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ACOPOS
MAACP2-E
ACOPOS
User´s Manual
U s e r ´s
Manual
Version 1.2
ACOPOS
User's Manual
Version:
Mod. No.:
1.2 (June 2003)
MAACP2-E
We reserve the right to change the contents of this manual without warning. The information
contained herein is believed to be accurate as of the date of publication, however, Bernecker +
Rainer Industrie-Elektronik Ges.m.b.H. makes no warranty, expressed or implied, with regards
to the products or the documentation contained within this book. In addition, Bernecker + Rainer
Industrie-Elektronik Ges.m.b.H. shall not be liable in the event of incidental or consequential
damages in connection with or arising from the furnishing, performance, or use of these
products. The software names, hardware names and trademarks used in this document are
registered by the respective companies.
ACOPOS User's Manual
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ACOPOS User's Manual
Chapter 1: General Information
Chapter 2: Technical Data
Chapter 3: Mounting
Chapter 4: Dimensioning
Chapter 5: Wiring
Chapter 6: Getting Started
ACOPOS User's Manual
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4
ACOPOS User's Manual
Chapter 7: Standards and Certifications
Figure Index
Table Index
Index
Model Number Index
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ACOPOS User's Manual
Table of Contents
Chapter 1: General Information ..................................................... 15
1. ACOPOS ............................................................................................................................
1.1 Secure Operation ..........................................................................................................
1.2 Taking it to the Limit ......................................................................................................
1.3 Individual I/O Configurations .........................................................................................
1.4 Configuring instead of Programming .............................................................................
1.5 Easy Service .................................................................................................................
1.6 Software and Hardware as a Unit .................................................................................
1.7 Plain Text for Functions .................................................................................................
1.8 Simple Function Test .....................................................................................................
1.9 Control Trigger ..............................................................................................................
1.10 Cam Profiles for Everyone ..........................................................................................
2. ACOPOS Configurations ....................................................................................................
2.1 General Information .......................................................................................................
2.2 CAN ...............................................................................................................................
2.2.1 Configuration 1 ........................................................................................................
2.2.2 Configuration 2 ........................................................................................................
2.3 Powerlink .......................................................................................................................
2.3.1 Recommended Topology ........................................................................................
2.3.2 Configuration 1 ........................................................................................................
2.3.3 Configuration 2 ........................................................................................................
3. Safety Guidelines ................................................................................................................
3.1 General Information .......................................................................................................
3.2 Intended Use .................................................................................................................
3.3 Transport and Storage ..................................................................................................
3.4 Installation .....................................................................................................................
3.5 Operation .......................................................................................................................
3.5.1 Protection against Touching Electrical Parts ..........................................................
3.5.2 Protection from Dangerous Movements .................................................................
3.6 Safety Guidelines ..........................................................................................................
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Chapter 2: Technical Data .............................................................. 31
1. ACOPOS Servo Family ......................................................................................................
1.1 Modular Servo Drive Concept .......................................................................................
1.2 General Description .......................................................................................................
1.2.1 24 VDC Supply during Power Failures ...................................................................
1.3 LEDs ..............................................................................................................................
1.3.1 LED Status ..............................................................................................................
1.4 ACOPOS 1022, 1045 and 1090 ....................................................................................
1.4.1 Order Data ..............................................................................................................
1.4.2 Technical Data ........................................................................................................
1.5 ACOPOS 1180, 1320 ....................................................................................................
1.5.1 Order Data ..............................................................................................................
1.5.2 Technical Data ........................................................................................................
1.6 ACOPOS 1640, 128M ...................................................................................................
1.6.1 Order Data ..............................................................................................................
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1.6.2 Technical Data ........................................................................................................
2. ACOPOS Plug-in Modules ..................................................................................................
2.1 General Information .......................................................................................................
2.2 Order Data .....................................................................................................................
2.3 AC110 - CAN Interface ..................................................................................................
2.3.1 General Description ................................................................................................
2.3.2 Order Data ..............................................................................................................
2.3.3 Technical Data ........................................................................................................
2.3.4 CAN Node Number Settings ...................................................................................
2.3.5 LEDs .......................................................................................................................
2.3.6 Firmware .................................................................................................................
2.4 AC112 - ETHERNET Powerlink Interface .....................................................................
2.4.1 General Description ................................................................................................
2.4.2 Order Data ..............................................................................................................
2.4.3 Technical Data ........................................................................................................
2.4.4 Powerlink Node Number Setting .............................................................................
2.4.5 LEDs .......................................................................................................................
2.4.6 Firmware .................................................................................................................
2.5 AC120 - EnDat Encoder Interface .................................................................................
2.5.1 General Description ................................................................................................
2.5.2 Order Data ..............................................................................................................
2.5.3 Technical Data ........................................................................................................
2.5.4 LEDs .......................................................................................................................
2.5.5 Firmware .................................................................................................................
2.6 AC122 - Resolver Interface ...........................................................................................
2.6.1 General Description ................................................................................................
2.6.2 Order Data ..............................................................................................................
2.6.3 Technical Data ........................................................................................................
2.6.4 LEDs .......................................................................................................................
2.6.5 Firmware .................................................................................................................
2.7 AC123 - Incremental Encoder and SSI Absolute Encoder Interface .............................
2.7.1 General Description ................................................................................................
2.7.2 Order Data ..............................................................................................................
2.7.3 Technical Data ........................................................................................................
2.7.4 LEDs .......................................................................................................................
2.7.5 Firmware .................................................................................................................
2.8 AC130 - Digital Mixed Module .......................................................................................
2.8.1 General Description ................................................................................................
2.8.2 Order Data ..............................................................................................................
2.8.3 Technical Data ........................................................................................................
2.8.4 LEDs .......................................................................................................................
2.8.5 Firmware .................................................................................................................
2.9 AC131 - Mixed Module ..................................................................................................
2.9.1 General Description ................................................................................................
2.9.2 Order Data ..............................................................................................................
2.9.3 Technical Data ........................................................................................................
2.9.4 LEDs .......................................................................................................................
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2.9.5 Firmware .................................................................................................................
3. Cables .................................................................................................................................
3.1 General Information .......................................................................................................
3.1.1 Prefabricated Cables ..............................................................................................
3.2 Motor Cables .................................................................................................................
3.2.1 Order Data ..............................................................................................................
3.2.2 Technical Data ........................................................................................................
3.3 EnDat Cable ..................................................................................................................
3.3.1 Order Data ..............................................................................................................
3.3.2 Technical Data ........................................................................................................
3.4 Resolver Cable ..............................................................................................................
3.4.1 Order Data ..............................................................................................................
3.4.2 Technical Data ........................................................................................................
4. Connectors .........................................................................................................................
4.1 General Information .......................................................................................................
4.2 Motor Connectors ..........................................................................................................
4.2.1 Order Data ..............................................................................................................
4.2.2 Technical Data for 8PM001.00-1 and 8PM002.00-1 ...............................................
4.2.3 Technical Data for 8PM003.00-1 ............................................................................
4.3 Encoder Connectors ......................................................................................................
4.3.1 Order Data ..............................................................................................................
4.3.2 Technical Data for EnDat Connector 8PE001.00-1 ................................................
4.3.3 Technical Data for Resolver Connector 8PR001.00-1 ............................................
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Chapter 3: Installation .................................................................... 83
1. General Information ............................................................................................................
2. Dimensional Diagrams and Installation Dimensions ...........................................................
2.1 ACOPOS 1022, 1045, 1090 ..........................................................................................
2.2 ACOPOS 1180, 1320 ....................................................................................................
2.3 ACOPOS 1640 ..............................................................................................................
2.4 ACOPOS 128M .............................................................................................................
3. Installation and Removal of Plug-in Modules ......................................................................
3.1 General Information .......................................................................................................
3.2 Installation .....................................................................................................................
3.3 Removal ........................................................................................................................
4. Installing Various ACOPOS Series Devices Directly Next to Each Other ..........................
5. Using Cooling Aggregates in Switching Cabinets ...............................................................
5.1 General Information .......................................................................................................
5.2 Cooling Aggregate on Top of the Switching Cabinet .....................................................
5.3 Placing a Cooling Aggregate on the Front of the Switching Cabinet .............................
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Chapter 4: Dimensioning ............................................................... 97
1. Power Mains Connection ....................................................................................................
1.1 General Information .......................................................................................................
1.1.1 System Configuration ..............................................................................................
1.1.2 Supply Voltage Range ............................................................................................
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1.1.3 Protective Ground Connection (PE) ........................................................................ 98
1.2 Dimensioning ................................................................................................................. 99
1.2.1 Individual ACOPOS Power Mains Connections ...................................................... 99
1.2.2 Implementing ACOPOS Power Mains Connections for Drive Groups .................. 102
1.3 Fault Current Protection .............................................................................................. 103
1.3.1 Rated Fault Current .............................................................................................. 103
1.3.2 Estimating the Discharge Current ......................................................................... 104
1.3.3 Manufacturer Used ............................................................................................... 104
2. DC Bus ............................................................................................................................. 105
2.1 General Information ..................................................................................................... 105
2.2 Wiring .......................................................................................................................... 106
2.3 Equal Distribution of the Applied Power via the Power Rectifiers ............................... 107
2.4 Equal Distribution of the Brake Power on the Braking Resistors ................................ 107
2.5 Connection of External DC Bus Power Supplies ......................................................... 108
3. Motor Connection ............................................................................................................. 109
4. Braking Resistor ............................................................................................................... 111
4.1 General Information ..................................................................................................... 111
4.2 External Braking Resistor Connection ......................................................................... 112
4.3 Dimensioning the Braking Resistor ............................................................................. 113
4.3.1 Resistance of the External Braking Resistor ......................................................... 114
4.3.2 Power Data for the External Braking Resistor ...................................................... 115
4.3.3 Nominal Voltage of the External Braking Resistor ................................................ 115
4.4 Setting Brake Resistor Parameters ............................................................................. 115
4.4.1 Using the Integrated Braking Resistors ................................................................ 115
4.4.2 Using External Braking Resistors ......................................................................... 116
5. Configuration of ACOPOS Servo Drives .......................................................................... 117
5.1 Maximum Power Output via the Four ACOPOS Servo Drive Slots ............................. 117
5.2 24 VDC Current Requirements for the ACOPOS Servo Drive .................................... 118
6. Formula Variables Used ................................................................................................... 119
Chapter 5: Wiring .......................................................................... 121
1. General Information ..........................................................................................................
1.1 Electromagnetic Compatibility of the Installation .........................................................
1.1.1 General Information ..............................................................................................
1.1.2 Installation Notes ..................................................................................................
1.2 Secure Restart Inhibit ..................................................................................................
1.2.1 General Information ..............................................................................................
1.2.2 Principle - Realization of the Safety Function .......................................................
1.2.3 External Wiring ......................................................................................................
