................................................................................................... 75

What’s in this Chapter ............................................................................... 75

Warning Messages ......................................................................................... 76

Warning Identification and Description ......................................................

Error Messages ..............................................................................................

Error Identification and Description ...........................................................

Troubleshooting............................................................................................... 81

Problems, Possible Causes and Corrective Actions.................................. 81

Appendix A Specifications

At a Glance...................................................................................................... 83

What’s in this Appendix .............................................................................

Performance Specifications.............................................................................

Performance Specifications Table ............................................................

Environmental and Mechanical Specifications ................................................

Environmental Specifications Table...........................................................

Mechanical Specifications Table ............................................................... 86

Electrical Specifications...................................................................................

What’s in this Section ................................................................................

Electrical Specifications - Power .................................................................... 88

Line Input Specifications Table .................................................................

Bias Input Specifications Table .................................................................

External Fuse Specifications Table ...........................................................

Motor Output Specifications Table ............................................................

Internal Power Dissipation Specifications Table........................................ 91

Electrical Specifications - Regen Resistor ......................................................

Regen Circuit Specifications .....................................................................

Electrical Specifications - Signal .....................................................................

Motor Overtemperature Input Specifications Table .................................. 93

Resolver Input Specifications Table ..........................................................

Encoder Input Specifications Table ...........................................................

Emulated Encoder Output (Incremental Format) Specifications Table...... 94

Encoder Output (Incremental Format) Timing Diagram ............................ 95

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Auxiliary Incremental Encoder Input Specifications Table ........................

Discrete Input Specifications Table ..........................................................

Discrete Output Specifications Table ........................................................

Fault Relay Output Specifications Table ...................................................

Brake Output Specifications Table ...........................................................

Analog Input Specifications Table ............................................................

Serial Communications Specifications Table ............................................

Wire Specifications ...................................................................................

Appendix B Parts List

At a Glance...................................................................................................... 101

What’s in this Appendix ............................................................................ 101

Lexium 17S Drives ......................................................................................... 102

Drives Available ........................................................................................ 102

External 24Vdc supply .................................................................................... 103

External 24Vdc supply .............................................................................. 103

Drive Cables ................................................................................................... 104

Drive to Motor Cables .............................................................................. 104

RS-232 Serial Communications Cable Part Table .................................... 104

Encoder Output Cable Parts Table ........................................................... 104

Fiber Optic Cables Parts Table ................................................................. 105

Optional External Regen Resistor Assemblies ............................................... 106

Optional Regen Resistor Assembly Part Table ......................................... 106

Optional Motor Choke ..................................................................................... 107

Optional Motor Choke Part Table .............................................................. 107

Spare Parts ..................................................................................................... 108

Spare Parts Table...................................................................................... 108

Appendix C Cable Connection Wiring Diagrams

At a Glance...................................................................................................... 109

What’s in this Appendix ............................................................................ 109

Wiring a Sub-D Connector with Shielding ...................................................... 110

Wiring the Sub-D Connector...................................................................... 110

Sub-D Connector Diagram ....................................................................... 111

Wiring the Motor Power Connector (Drive end) ............................................. 112

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Wiring the Motor Power Connector ........................................................... 112

Motor Power Connector (Drive end) Diagram (excluded BPH055) ........... 113

BPH055 Motor Power Connector (Drive end) Diagram ............................ 114

Serial Communication Interface Connection (X6) .......................................... 115

Serial Communication Interface Cable Connectors .................................. 115

Appendix C Servo Loop Diagrams

At a Glance...................................................................................................... 117

What’s in this Appendix ............................................................................. 117

17S Current Controller Overview .................................................................... 118

17S Current Controller Diagram ............................................................... 118

17S Velocity Controller Loop .......................................................................... 119

17S Velocity Controller Loop Diagram ...................................................... 119

17S Position Controller Loop .......................................................................... 120

17S Position Controller Loop Diagram....................................................... 120

Appendix D Optional External Regen Resistor Sizing

At a Glance...................................................................................................... 121

What’s in this Appendix.............................................................................. 121

Overview ................................................................................................... 122

Determining When Energy Is Absorbed .................................................... 122

Determining Optional External Regen Resistor Size ...................................... 123

Power Dissipation Calculation Procedure ................................................. 123

Drive Energy Absorption Capability .......................................................... 124

Example Regen Resistor Power Dissipation Calculation ............................... 125

Example Motor and Drive Specifications................................................... 125

Example Step 1.......................................................................................... 126

Example Step 2 ......................................................................................... 127

Example Step 3 ......................................................................................... 127

Example Step 4 ......................................................................................... 128

Example Step 5 ......................................................................................... 128

Example Step 6.......................................................................................... 128

Example Step 7 ......................................................................................... 128

Example Step 8 ......................................................................................... 129

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Contents

xiv

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Introduction

At a Glance

Document Scope This user guide contains complete installation, wiring interconnection, power

application, test and maintenance information on the Lexium 17S series SERCOS

drive.

What’s in this

Chapter

This chapter provides general information about this user guide and contains the

following topics:

Topic

Page

About this user guide

Related system components and standards

Related Documentation

Documents

Related documentation that covers all these system components is illustrated

below.

You will need these:

UniLink

Online Help

(included

in software)

Depending on which SERCOS motion controller you have, you will also need there:

QUANTUM:

Quantum

SERCOS

Multi-axis Motion

Controller

MMF

Programmer’s

Kit

User Guide

Guide

840 USE 116 X

890 USE 119 00

PREMIUM:

PREMIUM PLCs

Motion Control

SERCOS Module

TSX CSY 84

PL7 JUNIOR/PRO

PREMIUM PLCs

Application

Motion Control

SERCOS Module

TSX CSY 84

User Manual

TLXDS57PL740

TSXDM5740

If you have a BPH motor, you will also need this:

Lexium BPH

Series

Servo Motors

Motors Reference

Guide

* AMOMAN001U

* included in AM0 CSW 001V•00 (CDROM)

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Hazards, Warnings and Guidelines

Hazards and

Warnings

Read the following precautions very carefully to ensure the safety of personnel at

your site. Failure to comply will result in death, serious injury or equipment damage.

DANGER!

ELECTRIC SHOCK HAZARDS

During operation, keep all covers and cabinet doors closed.

Do not open the drives; depending on degree of enclosure protection, the

drives may have exposed components.

Control and power connections on the drive may be energized even if the

motor is not rotating.

Never attempt to disconnect the electrical connections to the drive with power

applied. Failure to comply may result in arcing at the contacts.

Wait at least five minutes after disconnecting the drive from the mains supply

voltage before touching energized sections of the equipment (for example,

contacts) or disconnecting electrical connections. Capacitors can still have

dangerous voltages present up to five minutes after switching off the supply

voltages. To ensure safety, measure the voltage in the DC Link circuit and wait

until it has fallen below 40V before proceeding.

Check to ensure all energized connecting elements are protected from

accidental contact. Lethal voltages up to 900V can be present. Never

disconnect any electrical connections to the drive with power applied;

capacitors can retain residual and dangerous voltage levels for up to five

minutes after switching off the supply power.

Failure to follow any one of these instructions will result in death, serious

injury or equipment damage.

Continued on next page

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Hazards, Warnings and Guidelines, continued

WARNING!

THERMAL HAZARD

During operation, the front panel of the drive, which is used as a heat sink, can

become hot and may reach temperatures above 80°C. Check (measure) the heat

sink temperature and wait until it has cooled below 40°C before touching it.

Failure to observe this precaution can result in severe injury.

WARNING!

OVERCURRENT, OVERLOAD AND OVERHEATING PROTECTION

Separate motor overcurrent, overload and overheating protection is required to be

provided in accordance with the Canadian Electrical Code, Part 1 and the National

Electrical Code.

Failure to observe this precaution can result in severe injury.

Continued on next page

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Hazards, Warnings and Guidelines, continued

CAUTION!

SAFETY INTERLOCKS

Schneider recommends the installation of a safety interlock with separate contacts

for each motor. Such a system should be hard wired with over–travel limit switches

and a suitable emergency stop switch. Any interruption of this circuit or fault

indication should:

Open the motor contacts

Shunt dynamic braking resistors across each motor, if they are present.

Failure to observe this precaution can result in equipment damage.

CAUTION!

ELECTROSTATIC COMPONENTS

The drives contain electrostatically sensitive components that may be damaged by

improper handling. Appropriately discharge yourself before touching the drive and

avoid contact with highly insulating materials (artificial fabrics, plastic film, and so

on). Place the drive on a conductive surface.

Failure to observe this precaution can result in equipment damage.

Continued on next page

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Hazards, Warnings and Guidelines, continued

Additional Safety Read this documentation and adhere to the safety guidelines contained herein

Guidelines

before engaging in any activities involving the drives.

Ensure that all wiring is in accordance with the National Electrical Code (NEC)

or its national equivalent (CSA, CENELEC, and so on), as well as in

accordance with all prevailing local codes.

Exercise extreme caution when using instruments such as oscilloscopes, chart

recorders, or volt–ohm meters with equipment connected to line power.

Handle the drives as prescribed herein. Incorrect handling can result in

personal injury or equipment damage.

Adhere to the technical information on connection requirements identified on

the nameplate and specified in the documentation.

The drives may only be operated in a closed switchgear cabinet with

appropriate compensation for ambient conditions (as defined in Appendix A).

Qualified

Personnel

Only properly qualified personnel having extensive knowledge in electrical and

drive technologies should install, commission and/or maintain the Lexium 17S

SERCOS drives.

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Standards and Compliances

European

The Lexium 17S SERCOS drives are incorporated into an electrical plant and into

Directives and

Standards

machinery for industrial use.

When the drives are built into machines or a plant, do not operate the drive until the

machine or plant fulfills the requirements of these European Standards:

EC Directive on Machines 89/392/EEC

EC Directive on EMC (89/336/EEC)

EN 60204

EN 292

In connection with the Low Voltage Directive 73/23/EEC, the associated standards

of the EN 50178 series in conjunction with EN 60439-1, EN 60146 and EN 60204

are applied to the drives.

The manufacturer of the machine or plant is responsible for meeting the

requirements of the EMC regulations.

EC Directive

Compliance

Compliance with the EC Directive on EMC 89/336/EEC and the Low Voltage

Directive 73/23/EEC is mandatory for all drives used within the European

Community.

The Lexium 17S SERCOS drives were tested by an authorized testing laboratory

and determined to be in compliance with the directives identified above.

Continued on next page

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Standards and Compliances, continued

SERCOS

Standard

If you want to reference the international SERCOS communications standard, get a

copy of:

International Standard IEC 1491, Electrical Equipment of Industrial Machines –

Serial Data Link for Real-Time Communication between Controllers and Drives.

SERCOS is an industry standard term that refers to a special type of fiber–optic

communication protocol, as defined by the SERCOS Interface, Inc., promotion

society. (SERCOS interface is a trademark of SERCOS Interface, Inc., promotion

society.)

UL and cUL

Compliance

UL Listed (cUL Certified) drives (Underwriters Laboratories Inc.) comply with the

relevant American and Canadian standards (in this case, UL 840 and UL 508C).

This standard describes the minimum requirements for electrically operated power

conversion equipment (such as frequency converters and drives) and is intended to

eliminate the risk of injury to personnel from electric shock or damage to equipment

from fire. Conformance with the United States and Canadian standard is

determined by an independent UL (cUL) fire inspector through the type testing and

regular checkups.

UL 508C

UL 508C describes the minimum requirements for electrically operated power

conversion equipment (such as frequency converters and drives) and is intended to

eliminate the risk of fire caused by that equipment.

