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Rexroth IndraDrive
Standard Application "Open Loop"
for Firmware MPB03VRS
Standard Application
About this Documentation
Title
STA02 Open Loop
Rexroth IndraDrive
Standard Application "Open Loop"
Type of Documentation
Application Manual
Document Typecode
Internal File Reference
BRC/SAL3
Document Number, STA02_Open_Loop
Purpose of Documentation
This documentation describes an example of commissioning.
Application OPEN LOOP with Rexroth IndraDrive.
Record of Revisions
Copyright
Description
Release
Date
Notes
2006.06.23
1. Edition
 2006 Bosch Rexroth AG
Copying this document, giving it to others and the use or communication
of the contents thereof without express authority, are forbidden. Offenders
are liable for the payment of damages. All rights are reserved in the event
of the grant of a patent or the registration of a utility model or design
(DIN 34-1).
Validity
Published by
The specified data is for product description purposes only and may not
be deemed to be guaranteed unless expressly confirmed in the contract.
All rights are reserved with respect to the content of this documentation
and the availability of the product.
Bosch Rexroth AG
Bgm.-Dr.-Nebel-Str. 2 • D-97816 Lohr a. Main
Telephone +49 (0)93 52/40-0 • Tx 68 94 21 • Fax +49 (0)93 52/40-48 85
http://www.boschrexroth.com/
Dept. (BRC/SAL3/NSP)
Note
STA02 Open Loop
Contents I
Contents
1
Introduction and Overview
1.1
1.2
1.3
1-1
Purpose of this Documentation ..................................................................................................... 1-1
Open-Loop Applications................................................................................................................ 1-1
Supplemental Documentation ....................................................................................................... 1-1
2
Notes Regarding Use
2-1
3
Safety Instructions for Electric Drives and Controls
3-1
3.1
3.2
General Information ...................................................................................................................... 3-1
Using the Safety Instructions and Passing them on to Others ................................................ 3-1
Instructions for Use .................................................................................................................. 3-1
Explanation of Warning Symbols and Degrees of Hazard Seriousness.................................. 3-3
Hazards by Improper Use ........................................................................................................ 3-4
Instructions with Regard to Specific Dangers ............................................................................... 3-5
Protection Against Contact with Electrical Parts...................................................................... 3-5
Protection Against Electric Shock by Protective Low Voltage (PELV) .................................... 3-6
Protection Against Dangerous Movements ............................................................................. 3-7
Protection Against Magnetic and Electromagnetic Fields During Operation and
Mounting .................................................................................................................................. 3-9
Protection Against Contact with Hot Parts ............................................................................. 3-10
Protection During Handling and Mounting ............................................................................. 3-11
Battery Safety......................................................................................................................... 3-11
Protection Against Pressurized Systems............................................................................... 3-12
4
Drive Sizing
4-1
5
Hardware and Firmware Used
5-1
5.1
5.2
5.3
5.4
5.5
6
General Connection, Block Diagram
6.1
6.2
6.3
6.4
6.5
7
Power Section ............................................................................................................................... 5-1
HCS Converter......................................................................................................................... 5-1
HMS Converters....................................................................................................................... 5-1
HMV Supply Units ................................................................................................................... 5-1
Type Codes Control Sections ....................................................................................................... 5-2
Type Codes Firmware................................................................................................................... 5-2
Motors ........................................................................................................................................... 5-3
Software Tool Rexroth DriveTop................................................................................................... 5-3
General Design of the HCS Drive Controllers............................................................................... 6-1
Overview Connection Plan / Block Diagram ................................................................................. 6-2
General Power Connection ........................................................................................................... 6-3
Example: Power Supply with HCS.......................................................................................... 6-3
Example for Group Power Supply with HCS ........................................................................... 6-3
Control Circuits for Power Connection of Rexroth IndraDrive C Drive Controllers....................... 6-4
EMC-Optimized Installation in the Control Cabinet ...................................................................... 6-5
Interfaces
7.1
6-1
7-1
Overview interfaces Control unit ................................................................................................... 7-1
II Contents
8
Drive Functions
8.1
8.2
8.3
8.4
8.5
8.6
8.7
8.8
8.9
8.10
8.11
8.12
8.13
9
9-1
Starting DriveTop .......................................................................................................................... 9-1
Loading Basic DriveTop Parameters ............................................................................................ 9-2
Selecting Function Packages........................................................................................................ 9-3
Drive Status................................................................................................................................... 9-4
Drive Application ........................................................................................................................... 9-5
Setting Drive Control Parameters ................................................................................................. 9-6
Selecting the Analog Input ............................................................................................................ 9-8
Motor Parameters ......................................................................................................................... 9-8
Operating Mode Selection............................................................................................................. 9-9
Scaling and Units .......................................................................................................................... 9-9
Gears............................................................................................................................................. 9-9
Operating Modes......................................................................................................................... 9-10
Drive Control ............................................................................................................................... 9-11
Drive Stop.................................................................................................................................... 9-15
Fault Reaction ............................................................................................................................. 9-16
Emergency Stop.......................................................................................................................... 9-16
Status Messages......................................................................................................................... 9-16
Special/Optional Drive Functions ................................................................................................ 9-17
10 Extras
10.1
10.2
10.3
10.4
8-1
Inputs/Outputs ............................................................................................................................... 8-1
Master Communication for Terminals X31 and X32 ..................................................................... 8-2
Plug 2, Serial Interface (RS232) for Commissioning and Programming ...................................... 8-4
Analog Input .................................................................................................................................. 8-5
Entering Motor Parameters ........................................................................................................... 8-5
Operating Mode Selection............................................................................................................. 8-6
Scaling and Units .......................................................................................................................... 8-7
Operating Mode ............................................................................................................................ 8-8
Drive Control ................................................................................................................................. 8-9
Drive Stop.................................................................................................................................... 8-12
Fault Reaction ............................................................................................................................. 8-13
Status Messages......................................................................................................................... 8-14
Special/Optional Drive Functions ................................................................................................ 8-16
Commissioning
9.1
9.2
9.3
9.4
9.5
9.6
9.7
9.8
9.9
9.10
9.11
9.12
9.13
9.14
9.15
9.16
9.17
9.18
STA02 Open Loop
10-1
Fan Drive..................................................................................................................................... 10-1
Command Value Generation....................................................................................................... 10-1
V/f Characteristic Curve .............................................................................................................. 10-2
Velocity Search Function ............................................................................................................ 10-3
Introduction and Overview 1-1
STA02 "Open Loop"
1
Introduction and Overview
1.1
Purpose of this Documentation
This documentation uses examples to describe the quick and simple
implementation of open-loop drives using Rexroth Indradrive drive control
devices. It supports the user in the quick design and commissioning of
applications using asynchronous machines without encoder feedback.
Typical functions of open-loop drives are clearly explained using specific
practical examples.
1.2
Open-Loop Applications
In operation without encoders, the velocity control loop in the drive is not
closed. The drive is operated under velocity control using a V/f control or
encoderless field-oriented vector control.
Open-loop drives are used for all applications with asynchronous motors
for which there are no unusually high demands in terms of speed or
torque precision. They represent an inexpensive solution for the variablespeed operation of asynchronous machines.
1.3
Supplemental Documentation
For further technical information regarding the products and components
mentioned in this documentation, please see the latest editions of the
product documentation:
IndraDrive Firmware for Drive Control Devices –
Description of Functions
R911 308328
IndraDrive Drive Control Devices –
Description of Parameters
R911 297316
IndraDrive – Notes Regarding Fault Clearance
R911 297318
IndraDrive C Drive Control Devices
Power Section HCS02.1 – Design
R911 306137
IndraDrive C Drive Control Devices
Power Section HCS03.1 – Design
R911 307048
IndraDrive M Drive Control Devices
Power Section – Design
R911 295013
IndraDrive Power Supply Devices – Design
R911 307048
IndraDrive Drive Control Devices, Control Section – Design R911 295011
IndraDrive Drive Systems – Design
R911 309635
IndraDrive Additional Components – Design
R911 306139
The current editions of these documents can be downloaded from
www.boschrexroth.com/BrcDoku.