1.3 Overview of the Terminal Cross Sections ..................................................................
2. Pin Assignments ACOPOS 1022, 1045, 1090 .................................................................
2.1 Pin Assignments for Plug X1 .......................................................................................
2.2 Pin Assignments for Plug X2 .......................................................................................
2.3 Pin Assignments for Plug X3 .......................................................................................
2.4 Pin assignments for plugs X4a, X4b ...........................................................................
2.4.1 Wiring the Output for the Motor Holding Brake .....................................................
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2.5 Pin Assignments for Plug X5 .......................................................................................
2.6 Protective Ground Connection (PE) ............................................................................
3. Pin Assignments ACOPOS 1180, 1320 ...........................................................................
3.1 Pin Assignments for Plug X1 .......................................................................................
3.2 Pin Assignments for Plug X2 .......................................................................................
3.3 Pin Assignments for Plug X3 .......................................................................................
3.4 Pin Assignments for Plugs X4a, X4b ...........................................................................
3.4.1 Wiring the Output for the Motor Holding Brake .....................................................
3.5 Pin Assignments for Plug X5 .......................................................................................
3.6 Pin Assignments for Plug X6 .......................................................................................
3.7 Protective Ground Connection (PE) ............................................................................
4. Pin Assignments ACOPOS 1640, 128M ..........................................................................
4.1 Pin Assignments for Plug X1 .......................................................................................
4.2 Pin Assignments X2 ....................................................................................................
4.3 Pin Assignments X3 ....................................................................................................
4.4 Pin Assignments for Plugs X4a, X4b ...........................................................................
4.4.1 Wiring the Output for the Motor Holding Brake .....................................................
4.5 Pin Assignments X5 ....................................................................................................
4.6 Pin Assignments X6 ....................................................................................................
5. Pin Assignments Plug-in Modules ....................................................................................
5.1 AC110 - CAN Interface ................................................................................................
5.1.1 Pin Assignments ...................................................................................................
5.2 AC112 - ETHERNET Powerlink Interface ...................................................................
5.2.1 Pin Assignments ...................................................................................................
5.3 AC120 - EnDat Encoder Interface ...............................................................................
5.3.1 Pin Assignments ...................................................................................................
5.4 AC122 - Resolver Interface .........................................................................................
5.4.1 Pin Assignments ...................................................................................................
5.5 AC123 - Incremental Encoder and SSI Absolute Encoder Interface ...........................
5.5.1 Pin Assignments ..................................................................................................
5.6 AC130 - Digital Mixed Module .....................................................................................
5.6.1 Pin Assignments ...................................................................................................
5.7 AC131 - Mixed Module ................................................................................................
5.7.1 Pin Assignments ...................................................................................................
5.8 Connecting Cables to Plug-in Modules .......................................................................
6. Cables ...............................................................................................................................
6.1 Motor Cable .................................................................................................................
6.1.1 Motor Cable Construction .....................................................................................
6.1.2 Pin Assignments for 8CMxxx.12-1, 8CMxxx.12-3 .................................................
6.1.3 Cable Schematic for 8CMxxx.12-1, 8CMxxx.12-3 ................................................
6.1.4 Pin Assignments for 8CMxxx.12-5 ........................................................................
6.1.5 Cable Schematic for 8CMxxx.12-5 .......................................................................
6.2 EnDat Encoder Cables ................................................................................................
6.2.1 EnDat Encoder Cable Construction ......................................................................
6.2.2 Pin Assignments ...................................................................................................
6.2.3 Cable Schematic ...................................................................................................
6.3 Resolver Cables ..........................................................................................................
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6.3.1 Resolver Cable Construction ................................................................................ 168
6.3.2 Pin Assignments ................................................................................................... 168
6.3.3 Cable Schematic ................................................................................................... 169
Chapter 6: Getting Started ........................................................... 171
1. Preparation .......................................................................................................................
1.1 Unpacking the ACOPOS Servo Drive .........................................................................
1.2 Installing and Connecting the ACOPOS Servo Drive ..................................................
1.3 Connecting the ACOPOS Servo Drive with a B&R PLC .............................................
2. Starting Up an ACOPOS Servo Drive ...............................................................................
2.1 General Information .....................................................................................................
2.1.1 Sample project ......................................................................................................
2.1.2 Preparing the Hardware for Sample Project acp10.gdm ......................................
2.2 Start-Up .......................................................................................................................
2.2.1 Load Sample Project .............................................................................................
2.2.2 Preset Values for the Sample Project ...................................................................
2.2.3 Preset Values Concerning Wiring .........................................................................
2.2.4 Downloading the Project .......................................................................................
2.2.5 Test Function ........................................................................................................
2.2.6 Starting the Motor Movement ................................................................................
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Chapter 7: Standards and Certifications .................................... 201
1. Valid European Guidelines ...............................................................................................
2. Valid Standards ................................................................................................................
3. Environmental Limits ........................................................................................................
3.1 Mechanical Conditions according to IEC 61800-2 ......................................................
3.1.1 Operation ..............................................................................................................
3.1.2 Transport ...............................................................................................................
3.2 Climate Conditions according to IEC 61800-2 ............................................................
3.2.1 Operation ..............................................................................................................
3.2.2 Storage .................................................................................................................
3.2.3 Transport ...............................................................................................................
4. Requirements for Immunity to Disturbances (EMC) .........................................................
4.1 Evaluation Criteria (performance criteria) ....................................................................
4.2 Low Frequency Disturbances according to IEC 61800-3 ............................................
4.2.1 Power Mains Harmonics and Commutation Notches / Voltage Distortions ..........
4.2.2 Voltage Changes, Deviations, Dips and Short-term Interruptions ........................
4.2.3 Asymmetric Voltage und Frequency Changes ......................................................
4.3 High Frequency Disturbances according to IEC 61800-3 ...........................................
4.3.1 Electrostatic Discharge .........................................................................................
4.3.2 Electromagnetic Fields ..........................................................................................
4.3.3 Burst ......................................................................................................................
4.3.4 Surge ....................................................................................................................
4.3.5 High Frequency Conducted Disturbances ............................................................
5. Requirements for Emissions (EMC) .................................................................................
5.1 High Frequency Emissions according to IEC 61800-3 ................................................
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Table of Contents
5.1.1 Emissions on the Power Connections ..................................................................
5.1.2 Electromagnetic Emissions ...................................................................................
6. Other Environmental Limit Values according to IEC 61800-2 ..........................................
7. International Certifications ................................................................................................
8. Standards, Definitions for Safety Techniques ...................................................................
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ACOPOS User's Manual
Chapter 1
General Information
General Information • ACOPOS
Chapter 1 • General Information
1. ACOPOS
With the ACOPOS product line, B&R provides the basis for complete and uniform automation
solutions. Branch specific functions and intuitive tools allow for short development times and
create more room for innovation.
1.1 Secure Operation
EMC was given special attention in order to guarantee proper operation in an industrial
environment. Field tests have been carried out under difficult conditions in addition to the tests
defined in the standard. The results confirm the excellent values measured by the testing
laboratory and during operation. The filters required to meet the CE guidelines are also
integrated in the device. This simplifies installation considerably.
Figure 1: Secure operation
ACOPOS User's Manual
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General Information • ACOPOS
The embedded parameter chip on the motor is one factor used to guarantee maximum security.
It contains all mechanical and electronic data relevant to the functionality of the motor.
Parameters no longer have to be set manually and start-up times are substantially reduced.
Secure operation also means that relevant data can be requested during service and the cause
of the problem can be determined.
1.2 Taking it to the Limit
Operational security is also improved by monitoring high temperature components (IGBT
modules, brake resistor, motor windings). Computer-based simulation allows component
temperatures which cannot be measured directly to be calculated. One example is the junction
temperature. This is a decisive value for the maximum load of a semiconductor. Using these
models, a sufficiently precise value can be determined for each IGBT. Hot spots can be ruled out
and the full dynamic properties of the device can be used at low rpm values and when stalled.
The brake resistor and motor windings are monitored in the same way.
This form of monitoring allows better use of absolute limits on the drive and provides the user
with the advantages of higher performance at lower costs.
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ACOPOS User's Manual
1.3 Individual I/O Configurations
The I/O points needed to operate a servo axis are part of the standard equipment for ACOPOS
drives. The user is provided two trigger inputs for tasks requiring precise measurements or print
mark control. Sensor and actuator configurations are made using modular plug-in modules. This
modular concept allows the optimum configuration to be selected to meet the requirements of
the application.
Figure 2: Individual I/O configurations
1.4 Configuring instead of Programming
Long-term cooperation with our customers has provided us with fundamental knowledge in many
positioning application areas. This knowledge can be passed on to our customers in the form of
clear and easy to use function blocks. Industry specific functionality can be quickly and easily
implemented in an application program.
1.5 Easy Service
All necessary data is placed in application memory on the controller so that service is limited to
simply exchanging the device. The program does not have to be changed. After the system is
started again, the controller installs the operating system that is used automatically (or when
requested by the user). After this procedure is complete, the parameters are sent to the servo
drive again. Problems resulting from different software versions or parameters can be ruled out.
ACOPOS User's Manual
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Chapter 1
General Information
General Information • ACOPOS
General Information • ACOPOS
1.6 Software and Hardware as a Unit
B&R integrates all relevant technologies in one tool - B&R Automation Studio™.
Adding a B&R ACOPOS servo drive is done in a Windows Look & Feel environment which
becomes routine after using the program a few times. Wizards and selection boxes ease
configuration of servo axis parameters. The target system is shown in a clear tree structure.
Detailed information concerning the target system, with integrated hardware documentation
ranging from software to terminal assignments, reduces project development times
considerably.
Figure 3: Software and hardware as a unit
1.7 Plain Text for Functions
NC Objects that can be accessed by the application program are also stored on the CPU (like
the application program).
Creating NC Objects (for axes, a CNC system or a cam profile) takes place using dialog boxes
and special data module editors. The individual hardware and software channels are assigned
symbolic names. This eases use and increases clarity. The initial parameters are set in a
separate editor in plain text.
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ACOPOS User's Manual
1.8 Simple Function Test
The built-in NC test allows an axis to be used without a line of program code being written. As
seen in the picture, several editors are grouped together as a single window. All movements,
ranging from point-to-point movements to gear functions, can be carried out using an NC Action.
The reaction of the axis can be seen online in the monitor window. If the trace function is turned
on, relevant data - from position to motor temperature - is recorded on the drive. The multiple
curve display in the trace window allows simple evaluation of the movement results.
Figure 4: Simple function test
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Chapter 1
General Information
General Information • ACOPOS
General Information • ACOPOS
1.9 Control Trigger
The oscilloscope in the drive allows movements to be monitored in real time. Many trigger
possibilities allow data required for analysis to be easily obtained. The graphic display of
diagnosis data supports the user when making fine adjustments and when optimizing the
movement. Measurement cursor and reference points allow µs precision.