UL 840

UL 840 describes air and insulation creepage spacings for electrical equipment and

printed circuit boards.

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Conventions

Acronyms and

Abbreviations

The acronyms and abbreviations used in this manual are identified and defined in

the table below.

Acronym or

Abbreviation Description

European Community (EC)

Clock signal

CLK

COM

cUL

Serial communication interface for a PC-AT

Underwriters Laboratory (Canada)

German Institute for Norming

Magnetic storage (diskette, hard disk)

Electrically erasable programmable read only memory

Electromagnetic compatibility

Electromagnetic Interference

European norm

DIN

Disk

EEPROM

EMC

EMI

ESD

IEC

Electrostatic discharge

International Electrotechnical Commission

Insulated Gate Bipolar Transistor

International Standardization Organization

Light Emitting Diode

IGBT

ISO

LED

Megabyte

MS-DOS

PC-AT

PELV

PWM

RAM

Regen

RBext

RBint

RFI

Microsoft Disk Operating System for PC-AT

Personal computer in AT configuration

Protected extra low voltage

Pulse-width modulation

Random Access Memory (volatile)

Regen resistor

External Regen resistor

Internal Regen resistor

Radio Frequency Interference

Continued on next page

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Conventions, continued

Acronyms and

Abbreviations,

Acronym or

Abbreviation Description

continued

PLC

Programmable Logic Controller

SERCOS

SRAM

SSI

Serial Realtime Communication System

Static RAM

Synchronous Serial Interface

Underwriters Laboratory

Voltage, Alternating Current

Voltage, Direct Current

Vac

Vdc

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Product Overview

At a Glance

Introduction

This chapter contains a product overview of the Lexium 17S series SERCOS drives

and includes:

Available drive models and related system components

Feedback and performance information

Power and signal electronics

Software and axis configuration

What’s in this

Chapter

This chapter contains the following topics:

Topic

Page

The 17S series SERCOS drive family

Modicon Multi-Axis Motion SERCOS

Network Configuration

Overview of usability features

Overview of 17S internal electronics

Overview of system software

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The 17S Series SERCOS Drive Family

Introducing the

17S SERCOS

Drive Family

Each member of the Lexium 17S series SERCOS drive family is comprised of a

three-phase brushless servo amplifier, power supply, high-performance digital

controller and SERCOS fiber optic interface all housed in a single enclosure.

Drives Available

The 17S drives are available in five models which are correlated to different output

current levels as identified in the following table.

Output Current (Peak)

17S Drive

4.2 A

8.4 A

16.8 A

28 A

MHDS1004N00

MHDS1008N00

MHDS1017N00

MHDS1028N00

MHDS1056N00

56 A

Implementing

the Drives

The Lexium 17S SERCOS drives are intended for incorporation into electrical

equipment or machinery and can only be commissioned as integral components of

those types of devices.

Applicable Servo The Lexium 17S SERCOS drives are intended to drive BPH series brushless servo

Motor Types

motors.

Continued on next page

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The 17S Series SERCOS Drive Family, continued

Electrical

Considerations

The Lexium 17S family of servo amplifiers is to be used on earthed three-phase

industrial mains supply networks (TN-system, TT-system with earthed neutral point,

not more than 5000 rms symmetrical amperes).

The Lexium drives are incompatible with the IT system because interference

suppression filters are internal and connected to earth. If the user wants to connect

Lexium drives to an IT system, he may:

use an insulation star transformer in order to re-create a local TT or TN system.

This way allows the rest of the wiring to stay an IT system (only warning in case

of the first fault.)

use a special Residual Current Circuit Breaker (RCCB) that is able to work with

dc and high peak currents. This device detects unbalance of phases with

regard to earth.

Warning: When the first fault occurs, the RCCB has to switch off quickly power

of the drives. Set of the residual current value must be carefully done and must

be started with the lowest available value (for example: 30mA.)

Following equipment of Merlin Gerin can be used:

Vigirex, model RH328AF (Reference: 50055)

One of these magnetic cores:

- model TA, 30mm in internal diameter (Reference: 50437)

- model PA, 50mm in internal diameter (Reference: 50438)

- model IA, 80mm in internal diameter (Reference: 50439)

If the servo amplifiers are used in residential areas, or in business or commercial

premises, then additional filter measures must be implemented by the user.

The Lexium 17S family of servo amplifiers is only intended to drive specific

brushless synchronous servomotors from the Lexium BPH series, with closed-loop

control of torque, speed and/or position. The dielectric withstand voltage of the

motors must be at least as hight as the DC-link voltage of the servo amplifier.

Use only copper wire. Wire size may be determinated from EN 60204 (or table 310-

16 of the NEC 60°C or 75°C column for AWG size).

We only guarantee the conformance of the servo amplifiers with the standards for

industrial areas, if the components (motors, cables, amplifiers etc) are delivered by

Schneider Automation.

Continued on next page

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The 17S Series SERCOS Drive Family, continued

17S Drive Family

Portrait

The following photograph shows a representative member of the 17S drive family.

The complete family consists of five models partitioned into two physical sizes.

Models MHDS1004N00, MHDS1008N00, MHDS1017N00 and MHDS1028N00

have dimensionally identical physical housings while Model MHDS1056N00 has a

wider housing. (See Chapter 3 for detailed dimensional information.)

Continued on next page

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The 17S Series SERCOS Drive Family, continued

17S Drives Front

View

The following photograph shows a typical 17S front view with legends and labels.

Continued on next page

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The 17S Series SERCOS Drive Family, continued

Equipment

Supplied

Each 17S SERCOS drive includes the following hardware.

Mating connectors X3, X4, X0 , X0 , X7 and X8

Read me first

Note: The mating Sub-D connectors and servo motor connector X9 are supplied

with the appropriate cable.

Equipment

Available

The following items are optionally available to you from Schneider for use with the

17S SERCOS drives:

Lexium BPH series brushless servo motors

Servo motor power and feedback cables

Note: Power and feedback cables are available in lengths from 5...75 m and are

supplied by Schneider with the connector for the servo motor attached to the cable

and with the connector for the drive unassembled and unattached to the cable. The

10 m length cable is supplied (from stock) by Schneider with connectors attached to

each end of the cable.

Optional servo motor choke (for motor power cable lengths exceeding 25m)

Optional external Regen resistor

Serial communications cable (between drive and PC)

SERCOS fiber optic cables in lengths of 0.3...38 m

Continued on next page

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The 17S Series SERCOS Drive Family, continued

17S System

Configuration

Diagram

The following illustration shows a typical 17S system configuration.

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Modicon Multi-Axis Motion SERCOS Network Configuration

Overview

The 17S drive is typically configured in a SERCOS network containing many axes.

A Schneider multi–axis motion controller configured with a SERCOS processor

board transmits motion instructions to all the 17S drives that are properly

configured in the fiber–optic loop.

Which Motion

Controllers run

a SERCOS

The controller that runs a network of many SERCOS axes is a Modicon Quantum

Automation Series SERCOS multi–axis motion controller (part number

141MMS42501) or TSX Premium CSY motion controller. Each controller supports

one independent SERCOS network ring. Each ring can contain up to 8 axes (8

drives and their motors). The 17S may also be configured with a compatible non–

Modicon SERCOS controller. Schneider also offers a 32-axis motion controller

(part number 141MMS53502).

Network

SERCOS Fiber-

Optic Transmit

and Receive

Each 17S drive has two SERCOS–compliant SMA type fiber–optic connectors:

TX (transmit)

RX (receive)

Connectors

Through a SERCOS–compliant, fiber–optic cable, the RX connector receives the

controller’s command instructions (as well as actual motion information from the

previous axes) from the previous drive in the ring. Likewise, the TX connector

transmits the controller’s command instructions (along with actual motion

information from the axes) to the next drive in the ring. The SERCOS multi–axis

motion controller also has a fiber–optic transmitter (TX) connector and a fiber–optic

receiver (RX) connector. The transmitter sends command instructions

(commanded motion) to all the 17S axes in the network ring. The receiver accepts

real feedback (actual motion information) from all the axes in the ring.

Transmission flows in one direction, with typical cycle times of 2ms to 4ms,

depending on the number or drives, volume of data, and data rate.

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Modicon Multi-Axis Motion SERCOS Network Configuration, continued

Example of a

Typical SERCOS

Network Ring

Configuration

The following figure shows a typical configuration of 17S SERCOS axes with

arbitrary node addresses receiving and transmitting instructions from a multi–axis

motion controller.

Continued on next page

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Modicon Multi-Axis Motion SERCOS Network Configuration, continued

Example of a

Typical SERCOS

Network Ring

Configuration,

continued

As shown in the figure, the ring has eight axes. These axes need not be configured

sequentially. Any axis in the ring can be identified as axis 1, axis 2, axis 3, and so

on. However, each address within a ring must be unique.

Benefits of

Fiber-Optic

Communication

The SERCOS multi–axis motion controller coordinates the motion activities of the

various SERCOS axes on the network ring. Fiber optic communication allows

efficient synchronization of multiple axes through flexible SERCOS networking

rather than through a constraining backplane bus configuration. SERCOS

networking allows you to place each drive close to its motor. This reduces and

eliminates cumbersome wiring from the motor to the controller. The fiber–optic

SERCOS protocol provides complete electrical isolation between drive axes as well

as between each drive axis and the motion controller. This eliminates wiring

difficulties, such as ground loops, which are present in hard–wired systems.

Two Types of

Fiber-Optic

The SERCOS protocol allows two types of communication simultaneously

throughout the network ring:

Communication

Constant real–time data updates

Slower intermittent messaging

This flexibility allows the communication to serve many different types of motion

applications.

Note: For more information on fiber optic connections and signal wiring, see

Chapter 4 and Appendix C.

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Overview of Usability Features

Digital Control

The 17S drive provides complete digital control of a brushless servo system. This

includes:

A digital field-oriented current controller operating at an update rate of 62.5 µs

A fully programmable digital PI-type speed controller operating at an update

rate of 250 µs

Full digital evaluation of motor position feedback (primary feedback) from either

a standard two-poles resolver or a high precision Sin-Cos type encoder

(hiperface).

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Overview of Usability Features, continued

Usability

Enhancements

The following features are incorporated into the 17S drive to facilitate the set-up

and operation of the servo system:

Two analog +/-10 V inputs can be programmed for a multitude of functions

depending upon the application. Both inputs incorporate automatic offset

compensation, dead-band limitation and slew-rate limitation.

Four fully programmable 24 V discrete inputs; two of which are typically defined

as hardware limit switches.

Two fully programmable 24 V outputs and a separate 24 V brake output

capable of driving a maximum of 2 Amps.

An integrated and fully isolated RS-232 connection for communication with a

PC; used to set configuration parameters and tune the system with the Unilink

configuration software.

A separate 24V bias supply input which may be connected through a UPS to

preserve system data in the event of an interruption in the AC mains supply.

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Overview of 17S Internal Electronics

17S Internal

Electronics

The following block diagram illustrates the 17S internal electronics and depicts

internal interfaces for power, signal I/O, and communication.