Notes Regarding Use 2-1
STA02 "Open Loop"
2
Notes Regarding Use
The information provided in this documentation regarding the use of the
devices and components serves only as examples of application and as
suggestions; it is not to be understood to be warranted properties in the
legal sense.
The machine manufacturer and person/company setting up the system
must:
• check the components delivered and the details specified in this
documentation regarding their use for his own application, and
• check that the application he has in mind meets the valid safety
regulations and standards and that he has carried out the required
measures, changes and additions.
When using the devices and components mentioned in this
documentation, the corresponding technical documents absolutely must
be observed in each case (also see section1.3), especially the notes
regarding use and safety contained therein.
Safety Instructions for Electric Drives and Controls 3-1
STA02 "Open Loop"
3
Safety Instructions for Electric Drives and Controls
3.1
General Information
Using the Safety Instructions and Passing them on to Others
Do not attempt to install or commission this device without first reading all
documentation provided with the product. Read and understand these
safety instructions and all user documentation prior to working with the
device. If you do not have the user documentation for the device, contact
your responsible Bosch Rexroth sales representative. Ask for these
documents to be sent immediately to the person or persons responsible
for the safe operation of the device.
If the device is resold, rented and/or passed on to others in any other
form, then these safety instructions must be delivered with the device.
WARNING
Improper use of these devices, failure to follow
the safety instructions in this document or
tampering with the product, including disabling
of safety devices, may result in material
damage, bodily harm, electric shock or even
death!
Instructions for Use
Read these instructions before the initial startup of the equipment in order
to eliminate the risk of bodily harm or material damage. Follow these
safety instructions at all times.
• Bosch Rexroth AG is not liable for damages resulting from failure to
observe the warnings provided in this documentation.
• Read the operating, maintenance and safety instructions in your
language before starting up the machine. If you find that you cannot
completely understand the documentation for your product, please ask
your supplier to clarify.
• Proper and correct transport, storage, assembly and installation as
well as care in operation and maintenance are prerequisites for
optimal and safe operation of this device.
• Only assign trained and qualified persons to work with electrical
installations:
• Only persons who are trained and qualified for the use and
operation of the device may work on this device or within its
proximity. The persons are qualified if they have sufficient
knowledge of the assembly, installation and operation of the
equipment as well as an understanding of all warnings and
precautionary measures noted in these instructions.
• Furthermore, they must be trained, instructed and qualified to
switch electrical circuits and devices on and off in accordance with
technical safety regulations, to ground them and to mark them
according to the requirements of safe work practices. They must
have adequate safety equipment and be trained in first aid.
• Only use spare parts and accessories approved by the manufacturer.
• Follow all safety regulations and requirements for the specific
application as practiced in the country of use.
3-2 Safety Instructions for Electric Drives and Controls
STA02 "Open Loop"
• The devices have been designed for installation in industrial
machinery.
• The ambient conditions given in the product documentation must be
observed.
• Only use safety-relevant applications that are clearly and explicitly
approved in the Project Planning Manual. If this is not the case, they
are excluded.
Safety-relevant are all such applications which can cause danger to
persons and material damage.
• The information given in the documentation of the product with regard
to the use of the delivered components contains only examples of
applications and suggestions.
The machine and installation manufacturer must
• make sure that the delivered components are suited for his
individual application and check the information given in this
documentation with regard to the use of the components,
• make sure that his application complies with the applicable safety
regulations and standards and carry out the required measures,
modifications and complements.
• Startup of the delivered components is only permitted once it is sure
that the machine or installation in which they are installed complies
with the national regulations, safety specifications and standards of the
application.
• Operation is only permitted if the national EMC regulations for the
application are met.
• The instructions for installation in accordance with EMC requirements
can be found in the documentation "EMC in Drive and Control
Systems".
The machine or installation manufacturer is responsible for
compliance with the limiting values as prescribed in the national
regulations.
• Technical data, connections and operational conditions are specified in
the product documentation and must be followed at all times.
Safety Instructions for Electric Drives and Controls 3-3
STA02 "Open Loop"
Explanation of Warning Symbols and Degrees of Hazard Seriousness
The safety instructions describe the following degrees of hazard
seriousness. The degree of hazard seriousness informs about the
consequences resulting from non-compliance with the safety instructions:
Warning symbol with signal
word
Degree of hazard seriousness according
to ANSI Z 535
Death or severe bodily harm will occur.
DANGER
Death or severe bodily harm may occur.
WARNING
Bodily harm or material damage may occur.
CAUTION
Fig. 3-1
Hazard classification (according to ANSI Z 535)
3-4 Safety Instructions for Electric Drives and Controls
STA02 "Open Loop"
Hazards by Improper Use
High electric voltage and high working current!
Risk of death or severe bodily injury by electric
shock!
DANGER
Dangerous movements! Danger to life, severe
bodily harm or material damage by
unintentional motor movements!
DANGER
High electric voltage because of incorrect
connection! Risk of death or bodily injury by
electric shock!
WARNING
Health hazard for persons with heart
pacemakers, metal implants and hearing aids in
proximity to electrical equipment!
WARNING
Hot surfaces on device housing! Danger of
injury! Danger of burns!
CAUTION
CAUTION
Risk of injury by improper handling! Risk of
bodily injury by bruising, shearing, cutting,
hitting, or improper handling of pressurized
lines!
Risk of injury by improper handling of batteries!
CAUTION
Safety Instructions for Electric Drives and Controls 3-5
STA02 "Open Loop"
3.2
Instructions with Regard to Specific Dangers
Protection Against Contact with Electrical Parts
Note:
This section only concerns devices and drive components with
voltages of more than 50 Volt.
Contact with parts conducting voltages above 50 Volts can cause
personal danger and electric shock. When operating electrical equipment,
it is unavoidable that some parts of the devices conduct dangerous
voltage.
High electrical voltage! Danger to life, electric
shock and severe bodily injury!
DANGER
⇒ Only those trained and qualified to work with or on
electrical equipment are permitted to operate,
maintain and repair this equipment.
⇒ Follow general construction and safety regulations
when working on electrical power installations.
⇒ Before switching on the device, the equipment
grounding conductor must have been nondetachably connected to all electrical equipment in
accordance with the connection diagram.
⇒ Do not operate electrical equipment at any time,
even for brief measurements or tests, if the
equipment grounding conductor is not permanently
connected to the mounting points of the components
provided for this purpose.
⇒ Before working with electrical parts with voltage
potentials higher than 50 V, the device must be
disconnected from the mains voltage or power
supply unit. Provide a safeguard to prevent
reconnection.
⇒ With electrical drive and filter components, observe
the following:
Wait 30 minutes after switching off power to allow
capacitors to discharge before beginning to work.
Measure the voltage on the capacitors before
beginning to work to make sure that the equipment is
safe to touch.
⇒ Never touch the electrical connection points of a
component while power is turned on.
⇒ Install the covers and guards provided with the
equipment properly before switching the device on.
Before switching the equipment on, cover and
safeguard live parts safely to prevent contact with
those parts.
⇒ A residual-current-operated circuit-breaker or r.c.d.
cannot be used for electric drives! Indirect contact
must be prevented by other means, for example, by
an overcurrent protective device according to the
relevant standards.
⇒ Secure built-in devices from direct touching of
electrical parts by providing an external housing, for
example a control cabinet.
3-6 Safety Instructions for Electric Drives and Controls
STA02 "Open Loop"
European countries: according to EN 50178/ 1998,
section 5.3.2.3.
USA: See National Electrical Code (NEC), National
Electrical Manufacturers' Association (NEMA), as well as
local engineering regulations. The operator must observe
all the above regulations at any time.
With electrical drive and filter components, observe the following:
High housing voltage and large leakage current!
Risk of death or bodily injury by electric shock!
DANGER
⇒ Before switching on, the housings of all electrical
equipment and motors must be connected or
grounded with the equipment grounding conductor to
the grounding points. This is also applicable before
short tests.