Figure 5: Control trigger
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ACOPOS User's Manual
1.10 Cam Profiles for Everyone
Modular technology plug-ins allow homogenous integration of high performance tools such as
the Cam Editor.
The mouse is used to define fixed points, synchronous sections or interpolations. Effects of
positioning behavior on speed, acceleration and jolt for the slaves axes connected can be
monitored directly.
Figure 6: Cam profiles for everyone
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Chapter 1
General Information
General Information • ACOPOS
General Information • ACOPOS Configurations
2. ACOPOS Configurations
2.1 General Information
The ACOPOS servo drives can be used in various configurations depending on the network type
(CAN, Powerlink) and the requirements of the application.
The following ACOPOS functions are possible with all ACOPOS configurations:
•
Point-to-point
•
Electronic gears
•
Electronic compensation gears
•
Cross cutter
•
Electronic cam profiles
•
Flying saw
•
Line shaft
•
CNC
2.2 CAN
2.2.1 Configuration 1
Figure 7: CAN configuration 1
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ACOPOS User's Manual
General Information • ACOPOS Configurations
Chapter 1
General Information
2.2.2 Configuration 2
Figure 8: CAN configuration 2
ACOPOS User's Manual
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General Information • ACOPOS Configurations
2.3 Powerlink
2.3.1 Recommended Topology
In the Powerlink network (seen from the manager), the tree structure should always come first
followed then by the line structure. Otherwise, the line structure delay affects the entire tree
beneath it.
Information:
It should be noted that the longest path is allowed a maximum of 10 hubs by the
manager.
Further Literature
Unless otherwise stated, these recommendations apply to the following documents:
•
"Industrial Ethernet
(www.iaona-eu.com)
Planning
and
Installation
Guide",
Draft 2.0,
IAONA
•
"Guide to Understanding and Obtaining High Quality Generic Cabling", 3P Third Party
Testing (www.3ptest.dk)
2.3.2 Configuration 1
Figure 9: Powerlink configuration 1 - star topology
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ACOPOS User's Manual
General Information • ACOPOS Configurations
Chapter 1
General Information
2.3.3 Configuration 2
Figure 10: Powerlink configuration 2 - line topology
The advantage compared to configuration 1 is the low cabling expenditure for the same
functionality.
ACOPOS User's Manual
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General Information • Safety Guidelines
3. Safety Guidelines
3.1 General Information
Danger!
Servo drives and servo motors can have bare parts with voltages applied (e.g.
terminals) or hot surfaces. Additional sources of danger result from moving
machine parts. Improperly removing the required covers, inappropriate use,
incorrect installation or incorrect operation can result in severe personal injury or
damage to property.
All tasks, such as transport, installation, commissioning and service, are only allowed to be
carried out by qualified personnel. Qualified personnel are persons familiar with transport,
mounting, installation, commissioning and operation of the product and have the respective
qualifications (e.g. IEC 60364). National accident prevention guidelines must be followed.
The safety guidelines, connection descriptions (type plate and documentation) and limit values
listed in the technical data are to be read carefully before installation and commissioning and
must be observed.
Danger!
Handling servo drives incorrectly can cause severe personal injury or damage to
property!
3.2 Intended Use
Servo drives are components designed to be installed in electrical systems or machines. They
are not being used as intended unless the machine meets EG regulation 98/37/EG (machine
regulation) as well as regulation 89/336/EWG (EMC regulation).
The servo drives are only allowed to be operated directly on grounded, three-phase industrial
mains (TN, TT power mains). When using the servo drives in living areas, shops and small
businesses, additional filtering measures must be implemented by the user.
The technical data as well as the values for connection and environmental guidelines can be
found on the type plate and in the documentation. The connection and environmental guidelines
must be met.
Electronic devices are generally not fail-safe. If the servo drive fails, the user is responsible for
making sure that the motor is placed in a secure state.
26
ACOPOS User's Manual
3.3 Transport and Storage
During transport and storage, the devices must be protected from excessive stress (mechanical
load, temperature, humidity, aggressive atmosphere).
Servo drives contain components sensitive to electrostatic charges which can be damaged by
inappropriate handling. During installation/removal of servo drives, provide the necessary safety
precautions against electrostatic discharges.
3.4 Installation
The installation must take place according to the documentation using suitable equipment and
tools.
The devices are only allowed to be installed without voltage applied and by qualified personnel.
Voltage to the switching cabinet should be switched off and prevented from being switched on
again.
The general safety regulations and national accident prevention guidelines (e.g. VBG 4) must be
observed when working with high voltage systems.
The electrical installation must be carried out according to the relevant guidelines (e.g. line cross
section, fuse, protective ground connection, also see chapter 4 "Dimensioning").
3.5 Operation
3.5.1 Protection against Touching Electrical Parts
Danger!
To operate servo drives, it is necessary that certain parts are carrying voltages over
42 VDC. A life-threatening electrical shock could occur if you touch these parts. This
could result in death, severe injury or material damage.
Before turning on the servo drive, make sure that the housing is properly connected to protective
ground (PE rail). The ground connection must be made, even when testing the servo drive or
when operating it for a short time!
Before turning the device on, make sure that all voltage carrying parts are securely covered.
During operation, all covers and switching cabinet doors must remain closed.
Control and high power contacts can have voltage applied, even when the motor is not turning.
Touching the contacts when the device is switched on is not permitted.
ACOPOS User's Manual
27
Chapter 1
General Information
General Information • Safety Guidelines
General Information • Safety Guidelines
Before working on servo drives, they must be disconnected from the power mains and prevented
from being switched on again.
Danger!
After switching off the device, wait until the DC bus discharge time of at least five
minutes has passed. The voltage currently on the DC bus must be measured with a
suitable measuring device before beginning work. This voltage must be less than
42 V DC to rule out danger. The Run LED going out does not indicate that voltage is
not present on the device!
The connections for the signal voltages (5 to 30 V) found on the servo drives are isolated circuits.
Therefore, the signal voltage connections and interfaces are only allowed to be connected to
devices or electrical components with sufficient isolation according to IEC 60364-4-41 or
EN 50178.
Never remove the electrical connections from the servo drive with voltage applied. In unfavorable
conditions, arcs can occur causing personal injury and damage to contacts.
3.5.2 Protection from Dangerous Movements
Danger!
Incorrect control of motors can cause unwanted and dangerous movements! Such
incorrect behavior can have various causes:
•
Incorrect installation or an error when handling the components
•
Incorrect or incomplete wiring
•
Defective devices (servo drive, motor, position encoder, cable, brake)
•
Incorrect control (e.g. caused by software error)
Some of these causes can be recognized and prevented by the servo drive using internal
monitoring. However, it is generally possible for the motor shaft to move every time the device
is switched on! Therefore protection of personnel and the machine can only be guaranteed using
higher level safety precautions.
The movement area of machines must be protected to prevent accidental access. This type of
protection can be obtained by using stabile mechanical protection such as protective covers,
protective fences, protective gates or photocells.
Removing, bridging or bypassing these safety features and entering the movement area is
prohibited.
A sufficient number of emergency stop switches are to be installed directly next to the machine.
The emergency stop equipment must be checked before commissioning the machine.
28
ACOPOS User's Manual
General Information • Safety Guidelines
Chapter 1
General Information
Remove shaft keys on free running motors or prevent them from being catapulted.
The holding brake built into the motors cannot prevent hoists from allowing the load to sink.
3.6 Safety Guidelines
The safety guidelines are handled as follows:
Safety Guidelines
Description
Danger!
Disregarding the safety regulations and guidelines can be life-threatening.
Warning!
Disregarding the safety regulations and guidelines can result in severe injury or major
damage to material.
Caution!
Disregarding the safety regulations and guidelines can result in injury or damage to
material.
Information:
Important information for preventing errors
Table 1: Description of the safety guidelines
ACOPOS User's Manual
29
General Information • Safety Guidelines
30
ACOPOS User's Manual
Technical Data • ACOPOS Servo Family
Chapter 2 • Technical Data
1.1 Modular Servo Drive Concept
Controlling your power transmission system with B&R ACOPOS servo drives allows you to fully
use the advantages of an optimized system architecture. Applications that require additional
positioning tasks such as torque limitation or torque control can be created quickly and elegantly.
The flexible system concept for B&R servo drives is achieved using matched hardware and
software components. You can select the optimal system configuration for your application and
increase your competitiveness.
•
Perfect integration in the B&R 2000 product family
•
Object-oriented axis programming minimizes development time and increases reusability
•
Integrated technology functions for branch specific tasks
•
Operation of synchronous and asynchronous motors possible
•
Current controller scan time up to 50 µs
•
Reduced commissioning and service times using "embedded motor parameter chip"
•
CAN and Powerlink network connection
•
Input voltage range from 400 - 480 VAC (±10 %) for use worldwide
•
Connection possibilities for all standard encoder systems
•
2 free slots for optional technology modules
•
Electronic secure restart inhibit integrated
ACOPOS User's Manual
31
Chapter 2
Technical Data
1. ACOPOS Servo Family
Technical Data • ACOPOS Servo Family
1.2 General Description
The ACOPOS servo drive series covers a current range from 2.2 - 128 A and a power range
from 1 - 64 kW with 7 devices in 3 groups. The devices in a group are designed using the same
basic concept.
Group
8V1022.00-2
8V1045.00-2
8V1090.00-2
8V1180.00-2
8V1320.00-2
8V1640.00-2
8V128M.00-2
Power Connections
Plug connection
Plug connection
Fixed
Integrated Line Filter
Yes
Yes
--- 1)
Mains Failure Monitoring
Yes
Yes
Yes
DC Bus Connection
Yes
Yes
Yes
External 2)
External or internal via DC bus
External or internal via DC bus
24 VDC Output
No
24 V / 0.5 A
24 V / 0.5 A
Integrated Brake Chopper
Yes
Yes
Yes
Internal Braking Resistor
Yes
Yes
Yes 3)
Connection of External Braking
Resistor Possible
No
Yes
Yes
Monitored Output for Motor
Holding Brake
Yes
Yes
Yes
Monitored Input for Motor
Temperature Sensor
Yes
Yes
Yes
24 VDC Supply
Table 2: General description of the ACOPOS servo drive series
1) Integrated line filter in preparation.
2) External DC bus power supply 0PS320.1 (24V / 20A) can be used.
3) The braking resistor integrated in the ACOPOS servo drives 1640 and 128M is dimensioned so that it is possible to brake to a stop (in
a typical drive situation).
The ACOPOS servo drives also provide a modular fieldbus interface in addition to connection
possibilities for all standard encoder systems.