Block Diagram

ROD

ROD SSI

SSI

Analog1 in+

Analog1 in-

+Rb ext

+Rb int

Analog2 in+

Analog2 in-

-Rb

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Overview of 17S Internal Electronics, continued

General

The Lexium 17S SERCOS drives are available in five peak output current ratings

Characteristics

(4.2, 8.4, 16.8, 28 and 56 A) that are partitioned into two groups based on the width

of the package; the 70 mm drives are rated to handle currents up to 28 A and the

120 mm wide drive is rated to handle currents up to 56 A. All Lexium drives operate

with an input voltage which may range from 208 V -10% 60 Hz, 230 V -10%

50 Hz through 480 V +10% 50-60 Hz.

Each drive provides:

Direct shield connection points

Two analog setpoint inputs

Integrated and electrically isolated RS-232 communications

Primary Power

A single phase input supply may be used for commissioning and set-up and for

continuous operation with various smaller drive/motor combinations. See the

Lexium 17/ BPH motor torque speed curves for details.

Fusing (e.g. fuse cut-out) is provided by the user.

Bias Power

The 17S drive requires 24 Vdc bias power from an external, electrically isolated

supply.

EMI Suppression EMI suppression for the 17S drives is integrally provided by filters on both the

primary power (EN550011, Class A, Group 1) input as well as on the 24 Vdc bias

supply (Class A) input.

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Overview of 17S Internal Electronics, continued

Internal Power

Section

The Internal power section of the 17S drive includes the following:

Power input: A rectifier bridge directly connected to the three-phase earthed

supply system, integral power input filter and inrush current limiting circuit.

Motor power output: PWM current-controlled voltage source IGBT-inverter with

isolated current measurement

Regen circuit: Dynamic distribution of Regen power between several drives on

the same DC Link circuit. An internal Regen resistor is standard; optional

external Regen resistors are available as required by your application.

DC Link voltage: 300...700 Vdc, nominal (900 Vdc, intermittent) and can be

operated in parallel.

DC Link

Capacitor

If the servo drive has been stored for longer than one year, then the DC Link

capacitors will have to be reconditionned as follows:

Reconditioning

Step

Action

Ensure that all electrical connections to the drive are disconnected.

Provide 230 Vac, single-phase power to connector XO (terminals L1/L2) on the

servo drive for about 30 minutes to recondition the capacitors.

Integrated Safe

Electrical

Separation

The 17S drive ensures safe electrical separation (in accordance with EN 50178)

between the power input/motor connections and the signal electronics through the

use of appropriate insulation-creepage distances and electrical isolation. The drive

also provides soft-start characteristics, overvoltage and overtemperature detection,

short-circuit protection and input phase-failure monitoring. When using BPH series

servo motors in conjunction with Schneider’s pre-assembled cables, the drive also

monitors the servo motor for overtemperature.

Keypad

The operation of the keypad on the front panel of the 17S drive is described in

System Operation. These two keys can be used (as an alternative to using the PC)

to enter the SERCOS address for the drive

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LED Display and

Discrete

Indicators

A three-character LED display on the front of the 17S drive indicates drive status

after the 24 Vdc bias supply is turned on. If applicable during operation, error and/

or warning codes are displayed. In addition, three individual LED indicators (one

red and two green) on the SERCOS communication card (at the top of the drive)

are used to indicate the status of that communications.

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Overview of System Software

Setup

Configuration software is used for setting up and storing the operating parameters

for the Lexium 17S series drives. The drive is commissioned with the assistance of

the UniLink software and, during this process, the drive can be controlled directly

through this software.

Setting

Parameters

You must adapt the SERCOS drives to the requirements of your installation. This is

usually accomplished by connecting a PC (programming unit) to the drive’s RS-232

serial interface then running the Schneider-supplied UniLink configuration software.

The UniLink software and the associated documentation are provided on a CD-

ROM. Use the UniLink software to alter parameters; you can instantly observe the

effect on the drive because there is a continuous (online) connection to the drive. In

addition, actual values are simultaneously received from the drive and displayed on

the PC monitor.

Default Settings

Motor-specific default settings for all the reasonable combinations of drive and

servo motor are incorporated into the drive’s firmware. In most applications, you will

be able to use these default values to get your drive running without any problems.

(Refer to the UniLink online help for additional information on default values.)

Continued on next page

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Overview of System Software, continued

UniLink

Commissioning

Software

The minimum PC system requirements needed for the UniLink commissioning

software are specified in the following table:

Item

Minimum Requirement

Operating System

Windows 95

Windows 98

Hardware:

Processor

Graphics adapter

RAM

486 or higher

VGA

8 Mbytes

Hard drive space

Communications

5 Mbytes available

One RS-232 serial port

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Mounting and Physical

Dimensions

At a Glance

What’s in this

Chapter

This chapter provides information on the mounting requirements for, and physical

dimensions of, the Lexium 17S series SERCOS drives and includes the following

topics:

Topic

Page

Installation safety precautions

Installation considerations

Drive mounting and physical dimensions

Optional external Regen resistor mounting and

dimensions

Optional choke mounting and dimensions

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Installation Safety Precautions

CAUTION!

MECHANICAL STRESS

Protect the drive from physical impact during transport and handling. In particular,

do not deform any exterior surfaces; doing so may damage internal components or

alter critical insulation distances.

Failure to observe this precaution can result in injury or equipment damage.

CAUTION!

ELECTRICAL STRESS

At the installation site, ensure the maximum permissible rated voltage at the Mains

and bias input connectors on the drive are not exceeded. (See EN 60204-1,

Section 4.3.1.) Excessive voltages on these terminals can result in destruction of

the Regen circuit and/or the drive’s electronics.

Failure to observe this precaution can result in injury or equipment damage.

CAUTION!

ELECTRICAL CONNECTIONS

Never disconnect the electrical connections to the SERCOS drive while power is

applied.

Failure to observe this precaution can result in injury or equipment damage.

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Installation Safety Precautions, continued

CAUTION!

CONTAMINATION AND THERMAL HAZARD

Ensure the 17S drive is mounted within an appropriately vented and closed

switchgear cabinet that is free of conductive and corrosive contaminants. Ensure

the ventilation clearances above and below the drive conform to requirements.

(Refer to Chapter 3 for additional information.)

Failure to observe this precaution can result in injury or equipment damage.

DANGER!

ELECTRIC SHOCK HAZARD

Residual voltages on the DC link capacitors can remain at dangerous levels for up

to five minutes after switching off the mains supply voltage. Therefore, measure the

voltage on the DC Link (+DC/-DC) and wait until the voltage has fallen below 40 V.

Control and power connections can still be energized, even when the motor is not

rotating.

Failure to observe these instructions will result in death or serious injury.

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Installation Considerations

Power Supply

Overcurrent

Protection

You are responsible for providing overcurrent protection (via circuit breakers and/or

fuses) for the Vac mains supply and the 24 Vdc bias supply that are connected to

the drive.

Earth

Ensure the drive and associated servo motor are properly connected to earth.

Connections

Cable Separation Route power and control (signal) cables separately. Schneider recommends a

separation of at least 20 cm. This degree of separation improves the performance

of the system. If a servo motor power cable includes wires for brake control, those

wires have a separate shield which must be connected to earth at both ends of the

cable.

Air Flow

Ensure that there is an adequate flow of cool, filtered air into the bottom of the

switchgear cabinet containing the drive.

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Drive Mounting and Physical Dimensions

17S Height,

The following diagram shows height, width and depth dimensions for the 17S drive.

Width and Depth

Dimensions

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Drive Mounting and Physical Dimensions, continued

17S Drive and

Mounting Area

Dimensions

The following diagram shows depth dimensions and mounting area requirements

for the 17S drive.

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Optional External Regen Resistor Mounting and Physical Dimensions

Optional

External Regen

Resistor

The following diagram shows the dimensions for all three optional external Regen

resistor assemblies.

Assembly

Dimensions

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Optional Motor Choke Mounting and Dimensions

Optional Motor

Choke Assembly

Dimensions

The following diagram shows the dimensions for the motor choke assembly

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Wiring and I/O

At a Glance

Introduction

This chapter describes and illustrates all power wiring connections, all signal wiring

connections, and I/O wiring connections on the 17S drive. Power and signal wiring

connections are:

AC mains power through a four-position, plug-in, terminal block connector

Bias power through four-position, plug-in, terminal block connector

Serial power connections among multiple drives

Servo motor power through a six-position, plug-in, terminal block connector

Optional Regen power resistor through a four-position, plug-in, terminal

block connector

Resolver feedback input through a nine-pin, plug-in, Sub-D connector

Encoder feedback input through a 15-pin, plug-in, Sub-D connector

Auxiliary encoder interface through a nine-pin, plug-in, Sub-D connector

Fiber optic Interface through two SMA connectors

Analog in and digital I/O through an 18-position, plug-in terminal block

connector

Serial communications interface through a nine-pin, plug-in, Sub-D

connector

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At a Glance, continued

What’s in this

Chapter

This chapter contains the following topics.

Topic

Page

Wiring and I/O initial considerations

Wiring overview

Cable shield connections

Power wiring

Signal wiring

Analog input connections

Fault Relay and Digital I/O connections

Serial communications connections

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Wiring and I/O Initial Considerations

Initial

Some descriptions and illustrations contained in this chapter are provided as

Considerations

examples. Actual implementation depends on the application of the equipment;

thus, appropriate variations are allowed provided they neither violate any safety

precautions nor jeopardize the integrity of the equipment.

DANGER!

ELECTRIC SHOCK HAZARD

Before you wire and connect cables, ensure the mains power supply, the 24 Vdc

bias power supply and the power supplies to any other connected equipment, are

OFF. Ensure any cabinet to be accessed is first electrically disconnected, secured

with a lock-out and tagged with warning signs.

Failure to observe these safety instructions will result in death or serious

injury.

Grounding

Ensure the drive mounting plate, SERCOS motor housing and Analog Com for the

controls are connected to common panel earth ground point.

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Wiring Overview

Overview of 17S

Wiring

The following diagram shows the wiring connections for the 17S drive.

Connections

CAUTION:

Do not connect a Modbus serial port to the X6 connector!

Pin1 carries +8 Vdc which would be shorted out by a Modbus cable.

Instead, use a standard 3-core null-modem cable (not a null-modem link cable) with only

pins 2, 3 and 5 wired.

Failure to observe this precaution can result in equipment damage.

Note: The connectors described above appear in many wiring diagrams throughout

the remainder of this document and are identified in those diagrams by their

alphanumeric designations only (for example, X4); the term connector is excluded.

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Connection diagram for Lexium 17S

Reference Safety Instructions

and Use As Directed!

+ +/-10V speed

setpoint1

referenced to GND

thermal control

included

Analog 1 in +

Analog 1 in -

Analog Com

Analog 2 in +

Analog 2 in -

high

resolution

single /

multiturn

Sine-Cosine

Encoder

GND

+ +/-10V speed

setpoint2

referenced to GND

thermal control

included

Reserved

Analog Com

Reserved

GND

Resolver

I/O-GND

+24V referenced

to 0V/GND

I/O Com

Input 3

Input 4

Input 1

Input 2

B+

B-

Brake+

Brake-

Enable

Remove jumper if external

regen resistor is connected

FB1

+RBint

-RB

Output 1

Digital1

Digital2

Output 2

Regeneration

resistor

+RBext

n.c.

FB2

Fault RA

Fault RB

Safety

circuit

X0A

encoder-

evaluation,

ROD

SSI

slave/master

amplifier

Ma./SI.