⇒ The equipment grounding conductor of the electrical
equipment and the units must be non-detachably
and permanently connected to the power supply unit
at all times. The leakage current is greater than
3.5 mA.
⇒ Over the total length, use copper wire of a cross
2
section of a minimum of 10 mm for this equipment
grounding connection!
⇒ Before start-up, also in trial runs, always attach the
equipment grounding conductor or connect with the
ground wire. Otherwise, high voltages may occur at
the housing causing electric shock.
Protection Against Electric Shock by Protective Low Voltage (PELV)
All connections and terminals with voltages between 5 and 50 Volt at
Rexroth products are protective extra-low voltage systems which are
provided with touch guard according to the product standards.
High electric voltage by incorrect connection!
Risk of death or bodily injury by electric shock!
WARNING
⇒ To all connections and terminals with voltages
between 0 and 50 Volt, only devices, electrical
components, and conductors may be connected
which are equipped with a PELV (Protective ExtraLow Voltage) system.
⇒ Connect only voltages and circuits which are safely
isolated from dangerous voltages. Safe isolation is
achieved for example by isolating transformers, safe
optocouplers or battery operation without mains
connection.
STA02 "Open Loop"
Safety Instructions for Electric Drives and Controls 3-7
Protection Against Dangerous Movements
Dangerous movements can be caused by faulty control of connected
motors. Some common examples are:
• improper or wrong wiring of cable connections
• incorrect operation of the equipment components
• wrong input of parameters before operation
• malfunction of sensors, encoders and monitoring devices
• defective components
• software or firmware errors
Dangerous movements can occur immediately after equipment is
switched on or even after an unspecified time of trouble-free operation.
The monitoring in the drive components will normally be sufficient to avoid
faulty operation in the connected drives. Regarding personal safety,
especially the danger of bodily harm and material damage, this alone
cannot be relied upon to ensure complete safety. Until the integrated
monitoring functions become effective, it must be assumed in any case
that faulty drive movements will occur. The extent of faulty drive
movements depends upon the type of control and the state of operation.
3-8 Safety Instructions for Electric Drives and Controls
STA02 "Open Loop"
Dangerous movements! Danger to life, risk of
injury, severe bodily harm or material damage!
DANGER
⇒ For the above reasons, ensure personal safety by
means of qualified and tested higher-level monitoring
devices or measures integrated in the installation.
They have to be provided for by the user according
to the specific conditions within the installation and a
hazard and fault analysis. The safety regulations
applicable for the installation have to be taken into
consideration. Unintended machine motion or other
malfunction is possible if safety devices are disabled,
bypassed or not activated.
To avoid accidents, bodily harm and/or material
damage:
⇒ Keep free and clear of the machine’s range of
motion and moving parts. Possible measures to
prevent people from accidentally entering the
machine’s range of motion:
- use safety fences
- use safety guards
- use protective coverings
- install light curtains or light barriers
⇒ Fences and coverings must be strong enough to
resist maximum possible momentum.
⇒ Mount the emergency stop switch in the immediate
reach of the operator. Verify that the emergency stop
works before startup. Don’t operate the device if the
emergency stop is not working.
⇒ Isolate the drive power connection by means of an
emergency stop circuit or use a safety related
starting lockout to prevent unintentional start.
⇒ Make sure that the drives are brought to a safe
standstill before accessing or entering the danger
zone.
⇒ Additionally secure vertical axes against falling or
dropping after switching off the motor power by, for
example:
- mechanically securing the vertical axes,
- adding an external braking/ arrester/ clamping
mechanism or
- ensuring sufficient equilibration of the vertical
axes.
The standard equipment motor brake or an external
brake controlled directly by the drive controller are
not sufficient to guarantee personal safety!
Safety Instructions for Electric Drives and Controls 3-9
STA02 "Open Loop"
⇒ Disconnect electrical power to the equipment using a
master switch and secure the switch against
reconnection for:
- maintenance and repair work
-
cleaning of equipment
- long periods of discontinued equipment use
⇒ Prevent the operation of high-frequency, remote
control and radio equipment near electronics circuits
and supply leads. If the use of such devices cannot
be avoided, verify the system and the installation for
possible malfunctions in all possible positions of
normal use before initial startup. If necessary,
perform a special electromagnetic compatibility
(EMC) test on the installation.
Protection Against Magnetic and Electromagnetic Fields During
Operation and Mounting
Magnetic and electromagnetic fields generated by current-carrying
conductors and permanent magnets in motors represent a serious
personal danger to those with heart pacemakers, metal implants and
hearing aids.
Health hazard for persons with heart
pacemakers, metal implants and hearing aids in
proximity to electrical equipment!
WARNING
⇒ Persons with heart pacemakers and metal implants
are not permitted to enter following areas:
- Areas in which electrical equipment and parts are
mounted, being operated or commissioned.
- Areas in which parts of motors with permanent
magnets are being stored, repaired or mounted.
⇒ If it is necessary for somebody with a pacemaker to
enter such an area, a doctor must be consulted prior
to doing so. The interference immunity of present or
future implanted heart pacemakers differs greatly, so
that no general rules can be given.
⇒ Those with metal implants or metal pieces, as well
as with hearing aids must consult a doctor before
they enter the areas described above. Otherwise
health hazards may occur.
3-10 Safety Instructions for Electric Drives and Controls
STA02 "Open Loop"
Protection Against Contact with Hot Parts
Hot surfaces at motor housings, on drive
controllers or chokes! Danger of injury! Danger
of burns!
CAUTION
⇒ Do not touch surfaces of device housings and
chokes in the proximity of heat sources! Danger of
burns!
⇒ Do not touch housing surfaces of motors! Danger of
burns!
⇒ According to operating conditions, temperatures can
be higher than 60 °C, 140 °F during or after
operation.
⇒ Before accessing motors after having switched them
off, let them cool down for a sufficiently long time.
Cooling down can require up to 140 minutes!
Roughly estimated, the time required for cooling
down is five times the thermal time constant
specified in the Technical Data.
⇒ After switching drive controllers or chokes off, wait
15 minutes to allow them to cool down before
touching them.
⇒ Wear safety gloves or do not work at hot surfaces.
⇒ For certain applications, the manufacturer of the end
product, machine or installation, according to the
respective safety regulations, has to take measures
to avoid injuries caused by burns in the end
application. These measures can be, for example:
warnings, guards (shielding or barrier), technical
documentation.
Safety Instructions for Electric Drives and Controls 3-11
STA02 "Open Loop"
Protection During Handling and Mounting
In unfavorable conditions, handling and assembling certain parts and
components in an improper way can cause injuries.
Risk of injury by improper handling! Bodily
injury by bruising, shearing, cutting, hitting!
CAUTION
⇒ Observe the general construction and safety
regulations on handling and assembly.
⇒ Use suitable devices for assembly and transport.
⇒ Avoid jamming and bruising by appropriate
measures.
⇒ Always use suitable tools. Use special tools if
specified.
⇒ Use lifting equipment and tools in the correct
manner.
⇒ If necessary, use suitable protective equipment (for
example safety goggles, safety shoes, safety
gloves).
⇒ Do not stand under hanging loads.
⇒ Immediately clean up any spilled liquids because of
the danger of skidding.
Battery Safety
Batteries consist of active chemicals enclosed in a solid housing.
Therefore, improper handling can cause injury or damages.
Risk of injury by improper handling!
CAUTION
Note:
⇒ Do not attempt to reactivate low batteries by heating
or other methods (risk of explosion and
cauterization).
⇒ Do not recharge the batteries as this may cause
leakage or explosion.
⇒ Do not throw batteries into open flames.
⇒ Do not dismantle batteries.
⇒ Do not damage electrical parts installed in the
devices.
Environmental protection and disposal! The batteries installed
in the product are considered dangerous goods during land,
air, and sea transport (risk of explosion) in the sense of the
legal regulations. Dispose of used batteries separate from
other waste. Observe the local regulations in the country of
assembly.