ACOPOS servo drives are suitable for both synchronous and asynchronous servo motors and
have built-in line filters to meet the limit values for CISPR11, Group 2, Class A.
Warning!
ACOPOS servo drives are suitable for power mains which can provide a maximum
short circuit current of 10000 Aeff at a maximum of 528 Veff.
32
ACOPOS User's Manual
Technical Data • ACOPOS Servo Family
In order to be able to provide the stop function for category 1 according to IEC 60204-1 during a
power failure, the 24 VDC supply voltage for the servo drives as well as encoders, sensors and
the safety circuit must remain active during the entire stopping procedure.
The ACOPOS servo drives recognize a power failure and can immediately initiate active braking
of the motor. The brake energy that occurs when braking is returned to the DC bus and the DC
bus power supply can use it to create the 24 VDC supply voltage 1) . An external DC bus power
supply must be used for ACOPOS servo drives 8V1022 to 8V1090. A DC bus power supply is
integrated in ACOPOS servo drives 8V1180 to 8V128M.
The ACOPOS servo drives with an integrated DC bus power supply provide the 24 VDC supply
for the servo drive and also a 24 VDC output to supply encoders, sensors and the safety circuit.
In may cases, it is not necessary to use an uninterruptible power supply (UPS) which is otherwise
needed.
1.3 LEDs
The ACOPOS servo drives are equipped with three LEDs for direct diagnosis:
Image
LED
Description
Color
1
Ready
Green
2
Run
Orange
3
Error
Red
Table 3: Status LEDs ACOPOS servo drives
If no LEDs are lit, the ACOPOS servo drive is not being supplied with 24 VDC.
Danger!
After switching off the device, wait until the DC bus discharge time of at least five
minutes has passed. The voltage currently on the DC bus must be measured with a
suitable measuring device before beginning work. This voltage must be less than
42 VDC to rule out danger. The Run LED going out does not indicate that voltage is
not present on the device!
1) WARNING: In some applications, there is not enough brake energy provided to guarantee that the 24 VDC supply voltage remains
active until the system is stopped.
ACOPOS User's Manual
33
Chapter 2
Technical Data
1.2.1 24 VDC Supply during Power Failures
Technical Data • ACOPOS Servo Family
Signal
LED
Ready
Green
Description
Lit when the ACOPOS servo drive is ready for operation and the power level can be enabled (operating
system present and booted, no permanent or temporary errors).
Run
Orange
Lit as soon as the power level is enabled for the ACOPOS servo drive.
Error
Red
Lit when a permanent or temporary error exists on the ACOPOS servo drive. After correcting the error,
the LED is automatically switched off.
Examples of permanent errors:
• Motor feedback not connected or defective
• Low level on the enable input
• Motor temperature sensor not connected or defective
• Internal error on the device (e.g. IGBT heat sink temperature sensor defective)
Examples of temporary errors:
• 24 VDC supply voltage exceeds the tolerance range
• DC bus voltage exceeds the tolerance range
• Internal 15 VDC control voltage exceeds the tolerance range
• IGBT current limit reached
• Over-temperature on the motor (temperature sensor)
• Over-temperature on the servo drive (IGBT junction, heat sink, conductive tracks)
• Over-temperature on braking resistor
• CAN or Powerlink network faulty
Table 4: LED status
1.3.1 LED Status
The following timing is used for the indication diagrams:
Block size:
125 ms
Repeats after:
3000 ms
Status changes when booting the operating system loader
Status
LED
Display
Green
1. Boot procedure for basic hardware active
Orange
Red
Green
2. Configuration of network plug-in module active
Orange
Red
Green
3. Waiting for network telegram
Orange
Red
Green
4. Network communication active
Orange
Red
Table 5: Status changes when booting the operating system loader
34
ACOPOS User's Manual
Technical Data • ACOPOS Servo Family
Error status with reference to the CAN plug-in module AC110
Status
LED
Display
Green
Boot error on CAN basic hardware
Orange
Red
Green
Orange
Chapter 2
Technical Data
Bus Off
Red
Green
CAN node number is 0
Orange
Red
Table 6: Error status with reference to the CAN plug-in module AC110
Error status with reference to the ETHERNET Powerlink plug-in module AC112
Status
LED
Display
Green
Boot error on Powerlink basic hardware
Orange
Red
Green
Error when booting the AC112-ARM
Orange
Red
Green
Powerlink node number is 0
Orange
Red
Table 7: Error status with reference to the ETHERNET Powerlink plug-in module AC112
ACOPOS User's Manual
35
Technical Data • ACOPOS Servo Family
1.4 ACOPOS 1022, 1045 and 1090
1.4.1 Order Data
Model Number
Short Description
Image
Servo Drives
8V1022.00-2
Servo drive 3 x 400-480V 2.2A 1kW, line filter, braking resistor and
electronic secure restart inhibit integrated
8V1045.00-2
Servo drive 3 x 400-480V 4.4A 2kW, line filter, braking resistor and
electronic secure restart inhibit integrated
8V1090.00-2
Servo drive 3 x 400-480V 8.8A 4kW, line filter, braking resistor and
electronic secure restart inhibit integrated
Accessories
8AC110.60-2
ACOPOS plug-in module, CAN interface
8AC112.60-1
ACOPOS plug-in module, ETHERNET Powerlink interface
8AC120.60-1
ACOPOS plug-in module, EnDat encoder interface
8AC122.60-2
ACOPOS plug-in module, resolver interface
8AC123.60-1
ACOPOS plug-in module, incremental encoder and SSI absolute
encoder interface
8AC130.60-1
ACOPOS plug-in module, 8 digital I/O configurable in pairs as
24V input or as output 400/100mA, 2 digital outputs 2A, Order TB712
terminal block separately
8AC131.60-1
ACOPOS plug-in module, 2 analog inputs ±10V, 2 digital I/O points
which can be configured as 24V input or 45mA output
0PS320.1
24 VDC power supply, 3-phase, 20 A, input 400..500 VAC (3 phases),
wide range, DIN rail mounting
Table 8: Order data for ACOPOS 1022, 1045 and 1090
1.4.2 Technical Data
Product ID
8V1022.00-2
8V1045.00-2
8V1090.00-2
General Information
C-UL-US Listed
Yes
Power mains connection
Mains Input Voltage
3 x 400 VAC to 480 VAC ±10 %
Power filter according to IEC 61800-3-A11 second environment
(Limits from CISPR11, Group 2, Class A)
Frequency
50 / 60 Hz ± 4 %
Installed Load
Starting Current at 400 VAC
Max. 3 kVA
Max. 5 kVA
Max. 10 kVA
4A
7A
7A
Switch-on Interval
> 10 s
Power Loss at Max. Device Power
without Brake Resistor
Approx. 120 W
Approx. 180 W
Approx. 200 W
Table 9: Technical data for ACOPOS 1022, 1045 and 1090
36
ACOPOS User's Manual
Technical Data • ACOPOS Servo Family
Product ID
8V1022.00-2
8V1045.00-2
8V1090.00-2
24 VDC Supply
Input Voltage 1)
24 VDC +25 % / -20 %
Input Capacitance
8200 µF
Current Requirements 2)
Max. 2.5 A + current for motor holding brake
Maximum Switching Frequency
20 kHz
20 kHz
10 kHz
Continuous Current at 400 VAC
2.2 Aeff
4.4 Aeff
8.8 Aeff
Continuous Current at 480 VAC
1.7 Aeff
3.3 Aeff
6.6 Aeff
Peak Current
14 Aeff
24 Aeff
24 Aeff
Maximum Motor Line Length
Chapter 2
Technical Data
Motor Connection
25 m
Protective Measures
Short circuit and ground fault protection
Motor Holding Brake Connection
Maximum Output Current
1A
Protective Measures
Short circuit and ground fault protection
Braking resistor
Peak Power Output
3.5 kW
7 kW
7 kW
Continuous Power Output
130 W
200 W
200 W
Operational Conditions
Environment Temperature during
Operation
0 to +40 °C
Relative Humidity during Operation
5 to 95 %, non-condensing
Reduction of the Continuous Current
at Installation Altitudes over 500 m
above Sea Level
10 % per 1000 m
2000 m 3)
Maximum Installation Altitude
Degree of Pollution according to
IEC 60664-1
2 (non-conductive material)
Over-voltage Category according to
IEC 60364-4-443:1999
II
Protection according to IEC 60529
IP20
Storage and Transport Conditions
Storage Temperature
-25 to +55 °C
Relative Humidity during Storage
5 to 95 %, non-condensing
Transport Temperature
-25 to +70 °C
Relative Humidity during Transport
95 % at +40 °C
Mechanical Characteristics
Dimensions
Width
Height
Depth
70.5 mm
375 mm
235.5 mm
Weight
4.0 kg
4.1 kg
4.4 kg
Table 9: Technical data for ACOPOS 1022, 1045 and 1090 (cont.)
1) When using motor holding brakes, the valid input voltage range is reduced. The input voltage range should be selected so that the
proper supply voltage for the brake can be maintained.
2) The current requirements depend on the configuration of the ACOPOS servo drive. To determine the current requirements, see
section 5 "Configuration of ACOPOS Servo Drives", on page 117.
3) Additional requirements are to be arranged with B&R.
ACOPOS User's Manual
37
Technical Data • ACOPOS Servo Family
1.5 ACOPOS 1180, 1320
1.5.1 Order Data
Model Number
Short Description
Image
Servo Drives
8V1180.00-2
Servo drive 3 x 400-480V 18A 9kW, line filter, braking resistor, DC
bus power supply and electronic secure restart inhibit integrated
8V1320.00-2
Servo drive 3 x 400-480V 32A 16kW, line filter, braking resistor, DC
bus power supply and electronic secure restart inhibit integrated
8AC110.60-2
ACOPOS plug-in module, CAN interface
8AC112.60-1
ACOPOS plug-in module, ETHERNET Powerlink interface
8AC120.60-1
ACOPOS plug-in module, EnDat encoder interface
Accessories
8AC122.60-2
ACOPOS plug-in module, resolver interface
8AC123.60-1
ACOPOS plug-in module, incremental encoder and SSI absolute
encoder interface
8AC130.60-1
ACOPOS plug-in module, 8 digital I/O configurable in pairs as
24V input or as output 400/100mA, 2 digital outputs 2A, Order TB712
terminal block separately
8AC131.60-1
ACOPOS plug-in module, 2 analog inputs ±10V, 2 digital I/O points
which can be configured as 24V input or 45mA output
0PS320.1
24 VDC power supply, 3-phase, 20 A, input 400..500 VAC (3 phases),
wide range, DIN rail mounting
Table 10: Order data for ACOPOS 1180, 1320
1.5.2 Technical Data
Product ID
8V1180.00-2
8V1320.00-2
General Information
C-UL-US Listed
Yes
Power mains connection
Mains Input Voltage
3 x 400 VAC to 480 VAC ±10 %
Power filter according to IEC 61800-3-A11 second environment
(Limits from CISPR11, Group 2, Class A)
Frequency
50 / 60 Hz ± 4 %
Installed Load
Max. 17 kVA
Starting Current at 400 VAC
Max. 30 kVA
13 A
Switch-on Interval
> 10 s
Power Loss at Max. Device Power without
Brake Resistor
Approx. 500 W
Approx. 800 W
Table 11: Technical data for ACOPOS 1180, 1320
38
ACOPOS User's Manual
Technical Data • ACOPOS Servo Family
Product ID
8V1180.00-2
8V1320.00-2
24 VDC Supply
Input Voltage
24 VDC +25 % / -20 %
Input Capacitance
40000 µF
Current Requirements 1)
Mains Input Voltage Applied
Mains Input Voltage not Applied
--- 2)
Max. 2.8 A + current for the motor holding brake + current on the 24 VDC output
Motor Connection
10 kHz
Continuous Current at 400 VAC
19 Aeff
34 Aeff
Continuous Current at 480 VAC
14 Aeff
25 Aeff
Peak Current
50 Aeff
Maximum Motor Line Length
Chapter 2
Technical Data
Maximum Switching Frequency
80 Aeff
25 m
Protective Measures
Short circuit and ground fault protection
Motor Holding Brake Connection
Maximum Output Current
1.5 A
Protective Measures
Short circuit and ground fault protection
Braking resistor
Peak Power Int. / Ext.