+24 Vdc

COM1/COM2

24 Vdc Com

X0B

L1 L2 L3 PE

PE-connection (protective earth)

earth connection (panel)

supply unit

24V DC

Master

DC+DC- DC+DC-

contactor

shield connection via plug

shield connection at the front panel

shielding if cable

is longer than 20cm

to other amplifiers

PE L1 L2 L3

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Pin assignments for LEXIUM 17 S

X6 PC

X5 ROD/SSI

X2 RESOLVER

X1 ENCODER

Analog Com 1

View: looking at the

face of the built-in

connectors

Fault Ra 2

Fault Rb 3

Analog 1 In+ 4

Analog 1 In- 5

Analog 2 In+ 6

Analog 2 In- 7

Reserved 8

Reserved 9

Analog Com 10

Input 1 11

Input 2 12

Input 3 13

Input 4 14

Enable 15

Output 1 16

Output 2 17

I/O Com 18

+24Vdc 1

+24Vdc 2

+24Vdc Com 3

+24Vdc Com 4

Coding

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Cable Shield Connections

Connecting

The following procedure and associated diagram describe how to connect cable

Cable Shields to

the Front Panel

shields to the front panel of the 17S drive:

Step Action

Remove a length of the cable’s outer covering and braided shield sufficient to

expose the required length of wires.

Secure the exposed wires with a cable tie.

Remove approximately 30 mm of the cable’s outer covering while ensuring the

braided shield is not damaged during the process.

At the front panel of the drive, insert a cable tie into a slot in the shielding rail.

Use the previously inserted cable tie to secure the exposed braided shield of

the cable firmly against the shielding rail.

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Cable Shield Connections, continued

Cable Shield

Connection

Diagram

The following diagram shows the cable shield connections at the front of the 17S

drive.

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Power Wiring

AC Mains Power

Supply

The following diagram shows the connections for the AC mains power supply input

to the 17S drive.

Connection

*3 x 230 V +10% max. with a BPH055 Servo motor

Bias Supply

Connection

The following diagram shows the connections for the bias power supply input to the

17S drive.

Continued on next page

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Power Wiring, continued

Serial Power

Connections

The following diagram shows the serial connections for the AC mains and bias

power among multiple 17S drives.

AC supply

Lexium 17S

+24

COM

X0A

X0B

X0A

X0B

X0A

X0B

Drive

+DC

-DC

+DC

-DC

+DC

-DC

+DC

-DC

+DC

-DC

+DC

-DC

DC supply

Lexium 17S

24 Vdc

Power Supply

POWER

SUPPLY

+24

COM

X0A

X0B

X0A

X0B

Drive

+DC

-DC

+DC

-DC

+DC

-DC

+DC

-DC

+DC

-DC

Fuse

Max fuse: 20 A

schielded if length > 20 cm

Notes: -Inrush current must be limited to 20 A between power supply and drives.

- Drives have to be configured (see Unilink commands) to suppress faults.

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Power Wiring, continued

Optional

External Regen

Resistor

The following diagram shows the connections between the optional external Regen

resistor and the 17S drive. The drive is shipped with a jumper installed on

connector X8, terminals R and R . If you are going to use an optional external

Bint

Connection

Regen resistor, then remove the jumper to disconnect (and thus disable) the

internal Regen resistor.

Fusing of the two lines to external Regen Resistor is mandatory.

Use high voltage AC/DC and fast fuses.

Regen Circuit

Functional

Description

During braking, energy from the servo motor is returned to the drive and converted

into heat in the Regen resistor. Operation of the Regen resistor is controlled by the

Regen circuit using thresholds that are adjusted to the main supply voltage that is

configured in the UniLink software. The following is an abbreviated functional

description of the Regen circuit operation.

Individual drive (not coupled through the DC Link circuit) - The circuit starts to

respond at a DC Link voltage of 400V, 720V or 840V (depending on the supply

voltage). If the energy fed back from the servo motor is higher than the preset

Regen power, then the drive issues a "Regen power exceeded" signal and the

Regen circuit will be switched off. Upon the next internal check of the DC Link

voltage, an overvoltage will be detected, the fault relay contact will be opened

and the drive will be switched off with the error message "Overvoltage".

Multiple drives (coupled through the DC Link circuit) - In this case, the Regen

energy is distributed equally among all the drives.

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Power Wiring, continued

Lexium BPH

Servo Motor

Connection

(excluded

The following diagrams show the connections between a servo motor (excluded

BPH055) and the 17S drive. When the interface cable length exceeds 25 m, a

motor choke must be installed as shown and at a distance of one meter or less from

the drive.

BPH055)

Continued on next page

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Power Wiring, continued

Lexium BPH 055

Servo Motor

Connection

The following diagrams show the connections between a BPH055 servo motor and

the 17S drive. When the interface cable length exceeds 25 m, a motor choke must

be installed as shown and at a distance of one meter or less from the drive.

WARNING!

With a BPH055 Servo motor, power supply of the 17S drive must be limited to

3 x 230 Vac +10%

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Power Wiring, continued

Servo Motor

(with Optional

Dynamic Brake

Resistors and

Contactor)

The following diagram shows the connections between a servo motor and the 17S

drive when the optional dynamic brake rersistors and associated contactor are

incorporated.

Connection

Continued on next page

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Power Wiring, continued

Servo Motor

Holding-Brake

Control

Functional

Description

A 24V holding brake in the servo motor is controlled directly by the 17S drive

through software-selectable BRAKE parameter settings. The time and functional

relationships between the ENABLE signal, speed setpoint, speed and braking force

are shown in the following diagram.

During the fixed ENABLE delay time of 100 ms, the speed setpoint of the drive is

internally driven down a 10 ms ramp to 0V. The 3 % region of actual speed is

scaled to V

LIM

Note: The set and release times of the holding brake vary with the servo motor and

thus must be considered when setting parameters.

Continued on next page

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Power Wiring, continued

WARNING!

IMPACT HAZARD

The off-the-shelf configuration of the holding-brake function does not ensure the

safety of personnel. In order to make this function safe for personnel, a normally-

open contact and a user-installed suppressor device (varistor) must be

incorporated into the brake circuit as shown in the following diagram.

Failure to observe this precaution can result in severe injury or equipment

damage.

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Signal Wiring

Lexium BPH

Resolver

The following diagram shows the connections between the resolver and the 17S

drive.

Connection

(excluded

BPH055)

Note: The standard Lexium BPH series servo motors are equipped with two-pole,

integral resolvers. The thermistor contact in the servo motor is connected via the

resolver cable to the 17S drive.

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Signal Wiring, continued

Lexium BPH055

Resolver

The following diagram shows the connections between the resolver and the 17S

drive.

Connection

Note: The BPH055 servo motors are equipped with two-pole, integral resolvers.

The thermistor contact in the servo motor is connected via the resolver cable to the

17S drive.

BPH055

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Signal Wiring, continued

Encoder Input

Connection

The following diagram shows the encoder input connections between the encoder

and the 17S drive.

Note: The BPH series servo motors can be optionally fitted with a single-turn or

multi-turn sine-cosine encoder, which is used by the 17S drive as the primary

feedback device for operations requiring highly precise positioning or extremely

smooth running. In addition, the thermistor contact in the servo motor is connected

via the encoder cable to the 17S drive.

Continued on next page

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Signal Wiring, continued

Auxiliary

Encoder

Interface

Master-slave Operation of Drives Diagram.

The encoder interface can be used to link one or more drives together in a

master-slave operation, as shown in the following diagram. Up to 16 slave

drives can be controlled by a designated master drive via the encoder output.

The UniLink software allows you to setup the parameters for the slave drive(s)

and to adjust the gear ratio (number of pulses/turn).

Note: In this configuration, the analog setpoint inputs are disabled and Analog Com

and I/O Com (connector X3) must be connected.

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Signal Wiring, continued

Incremental-Encoder Input Connection.

The following diagram shows the incremental encoder input connections between

the 17 drive and an external incremental encoder.

Note: The receivers are supplied from an internal supply voltage.

must always be connected to the encoder ground.

Com

Incremental encoder is powered by an external Power Supply.

Incremental encoder

Lexium 17S

RS-485

A+

RS-485

Chan A

A-

M+

Marker

RS-485

M-

Reserved

P^Com

Gnd

B+

B-

RS-485

Chan B

RS-485

+Vdc

Gnd

Power

Supply

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Signal Wiring, continued

SSI Encoder Input Connection:

The following diagram shows the connections between an external SSI encoder

and the drive.

Note: The drivers are supplied from an internal supply voltage.

must always be connected to the encoder ground.

Com

SSI encoder is powered by an external Power Supply

SSI encoder

Lexium 17S

Data

RS-485

Data

P^Com

Reserved

Gnd

Clock

RS-485

+Vdc

Gnd

Power

Supply

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Analog Input Connection

Analog Inputs

The following diagram shows the connections between the two fully programmable,

differential analog inputs on the 17S drive and a user device. (Refer to the list of

pre-programmed functions contained in the UniLink online help.)

Note: The Analog Com must always be connected to the user device Com as a

ground reference.

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Fault Relay and Digital I/O Connection

Digital Inputs

and Outputs

The following diagram shows the connections between the fault relay, the four fully-

programmable, digital inputs, dedicated enable input and two digital outputs on the

17S drive and typical user devices. (A list of pre-programmed functions is contained

in the UniLink online help.)

Ω

Continued on next page

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Fault Relay and Digital I/O Connection, continued

Using Functions

Fault Relay- The isolated fault relay contacts are closed during normal operation

Pre-programmed and open when a fault condition exists. The relay state is not affected by the enable

into the Drive

signal, I t limit or warnings. All faults cause the Fault RA/RB contact to open and

the switch-off of the output stage. A list of error messages can be found in chapter

Troubleshooting.

Digital Inputs 1, 2, 3 and 4 - You can use the four digital inputs to initiate pre-

programmed functions that are stored in the drive.

Digital Outputs 1 and 2 - You can use the two digital outputs to send messages

from pre-programmed functions that are stored in the drive.

Enable Input - This is a dedicated, level-sensitive (as opposed to edge-sensitive)

hardware input which will enable the output stage of the drive when 24 Vdc is

applied and no fault conditions exist.

Note: The hardware enable is powered up upon detection of state sense versus

transition sensitivity. Refer to the UniLink on-line help for software enable

information.

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Serial Communications Connection

RS-232 Null

Modem Type

Communication

Connection

Diagram

The following diagram depicts the RS-232 communication connection between the

Lexium 17S and a PC.

See wiring in Appendix C

The setting of the operating, position control, and motion-block parameters can be

carried out with an ordinary commercial PC.

Connect the PC interface (X6) of the servo amplifier while the supply to the

equipment is switched off via a normal commercial 3-core cable to a serial

interface on the PC. Do not use a null-modem link cable!

The interface is electrically isolated through an optocoupler, and is at the same

potential as the CANopen interface.

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System Operation

At a Glance

What’s in this

Chapter

This chapter provides information on operating the Lexium 17S series servo drives

and includes the following topics:

Topic

Page

Powering up and powering down the system 68

Procedure for verifying system operation

Front panel controls and indicators

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Powering Up and Powering Down the System

Power-on and

Power-off

The following diagram illustrates the functional sequence that occurs when the

drive is turned on and off.

Characteristics

5 min.

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Powering Up and Powering Down the System

Stop Function

If a fault occurs the output stage of the servo amplifier is switched off and the

Fault RA/RB contact is opened. In addition, a global error signal can be given out at

one of the digital outputs (terminals X3/16 and X3/17). These signals can be used

by the higher-level control to finish the current PLC cycle or to shut down the drive

(with additional brake or similar.).

Instruments which are equipped with a selected "Brake" function use a special

sequence for switching off the output stage.

The Stop functions are defined in EN 60204 (VDE 0113), Para. 9.2.2, 9.2.5.3.