3-12 Safety Instructions for Electric Drives and Controls
STA02 "Open Loop"
Protection Against Pressurized Systems
According to the information given in the Project Planning Manuals,
motors cooled with liquid and compressed air, as well as drive controllers,
can be partially supplied with externally fed, pressurized media, such as
compressed air, hydraulics oil, cooling liquids, and cooling lubricating
agents. In these cases, improper handling of external supply systems,
supply lines, or connections can cause injuries or damages.
CAUTION
Note:
Risk of injury by improper handling of pressurized
lines!
⇒ Do not attempt to disconnect, open, or cut
pressurized lines (risk of explosion).
⇒ Observe the respective manufacturer's operating
instructions.
⇒ Before dismounting lines, relieve pressure and
empty medium.
⇒ Use suitable protective equipment (for example
safety goggles, safety shoes, safety gloves).
⇒ Immediately clean up any spilled liquids from the
floor.
Environmental protection and disposal! The agents used to
operate the product might not be economically friendly.
Dispose of ecologically harmful agents separate from other
waste. Observe the local regulations in the country of
assembly.
Drive Sizing 4-1
STA02 "Open Loop"
4
Drive Sizing
Rexroth IndraSize
IndraSize - the comfortable program for sizing drives - helps you to find
the optimum drive for your machine or system at once.
indrasize.jpg
Fig. 4-1:
IndraSize
The user sizes all common drive mechanisms as e.g.
• ball-and-screw spindle drive with rotating spindle or nut,
• rack and pinion combinations,
• toothed belts,
• linear and rotating direct drives, etc.
Supported by the graphic features, simply mirror your machine kinematics
with graphical support. To this end, connect the motor and the selected
mechanical system with the different transmission elements (e.g. gears,
belt drive, …).
IndraSize allows you to freely assemble a complete motion profile from
individual motion sequences and leads you to the optimum drive in a
menu-driven selection process.
Download IndraSize from www.boschrexroth.com/indrasize
Hardware and Firmware Used 5-1
STA02 "Open Loop"
5
Hardware and Firmware Used
The drive controller to be used with converters comprises 3 parts: Power
section, control section, and firmware. When used with inverters, a supply
device is required in addition to power section, control section and
firmware.
5.1
Power Section
HCS Converter
HCS02 types are available for max. currents of 12, 28, 54, and 70A.
HCS03 types are available for max. currents of 70, 100, 150, and 210A.
350A is in preparation.
Type Code
HCS02.1E-Wxxxx-A-03-NNNN
Basic version
HCS02.1E-Wxxxx-A-03-NNNV
Version with integrated
power supply
HCS03.1E-Wxxxx-A-03-NNNN
Basic version
HCS03.1E-Wxxxx-A-03-NNNV
Version with integrated
power supply
Wxxxx stands for the temporarily available maximum current in A, e.g.
W0070 => maximum current 70 A
HMS Converters
Type Code HMS
HMS01.1N-Wxxxx-A-07-NNNN
Basic version
Wxxxx stands for the temporarily available maximum current in A,
e.g. W0070 => maximum current 70 A
Available versions: max. current 20, 36, 54, 70, 150, 210 A
The converter module for 2 axes (HMD) cannot be operated with the open
loop. control
When converters (HMS) are used, an additional power supply device
(HMV) is required.
HMV Supply Units
Type Code Supply Units (HMV)
HMV01.1E-Wxxxx-A-07-NNNN without regenerative feedback
HMV01.1R-Wxxxx-A-07-NNNN with regenerative feedback
Wxxxx stands for the continuous power when operated with external line
reactor, e.g. W0030 => continuous power 30 kW
5-2 Hardware and Firmware Used
5.2
STA02 "Open Loop"
Type Codes Control Sections
This applicatin is done with the following control section
CSB01.1C-AN-ENS-NNN-NN-S-NN-FW
Single axis BASIC
Contact us to ask about other control section options, also with different
encoder types.
5.3
Type Codes Firmware
FWA-INDRV*-MPB-03VRS-D5-1-NNN-NN
firmware version
The firmware is available in graduated scaling. For this application, the
basic version kit specified here is sufficient.
Various extension packages are available, e.g. internal Motion Logic
control, synchronization, etc.
Hardware and Firmware Used 5-3
STA02 "Open Loop"
5.4
Motors
An extensive range of robust housing and assembly kit motors provides
the right motor for various applications.
IndraDyn A: Asynchronous servo motors (MAD or MAF) for high ratings
of up to 83KW continuous power.
Third party motors
5.5
Software Tool Rexroth DriveTop
For setup, operation and visualization of the drive, the Rexroth DriveTop
software tool is available which has been used in the following
descriptions. Thanks to the self-explanatory menu navigation, standard
knowledge of servo drives is sufficient to set up the drive.
Fig. 5:
DriveTop start screen
This program can be ordered under order no. SWA-DTOP**-INB-16VRSMS-CD650-COPY.
To connect the drive to the PC, a ready-made interface cable
(IKB0041/005,0) is available in various lengths (2m / 5m / 10m / 15m).
Order no. for 5 m: IKB0041/005,0; R911296710
General Connection, Block Diagram 6-1
STA02 "Open Loop"
6
General Connection, Block Diagram
6.1
General Design of the HCS Drive Controllers
1 Power section
2 Control section
with firmware
Fig. 6-1:
1. Power section converter (HCS) or inverter (HMS or HMD with double
axis).
2. Control Section Advances (CSH) or double axis (CBD)
Electrical connection must be done by professionals.
6-2 General Connection, Block Diagram
Control voltage
(Contact bars)
DC - BUS
AC - Motor
0V
+24 V
L-
L+
..
..
1*
2*
1*
(POWER SUPPLY)
Contact bars
X1
Ribbon Cable
Bus Connection
Overview Connection Plan / Block Diagram
X31 X32
X6
X12
2
MotTemp-
A1 A2 A3
L3
L2
L1
X3
+24 V
Steuerspannung
0V
L(POWER SUPPLY)
contact bars
L+
(Stromschienen)
DC - BUS
..
..
Ribbon Cable l
Bus Connection
X1
1*
1* not for HCS02.1E-W0012-A-03-NNNX
2* only for multi axis application or with HMS-Geräte
For more information see Application Manual HCS02.1 a nd HCS03.1
Connection plan
Option
Brake
Resistor
Mains Supply
3AC 400 ... 500 V
+10 %, -15%
50/60 Hz
X9 1
2
X5
A
Display
Fig. 6-21:
3
B
X2
1*
2*
Holding
Brake
C
Connector X2
RS 232
Option
3
U
0VBr
+24VBr
D
Control Section
4
F
X36
Connector
X35 / X36
I/O
E
X35
Power Section
1
MotTemp+
M
Connector
X11 / X12
I/O
G
X11
PTC /
NTC /
KTY84
(Depends on Motor type
Grounding
Motor cablel
Connector
X31 / X32
I/O
H
6.2
STA02 "Open Loop"
General Connection, Block Diagram 6-3
STA02 "Open Loop"
6.3
General Power Connection
Example: Power Supply with HCS
Optional
for HCS02
Optional
transformer for
mains voltage
Optional for
multi axis
HMS is also
possible
Mains fuse,
mains Mains
Line filter is in some
countries optional.
Mains fuse, mains transformer, line filter, power choke
The optionally required components are shown shaded in grey.
Additional drive controllers and accessories can be connected to the HCS
drive controller.
Example for Group Power Supply with HCS
Note:
for the exemplary single infeed with HCS and group infeed
1. In addition to the connection of the drive controller to the
mains, the following connections must be wired:
• 'Ready for operation' Bb contact at the control section
(see project planning control section)
• Control voltage supply
• Protective conductor
2. If the components HCS03.1E to HNK01.1 are used, the
internal line contactor is to be connected electrically
between the power connection and the HNK.
3. DC bus linking of devices which are not connected to the
mains via various internal line contactors is not
permissible.
6-4 General Connection, Block Diagram
6.4
STA02 "Open Loop"
Control Circuits for Power Connection of Rexroth
IndraDrive C Drive Controllers
The upstream internal line contactor controls the energy flow to the drive
controller, thus permitting its separation from the mains in case of error.