14 / 40 kW
Continuous Power Int. / Ext.
0.4 / 8 kW
Operational Conditions
Environment Temp. during Operation
0 to +40 °C
Relative Humidity during Operation
5 to 95 %, non-condensing
Reduction of the Continuous Current at
Installation Altitudes over 500 m above
Sea Level
10 % per 1000 m
2000 m 3)
Maximum Installation Altitude
Degree of Pollution acc. to IEC 60664-1
2 (non-conductive material)
Over-voltage Category according to
IEC 60364-4-443:1999
II
Protection according to IEC 60529
IP20
Storage and Transport Conditions
Storage Temperature
-25 to +55 °C
Relative Humidity during Storage
5 to 95 %, non-condensing
Transport Temperature
-25 to +70 °C
Relative Humidity during Transport
95 % at +40 °C
Mechanical Characteristics
Dimensions
Width
Height
Depth
200 mm
375 mm
234 mm
Weight
10.7 kg
11.3 kg
Table 11: Technical data for ACOPOS 1180, 1320 (cont.)
1) The current requirements depend on the configuration of the ACOPOS servo drive. To determine the current requirements, see
section 5 "Configuration of ACOPOS Servo Drives", on page 117.
2) The 24 VDC supply voltage for the ACOPOS servo drive is created by the integrated DC bus power supply, which reduces the 24 VDC
current requirements (I24VDC) to 0. Mains Input Voltage: 3 x 400 VAC to 480 VAC ± 10 %.
3) Additional requirements are to be arranged with B&R.
ACOPOS User's Manual
39
Technical Data • ACOPOS Servo Family
1.6 ACOPOS 1640, 128M
1.6.1 Order Data
Model Number
Short Description
Image
Servo Drives
8V1640.00-2
Servo drive 3 x 400-480V 64A 32kW, line filter, braking resistor, DC
bus power supply and electronic secure restart inhibit integrated 1)
8V128M.00-2
Servo drive 3 x 400-480V 128A 64kW, line filter, braking resistor, DC
bus power supply and electronic secure restart inhibit integrated 1)
8AC110.60-2
ACOPOS plug-in module, CAN interface
8AC112.60-1
ACOPOS plug-in module, ETHERNET Powerlink interface
8AC120.60-1
ACOPOS plug-in module, EnDat encoder interface
Accessories
8AC122.60-2
ACOPOS plug-in module, resolver interface
8AC123.60-1
ACOPOS plug-in module, incremental encoder and SSI absolute
encoder interface
8AC130.60-1
ACOPOS plug-in module, 8 digital I/O configurable in pairs as
24V input or as output 400/100mA, 2 digital outputs 2A, Order TB712
terminal block separately
8AC131.60-1
ACOPOS plug-in module, 2 analog inputs ±10V, 2 digital I/O points
which can be configured as 24V input or 45mA output
0PS320.1
24 VDC power supply, 3-phase, 20 A, input 400..500 VAC (3 phases),
wide range, DIN rail mounting
Table 12: Order data for ACOPOS 1640, 128M
1) Integrated line filter in preparation.
1.6.2 Technical Data
Product ID
8V1640.00-2
8V128M.00-2
General Information
C-UL-US Listed
Yes
Power mains connection
Mains Input Voltage
3 x 400 VAC to 480 VAC ±10 %
Power filter according to IEC 61800-3-A11 second environment
(Limits from CISPR11, Group 2, Class A) 1)
Frequency
50 / 60 Hz ± 4 %
Installed Load
Max. 54 kVA
Starting Current at 400 VAC
Max. 98 kVA
26 A
Switch-on Interval
> 10 s
Power Loss at Max. Device Power without
Brake Resistor
Approx. 1600 W
Approx. 3200 W
Table 13: Technical data for ACOPOS 1640, 128M
40
ACOPOS User's Manual
Technical Data • ACOPOS Servo Family
Product ID
8V1640.00-2
8V128M.00-2
24 VDC Supply
Input Voltage
24 VDC +25 % / -20 %
Input Capacitance
32800 µF
Current requirements at 24 VDC 2)
Mains Input Voltage Applied
Mains Input Voltage not Applied
--- 3)
Max. 6 A + 1.4 * (current for the motor holding brake + current on the 24 VDC output)
Maximum Switching Frequency
10 kHz
5 kHz
Continuous Current at 400 VAC
64 Aeff
128 Aeff
Continuous Current at 480 VAC
48 Aeff
96 Aeff
Peak Current
200 Aeff
300 Aeff
Maximum Motor Line Length
Chapter 2
Technical Data
Motor Connection
25 m
Protective Measures
Short circuit and ground fault protection
Motor Holding Brake Connection
Maximum Output Current
3A
Protective Measures
Short circuit and ground fault protection
Braking resistor
Peak Power Int. / Ext.
7 / 250 kW
8.5 / 250 kW
Continuous Power Int. / Ext.
0.2 / 24 kW
0.24 / 24 kW
Operational Conditions
Environment Temp. during Operation
0 to +40 °C
Relative Humidity during Operation
5 to 95 %, non-condensing
Reduction of the Continuous Current at
Installation Altitudes over 500 m above
Sea Level
10 % per 1000 m
2000 m 4)
Maximum Installation Altitude
Degree of Pollution acc. to IEC 60664-1
2 (non-conductive material)
Over-voltage Category according to
IEC 60364-4-443:1999
II
Protection according to IEC 60529
IP20
Storage and Transport Conditions
Storage Temperature
-25 to +55 °C
Relative Humidity during Storage
5 to 95 %, non-condensing
Transport Temperature
-25 to +70 °C
Relative Humidity during Transport
95 % at +40 °C
Mechanical Characteristics
Dimensions
Width
Height
Depth
Weight
276 mm
460 mm
295 mm
402 mm
460 mm
295 mm
24.1 kg
33.8 kg
Table 13: Technical data for ACOPOS 1640, 128M (cont.)
1) Integrated line filter in preparation.
2) The current requirements depend on the configuration of the ACOPOS servo drive. To determine the current requirements, see
section 5 "Configuration of ACOPOS Servo Drives", on page 117.
3) The 24 VDC supply voltage for the ACOPOS servo drive is created by the integrated DC bus power supply, which reduces the 24 VDC
current requirements (I24VDC) to 0. Mains Input Voltage: 3 x 400 VAC to 480 VAC ± 10 %.
4) Additional requirements are to be arranged with B&R.
ACOPOS User's Manual
41
Technical Data • ACOPOS Plug-in Modules
2. ACOPOS Plug-in Modules
2.1 General Information
The ACOPOS drives are equipped with four plug-in module slots. You can select the plug-in
modules required for your application and insert them into the ACOPOS servo drive.
2.2 Order Data
Model Number
Short Description
8AC110.60-2
ACOPOS plug-in module, CAN interface
8AC112.60-1
ACOPOS plug-in module, ETHERNET Powerlink interface
8AC120.60-1
ACOPOS plug-in module, EnDat encoder interface
8AC122.60-2
ACOPOS plug-in module, resolver interface
8AC123.60-1
ACOPOS plug-in module, incremental encoder and SSI absolute encoder interface
8AC130.60-1
ACOPOS plug-in module, 8 digital I/O configurable in pairs as 24V input or as output 400/100mA, 2 digital outputs 2A, Order
TB712 terminal block separately
8AC131.60-1
ACOPOS plug-in module, 2 analog inputs ±10V, 2 digital I/O points which can be configured as 24V input or 45mA output
Table 14: Order data for plug-in modules
42
ACOPOS User's Manual
Technical Data • ACOPOS Plug-in Modules
2.3 AC110 - CAN Interface
2.3.1 General Description
The AC110 plug-in module can be used in an ACOPOS slot. The module is equipped with a CAN
interface. This fieldbus interface is used for communication and setting parameters on the
ACOPOS servo drive for standard applications.
Model Number
Short Description
Chapter 2
Technical Data
2.3.2 Order Data
Image
Plug-in Module
8AC110.60-2
ACOPOS plug-in module, CAN interface
Accessories
7AC911.9
Bus connector, CAN
0AC912.9
Bus adapter, CAN, 1 CAN interface
0AC913.92
Bus adapter, CAN, 2 CAN interfaces, including 30 cm connection
cable
Table 15: Order data for AC110
2.3.3 Technical Data
Product ID
8AC110.60-2
General Information
C-UL-US Listed
Module Type
Slot
Power Consumption
Yes
ACOPOS plug-in module
Slot 1
Max. 0.7 W
CAN Interface
Connection, Module Side
9 pin DSUB plug
LEDs
RXD/TXD LEDs
Electrical isolation
CAN - ACOPOS
Yes
Table 16: Technical Data for AC110
ACOPOS User's Manual
43
Technical Data • ACOPOS Plug-in Modules
Product ID
8AC110.60-2
Maximum Distance
60 m
Baud Rate
500 kBit/s
Network Capable
Yes
Bus Termination Resistor
Externally wired
Operational Conditions
Environment Temperature during
Operation
0 to +50 °C
Relative Humidity during Operation
5 to 95 % (non condensing)
Storage and Transport Conditions
Storage Temperature
-25 to +55 °C
Relative Humidity during Storage
5 to 95 %, non-condensing
Transport Temperature
-25 to +70 °C
Relative Humidity during Transport
95 % at +40 °C
Table 16: Technical Data for AC110 (cont.)