There are three categories of Stop functions:

Category 0: Shut down by immediately switching off the supply of energy to the

drive machinery (i.e an uncontrolled shut-down);

Category 1: A controlled shut-down, during which the supply of energy to the

drive machinery is maintained to perform the shut-down, and where the energy

supply is only interrupted when the shut-down has been completed;

Category 2: A controlled shut-down, where the supply of energy to the drive

machinery is maintained.

Every machine must be equipped with a Stop function to Category 0. Stop

functions to Categories I and/or 2 must be provided if the safety or functional

requirements of the machine make this necessary.

Emergency Stop

strategies

The Emergency Stop function is defined in EN 60204 (VDE 0113), Para. 9.2.5.4.

Implementation of the Emergency Stop function:

Category 0: The controller is switched to "disable", the electrical supply

(400VAC) is disconnected.

The motor must be held by an electromagnetic holding device (brake).

In multiaxis systems with connected DC-link bus (intermediate circuit) the

motor leads have to be disconnected by a changeover switch and short-

circuited by resistors connected in a star configuration.

Category 1: If hazardous conditions can result from an emergency stop switch-

off with an unbraked run-down, then the drive can be switched off by a

controlled shut-down.

Stop Category 1 permits electromotive braking with a switch-off when zero

speed has been reached. Safe shut-down can be achieved, when the loss of

the mains supply is not rated as a fault and the control takes over the disabling

of the servo amplifier.

In the normal situation, only the supply power is switched off in a safe manner.

The 24V auxiliary supply remains switched on.

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Powering Up and Powering Down the System

Wiring example

Stop and Emergency Stop function (Category 0)

K10

XOA

K20

LEXIUM 17S

24 Vdc Com

Brake-

Brake+

24 Vdc

Gnd

(Green)

Servo

Motor

R^BRB

Fault RA/RB

K10

K11

K30

+24Vdc

Emergency-Off

OFF

K10

K30

K10

K11

K30

K20

K11 is normally closed

(no fault of equipement)

+24Vdc Com

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Procedure for Verifying System Operation

Overview

The following procedure and associated information verifies operation of the

system without creating a hazard to personnel or jeopardizing the equipment.

Note: Default parameters for each Lexium BPH series motor are loaded into your

drive at the factory and contain valid and safe values for the current and speed

controllers. A database for the servo motor parameters is stored in the drive. During

commissioning, you must select the data set for the connected servo motor and

store it in the drive. For most applications, these settings will provide good servo

loop efficiency. For a description of all parameters and motor tuning, see the

UniLink online help.

Quick Tuning

Procedure

This procedure will enable you to rapidly assess the operational readiness of the

system.

Step

Action

Disconnect the drive from the power source.

WARNING!

MECHANICAL MOVEMENT HAZARD

Ensure the motor is securely mounted and that the load is disconnected

from the motor.

Failure to observe this precaution can result in severe injury or

equipment damage.

Ensure 0 V is applied to the enable input (connector X3, terminal 15).

Connect the PC to the drive via the serial communications cable.

Turn on the 24 Vdc bias supply. After the initialization procedure

(< 5 seconds) the status is shown in the LED display.

Switch on the PC, start the UniLink software and select the serial

communication port to which the drive is connected. (The parameters that

are stored in the SRAM of the drive are transferred to the PC.)

Continued on next page

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Procedure for Verifying System Operation, continued

Quick Tuning

Procedure,

Step

Action

continued

Use the UniLink software to check/establish the following:

Drive Parameters - Set/restore the drive parameters to the factory

default values.

Supply voltage - Set the supply voltage to the actual mains supply

voltage.

Servo Motor - Select the applicable BPH servo motor.

Feedback - Ensure the feedback matches the feedback unit in the

servo motor.

Check safety devices such as hardware limit switches, emergency stop

circuitry and so forth.

WARNING!

MECHANICAL MOVEMENT HAZARD

Ensure personnel, tools and all other obstructions are clear of the

equipment.

Failure to observe this precaution can result in severe injury or

equipment damage.

Turn on the AC mains power supply.

Enable 24 Vdc on connector X3, terminal 15. Observe that 500 ms after

the power supply was switched on, the servo motor is motionless with a

standstill torque of M₀.

Using the UniLink Oscilloscope Service Function, program a small 50-rpm

velocity command. If the servo motor oscillates, the Kp parameter in the

"speed controller" menu page must be adjusted.

Note: The Kp parameter may have to be adjusted after connecting the

load. Refer to UniLink on-line help for more tuning information.

Note: The hardware enable is powered up upon detection of state sense versus

transition sensitivity.

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Front Panel Controls and Indicators

Keypad

The operation of the keypad on the front panel of the 17S drive is described in the

Operation

following table. The two keys can be used (as an alternative to using the PC) to

specify and enter the SERCOS address for the drive.

Key

Function

Press once: Increments address by 1

Press twice in rapid succession: Increments address by 10

Press once: Decrements address by 1

Press twice in rapid succession: Decrements address by 10

Press and hold right key, then press left key: Enters the

address specified above.

Note: The drive must be powered down then powered up again to confirm an

address change.

LED Display

The alphanumeric display indicates drive power status conditions, error codes and

warning codes. The power status conditions are shown below; error and warning

codes are identified and described in the Troubleshooting chapter.

Continued on next page

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Front Panel Controls and Indicators, continued

SERCOS

The following illustration shows the location of the three SERCOS communication

Communication

LED Indicators

LED indicators on the SERCOS communication card at the top of the drive. The

Rec_T and Tra_T LEDs are green and (when illuminated) respectively indicate

information is being received or transmitted. The Error LED is red and illuminates

when a SERCOS communication error occurs.

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Troubleshooting

At a Glance

What’s in this

Chapter

This chapter provides information on correcting problems with the 17S drive and

contains the following topics:

Topic

Page

Warning messages

Error messages

Troubleshooting

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Warning Messages

Warning

A warning is generated when a non-fatal fault occurs. Non-fatal faults allow the

Identification

and Description

drive to remain enabled and the fault relay contact to remain closed. Either of the

programmable digital outputs can be programmed to indicate that a warning

condition has been detected. The cause of the warning is presented as an

alphanumeric code on the drive’s front panel LED display; these warning codes are

identified and described in the following table.

Warning

Code

Designation

I²t warning

Explanation

n01

n02

n03

Current threshold set by “I²t Message” parameter

was exceeded.

Regen power

Following Fault

Power threshold set by “Max Regen Power”

parameter was exceeded.

Following error threshold set by “Following Error”

parameter was exceeded.

n04

n05

Response monitoring

Mains phase

Response monitoring (fieldbus)is active.

Mains phase missing. Can be disabled for single

phase operation with the “Mains Phase Missing”

parameter.

n06

n07

n08

n09

Sw limit-switch 1

Sw limit-switch 2

Motion task error

Passed software limit-switch 1.

Passed software limit-switch 2.

A faulty motion task was started.

No “Home” reference point Motion task started with no “Home” reference

point set.

n10

n11

n12

n13

n14

Positive Limit

Positive limit-switch activated.

Negative Limit

Default values

SERCOS interface

Negative limit-switch activated.

Only HIPERFACE®: motor default values loaded.

SERCOS interface not functioning correctly.

HIPERFACE®-reference

mode

Attempt to reset while HIPERFACE®-reference

mode was active.

n15

Table error

Velocity current table INXMODE 35 error

reserved

n16 ... n31 Reserved

n32

Firmware beta version

Reset

The firmware is not a released beta version

RESET is active at DIGITAL IN x

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Error Messages

Error

Identification

and Description

Errors are generated when a fatal fault occurs. Fatal faults cause the drive to be

disabled, the brake (if installed) to be activated and the fault relay contacts to open.

Either of the programmable digital outputs can also be programmed to indicate that

an error has been detected. The cause of the error is presented as an

alphanumeric code on the drive’s front panel LED display; these error codes are

identified and described in the following table.

Error Error (Fault)

Code

Possible Cause/Corrective Action

F01

Drive heat sink

- Improve ventilation.

overtemperature.

- Reduce motion profile duty cycle.

F02

DC link voltage limit

exceeded.

- Check Parameter “Mains Supply Voltage” for correct

setting.

- Supply voltage too high; use a mains transformer.

- Regen power limit was exceeded; adjust motion

profile or install larger regen resistor.

F03

F04

Following error limit

exceeded.

- Increase I

range).

or I

(keep within motor operating

rms

peak

- SW ramp parameters set too large.

Feedback signals missing - Defective feedback device.

or incorrect.

- Check for correct device type selected in “Feedback

Type” parameter.

- Check feedback cable and connections.

F05

DC-link voltage less then Supply voltage not present or too low when drive was

factory preset (100V).

enabled. Only enable the drive when the mains supply

voltage has been on longer than 500 ms.

Continued on next page

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Error Messages, continued

Error

Identification

Error Error (Fault)

Code

Possible Cause/Corrective Action

- I

or I set too high.

and Description,

continued

F06

Motor overtemperature.

rms

peak

- Defective motor

- If motor is not hot, check feedback cables and

connectors.

- Reduce motion profile duty cycle

- Improve ventilation of the motor

Return drive to manufacturer

F07

F08

Internal 24 Vdc fault.

Motor speed limit

exceeded.

- Feedback parameters not set correctly.

- Incorrect feedback wiring.

- Motor phases reversed.

- Check Parameter “Overspeed” for correct setting.

F09

F10

EEPROM checksum error. Return drive to manufacturer.

Flash-EPROM checksum Return drive to manufacturer.

error.

F11

Motor brake fault.

- Brake parameter set to “WITH” when brake does not

exist.

- Defective brake.

- Check motor power cable and connections.

- Defective motor.

F12

F13

Motor phase missing.

- Check motor power cable and connections

Drive internal temperature - Improve ventilation.

exceeded.

- Reduce motion profile duty cycle.

Continued on next page

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Error Messages, continued

Error

Identification

Error Error (Fault)

Code

Possible Cause/Corrective Action

and Description,

continued

F14

Drive output stage fault.

- Check motor cable for damage or shorts.

- Output module is overheated; improve ventilation.

- Short-circuit or short to ground in the external Regen

resistor.

- Motor has short-circuit/ground short; replace motor.

- Output stage is faulty; return drive to manufacturer.

F15

I²t maximum value

exceeded.

- I

or I

set incorrectly.

rms

peak

- Reduce motion profile duty cycle.

F16

Mains supply missing two - Check mains fuses.

or three phases.

- Check mains wiring and connections on drive.

F17

F18

A/D converter error.

Return drive to manufacturer

Regen circuit faulty or

incorrect setting.

- Check jumper on X8 if using internal regen resitor.

- Check wiring of external regen resistor if used.

- Check fuses of external regen resistor.

F19

Mains supply missing one - For single phase operation, set “Phase Missing”

phase.

parameter to “no message”.

- Check mains supply fuses.

- Check mains connector on drive.

- Check mains supply wiring.

Hardware fault of the expansion card

Software fault of the expansion card

Reserved

F20

F21

F22

F23

F24

F25

Slot fault

Handling fault

Reserved

Commutation error

Encoder system only

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Error Error (Fault)

Code

Possible Cause/Corrective Action

F26

F27

F28

F29

F30

F31

F32

Reserved

SERCOS error

SERCOS time out

Reserved

SERCOS systems only

Reserved

System error

System software not responding correctly, return drive

to manufacturer.

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Troubleshooting

Problems,

The following table identifies some common system problems, their possible

causes and recommended corrective actions. However, the configuration of your

installation may create other reasons, and consequently other corrections, for the

problem.

Possible Causes

and Corrective

Actions

Problem

Possible Causes

Corrective Actions

- Wrong cable used.

- Check cable.

communication

with PC

- Cable plugged into wrong

position in drive or PC.