The control circuit is mainly operated by the 'ready for operation' Bb
contract at the drive controller's control section or the 'ready for operation'
Bb contract of the prime power.
General Functions
The power voltage is connected to the drive package only after the 'ready
for operation' Bb contact, by being closed, signals readiness for
connection of power voltage.
Control via External Mains Contactor - HCS02 and
HCS03
Standard Version for HCS02 and HCS03 Drive Controller
Fig. 6-5:
1. Integration of the 'ready for operation' Bb contacts of other devices
(also see description of firmware functions: "Power supply" and
firmware parameter description P-0-0300 and P-0-0861).
2. Observe the breaking capacity of the 'ready for operation' Bb contact.
General Connection, Block Diagram 6-5
STA02 "Open Loop"
6.5
EMC-Optimized Installation in the Control Cabinet
Separation of interference-free and interference-prone areas in the
control cabinet
area A
area B
area C
signal lines
probes
reference cams
bus cables
control cabinet
d5 =
min.
100 mm
distance to
motor power
cable
LINE
fuses
drives
mains filter
NT
=
~
distribution
LOAD
other loads
of
installation
T
Q2
motor encoder
connection
auxiliary or
control voltage
(single-phase or
three-phase)
drive system
connection connection
motor
motor
connection
mains
d1: min.
200 mm
Z2
DR1
Z2
main switch
d4: min. 400 mm
E3
E1 E2
L1, L2, L3
input
terminals
control cabinet
PE
earth-circuit connector:
connect to mounting plate
over large surface area
firmly connected
equipment grounding
conductor
d3: min. 200 mm
power supply cable
Q2: fusing
NT:
power supply unit (if available)
T:
transformer (if available)
Z1
blower connection
single-phase or
three-phase
DR1: mains choke (if available)
ML: motor blower (if available)
G:
motor encoder connection
Z1
ML
M
3~
ML
M
3~
DA000011v01_en.FH7
EN_DA000011v02.EPS
Fig. 6-6:
EMC-Optimized Installation
Area A: Interference-free area
Area B: Interference-prone area
Area C: Heavily interference-prone area
Under no circumstances may lines from one area be routed parallel to
lines from another area.
Motor power cables and motor encoder cables must likewise not be
routed parallel to each other.
Ensure that there is enough space between the cables. Preferably, the
cables should be routed in separated cable ducts.
STA02 "Open Loop"
7
Interfaces
7.1
Overview interfaces Control unit
Interfaces 7-1
BASIC OPEN LOOP
Connector X31/X32
Connector X11 /X12
Connector X35/X36
Connector X2 RS232 to
PC for commissioning
Drive Functions 8-1
STA02 "Open Loop"
8
Drive Functions
8.1
Inputs/Outputs
The output assignment described in the following is the default
assignment for the Rexroth DriveTop commissioning program using the
BASIC OPEN LOOP control card. This assignment is different from the
application described in chapter 9.
Overview of the inputs and outputs in the Rexroth
DriveTop commissioning program
Path: Rexroth DriveTop => Drive functions => Guide communication =>
I/O-X31/X32 , X11/X12
click on, this
button then you
get Fig 8.2
Fig 8.1:
Digital I-O
Fig 8.2
Digital I-O
8-2 Drive Functions
8.2
STA02 "Open Loop"
Default Communication for Terminals X31 and X32
The input and output assignment described in the following is the default
assignment for the Rexroth DriveTop commissioning program.
Individual modifications are possible if desired.
Enabling the drive can lead
to dangerous movements.
WARNING
Plug X31
(default assignment)
Pin E/A (I/O) Parameter
Function:
Note:
0
Without function
Not assigned
S-0-0099
0
Reset command 500
Status class 1
1, 2
3
Bit
4
E
P-0-4028
15
Drive on (status AB on AF)
5
E
P-0-0222
0
Travel range limit switch +
6
E
P-0-0222
1
Travel range limit switch -
7
E
S-0-0000
0
Wildcard
8
+24 V power supply
9
0 V power supply
Plug X32
Not assigned for commercial
availability
(default assignment)
Pin E/A (I/O) Parameter
Bit
Function:
1
EAn2
Analog input 2 U+
2
EAn2
Analog input 2 U-
3
GND
Analog 0 V reference point
4
EAn1
Analog input 1 U+
5
Ean1
Analog input 1 U-
6
E (A)*
P-0-0223
0
Emergency stop input
7
E (A)*
P-0-4028
13
Drive enablement
8
E (A)*
S-0-0000
9
EAn1
Wildcard
Analog output 1
*can also be configured as an output
Note:
Message to drive: “Emergency
stop”
Commercially available
Drive Functions 8-3
STA02 "Open Loop"
Plug X11
(default assignment)
Pin E/A (I/O) Parameter
Function:
Note:
1
Without function
Not assigned
2
Without function
Not assigned
3
Rel3
4
Rel3
5
Rel3
Plug X12
Relay 3
S-0-0000
Relay 3, root
(default assignment)
1
Rel1
P-0-0115
2
Rel1
P-0-0115
3
Rel2
4
Rel2
5
Rel2
Bit
Function:
Note:
Ready for operation
0
Ready for operation
Relay 3
S-0-0000
Relay 3, root
Commercially available
Relay 3
(default assignment)
Pin E/A (I/O) Parameter
Bit
Function:
1
+24 V power output
2
0V power output
3
Commercially available
Relay 3
Pin E/A (I/O) Parameter
Plug X35
Bit
An2
Note:
Analog output 2
4
Analog 0V
Plug X36
(default assignment)
Pin E/A (I/O) Parameter
Bit
Function:
Note:
1
A 1I +
Analog input 1 I +
Power input 1
2
A 1I -
Analog input 1 I -
Power input 1
3
A 2I +
Analog input 2 I +
Power input 2
4
A 2I -
Analog input 2 I -
Power input 2
8-4 Drive Functions
8.3
STA02 "Open Loop"
Plug 2, Serial Interface (RS232) for Commissioning and
Programming
Interface X2 is an RS232 connection to the drive.
This plug is used to set the parameters of the drive control using the
REXROTH DRIVETOP PC software tool (see section 5.5) and to put it
into operation.
Fig 8.3:
RS232
Fig 8.3:
RS232-1
Note: The interfacedoes not have an electrical isolation. The electrode
voltage between control section and connected data terminal equipment
must not exeed 1V
Drive Functions 8-5
STA02 "Open Loop"
8.4
Analog Input
Two analog inputs are available on terminal strip X32 (right). These
analog inputs are configured using the following dialog box in DriveTop.
Rexroth DriveTop => Drive functions => Master communication =>
Analog inputs
Fig 8.4:
8.5
Analog inputs
Entering Motor Parameters
Selection using dialog box:
Rexroth DriveTop => Drive functions => Motor parameters
After the asynchronous third-party motor is selected, the motor type label
data for the rated current, rated voltage, rated frequency, rated speed,
power factor and the rated power are entered. Then press the “Calculate
motor data” button to determine the motor-specific data. The current
control is now preset by the successfully executed calculation procedure;
generally, no additional modifications need to be made in this area.
Motor options such as various temperature sensors and a motor holding
brake can be selected in the lower portion of the dialog box.
8-6 Drive Functions
STA02 "Open Loop"
P-0-4034
P-0-4035
P-0-4037
Fig 8.5 Motor parameters
In the case of third-party motors, contact the motor manufacturer for
parameters P-0-4034, P-0-4035 and P4037.
8.6
Operating Mode Selection
Only the Velocity control operating mode is supported in the model
without an encoder.
Select using:
Rexroth DriveTop => Drive functions => Operating mode selection
Fig 8.6 Operating mode selection
Drive Functions 8-7
STA02 "Open Loop"
8.7
Scaling and Units
Various units can be selected here depending on the corresponding
application. For the Velocity control operating mode selection, Speed
(rpm), Acceleration time and Braking time (sec) and torque and Power
data (%) are selected.