2.3.4 CAN Node Number Settings
The CAN node number can be set using two HEX code switches: 1)
Code Switch
CAN Node Number
Top
16s position (high)
Bottom
1s position (low)
Table 17: Setting the CAN node number with the two HEX code switches
Changing the node number becomes active the next time the ACOPOS servo drive is switched
on.
There must be a terminating resistor (120 Ω, 0.25 W) between CAN_H and CAN_L at the
beginning and end of the CAN bus.
2.3.5 LEDs
The status LEDs show if data is being received (RXD) or sent (TXD).
2.3.6 Firmware
The firmware is part of the operating system for the ACOPOS servo drives. The firmware is
updated by updating the ACOPOS operating system.
1) Changing the node number using software is not possible (Basis CAN ID can be changed).
The ACOPOS Manager only supports node numbers from 1 - 32.
When using the NC157 positioning module, only node numbers from 1 - 8 are possible.
44
ACOPOS User's Manual
Technical Data • ACOPOS Plug-in Modules
2.4 AC112 - ETHERNET Powerlink Interface
2.4.1 General Description
The plug-in module is set up as a 2x hub. This makes it easy to establish a device to device
connection (line topology).
2.4.2 Order Data
Model Number
Short Description
Image
Plug-in Module
8AC112.60-1
ACOPOS plug-in module, ETHERNET Powerlink interface
Table 18: Order data for AC112
2.4.3 Technical Data
Product ID
8AC112.60-1
General Information
C-UL-US Listed
Module Type
Slot
Power Consumption
Yes
ACOPOS plug-in module
Slot 1
Max. 2.5 W
Table 19: Technical data for AC112
ACOPOS User's Manual
45
Chapter 2
Technical Data
The AC112 plug-in module can be used in an ACOPOS slot. The module is equipped with an
ETHERNET Powerlink interface. This fieldbus interface is used for communication and setting
parameters on the ACOPOS servo drive for complex and time critical applications.
Technical Data • ACOPOS Plug-in Modules
Product ID
8AC112.60-1
Powerlink Interface
Connection, Module Side
2 x RJ45 socket
LEDs
Status LEDs
Yes
Electrical isolation
ETHERNET - ACOPOS
100 m 1)
Maximum Distance per Segment
Baud Rate
100 Mbit/s
Network Capable
Yes
Hub, 2x
Yes
Maximum Number of Hub Levels
10; see section 2 "ACOPOS Configurations", on page 22
Cabling Topology
Star or tree with level 2 hubs
Possible Station Operating Modes
Synchronous to Powerlink cycle
Watchdog Function
Hardware
Software
Yes (via ACOPOS servo drive)
Yes (via ACOPOS servo drive)
Operational Conditions
Environment Temperature during
Operation
0 to +50 °C
Relative Humidity during Operation
5 to 95 %, non-condensing
Storage and Transport Conditions
Storage Temperature
-25 to +55 °C
Relative Humidity during Storage
5 to 95 %, non-condensing
Transport Temperature
-25 to +70 °C
Relative Humidity during Transport
95 % at +40 °C
Table 19: Technical data for AC112 (cont.)
1) With a cycle time of 400 µs and 10 ACOPOS servo drives, the maximum total cable length is 200 m.
2.4.4 Powerlink Node Number Setting
The Powerlink node number can be set using two HEX code switches:
Code Switch
Powerlink Node Number
Top
16s position (high)
Bottom
1s position (low)
Table 20: Setting the Powerlink node number with the two HEX code switches
Changing the node number becomes active the next time the ACOPOS servo drive is switched
on.
46
ACOPOS User's Manual
Technical Data • ACOPOS Plug-in Modules
Chapter 2
Technical Data
2.4.5 LEDs
Figure 11: Status LEDs AC112
The status is indicated on the AC112 using one green and one red LED.
LED Test
Immediately after resetting the module, both LEDs are switched off for 0.5 s, then switched on
for 1.5 s.
Then the green LED is cleared for one second and the following boot procedure. After proper
initialization, the red LED is switched off and the green LED is switched on.
Status of the LEDs
The following timing is used for the indication diagram:
Block size:
150 ms
Status
LED
Display
Green
Error-free operation
Red
Green
Fatal system error 1)
Red
Green
Master has dropped out
Red
Green
System stop 2)
Red
See System Stop Error Codes
Table 21: Indication diagram for the AC112 status LEDs
1) This is a problem which cannot be repaired, the system can no longer carry out tasks correctly.
This status can only be changed by resetting the module.
2) The red LED blinks an error code, the output of the error code occurs in 4 short (150 ms) or long (600 ms) phases.
ACOPOS User's Manual
47
Technical Data • ACOPOS Plug-in Modules
System stop error codes
The following timing is used for the indication diagram:
Block size:
150 ms
Pause:
2000 ms
Error
Display
Stack overflow
RAM error
Undefined address 1)
Instruction fetch memory abort 2)
Data access memory abort 3)
Assertion failed 4)
Programming failed 5)
Table 22: System stop error codes
1)
2)
3)
4)
5)
Access of non-existent address.
Invalid memory access during instruction fetch (e. g. WORD access of add numbered address).
Invalid memory access during data access (e. g. WORD access of add numbered address).
This system stop code only occurs in debug mode. The condition for a software assertion was not fulfilled.
Error during programming.
2.4.6 Firmware
The firmware is part of the operating system for the ACOPOS servo drives. The firmware is
updated by updating the ACOPOS operating system.
48
ACOPOS User's Manual
Technical Data • ACOPOS Plug-in Modules
2.5 AC120 - EnDat Encoder Interface
2.5.1 General Description
This module can be used to evaluate encoders which are built into B&R servo motors and also
encoders for external axes (encoders that evaluate any machine movement). The input signals
are monitored. In this way, broken connections, shorted lines and encoder supply failure can be
recognized.
EnDat Encoder:
EnDat is a standard developed by Johannes Heidenhain GmbH (www.heidenhain.de),
incorporating the advantages of absolute and incremental position measurement and also offers
a read/write parameter memory in the encoder. With absolute position measurement (absolute
position is read in serially), the homing procedure is usually not required. When necessary, a
multi-turn encoder (4096 revolutions) should be installed. To save costs, a single-turn encoder
and a reference switch can also be used. In this case, a homing procedure must be carried out.
The incremental process allows the short delay times necessary for position measurement on
drives with exceptional dynamic properties. With the sinusoidal incremental signal and the fine
resolution in the EnDat module, a very high positioning resolution is achieved in spite of the
moderate signal frequencies used.
The parameter memory in the EnDat encoder is used by B&R to store motor data (among other
things). In this way, the ACOPOS servo drives are always automatically provided the correct
motor parameters and limit values. This is referred to as the "embedded parameter chip".
During start-up, the module is automatically identified, configured and its parameters set by the
ACOPOS servo drive operating system.
Incremental encoder with sine formed output signal:
When using the AC120 plug-in module to evaluate simple incremental encoders with sine formed
output signal, only the incremental transfer channel is now used. The "embedded parameter
chip" it not available in this case because this encoder does not have parameter memory. The
absolute position is also not available immediately after switching the device on. In this situation,
a homing procedure normally has to be carried out. The module is equipped with a reference
pulse input for this purpose.
1) Starting with revision F0.
ACOPOS User's Manual
49
Chapter 2
Technical Data
The AC120 plug-in module can be used in an ACOPOS slot. The module has an EnDat encoder
interface, but can also be used to evaluate simple incremental encoders with sine formed output
signal 1) .
Technical Data • ACOPOS Plug-in Modules
2.5.2 Order Data
Model Number
Short Description
Image
Plug-in Module
8AC120.60-1
ACOPOS plug-in module, EnDat encoder interface
Accessories
8CE005.12-1
EnDat cable, length 5m, 10 x 0.14mm² + 2 x 0.5mm², EnDat
connector 17 pin Intercontec socket, servo connector 15-pin DSUB
plug, can be used in cable drag chains, UL/CSA listed
8CE007.12-1
EnDat cable, length 7m, 10 x 0.14mm² + 2 x 0.5mm², EnDat
connector 17 pin Intercontec socket, servo connector 15-pin DSUB
plug, can be used in cable drag chains, UL/CSA listed
8CE010.12-1
EnDat cable, length 10m, 10 x 0.14mm² + 2 x 0.5mm², EnDat
connector 17 pin Intercontec socket, servo connector 15-pin DSUB
plug, can be used in cable drag chains, UL/CSA listed
8CE015.12-1
EnDat cable, length 15m, 10 x 0.14mm² + 2 x 0.5mm², EnDat
connector 17 pin Intercontec socket, servo connector 15-pin DSUB
plug, can be used in cable drag chains, UL/CSA listed
8CE020.12-1
EnDat cable, length 20m, 10 x 0.14mm² + 2 x 0.5mm², EnDat
connector 17 pin Intercontec socket, servo connector 15-pin DSUB
plug, can be used in cable drag chains, UL/CSA listed
8CE025.12-1
EnDat cable, length 25m, 10 x 0.14mm² + 2 x 0.5mm², EnDat
connector 17 pin Intercontec socket, servo connector 15-pin DSUB
plug, can be used in cable drag chains, UL/CSA listed
Table 23: Order data for AC120
2.5.3 Technical Data
Product ID
8AC120.60-1
General Information
C-UL-US Listed
Module Type
Slot 1)
Power Consumption
E0 ... EnDat single-turn, 512 lines
E1 ... EnDat multi-turn, 512 lines
E2 ... EnDat single-turn, 32 lines (inductive)
E3 ... EnDat multi-turn, 32 lines (inductive)
E4 ... EnDat single-turn, 512 lines
E5 ... EnDat multi-turn, 512 lines
Yes
ACOPOS plug-in module
Slots 2, 3 and 4
Max. 1.8 W
Max. 2.5 W
Max. 2.2 W
Max. 1.9 W
Max. 1.7 W
Max. 2.2 W
Encoder Input 2)
Connection, Module Side
LEDs
Electrical isolation
Encoder - ACOPOS
Encoder Monitoring
15 pin DSUB socket
UP/DN LEDs
No
Yes
Table 24: Technical data for AC120
50
ACOPOS User's Manual
Technical Data • ACOPOS Plug-in Modules
8AC120.60-1
Encoder Supply
Output Voltage
Load
Sense Lines
Typ. 5 V
200 mA
2, compensation of max. 2 x 0.7 V
Sine Cosine Inputs
Signal Transfer
Differential Voltage
Common Mode Voltage
Terminating Resistance
Signal Frequency
Resolution 3)
Precision 4)
Differential signal, symmetric
0.5 ... 1.25 Vss
Max. ±7 V
120 Ω
DC ... 400 kHz
16384 * number of encoder lines
---
Reference Input
Signal Transfer
Differencial Voltage for High
Differencial Voltage for Low
Common-mode Voltage
Terminating Resistance
Chapter 2
Technical Data
Product ID
Differential signal, symmetric
≥ +0.2 V
≤ -0.2 V
Max. ± 7 V
120 Ω
Serial Interface
Signal Transfer
Baud Rate
Synchronous
RS485
625 kBaud
Operational Conditions
Environment Temperature during Operation
Relative Humidity during Operation
0 to +50 °C
5 to 95 %, non-condensing
Storage and Transport Conditions
Storage Temperature
Relative Humidity during Storage
Transport Temperature
Relative Humidity during Transport
-25 to +55 °C
5 to 95 %, non-condensing
-25 to +70 °C
95 % at +40 °C
Table 24: Technical data for AC120 (cont.)