- Plug cable into the correct

sockets on the drive and PC.

- Wrong PC interface selected.

- Drive not enabled.

- Select correct interface.

- Apply enable signal

Motor does not

rotate

- Break in SERCOS fiber optic

cable.

- Check cable

- Correct motor phase sequence

- Check brake control

- Check mechanism

- Motor phases swapped.

- Brake not released.

- Motor is mechanically blocked.

- Set motor pole number.

- Set up feedback correctly.

- Motor pole number set

incorrectly.

- Feedback set up incorrectly.

Continued on next page

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Troubleshooting, continued

Problems,

Possible Causes

Problem

Possible Causes

Corrective Actions

and Corrective

Actions,

Motor oscillates

- Gain too high (speed controller). - Reduce Kp (speed controller).

continued

- Shielding in feedback cable has - Replace feedback cable.

a break.

Poor drive

- Kp (speed controller) too low.

- Increase Kp (speed controller).

performance

(drive too soft)

- Tn (speed controller) too high.

- Use motor default value for Tn

(speed controller).

- PID-T2 too high.

- Reduce PID-T2.

- T-Tacho too high.

- Reduce T-Tacho.

Motor runs

roughly

- Kp (speed controller) too high.

- Reduce Kp (speed controller).

- Tn (speed controller) too low.

- Use motor default value for Tn

(speed controller).

- PID-T2 too low.

- T-Tacho too low.

- Increase PID-T2.

- Increase T-Tacho.

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Specifications

At a Glance

What’s in this

Appendix

This appendix contains the following topics.

Topic

Page

Performance specifications

Environmental and mechanical specifications

Electrical specifications

Wire specifications (recommended)

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Performance Specifications

Performance

Specifications

Table

The following table lists 17S performance specifications.

PERFORMANCE

Servo updates

Torque

Velocity

Position

62.5 µs

250 µs

Tuning procedure UniLink application*

* Included in AM0CSW001V•00 (CD-ROM)

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Environmental and Mechanical Specifications

Environmental

Specifications

Table

The following table provides 17S environmental specifications.

ENVIRONMENTAL

Storage

High temperature,

non–operating

+70°C maximum

Low temperature,

non–operating

–25°C minimum

Humidity

Non–operating

Operating

95% RH maximum,

non-condensing

85% RH maximum,

non-condensing

Operating temperature

(ambient measured at fan inlet)

Full power

0 ... 45°C

With linear derating

2,5% / °C

45 ... 55°C max

(available power: 75% of

^{rated output at 55}°C)

Vibration (operational)

Air pressure

10 ... 57 Hz

Sinusoidal, 0.75 mm

amplitude

57 ... 150 Hz

Operating:

1.0 g

Full power

1000 m (90 kPa)

With linear derating 1000 ... 2500m (73kPa) max

1,5% / 100m

(available power: 75%

of rated output at

2500m)

Transport

57 kPa (4540 m)

Contaminants

Cooling

Pollution degree 2, as defined in EN60204/EN50178

Models:

Integrated heatsink with

internal fan.

MHDS1004N00

MHDS1008N00

MHDS1017N00

MHDS1028N00

MHDS1056N00

Continued on next page

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Environmental and Mechanical Specifications, continued

Mechanical

Specifications

Table

The following table provides 17S mechanical specifications.

Drive Model Number Height

Width

Depth

Weight

MHDS1004N00

MHDS1008N00

MHDS1017N00

MHDS1028N00

MHDS1056N00

325 mm

70 mm

265 mm

2.5 kg

325 mm

120 mm

265 mm

3.0 kg

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Electrical Specifications

What’s in this

Section

This section provides tables for the following topics.

Topic

Page

Electrical Specifications - Power

Electrical Specifications - Regen resistor

Electrical Specifications - Signal

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Electrical Specifications - Power

Line Input

Specifications

Table

The following table provides 17S line input specifications.

LINE INPUT

Voltage

208 Vac -10% 60 Hz, 230 Vac -10% 50 Hz.

480 Vac +10%, 50 - 60 Hz, three-phase*

Current

MHDS1004N00

MHDS1008N00

MHDS1017N00

MHDS1028N00

MHDS1056N00

Internally limited

Greater than 98%

1.8 A RMS**

3.6 A RMS

7.2 A RMS

12 A RMS

24 A RMS

Inrush current

Efficiency

Read carefully “Electrical considerations”

** Single-phase operation permitted.

Continued on next page

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Electrical Specifications - Power, continued

Bias Input

Specifications

Table

The following table provides 17S bias input specifications.

Motor Brake Present

Bias Input

Voltage

Current

Voltage

Current

Value

20 ... 30 Vdc

0.75 A to 1.2 A

24 Vdc -10%, +5%

3 A max.

Yes

Note: The bias input also provides power to the optional motor brake.

External Fuse

Specifications

Table

The following table provides 17S external fuse specifications.

Input Type

Model Number

MHDS1004N00

MHDS1008N00

MHDS1017N00

MHDS1028N00

MHDS1056N00

MHDS1004N00

MHDS1008N00

MHDS1017N00

MHDS1028N00

MHDS1056N00

Fuse

Line

6 A, time delay

10 A, time delay

20 A, time delay

4 A, fast acting*

Optional external

Regen

6 A, fast acting*

*Two fuses in series, >= 500 V, dimensions: 10 x 38.

Continued on next page

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Electrical Specifications - Power, continued

Motor Output

Specifications

Table

The following table provides 17S motor output specifications.

Parameter

Type

Model Number

MHDS1004N00*

MHDS1008N00

MHDS1017N00

MHDS1028N00

MHDS1056N00

MHDS1004N00

MHDS1008N00

MHDS1017N00

MHDS1028N00

MHDS1056N00

Current

1.5 A

3 A

Output current (RMS)

Continuous

6 A

10 A

20 A

3 A

Intermittent**

6 A

12 A

20 A

40 A

Switching frequency

8 kHz ± 0.1%

Cable length***

75 m (maximum)

Maximum cable capacitance (motor 150 pF/m

phase to ground or shield)

* For single phase main connection, the output current is limited to the output

current specifed above or 4 amps, whichever is lower.

** Duration depends on settings in Unilink.

*** Cable lengths exceeding 25 m require the use of motor choke AM0FIL001V056

Note: Motors must be compatible with following table:

Motor Inductance:

Model

Min (mH) Max (mH)

MHDS1004N00

MHDS1008N00

MHDS1017N00

MHDS1028N00

MHDS1056N00

400

200

100

3.5

1.5

Continued on next page

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Electrical Specifications - Power, continued

Internal Power

Dissipation

Specifications

Table

The following table provides 17S internal power dissipation at maximum continuous

output power. This information may be useful to size the thermal capability of the

mounting cabinet.

Model Number

MHDS1004N00

MHDS1008N00

MHDS1017N00

MHDS1028N00

MHDS1056N00

Power

30 W

40 W

60 W

90 W

200 W

Note: These power dissipations are measured at maximum continuous power and

should be considered worst case. Often in sizing servo systems, factors such as

profile duty cycle may reduce these numbers. These values do not include power

dissipated in the Regen resistor. This is application-specific and must be calculated

separately.

Quiescent dissipation when output stage is disabled is 15 W

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Electrical Specifications - Regen Resistor

Regen Circuit

Specifications

The following table provides technical data on the Regen circuit.

Parameter

Rated data

Units

Model Number

(prefix with MHDS10)

04N00

08N00

17N00

28N00

56N00

Supply Voltage

3 phase,

230 V

Upper switch-on level of Regen circuit

Switch-off level of Regen circuit

400 - 430

380 - 410

200

Continuous power of Regen circuit (RBint)

Continuous power of Regen circuit (RBext) kW

maximum.

0.25

0.75

Pulse power, internal (RBint max. 1s)

Pulse power, external (RBext max. 1s)

Upper switch-on level of Regen circuit

Switch-off level of Regen circuit

2.5

3 phase,

400 V

720 - 750

680 - 710

200

Continuous power of Regen circuit (RBint)

Continuous power of Regen circuit (RBext) kW

max.

0.4

1.2

Pulse power, internal (RBint max. 1s)

Pulse power, external (RBext max. 1s)

Upper switch-on level of Regen circuit

Switch-off level of Regen circuit

3 phase,

480 V

840 - 870

800 - 830

200

Continuous power of Regen circuit (RBint)

Continuous power of Regen circuit (RBext) kW

maximum.

0.5

1.5

Pulse power, internal (RBint maximum 1s)

10.5

Pulse power, external (RBext maximum 1s) kW

External Regen resistor

Internal Regen resistor

Ω

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Electrical Specifications - Signal

Motor

The following table provides 17S motor overtemperature input specifications.

Overtemperature

Input

MOTOR OVERTEMPERATURE INPUT

Specifications

Table

PTC will generate fault when resistance exceeds 290Ω ± 10%*

(default value)

Thermistor

Closed for normal operation

Thermostat

* The value of the threshold is adjustable by the parameter MAXTEMPM

(see Unilink commands)

Resolver Input

Specifications

Table

The following table provides resolver input specifications.

RESOLVER

Reference

8kHz ± 0.1%

35 mA RMS

4.75V RMS

1 (default)

Drive capability

Amplitude

Pair of poles

Resolution

14 bits (0.02°)

Accuracy

12 bits (0.09°)

Tracking

Conversion method

Resolver type

Transmit mode

0.5

Resolver transformation

ratio

Loss of feedback

Detection circuit included

Maximum cable length

75 m

Maximum cable

120 pF/m

capacitance (signal

connector to shield)

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Electrical Specifications - Signal, continued

Encoder Input

Specifications

Table

The following table provides 17S encoder input specifications

ENCODER INPUT

Internal power supply Voltage

9V ± 5%

200 ma

Current (maximum)

Input Signal

Sin-Cos encoder

(cyclic absolute)

Absolute

accuracy

15 bits (39

arc-seconds

or 0.01°)

Resolution

20 bits (1.2

arc-seconds

or 0.0003°)

Sin-Cos encoder

Turn counter 12 bits

(multi-turn absolute)

Absolute

accuracy

within one

turn

15 bits (39

arc-seconds

or 0.01°)

Resolution

within one

turn

20 bits (1.2

arc-seconds

or 0.0003°)

Emulated

The following table provides 17S emulated encoder output (in incremental format)

specifications.

Encoder Output

(Incremental

Format)

EMULATED ENCODER OUTPUT (INCREMENTAL FORMAT)

Specifications

Table

Channels

Type

A, B, and Marker

Differential, RS-485 compliant

Resolution with:

Resolver feedback

512, 1024 line count; 1024/2048/4096 edges

Sin-Cos Encoder feedback 512/1024/2048/4096/8192/16384 line count

Continued on next page

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Electrical Specifications - Signal, continued

The following diagram shows the timing for the encoder output (incremental format).

Encoder Output

(Incremental

Format) Timing

Diagram

Auxiliary

The following table provides 17D encoder input (slave) specifications.

Incremental

Encoder Input

Specifications

Table

ENCODER INPUT (SLAVE)

Channels

Type

A and B

Differential, RS-485 compliant

8 V nominal

Voltage

Current

200 mA (maximum)

500 kHz

Maximum frequency

Rise time

Fall time

< 0.1 µs

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Electrical Specifications - Signal, continued

Discrete Input

Specifications

Table

The following table provides 17S discrete input specifications.