Select using:
Rexroth DriveTop => Drive functions => Scaling
Fig 8.7 Scaling units
Press the “Advanced” button to specify the settings for speed, acceleration and
torque.
Select unit here
Fig 8.8:
Scaling units advanced
8-8 Drive Functions
STA02 "Open Loop"
In all basic settings, the motor shaft is the reference.
In the default setting, speed values are entered in rpm and acceleration
values in rad/sec2. Changes can be made in other scaling types.
8.8
Operating Mode
In the operating mode, various fixed speeds, speed limits, speed
suppressions, run-up times and additive command speed values can be
specified, depending on the application.
Select using:
Rexroth DriveTop => Drive functions => Operating mode selection
Command speed
value:
Assignment of the
analog input signal
Activation of
fixed speeds
Click window
Five fixed
speeds
Fig 8.9:
Primary operation mode
The current command speed specification of the selected analog input is
shown under Vcomm.
Internal fixed speed values can be entered directly in the five fixed speed
value fields. These values can also be entered using parameter P-0-1206.
The five boxes in the upper left section are used to assign the appropriate
command value. Selection is possible by directly clicking the box or by
assigning parameter P-0-1200 using digital inputs according to the
following schema.
Structur
Drive Functions 8-9
STA02 "Open Loop"
Additional detailed functions can be selected using the two windows
Speed suppression or Ramp-function encoder.
Fig 8.9:
Primary operation mode
In the Ramp-function generator function, two ramp times each can be
specified (depending on the speed) for the ramp-up and ramp-down
times.
8.9
Drive Control
Settings in the drive control permit the drive to be adapted to the machine.
Select using:
Rexroth DriveTop => Drive functions => Drive control
Max. command
value change
Open window by
clicking it
Fig 8.10:
Drive control
8-10 Drive Functions
STA02 "Open Loop"
After the V/f control point has been selected, various functions, such as
Tipping protection control, Slip compensation, Voltage characteristic
curve, Voltage increase, IxR boost, Oscillation damping and Power limit
control can be adjusted.
Current
output voltage
Current actual
values
Fig 8.11:
open-loop U-f
• Tipping protection control
Description of functions: When the torque limit is attained, the tipping
protection control prevents tipping of the machine and, if desired, reduces
the output frequency of the drive control.
• Slip compensation
Description of functions: Since the open-loop model can not record actual
velocity values, this parameter can be used to set a load-dependent
velocity compensation.
• Voltage increase
Function: In the case of high breakaway torques or steep start-up ramps,
the voltage must be adjusted in the start-up area. The motor voltage is set
for low output frequencies here.
• Quadratic
Function: In the case of fans, ventilators and pumps with low start-up
torques and a quadratic counter-torque, a quadratic voltage/frequency
characteristic curve can be selected to save power.
• Magnetization-controlled
Function: Depending on the load states on the drive machine, the output
voltage is increased or decreased. This results in a power savings for the
overall system.
Drive Functions 8-11
STA02 "Open Loop"
• IxR boost
Function: Due to the voltage drop of the supply line and the motor coil, the
IxR boost can be used to set a load-dependent feed forward control.
• Oscillation damping
Function: In partial load or idling mode, velocity oscillations can occur in
asynchronous motors. Adjusting this parameter can prevent this.
• Power limit control
Function: This parameter is used to protect the end stage; it is affected by
the switching frequency and the controller performance.
Selection of the current limit dialog box
S-0-0109
S-0-0112
S-0-0111
P-0-4046
P-0-4045
Fig 8.12:
Current limits
In the Motor parameters dialog box, the parameters
P-0-04037 Thermal short-term overload of the coil
P-0-4035 Thermal time constant of the motor
P-0-4034 Thermal time constant of the coil
have been specified.
S-0-0110
8-12 Drive Functions
STA02 "Open Loop"
S-0-0092
P-0-0109
S-0-0083
S-0-0082
resulting
minimum value
Fig 8.13:
Torque-force limits
The torque/force limits can be freely programmed; they can be set so that
they are either bipolar or unipolar.
Unipolar limit S-0-0082; S-0-0083
Bipolar limit S-0-0092; P-0-0109
Parameter S-0-0092 affects all command torque values.
Parameter P-0-0109 cannot be written cyclically; it specifies the absolute
limits of the torque/force data of the power train.
8.10 Drive Stop
The Drive stop function has been included in the Master communication
dialog box using the I/O terminal bar of plug X32, terminal 7. P-0-4028 bit
13. The following dialog box is used to enter the ramp time for the Drive
stop function and the velocity value of the Standstill message.
Path:
RexrothDriveTop => Drive functions => Drive stop.
S-0-0372
Delay
S-0-0124
Standstill window
Fig 8.14:
drive halt
Parameter P-0-0115 is used to set bit 4 after the velocity drops below its
threshold.
Drive Functions 8-13
STA02 "Open Loop"
8.11 Fault Reaction
The parameters of the fault reaction must have been set before the
drive ca be enabled.
:::WARNING
This dialog box is used to specify the fault reaction of the drive.
Path:
RexrothDriveTop => Drive functions => Drive fault reaction.
P-0-0117
Activation of
delayed
shutdown
P-0-0119
Best-possible
deceleration
S-0-0273
Maximum time
for Drive off
Fig 8-15:
Error reaction
P-0-0117 is used to delay switching off the drive for the corresponding
fault class. If a superordinate control is used, corresponding temporary
measures can be made by the control. This function is possible only if
non-fatal faults occur.
P-0-0119 is used to determine the type of drive shutdown in the case of
interface faults, non-fatal faults, switching the communication phase back
and enabling the drive.
Parameter S-0-0273 is used to enter the calculated maximum time for the
braking procedure for the drive in the worst-case scenario. The motor
brake (holding brake) is then closed depending on P-0-0525, Brake
control word.
The Emergency stop function (P-0-0223) is assigned to input X32,
terminal 6.
The following functions can be selected using parameter P-0-0008.
8-14 Drive Functions
STA02 "Open Loop"
Fig 8-16:
E-Stop
Path:
RexrothDriveTop => Drive functions => Emergency stop function.
This message is deactivated
for single devices.
Fig 8-17:
Error reaction, supply module
8.12 Status Messages
The Status messages dialog box can be used to specify system-specific
threshold values for various messages.
Path:
RexrothDriveTop => Drive functions => Status messages.
Drive Functions 8-15
STA02 "Open Loop"
Fig 8-18:
Status messages
Parameter S-0-0124: Standstill message
Parameter S-0-0157: Actual speed = command speed message
Parameter S-0-0091: Command speed > limit value message
Parameter S-0-0125: Actual speed < nx threshold message
Parameter S-0-0126: Torque/force > Mdx threshold message
Parameter S-0-0158: Power value >= Px threshold message
Status word P-0-0555 is used to assign the individual messages to the
following bits.
Fig 8-19:
P555-1
8-16 Drive Functions
STA02 "Open Loop"
8.13 Special/Optional Drive Functions
Drive-specific functions are assigned to the analog outputs in this dialog
box.
In addition, the associated Velocity search dialog box makes it possible to
switch on a freely slowing drive without jolts or standstill braking. This
function is used especially in machines with high moments of inertia.
Path:
RexrothDriveTop => Drive functions => Special/optional drive functions
Activation using control
word P-0-0045
Search in both
directions of rotation
Constrained-current
operation
At the startup time, this factor is added
to the output frequency 100 % =
nominal slip of the machine.
Fig 8-21:
Velocity search mode
Fig 8-22:
Average value filter for display
Signal selection
Low-pass filter
for signal
smoothing
Use the following selection list to assign individual parameters to the
outputs.
Drive Functions 8-17
STA02 "Open Loop"
Structure:
The following parameters are contained in the signal list
P-0-0396
Fig 8-23:
Signal choices average value filter
Commissioning 9-1
STA02 "Open Loop"
9
Commissioning
9.1
Starting DriveTop
Note: Not every DriveTop screen is documented here.
If a DriveTop screen is not needed, click “Next ”.
Start the “Rexroth DriveTop” commissioning program version (16VRS).