1) The AC120 is an encoder module. Several encoder modules can also be inserted. In this case, the encoder module in the slot with the
lowest number is automatically used for motor feedback.
2) The EnDat encoder must be wired using a cable with a single shield.
3) Noise on the encoder signal reduces the resolution that can be used by approx. 4 bits (factor of 16).
4) The precision is actually limited by the encoder.
2.5.4 LEDs
The UP/DN LEDs are lit depending on the rotational direction and the speed of the connected
encoder.
UP LED ... lit when the encoder position changes in the positive direction.
DN LED ... lit when the encoder position changes in the negative direction.
The faster the encoder position changes, the brighter the respective LED is lit.
2.5.5 Firmware
The firmware is part of the operating system for the ACOPOS servo drives. The firmware is
updated by updating the ACOPOS operating system.
ACOPOS User's Manual
51
Technical Data • ACOPOS Plug-in Modules
2.6 AC122 - Resolver Interface
2.6.1 General Description
The AC122 plug-in module can be used in an ACOPOS slot. The module is equipped with a
resolver interface.
The plug-in module handles the output from resolvers which are built into B&R servo motors or
used as an encoder for external axes. This resolver delivers the absolute position over one
revolution. Normally, the movement path is longer than one revolution. In this case, a reference
switch must be used and a homing procedure carried out.
The encoder input signals are monitored. In this way, broken connections, shorted lines and
encoder supply failure (reference signal) can be recognized.
During start-up, the AC122 module is automatically identified by the ACOPOS operating system.
Making automatic adjustments to the motor (resolution parameter) and reading the motor
parameters and limit values is not possible because the resolver does not have parameter
memory like the EnDat encoder.
If the precision, resolution, bandwidth or ease of setting parameters is not sufficient with the
resolver, the EnDat system should be used (see section 2.5 "AC120 - EnDat Encoder Interface",
on page 49).
2.6.2 Order Data
Model Number
Short Description
Image
Plug-in Module
8AC122.60-2
ACOPOS plug-in module, resolver interface
Accessories
8CR005.12-1
Resolver cable, length 5m, 3 x 2 x 24 AWG/19, resolver connector
12 pin Intercontec socket, servo plug 9-pin DSUB plug, can be used
in cable drag chains, UL/CSA listed
8CR007.12-1
Resolver cable, length 7m, 3 x 2 x 24 AWG/19, resolver connector
12 pin Intercontec socket, servo plug 9-pin DSUB plug, can be used
in cable drag chains, UL/CSA listed
8CR010.12-1
Resolver cable, length 10m, 3 x 2 x 24 AWG/19, resolver connector
12 pin Intercontec socket, servo plug 9-pin DSUB plug, can be used
in cable drag chains, UL/CSA listed
8CR015.12-1
Resolver cable, length 15m, 3 x 2 x 24 AWG/19, resolver connector
12 pin Intercontec socket, servo plug 9-pin DSUB plug, can be used
in cable drag chains, UL/CSA listed
8CR020.12-1
Resolver cable, length 20m, 3 x 2 x 24 AWG/19, resolver connector
12 pin Intercontec socket, servo plug 9-pin DSUB plug, can be used
in cable drag chains, UL/CSA listed
8CR025.12-1
Resolver cable, length 25m, 3 x 2 x 24 AWG/19, resolver connector
12 pin Intercontec socket, servo plug 9-pin DSUB plug, can be used
in cable drag chains, UL/CSA listed
Table 25: Order data for AC122
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ACOPOS User's Manual
Technical Data • ACOPOS Plug-in Modules
2.6.3 Technical Data
Product ID
8AC122.60-2
General Information
C-UL-US Listed
Module Type
Slot 1)
Power Consumption
Yes
ACOPOS plug-in module
Slots 2, 3 and 4
Max. 1.2 W
Resolver Type
Number of Poles
Nominal Voltage Ratio
Input Frequency
Input Voltage
Max. Phase Shift
Max. El. Angular Error
BRX 3)
2 pin
0.5 ± 5 %
10 kHz
3 to 7 Vrms
± 3°
± 10 angular minutes
Connection, Module Side
9 pin DSUB socket
LEDs
Electrical Isolation
Resolver - ACOPOS
Encoder Monitoring
UP/DN LEDs
No
Yes
Resolution
Depends on the maximum speed
14 bits/rev for n < 3900 min-1
12 bits/rev for n < 15600 min-1
Bandwidth
1.7 kHz for n < 3900 min-1
2.5 kHz for n < 15600 min-1
Precision
± 8 angular minutes
Reference Output
Signal Transfer
Differential Voltage
Output Current
Frequency
Differential signals
Typically 3.4 Veff
Max. 50 mAeff
10 kHz
Sine-Cosine Inputs
Signal Transfer
Input Impedance at 10 kHz (per pin)
Electrical Isolation Encoder-ACOPOS
Chapter 2
Technical Data
Resolver Input 2)
Differential signals
10.4 kΩ - j 11.1 kΩ
No, common-mode voltage on the sine cosine inputs max ± 20 V
Operational Conditions
Environment Temperature during
Operation
Relative Humidity during Operation
0 to +50 °C
5 to 95 %, non-condensing
Storage and Transport Conditions
Storage Temperature
Relative Humidity during Storage
Transport Temperature
Relative Humidity during Transport
-25 to +55 °C
5 to 95 %, non-condensing
-25 to +70 °C
95 % at +40 °C
Table 26: Technical data for AC122
1) The AC122 is an encoder module. Several encoder modules can also be inserted. In this case, the encoder module in the slot with the
lowest number is automatically used for motor feedback.
2) The resolver must be wired using a cable with a single shield and twisted pair signal lines.
3) BRX resolvers are fed with a sine signal (reference signal) from the module and provide two sine signals with a 90° phase shift as a
result. The amplitudes of these signals change with the angular position of the resolver.
Unlike BRX resolvers, BRT resolvers can be fed with two sine signals which are offset by 90°. A single sine signal with constant
amplitude is returned. The phase position of this signal changes with the angular position of the resolver.
ACOPOS User's Manual
53
Technical Data • ACOPOS Plug-in Modules
2.6.4 LEDs
The UP/DN LEDs are lit depending on the rotational direction and the speed of the connected
encoder.
UP LED ... lit when the encoder position changes in the positive direction.
DN LED ... lit when the encoder position changes in the negative direction.
The faster the encoder position changes, the brighter the respective LED is lit.
2.6.5 Firmware
The firmware is part of the operating system for the ACOPOS servo drives. The firmware is
updated by updating the ACOPOS operating system.
54
ACOPOS User's Manual
Technical Data • ACOPOS Plug-in Modules
2.7 AC123 - Incremental Encoder and SSI Absolute Encoder Interface
2.7.1 General Description
With incremental encoders, the maximum counter frequency is 200 kHz. Single and multi-turn
encoders with a maximum of 31 bits at 200 kBaud can be read as absolute SSI encoders.
The position is determined cyclically (initiated by the module) and is exactly synchronized with
the ACOPOS controller clock. The input signals are monitored for both encoder types. In this
way, broken connections, shorted lines and encoder supply failure can be recognized.
With incremental encoders the count frequency and distance between edges is also monitored.
With absolute encoders, the parity bit is evaluated and a plausibility check carried out.
2.7.2 Order Data
Model Number
Short Description
Image
Plug-in Module
8AC123.60-1
ACOPOS plug-in module, incremental encoder and SSI absolute
encoder interface
Table 27: Order data for AC123
ACOPOS User's Manual
55
Chapter 2
Technical Data
The ACOPOS plug-in module AC123 is used to connect standard industrial incremental or
absolute encoders with a synchronous serial interface (SSI) to ACOPOS servo drives. For
example, this allows electronic gears to be configured which read master movements using
external encoders. If the encoder resolution is high enough, motor feedback for asynchronous
motors is also possible.
Technical Data • ACOPOS Plug-in Modules
2.7.3 Technical Data
Product ID
8AC123.60-1
General Information
C-UL-US Listed
Module Type
Slot 1)
Power Consumption
Yes
ACOPOS plug-in module
Slots 2, 3 and 4
Max. 7.5 W
Depends on the current requirements for the encoder connected 2)
Encoder Input 3)
Connection, Module Side
LEDs
Electrical Isolation
Encoder - ACOPOS
Encoder Monitoring
15 pin DSUB socket
UP/DN LEDs
Yes
Yes
Signal Transfer
Differential signal transfer
Cable Length 4)
Max. 50 m
Encoder Supply
Supply Voltages
Internal, select between 5 V/15 V
Sense Lines
for 5 V
for 15 V
Yes, 2, compensation of max. 2 V
No
Load
5V
15 V
Short Circuit Protection, Overload
Protection
350 mA
350 mA
Yes
Incremental encoder 5)
Signal Form
Evaluation
Square wave pulse
4-fold
Input Frequency
Max. 200 kHz
Count Frequency
Max. 800 kHz
Reference Frequency
Max. 200 kHz
Distance between Edges
Counter Size
Inputs
Differential Voltage Inputs A, B, R
Minimum
Maximum
Min. 0.6 µs
32-bit
A, A, B, B, R, R
2.5 V
6V
SSI Absolute Encoder
Baud Rate
200 kBaud
Word Size
Max. 31 bit
Differential Voltage Clock Output - 120 Ω
Minimum
Maximum
2.5 V
5V
Differential Voltage Data Input
Minimum
Maximum
2.5 V
6V
Table 28: Technical data for AC123
56
ACOPOS User's Manual
Technical Data • ACOPOS Plug-in Modules
Product ID
8AC123.60-1
Operational Conditions
Environment Temperature during
Operation
0 to +50 °C
Relative Humidity during Operation
5 to 95 %, non-condensing
Storage and Transport Conditions
Storage Temperature
-25 to +55 °C
Relative Humidity during Storage
5 to 95 %, non-condensing
Transport Temperature
-25 to +70 °C
95 % at +40 °C
Chapter 2
Technical Data
Relative Humidity during Transport
Table 28: Technical data for AC123 (cont.)