DISCRETE INPUT

Channels

Five (four programmable and one dedicated for enable)

Solid state, optically isolated, compatible IEC 1131-2 type 1

250 Vac (channel to chassis)

Type

Transient

isolation voltage

maximum

30 Vdc

@ V = 24 V

5 mA

minimum

12 V (minimum input voltage to be recognized as high – true)

7 V (maximum input voltage to be recognized as low – false)

maximum

Scan time:

Normal

1 ms

High speed

< 50 µs

Discrete Output

Specifications

Table

The following table provides 17S discrete output specifications.

DISCRETE OUTPUT

Channels

Type

Two

Solid state: open collector 30 Vdc max., optically isolated

250 Vac (channel to chassis)

Transient

isolation voltage

Sense

True low, sinking

10 mA maximum

OUT

Protection

Yes (PTC resistor: 25 Ω)

Scan time

1 ms

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Electrical Specifications - Signal, continued

Fault Relay

Output

The following table provides 17S fault relay output specifications.

FAULT RELAY OUTPUT

Specifications

Table

Type

Relay contact

True (open)

Sense

30 Vdc; 42 Vac

MAX

500 mA resistive

OUT

Brake Output

Specifications

Table

The following table provides 17S brake output specifications.

BRAKE OUTPUT

Internally connected to

bias supply

OUT

2 A (maximum)

OUT

Note: An external brake relay is required for cable lengths greater than 50 m.

Continued on next page

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Electrical Specifications - Signal, continued

Analog Input

Specifications

Table

The following table lists the analog inputs specifications.

ANALOG INPUTS

Channels

Two

Type

Differential, non–isolated

±10V

Maximum common mode

voltage referenced to AGND

Measurement range

±10 Vdc

±12 V

Maximum differential input

Accuracy

12 bits

Resolution

Input 1 = 14 bits (±10V range)

Input 2 = 12 bits (±10V range)

Input impedance

Scan time

20 kΩ

250 µs

Serial

The following table lists the serial communications specifications.

Communications

Specifications

Table

SERIAL I/O

Data bits

Stop bits

Parity

Eight

One

None

9600

Baud rate

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Wire Specifications (Recommended)

Wire

Specifications

The following table lists the recommended wire specifications. Use only copper wire

with insulation rated at 75°C or greater, unless otherwise specified.

Item

Drive Model No.

Wire Size

Notes

AC mains

MHDS1004N00

MHDS1008N00

MHDS1017N00

MHDS1028N00

1.5 mm (14 AWG)

MHDS1056N00

All

4.0 mm (12 AWG)

Protective earth

DC Link

4.0 mm (12 AWG)

MHDS1004N00

MHDS1008N00

MHDS1017N00

MHDS1028N00

Shielded for lengths

greater than 20cm

1.5 mm (14 AWG)

MHDS1056N00

Shielded for lengths

greater than 20cm

4.0 mm (12 AWG)

Analog signals

All

Twisted pairs,

shielded

0.25 mm (22 AWG)

minimum

Digital I/O and Fault

Relay

All

0.5 mm (20 AWG)

minimum

Brake

Shielded

1.0 mm (18 AWG)

minimum

Bias power

2.5 mm (14 AWG)

maximum

Optional external

Regen resistor

High temperature

insulation (155°C or

greater)

1.5 mm (14 AWG)

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100

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Parts List

At a Glance

What’s in this

Appendix

This appendix contains information about the following Lexium 17S parts and

assemblies.

Topic

Page

102

103

104

106

107

108

Lexium 17S drives

External 24Vdc supply

Drive cables

Optional external Regen resistor assemblies

Optional motor choke

Spare parts

101

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Lexium 17S Drives

Drives Available

The Lexium 17S drives are available in five models according to different output

current levels as identified in the following table.

Model

Intermittent (Peak)

Output Current

Continuous (RMS)

Output Current

MHDS1004N00

MHDS1008N00

MHDS1017N00

MHDS1028N00

MHDS1056N00

4.2 A

1.5 A

3.0 A

6.0 A

10.0 A

20.0 A

8.4 A

16.8 A

28.0 A

56.0 A

102

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External 24Vdc supply

External 24Vdc

supply

A reminder of the a 24 V compsumption for the Lexium MHDA/MHDS servodrives

with BHP motors is given below.

Lexium servodrive

MHD•1004/

1008N00

MHD•1017N00 MHD•1028N00

MHD•1056N00

Associated BPH motor

075•

095•

0.75

1.45

115•

0.75

1.55

095• 115•

142• 142•

190•

1.2

Current without brake (A) 0.75

0.75

1.45

0.75

1.45

0.75

1.55

0.75

1.75

1.2

2.2

Current with brake (A)

Description

1.25

2.7

Output voltage

Rating

Parallel connection Ref.

Weight

24 Vdc

SELV

Yes

TSX SUP 1011

(1) (2)

0.720

1.1

^Module∼ 100...240 V

50/60 - 400 Hz

and 125 Vdc

24 Vdc

SELV

2.2

Yes

TSX SUP 1021

(1) (2)

1.090

1.120

2.100

^Module∼ 100...120 V

^and∼ 200...240V,

50/60 - 400 Hz

TSX SUP 1051

(1) (2)

24 Vdc

SELV

TSX SUP 1101

(1)

^Unit∼ 100...120V and

∼ 200...240V,

50/60 - 400 Hz

(1) Product supplied as standard with a bilingual reference guide: French and English.

(2) Mounted in Premium TSX RKY 6/8/12/6E/8E/12E racks (any slot except the slot for TSX PSY••0M

power supply modules), on AM1-DE200/DP200 rails or on AM1-PA mounting plate.

103

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Drive Cables

Drive to Motor

Cables

Consult the BPH motors manual for drive-to-motor cable part numbers and motor

part numbers.

RS-232 Serial

To connect the drive’s serial interface port to your PC, use the following cable.

Communications

Cable Part Table

Part Number

Description

AM0CAV001V003

3 m cable

Encoder Output

Cable Parts

Table

The following table lists encoder output cable for the Lexium 17S drive.

Part Number

Description

690MCI00206

6 m 17S to tinned leads

Continued on next page

104

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Drive Cables, continued

Fiber Optic

Cables Parts

Table

The following table lists part numbers for SMA 1000 micron plastic SERCOS fiber

optic cables. These cables range in length from 0.3...38 m. Each cable terminates

with an SMA type connector.

CAUTION!

The minimum bend radius for these fiber optic cables is 25 mm (1 inch). Do NOT

exceed this bend radius.

Failure to stay within the 25 mm (1 inch) bend radius can result in damaged

cables.

The maximum tensile load during installation is 25 Kg/cable. Operating

temperature is -40°C ... 80°C.

Part Number

Description

1 ft cable

Length (m)

0.3

990MCO00001

990MCO00003

990MCO00005

990MCO00015

990MCO00025

990MCO00035

990MCO00045

990MCO00055

990MCO00065

990MCO00075

990MCO00085

990MCO00095

990MCO00105

990MCO00115

990MCO00125

990MCI00008

3 ft cable

0.9

5 ft cable

1.5

15 ft cable

25 ft cable

35 ft cable

45 ft cable

55 ft cable

65 ft cable

75 ft cable

85 ft cable

95 ft cable

105 ft cable

115 ft cable

125 ft cable

Bulk head connector

4.6

7.6

10.7

13.7

16.8

19.8

22.9

25.9

37.5

105

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Optional External Regen Resistor Assemblies

Optional Regen

Resistor

The following table identifies the optional external Regen resistor assemblies

available for the Lexium 17S drive.

Assembly Part

Table

Part Number

Description

AM0RFE001V025

AM0RFE001V050

AM0RFE001V150

33Ω, 250 W, Regen resistor

33Ω, 500 W, Regen resistor

33Ω, 1,500 W, Regen resistor

106

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Optional Motor Choke

Optional Motor

These following table identifies the servo motor choke available for the Lexium 17S

Choke Part Table drive.

Part Number

AM0FIL001V056

Description

Motor choke

107

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Spare Parts

Table

These field-replaceable spare parts are available from Schneider.

Part Number

Description

AM0SPA001V000

17S Connector Kit:

I/O connector

24 V connector

DC Bus connector

Regen resistor connector

Mains supply connector

108

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Cable Connection Wiring

Diagrams

At a Glance

What’s in this

Appendix

This appendix provides procedures and diagrams that show you how to wire

certain cable connectors that are used with the Lexium 17S drive.

This appendix presents the following topics.

Topic

Page

110

Wiring a Sub-D connector with shielding

Wiring up the motor power connector (drive end)

Serial communications interface connector (X6)

112

115

109

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Wiring a Sub-D Connector with Shielding

Wiring the Sub-D If you construct your own Sub-D connector with shielding, please do so according

Connector

to the following procedure which correlates to the eight steps in the diagram that

follows this procedure.

Step Action

Carefully remove about 25mm of the outer covering while taking care not to

damage the braided shield.

Push the exposed braided shield back over the outer covering.

Leave the first 12mm of the braided shield free and insulate the rear portion

with shrink tubing.

Carefully strip about 5mm from the individual wires while taking care not to

damage the copper strands.

Verify pin assignments then solder the individual wires to the solder cups of the

Sub-D connector. (Check the wire colors.)

Attach the cable to the connector housing strain relief; the strain relief must

have good contact with the exposed shielding of the cable.

Place the knurled screws in position.

Place the Sub-D connector in the groove of the half-housing (pin 1 at bottom)

and press the two halves together.

Note: Once the halves of the housing have been pressed together, they cannot

be opened without damaging them.

Continued on next page

110

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Wiring a Sub-D Connector with Shielding, continued

Sub-DConnector The following diagram shows the eight steps required to wire a Sub-D connector

Diagram

with shielding.

111

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Wiring the Motor Power Connector (Drive end)

Wiring the Motor

If you construct your own motor power connector, please do so according to the

PowerConnector following procedure which correlates to the 13 steps in the diagram that follows this

procedure.

Step Action

Carefully remove about 70 mm of the outer jacket while taking care not to

damage the braided shield.

Push the grommet over the cable until the end is flush with the jacket.

Push the outer braided shield back over the grommet.

Position the shielding for the brake wires over the outer shielding braid and

ensure good electrical contact.

Push the filling wires and protective cloth back over the shielding.

Push the shrink tubing (30mm long) over the shielding and leave about 15mm

exposed.

Use a hot-air blower to shrink the tubing then shorten the wires for U, V, W to

45mm and those for BR+, BR- to 55mm.

Carefully remove about 10mm of the ends of the wires while taking care not to

damage the copper strands.

Attach crimp ferrules to the ends of the wires

Place the shielding plate in the connector housing and push the contact tabs

into the PE terminal clamp of the connector.

Attach the cable with the strain relief.

Ensure the clamping loop of the strain relief sits properly on the shielding braid.

Push the wire ferrules into the corresponding terminals in the connector and

tighten.

Continued on next page

112

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Wiring the Motor Power Connector (Drive end), continued

Motor Power

The following diagram shows the 13 steps required to wire a motor power

Connector (Drive connector (excluded BPH055).

end) Diagram

(excluded

BPH055)

113

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Wiring the Motor Power Connector (Drive end), continued

BPH055 Motor

The following diagram shows the 13 steps required to wire a BPH055 motor power

PowerConnector connector.

(Drive end)

Diagram

114

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Serial Communication Interface Connection (X6)

Serial

The following diagram details the null modem connection between the drive and a

Communication

Interface Cable

Connectors

PC.

115

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116

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Servo Loop Diagrams

At a Glance

What’s in this

Appendix

This appendix illustrates several servo loops within a 17S SERCOS drive system.

Topic

Page

118

17S current controller overview

17S velocity controller loop

17S position controller loop

119

120

117

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17S Current Controller Overview

17S Current

Controller

Diagram

The following diagram shows an overview of the 17S current controller servo loop.