For IndraDrive, commissioning can be carried out online only.
Screenshots from Rexroth DriveTop
Fig 9-01:
DriveTop start screen
Note:
The DriveTop commissioning tool is used up to firmware version MPX03.
IndraWorks –D is used as of firmware version MPX04.
9-2 Commissioning
9.2
STA02 "Open Loop"
Loading Basic DriveTop Parameters
When the basic parameters are loaded, the interfaces are assigned in the
manner documented in this description.
Screenshots from Rexroth DriveTop
Fig 9-02:
Initial start-up drive
Fig 9-03:
first time setup
Click “Execute commissioning”.
All the relevant parameters are set to the default values.
Press the “Next” button and move through the various screens.
In menu Scaling/Unit – Drive x, Application type,
two fundamentally different mechanical systems are available.
Commissioning 9-3
STA02 "Open Loop"
9.3
Selecting Function Packages
Screenshots from Rexroth DriveTop
Fig 9-04:
Functional packages
9-4 Commissioning
9.4
STA02 "Open Loop"
Drive Status
This display provides an overview of the most important status messages.
Rexroth DriveTop => View => Drive status
1)
2)
3,4)
5)
7)
6)
8)
9)
10)
Fig 9-05:
Drive status
Explanations of Status Messages
• 1)
P-0-0115
Bit 15
Collective fault message
• 2)
P-0-0115
Bit 14
Drive following command value, main
operating mode
• 3)
P-0-0115
Bit 0
“Ready for operation” contact
• 4)
P-0-0115
Bit 1
Drive ready
5)
S-0-0013
Bit 1
Comparison of the current speed with
standstill window S-0-0124 (any value
can be selected)
• 6)
S-0-0013
Bit 6
Comparison of the current power of
the motor with parameter S-0-0158
(motor power threshold)
• 7)
S-0-0013
Bit 2
Comparison of the current velocity
with parameter S-0-0124 (velocity
threshold Px)
• 8)
S-0-0013
Bit 7
Comparison of the command velocity
with the actual velocity, parameter
S-0-157 (velocity window)
• 9)
S-0-0013
Bit 3
Comparison of the current torque
with the value in parameter S-0-126
(velocity threshold nx)
• 10) S-0-0013
Bit 4
The current actual torque/force value is
greater than the limit value for the torque
(S-0-0082, S-0-0083, S-0-0092,
P-0-0109)
Commissioning 9-5
STA02 "Open Loop"
9.5
Drive Application
Application description:
A grinding wheel is driven directly by an asynchronous machine. To
ensure that the grinding result is proper, the load-dependent velocity dip
that occurs during the grinding process must be compensated for. In the
open-loop model, slip compensation is used for this purpose.
The guide communication is executed using the digital I/Os of terminal
strips X31 and X32. The command value specification exists as an analog
signal of 0-10V.
Interface function:
Inputs:
External reset
Drive on
Drive stop
Emergency stop
Outputs:
Actual velocity = command velocity
Drive ready
Power limit = threshold
Analog inputs:
Command value specification 0-10V (speed)
Analog outputs:
Torque/force
Control card:
CSB01.1N-FC-NNN-NNN-NN-C-NN-FW
Technical data of the asynchronous machine
Type label data
Power: 2.2 kW
Nominal voltage: 380 V; 50 Hz
Nominal current: 5.37 A
Cos phi: 0.83
Nominal speed: 1390 rpm
9-6 Commissioning
9.6
STA02 "Open Loop"
Setting Drive Control Parameters
Allocation and assignment of the digital inputs/outputs
Plug X31
Pin E/A (I/O) Parameter
Function:
Note:
0
Without function
Not assigned
S-0-0099
0
Reset command 500
Status class 1
1, 2
3
Bit
4
E
P-0-4028
15
Drive on
5
E
P-0-4028
13
Drive stop
6
E
S-0-0000
0
7
E
S-0-0000
0
Wildcard
8
+24 V power supply
9
0 V power supply
Not assigned for commercial
availability
Plug X32
Pin E/A (I/O) Parameter
Bit
Function:
1
EAn2
Analog input 2 U+
2
EAn2
Analog input 2 U-
3
GND
Analog 0 V reference point
4
EAn1
Analog input 1 U+
5
Ean1
Analog input 1 U-
6
E (A)*
P-0-0223
0
7
E (A)*
S-0-0000
0
8
E (A)*
S-0-0000
9
EAn1
Note:
Emergency stop input
Message to drive: “Emergency
stop”
Wildcard
Commercially available
Analog output 1
Speed signal 0-10V /0-1500 rpm
Enabling the drive can lead to incorrect movement of the drive
: :WARNING
Commissioning 9-7
STA02 "Open Loop"
Plug X11
Pin E/A (I/O) Parameter
Function:
Note:
1
Without function
Not assigned
2
No function
Not assigned
3
Rel3
4
Rel3
5
Rel3
Bit
Relay 3
S-0-0330
Relay 3, root
Nact=Ncomm
Relay 3
Plug X12
Pin E/A (I/O) Parameter
1
Rel1
P-0-0115
2
Rel1
P-0-0115
3
Rel2
4
Rel2
5
Rel2
Bit
Function:
Note:
Ready for operation
0
Ready for operation
Relay 3
S-0-0333
Relay 3, root
Relay 3
Load threshold, Mx > Mcomm
9-8 Commissioning
9.7
STA02 "Open Loop"
Selecting the Analog Input
Analog input 1 is selected for the speed specification.
Command value specification 0-10V. The power inputs of terminal strip
X36 are not used.
Path:
DriveTop Drive function Guide communication Analog inputs
Current command current value
Fig 9-06:
Drive status
The analog signal is adjusted as follows:
Input the value 1500 = 10V
Then specify a command value of 0V.
Compensate for the input offset signal in field “Signal value at zero volts”
Enter the max. command value voltage; the maximum speed can be read
out using the check in the lower display field.
Differentiation of the analog inputs:
Channel A: scanning in position control cycle.
Channel B: scanning with a cycle of T = 2 ms
9.8
Motor Parameters
Entry of the motor parameters acc. to the motor type label, followed by
calculation.
Path:
Drivetop Drive function Motor parameters
Select the asynchronous third-party motor
Nominal current: 5.37 A
Nominal voltage: 380 V
Commissioning 9-9
STA02 "Open Loop"
Frequency: 50 Hz
Rated speed: 1390 rpm
Cos phi: 0.83
Power: 2.2 kW
Calculate the motor data.
Fig 9-07:
9.9
Motor parameters
Operating Mode Selection
The default values can be retained.
Path:
Drivetop Drive functions Operating mode selection
Setting the velocity control
9.10 Scaling and Units
Rpm is used for scaling the velocity; sec (with a speed reference of 1500
rpm) is entered for acceleration.
Path:
Drivetop Drive functions Scaling and units
9.11 Gears
No changes are required for this application.
Path:
Drivetop Drive functions Gears
9-10 Commissioning
STA02 "Open Loop"
9.12 Operating Modes
The acceleration and braking times are set in this dialog box.
Drivetop Drive functions Operating modes
Click
Fig 9-08:
Primary operation mode
Fig 9-09:
Run-up generator
Short ramp
time
Commissioning 9-11
STA02 "Open Loop"
9.13 Drive Control
This is used to set the current and torque limits as well as the parameters
of the V/f control.
These windows
open when they
are clicked
The max. stator
frequency change
is preset via the
motor data.
Fig 9-10:
Drive control
Standstill current
calculated in Motor
parameters menu
Fig 9-11:
The maximum
value results
from the display
fields above
Current limits
Incorrect entries can cause the overload capability to be too high.
… WARNING
9-12 Commissioning
STA02 "Open Loop"
Effective peak
current from
Current limitation
menu
Fig 9-12:
Torque-force limits
The two limits of the actual torque value can be calculated as follows:
Effective peak current ( P-0-4046 ) x 100% / standstill current of motor (S0-0111)
Fig 9-13:
open loop U-f control
Adapting the slip compensation (P-0-0572) to the load conditions.
The parameter was increased successively during the machining
process. The velocity dip after the load impulse was determined using an
additional attached encoder; the stabilization time was also determined.
The best results using this application were achieved with a P-0-0572
value of 130%.
Commissioning 9-13
STA02 "Open Loop"
50% step load change
Stabilization time
approx. 150 ms
In order to attain increased dynamics, the magnetization character curve
is controlled and set to a value of 100%. This prevents a decrease in the
voltage during the idling phase of the machine. In this application, the
speed dip determined over the short term is approx. 30 rpm. The
stabilization time after the load impulse was approx. 150ms. The values
attained are not generally applicable; they must be determined for each
application.
Oscillation damping did not have to be adjusted for this application.
Furthermore, a start-up time of approx.0.5 sec (0-1500 rpm) must have
been attained at an overall moment of inertia of approx. 2xJmot. A control
measurement was carried out, as in the example above using the
additional attached encoder. Adjusting the voltage increase from 0 to 15 V
using parameter P-0-0568 provided the best results in the start-up phase
of the machine.
500 ms
run-up time
1500 rpm final
speed
Note: Since the measuring encoder was attached less than optimally, the
speed signal during the start-up phase is not linear.
9-14 Commissioning
STA02 "Open Loop"
Load shedding
Run-up phase
with load
Load
P-0-0048 Effectiv
velocity command
value
P-0-0043 Torquegenerating current,
actual value
S-0-0040 Velocity
feedback value
S-0-0084 Torque/
force feedback
value
Command speed value
Recording of the internal command speed value signal using the
oscilloscope function of DriveTop.
The stall protection control was deactivated for the first attempts.
Due to the determined load conditions, the tipping protection control was
not allowed to go into effect during the start-up phase. This was confirmed
during the subsequent measurements.
To check the functioning of the stall protection control, the current limit
threshold had to be lowered to 100% and the acceleration phase had to
be decreased to 250 ms. The following measurement was carried out
using the attached measuring encoder.
Activation of tipping
protection control
Commissioning 9-15
STA02 "Open Loop"
In addition, the oscilloscope function of DriveTop can be used to
determine the activation of the tipping protection control.
Command value
specification
P-0-0048
Actual speed value
acc. to tipping
protection control
S-0-0040
Activation of tipping
protection control
For the sake of clarity, the display has zoomed into the “tipping protection
control activation” section of the curve.
Zoomed signal to
improve the display
of the activation of
the tipping protection
control
9.14 Drive Stop
Adapt the braking time for Drive stop and max. speed
. WARNING
The shortest braking time for the emergency stop function has been set to
2 sec. The standstill window has been set to 5 rpm.
9-16 Commissioning
STA02 "Open Loop"
9.15 Fault Reaction
Check fault reaction of the drive before operating enablement.
: WARNING
Path:
Drivetop Drive functions Fault reaction
No changes were made in this dialog box.
The Fault reaction supply module window is opened by pressing the
“Next” button. In the case of single devices, the
• reaction to fault in the module network and
• package reaction triggering in case of fault
fault reactions must be deactivated.
9.16 Emergency Stop
Path:
Drivetop Drive functions Emergency stop
Since the emergency stop function has been assigned to terminal X32,
pin 6 (P-0-0223) in the Guide communication dialog box, this function is to
be activated here.
If desired, the fault reaction can then be selected as a fault or a warning
message.
The reaction type is set to “as for best possible shutdown”.
9.17 Status Messages
Parameters “Actual velocity = command velocity message” and “Actual
torque/force value > MDx threshold message” have been used for the
assignment to the relay outputs.
Path:
Drivetop Drive functions Status messages
Commissioning 9-17
STA02 "Open Loop"
X11 pins 3,4,5 assigned
X12 pins 3,4,5
assigned
Fig 9-14:
Status messages
9.18 Special/Optional Drive Functions
Velocity search is not used in this application.
The parameters for the average value filter for the display are set
according to the following diagram.
P395.0
Analog output
1, plug X32 pin
P395 .1
Analog output 2,
plug X35 pin 3
Fig 9-15:
Average value filter
In addition, separate reference points can be specified for the two analog
outputs for an output voltage of zero volts.
Analog output 1 P-0-0418
Analog output 2 P-0-0419
9-18 Commissioning
STA02 "Open Loop"
The two outputs are scaled via the parameters
Analog output 1 P-0-0422
Analog output 2 P-0-0425
Furthermore, control parameter P-0-0427 must be used for the
assignment for each analog output. The overflow/limit and the output of
parameter values are to be set.
Functionally, “overflow” means that the output voltage starts again from
zero volts after the maximum output value has been exceeded.
The following setting has been selected.
Fig 9-16:
Analog Outputs
The two analog signals were output at a velocity jump of 0-1500 rpm and
were recorded using an oscilloscope.
Fig 9-17:
Oscilloscope
Evaluation of channel 1 2V/div; Evaluation of channel 2 2V/div
Extras 10-1
STA02 "Open Loop"
10
Extras
10.1 Fan Drive
Using the fan drive as an example, this section describes the various V/f
characteristic curves, the Velocity search function and speed masking.
10.2 Command Value Generation
Due to the construction of a machine, resonance phenomena may occur
in individual cases for specific velocity points of the overall system. For
this reason, 4 speed masking windows can be set in the command value
specification. This means that the speeds / command values defined in
the masking window cannot be used continuously. Depending on the
defined upper/lower limit points of the window, the internal command
speed value specification can be decreased or increased.
Path:
RexrothDriveTop => Drive functions => Operating modes.
Current command
value within the
masking window
P-0-01208
Masking window is
processed with the time
Factor X ramp time
P-0-01207
Speed masking window
with n = 50 rpm
Fig 10-01: Speed masking window
10-2 Extras
STA02 "Open Loop"
Command speed value
Command speed
value after
suppression
Fig 8-9 Primary operation mode.jpg[Hier doppelklicken, um eine Grafik einzufügen]
Fig 8-9:
Primary operation mode
10.3 V/f Characteristic Curve
To save power and optimize the sound quality, the quadratic V/f
characteristic curve can be selected for systems with a quadratic torque
path.
Path:
RexrothDriveTop => Drive functions => Drive control
P-0-0045 Bit 13
Linear/quadratic
characteristic curve
Fig 10-02:
Open loop U-f
Lowering factor of the
output voltage 100% =
quadratic characteristic
curve
Extras 10-3
STA02 "Open Loop"
Run-up time
5 sec
Rated slip of the
asynchronous machine
Quadratic voltage
characteristic curve
with lowering factor of
100%.
The magnetization characteristic curve is set to “controlled”. If the
controlled characteristic curve is deactivated, the terminal voltage
(magnetization current) is adapted according to the load. The settings
must be checked statically and dynamically for the corresponding
application.
10.4 Velocity Search
Controller enablement is granted.
:
WARNING
In order to permit enablement on a turning machine after the control has
been released, the Velocity search function can be activated. This occurs
using current controller control word P-0-0045, bits 8 and 9.
P-0-0045 Current
control unit
control word
Bit 8 Serach
Bit 9 Bidirectional
P-0-0575 Search current =
magnetization current *
P-0-0575 / 100%
P-0-0576 - 100%
rated slip of the
machine
Fig 10-03:
Velocity search mode
10-4 Extras
STA02 "Open Loop"
Synchronization
Speed reduction of the
set command value
Actual speed
value 1065 rpm
Drive controller
off
Speed output 1185
rpm after
asynchronization
The synchronization procedure was determined using an encoder that
was temporarily attached to the machine. The standard “Find point” slip
factor of 100% was selected for the measurement. According to the curve
above, the determined velocity difference is approx. 120 rpm. The
nominal speed of the motor is 1390 rpm. The set synchronization point is
thus approx. 110 rpm. Additional improvements to the synchronization
procedure can be made by reducing the parameters “Find point slip
factor” and “Search current factor”.
Internal
corrected
command
vlaue
Actual speed value
for the search
procedure
Search current
The internal signals during the synchronization procedure were recorded
using Drivetop’s oscilloscope function.