118

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17S Velocity Controller Loop

17S Velocity

Controller Loop

Diagram

The following diagram shows a 17S velocity controller servo loop.

119

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17S Position Controller Loop

17S Position

Controller Loop

Diagram

The following diagram shows a 17S position controller servo loop.

120

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Optional External Regen Resistor

Sizing

At a Glance

What’s in this

Appendix

This appendix contains descriptions and procedures for calculating the power

dissipation requirements for the optional external Regen resistor.

This appendix presents the following topics.

Topic

Page

123

125

Determining external Regen resistor size

Example Regen resistor power dissipation calculation

Continued on next page

121

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At a Glance, continued

Overview

When the drive is braking or decelerating a moving load, the kinetic energy of the

load must be absorbed by the drive. As the drive decelerates the load, this energy

charges the DC link capacitors to successively higher voltages. To prevent damage

to the internal electronics, a shunt regulator circuit will apply the Regen resistor

across the capacitors when the voltage rises to a set voltage level (determined by

the “Mains Voltage” parameter). This dissipates the remaining energy as heat in the

Regen resistor. The energy dissipated by the Regen resistor must be calculated in

order to determine the proper power rating of the resistor.

Determining

When Energy Is

Absorbed

To determine when the drive is absorbing energy, examine the motion profile (that

is, a graphical plot) of axis speed and torque applied to the motor. Whenever the

sign (+ or -) of the torque applied to the motor is opposite that of the speed, the

drive is absorbing energy. This typically happens when the drive is decelerating the

motor, the motor is controlling tension in a web application, or the motor is lowering

a mass in a vertical axis.

122

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Determining Optional External Regen Resistor Size

Power

The following is the procedure for calculating the power dissipated by the Regen

Dissipation

Calculation

Procedure

resistor in a simple system wherein friction is negligible. Ignoring friction in the

following calculations gives worst case results since friction will absorb a portion of

the energy during deceleration. An example of each step in this procedure is

provided later in this chapter.

Step Action

Plot speed versus time and torque versus time for the entire move cycle.

(Magnitude of the torque is not required; only the direction is required.)

Identify each section of the plot where the drive is decelerating the load or

where speed and torque have opposite signs.

Calculate the energy returned to the drive in each deceleration using the

formula E = ½ J ω

Where

E = Energy in joules

J = Total system inertia, including motor, in kg(m )

ω = Speed at start of deceleration in radians per second

(ω = 2 π RPM / 60)

Compare the energy in each deceleration with the energy required to turn

on the Regen circuit. (See Drive Energy Absorption Capability table.) If the

energy is less than that listed in the table, disregard that deceleration for

the remainder of the calculations.

Calculate the energy dissipated by the Regen resistor by subtracting the

energy listed in the table from the energy of the deceleration.

= E

– E

dissipated

generated

absorbed by capacitors

Calculate the pulse power of each deceleration by dividing the dissipated

energy by the time of the deceleration.

= E

/ T

pulse

dissipated decel (seconds)

Calculate the continuous power dissipated by the Regen resistor by

totaling all the dissipated energy and dividing it by the total cycle time.

= (E1

+ E2

+… +En

) / T

dissipated total cycle (seconds)

continuous

dissipated

Continued on next page

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Determining External Regen Resistor Size, continued

Power

Dissipation

Calculation

Step Action

Procedure,

Compare the pulse power and the continuous power calculated with the

continued

ratings of the internal Regen resistor in the drive. If either one is greater

then an optional external Regen resistor must be chosen and installed.

(See the Parts List appendix for a list of the available optional external

Regen resistors.)

Drive Energy

Absorption

Capability

The drive energy absorption capability values (in joules) that are needed during the

sizing calculations are provided in the following table.

Drive Energy Absorption Capability (joules)

Line Voltage

230 VAC

400 VAC

480 VAC

Drive

MHDS1004N00

Model

Number

MHDS1008N00

MHDS1017N00

MHDS1028N00

MHDS1056N00

Note: Multiple drives can be interconnected via the DC-Link. When this is done, the

energy absorption capability of the drives and the continuous power ratings of the

Regen resistors are additive. The energy absorbed by the drives must be

calculated by superimposing all the time speed plots and calculating the energy

generated by each axis. (For calculating the power in complex multi-drive

applications contact Schneider Electric for assistance.)

124

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Example Regen Resistor Power Dissipation Calculation

Example Motor

and Drive

Specifications

The following is an example application of each step in the power dissipation

calculation procedure using the motor, drive and input power specifications

identified below. Refer to the power dissipation calculation procedure presented

earlier in this chapter.

Motor = BPH1423N with brake

Total Inertia (J ) = J + J + J = 0.002 + 0.001 + 0.007 = 0.01 kgm

where:

Motor inertia (J ) = 0.002 kg(m )

Brake inertia (J ) = 0.001 kg(m )

Load inertia (J ) = 0.007 kg(m )

Drive = MHDS1028N00

Line Voltage = 480 Vac

Continued on next page

125

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Example Regen Resistor Power Dissipation Calculation, continued

Example Step 1

Plot speed versus time and torque versus time for the entire move cycle.

Continued on next page

126

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Example Regen Resistor Power Dissipation Calculation, continued

Example Step 2

Identify each deceleration of the plot where the drive is decelerating the load.

Example Step 3

Calculate the energy returned to the drive in each deceleration as follows:

Deceleration 1

ω = 2 π 3000RPM / 60 = 314 radians/sec

E = ½ 0.01kgm (314 radians/sec) = 493 joules

Deceleration 2

ω = 2 π 600RPM / 60 = 63 radians/sec

E = ½ 0.01kgm (63 radians/sec) = 20 joules

Deceleration 3

ω = 2 π 3450RPM / 60 = 361 radians/sec

E = ½ 0.01kgm (361 radians/sec) = 652 joules

Continued on next page

127

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Example Regen Resistor Power Dissipation Calculation, continued

Example Step 4

Compare the energy in each deceleration with the energy required to turn on the

Regen circuit (that is, the energy absorbed by the internal capacitors).

As specified in the Drive Energy Absorption Capability table, the MHDS1028N00

drive at 480 Vac can absorb 23 joules without turning on the Regen resistor circuit.

Deceleration 1: 493 joules > 23 joules

Deceleration 2: 20 joules < 23 joules (disregard this segment in the remaining

steps)

Deceleration 3: 652 joules > 23 joules

Example Step 5

Example Step 6

Example Step 7

Calculate dissipated energy as follows:

Deceleration 1: E = 493 – 23 = 470 joules

Deceleration 3: E = 652 – 23 = 629 joules

Calculate the pulse power as follows:

Deceleration 1: P

= 470 joules / 0.5 seconds = 940 watts

= 629 joules / 0.5 seconds = 1258 watts

pulse

Deceleration 3: P

Calculate continuous power as follows:

= (470 joules + 629 joules) / 4.75 seconds = 231 watts

continuous

Continued on next page

128

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Example Regen Resistor Power Dissipation Calculation, continued

Example Step 8

Compare the ratings as follows:

Internal Regen resistor ratings of the MHDS1028N00:

= 21 kW

pulse

= 200W

continuous

Deceleration 1: P

Deceleration 2: P

= 940W < 21 kW rating

= 1258W < 21 kW rating

pulse

= 231W > 200W

continuous

Requires an optional external Regen resistor be used. Select the 250W

optional external Regen resistor or modify the profile to reduce the continuous

power dissipated.

129

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Index

DC Link capacitor reconditioning, 29

default settings, 31

AC mains power supply, connection, 49

acronyms and abbreviations, 12

additional safety guidelines, 9

air flow, 36

determining external regen resistor size,

123

digital control, 25

analog

digital inputs and outputs connection, 64

dimensions, physical, 44, 48, 55

discrete

input connection, 63

input specifications, 98

auxiliary encoder interface, 60

input specifications, 96

output specifications, 96

document scope, 1

bias

drive dimensions, 37

drive energy absorption capability, 124

drive implementation, 16

drive models, 16, 102

drive mounting and physical dimensions,

37, 38

input specifications, 89

power, 28

supply, connection, 49

BPH055 Motor Power Connector (Drive

end) Diagram, 114

drives available, 16

drives, family, 18

brake output specifications, 97

drives, front view, 19

cable

drive-to-motor cables, 104

separation, 36

shield connections, 47, 48

cables

earth connections, 36

EC directive compliance, 10

electric shock hazards, 6

electrical considerations, 17

electrical specifications, 87, 91

regen resistor, 92

parts list, 104

current controller servo loop, 118

signal, 93

890 USE 121 00

131

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Index

electrostatic components precaution, 8

internal power, 29

emergency stop strategies, 69

EMI suppression, 28

internal power dissipation specifications,

encoder

input connection, 59

input specifications, 94

output cables, 104

keypad operation, 73

output specifications, 94, 95

environmental and mechanical

specifications, 85

environmental specifications, 85

equipment available, 20

equipment supplied, 20

error identification and description, 77

error messages, 77

European directives and standards, 10

example motor and drive specifications,

125

External 24Vdc supply, 103

external fuse specifications, 89

external Regen resistor mounting and

physical dimensions, 39

external regen resistor, connections, 51

LED display, 30, 73

Lexium 17S, 44, 46

connection diagram, 45

drives, 102

system configuration, diagram, 21

Lexium BPH resolver connection (excluded

BPH055), 57

Lexium BPH055 resolver connection, 58

line input specifications, 88

mechanical specifications, 86

models, drive, 16, 102

motor

output specifications, 90

fault relay and digital I/O, connection, 64

fault relay output specifications, 97

fiber optic cables parts table, 105

front panel controls and indicators, 73

overtemperature specifications, 93

to drive cables, 104

motor choke mounting and dimensions, 40

motor power connector wiring diagram

(excluded BPH055), 113

general characteristics, 28

grounding, 43

optional external Regen resistor assembly

dimensions, 39

optional motor choke, 107

optional motor choke assembly

dimensions, 40

hazards and warnings, 6

output cables, 104

overcurrent protection, 36

overview

installation considerations, 36

drive models, 16, 102

installation safety precautions, 34

internal electronics, block diagram, 27

132

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Index

parts list

safe electrical separation, 29

SERCOS

cables, 104

overview, 101

regen resistor assemblies, 106

spare parts, 107, 108

communication LED indicators, 74

fiber- optic transmit and receive

connectors, 22

performance specifications table, 84

physical dimensions, 37

pin assignments, 46

network overview, 22

Network Ring Configuration, 23

standard, 11

position servo loop, 120

power

serial communications specifications table,

dissipation calculation, 123

electrical specifications, 88

supply overcurrent protection, 36

wiring, 49

serial communications, connection, 66

serial power, connections, 50

servo loops

current controller, 118

power-on and power-off characteristics, 68

pre-programmed functions, use, 65

primary power, 28

problems, possible causes and corrective

actions, 81

position controller, 120

velocity controller, 119

servo motor (with brake) (excluded

BPH055), connection, 52

servo motor (with Optional Dynamic Brake

Resistors and Contactor), connection, 54

servo motor BPH 055 (with options),

connection, 53

products, introduction, 15

servo motor holding-brake control, 55

servo motors, types, 16

qualified personnel, 9

quick start procedure, 71

setting parameters, 31

signal wiring, 57

software setup, 31

spare parts, 107, 108

regen circuit functional description, 51

regen circuit specifications, 92

regen resistor

assembly parts list, 106

determining when energy is absorbed,

122

power dissipation calculation, example,

125