1) The AC123 is an encoder module. Several encoder modules can also be inserted. In this case, the encoder module in the slot with the
lowest number is automatically used for motor feedback.
2) The power consumption of the plug-in module can be approximated using the following formula:
PModule [W] = PEncoder [W] . k + 0.6 W
The power consumed by the encoder PEncoder is calculated from the selected encoder supply voltage (5 V / 15 V) and the current
required:
PEncoder [W] = UEncoder [V] . IEncoder [A]
The following values must be used for k:
k = 1.2 (with 15 V encoder supply)
k = 1.75 (with 5 V encoder supply)
3) The encoder must be wired using a cable with a single shield and twisted pair signal lines (e.g. 4 x 2 x 0.14 mm² + 2 x 0.5 mm²).
4) A cable with at least 4 x 2 x 0.14 mm² + 2 x 0.5 mm² is required for the maximum cable length. The sense lines must be used.
5) Incremental encoders can be used as motor feedback only for asynchronous motors, but can only provide limited control quality for
this purpose. An encoder with at least 1000 lines must be used for motor feedback.
2.7.4 LEDs
The UP/DN LEDs are lit depending on the rotational direction and the speed of the connected
encoder.
UP LED ... lit when the encoder position changes in the positive direction.
DN LED ... lit when the encoder position changes in the negative direction.
The faster the encoder position changes, the brighter the respective LED is lit.
2.7.5 Firmware
The firmware is part of the operating system for the ACOPOS servo drives. The firmware is
updated by updating the ACOPOS operating system.
ACOPOS User's Manual
57
Technical Data • ACOPOS Plug-in Modules
2.8 AC130 - Digital Mixed Module
2.8.1 General Description
The AC130 plug-in module can be used in an ACOPOS slot. A maximum of 8 digital inputs or
10 digital outputs are available.
I/O points can be configured in pairs as inputs or outputs. The first three inputs have incremental
encoder functionality (A, B, R). The first two outputs can be operated in pulse width modulation
(PWM) mode.
The inputs are divided into 4 standard (max. 10 kHz) and 4 high speed (max. 100 kHz) inputs.
The outputs include 4 high speed (push-pull) outputs with a maximum current of 100 mA,
4 standard (high-side) outputs with a maximum current of 400 mA and 2 low speed (high-side)
outputs with a maximum current of 2 A. All outputs can be read.
2.8.2 Order Data
Model Number
Short Description
Image
8AC130.60-1
ACOPOS plug-in module, 8 digital I/O configurable in pairs as
24V input or as output 400/100mA, 2 digital outputs 2A, Order TB712
terminal block separately
Plug-in Module
Accessories
7TB712.9
Terminal block, 12 pin, screw clamps
7TB712.91
Terminal block, 12 pin, cage clamps
7TB712:90-02
Terminal block, 12 pin, 20 pcs., screw clamps
7TB712:91-02
Terminal block, 12 pin, 20 pcs., cage clamps
Table 29: Order data for AC130
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ACOPOS User's Manual
Technical Data • ACOPOS Plug-in Modules
2.8.3 Technical Data
Product ID
8AC130.60-1
General Information
Module Type
Slot 1)
Power Consumption
Yes
ACOPOS plug-in module
Slots 2, 3 and 4
Max. 0.8 W
Chapter 2
Technical Data
C-UL-US Listed
Inputs/Outputs
Connection, Module Side
Configuration of the Inputs/Outputs
LEDs
12 conductor pin-connector
Can be configured in pairs as input or output
24 V LED
Supply Voltage
Power Supply
Minimum
Nominal
Maximum
Reverse Polarity Protection
Voltage Monitoring (24 V - LED)
18 VDC
24 VDC
30 VDC
Yes
Yes, supply voltage > 18 V
Digital Inputs 2)
Number of Inputs
Max. 8
Wiring
Sink
Electrical Isolation
Input - ACOPOS
Input - Input
Yes
No
Input Voltage
Nominal
Maximum
24 VDC
30 VDC
Switching Threshold
LOW
HIGH
<5V
> 15 V
Input Current at Nominal Voltage
Inputs 1 -4
Inputs 5 - 8
Switching Delay
Inputs 1 -4
Inputs 5 - 8
Approx. 10 mA
Approx. 5.5 mA
Max. 5 µs
Max. 35 µs
Event Counter
Signal Form
Input Frequency
Counter Size
Inputs
Input 1
Input 2
Square wave pulse
Max. 100 kHz
16-bit
Counter 1
Counter 2
Table 30: Technical data for AC130
ACOPOS User's Manual
59
Technical Data • ACOPOS Plug-in Modules
Product ID
8AC130.60-1
Incremental encoder
Signal Form
Square wave pulse
Evaluation
4-fold
Encoder Monitoring
Input Frequency
No
Max. 62.5 kHz
Count Frequency
Max. 250 kHz
Reference Frequency
Max. 62.5 kHz
Distance between Edges
Counter Size
Inputs
Input 1
Input 2
Input 3
Min. 2.5 µs
16-bit
Channel A
Channel B
Reference pulse R
Outputs
Number of Outputs
Max. 10
Type
Outputs 1 -4
Outputs 5 - 10
Transistor outputs
Push-pull
High-side
Electrical Isolation
Output - ACOPOS
Output - Output
Yes
No
Switching Voltage
Minimum
Nominal
Maximum
18 VDC
24 VDC
30 VDC
Continuous Current
Outputs 1 -4
Outputs 5 -8
Outputs 9 - 10
Max. 100 mA
Max. 400 mA
Max. 2 A
Switching Delay 0 -> 1 and 1 -> 0
Outputs 1 -4
Outputs 5 -8
Outputs 9 - 10
Max. 5 µs
Max. 50 µs
Max. 500 µs
Switching Frequency (resistive load)
Outputs 1 -2
Outputs 3 -4
Outputs 5 -8
Outputs 9 - 10
PWM Outputs 1 - 2
Resolution of the Pulse Width
Period Duration
Protection
Short Circuit Protection
Overload Protection
Max. 10 kHz (max. 20 kHz in PWM mode)
Max. 10 kHz
Max. 5 kHz
Max. 100 Hz
13-bit
50 µs - 400 µs
Yes
Yes
Table 30: Technical data for AC130 (cont.)
60
ACOPOS User's Manual
Technical Data • ACOPOS Plug-in Modules
Product ID
8AC130.60-1
Short Circuit Current at 24 V (until cut-off)
Outputs 1 -4
Outputs 5 -8
Outputs 9 - 10
Approx. 1 A
Approx. 1.2 A
Approx. 24 A
Readable Outputs
Yes
Operational Conditions
Relative Humidity during Operation
0 to +50 °C
Chapter 2
Technical Data
Environment Temperature during
Operation
5 to 95 %, non-condensing
Storage and Transport Conditions
Storage Temperature
Relative Humidity during Storage
Transport Temperature
Relative Humidity during Transport
-25 to +55 °C
5 to 95 %, non-condensing
-25 to +70 °C
95 % at +40 °C
Table 30: Technical data for AC130 (cont.)
1) The AC130 can also be used as an encoder module. Several encoder modules can also be inserted. In this case, the encoder module
in the slot with the lowest number is automatically used for motor feedback.
2) Shielded cables must be used for inputs 1 - 4.
2.8.4 LEDs
The 24V LED is lit as soon as the supply voltage for the plug-in module goes above 18 VDC.
2.8.5 Firmware
The firmware is part of the operating system for the ACOPOS servo drives. The firmware is
updated by updating the ACOPOS operating system.
ACOPOS User's Manual
61
Technical Data • ACOPOS Plug-in Modules
2.9 AC131 - Mixed Module
2.9.1 General Description
The AC131 plug-in module can be used in an ACOPOS slot. A maximum of 2 analog inputs (±10
V differential inputs or single-ended inputs) and 2 digital inputs or digital outputs are available.
The analog inputs have a resolution of 12 bits and are scanned synchronously using the 50 µs
clock for the ACOPOS servo drive. The analog inputs have a 10 kHz analog input filter (low pass
3rd order).
The digital inputs and outputs can be configured individually as input or output. The digital inputs
are equipped with a counter function. The digital outputs (push-pull) can be read.
2.9.2 Order Data
Model Number
Short Description
Image
Plug-in Module
8AC131.60-1
ACOPOS plug-in module, 2 analog inputs ±10V, 2 digital I/O points
which can be configured as 24V input or 45mA output
Accessories
7TB712.9
Terminal block, 12 pin, screw clamps
7TB712.91
Terminal block, 12 pin, cage clamps
7TB712:90-02
Terminal block, 12 pin, 20 pcs., screw clamps
7TB712:91-02
Terminal block, 12 pin, 20 pcs., cage clamps
Table 31: Order data for AC131
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ACOPOS User's Manual
Technical Data • ACOPOS Plug-in Modules
2.9.3 Technical Data
Product ID
8AC131.60-1
General Information
C-UL-US Listed
Module Type
Slot
Power Consumption
Yes
ACOPOS plug-in module
Slots 2, 3 and 4
Max. 1 W
Connection, Module Side
Configuration of the Digital Inputs/Outputs
LEDs
Chapter 2
Technical Data
Inputs/Outputs
12 conductor pin-connector
Can be configured individually as digital input or output
24 V LED
Supply Voltage
Power Supply
Minimum
Nominal
Maximum
Reverse Polarity Protection
Voltage Monitoring (24 V - LED)
18 VDC
24 VDC
30 VDC
Yes
Yes, supply voltage > 18 V
Digital Inputs
Number of Inputs
Max. 2
Wiring
Sink
Electrical isolation
Input - ACOPOS
Input - Input
Yes
No
Input Voltage
Minimum
Nominal
Maximum
18 VDC
24 VDC
30 VDC
Switching Threshold
LOW
HIGH
<5V
> 15 V
Input Current at Nominal Voltage
Switching Delay
Counters
Digital Input
Modulation Compared to Ground
Potential
Approx. 8 mA
Max. 5 µs
Max. 55 µs (digitally filtered)
Max. ±50 V
Event Counter
Signal Form
Input Frequency
Counter Size
Inputs
Input 1
Input 2
Square wave pulse
Max. 100 kHz
16-bit
Counter 1
Counter 2
Table 32: Technical data for AC131
ACOPOS User's Manual
63
Technical Data • ACOPOS Plug-in Modules
Product ID
8AC131.60-1
Digital Outputs
Number of Outputs
Type
Electrical Isolation
Output - ACOPOS
Output - Output
Max. 2
Transistor outputs push-pull
Yes
No
Switching Voltage
Minimum
Nominal
Maximum
18 VDC
24 VDC
30 VDC
Continuous Current
Max. 45 mA
Switching Delay 0 -> 1 and 1 -> 0
Switching Frequency (resistive load)
Protection
Short Circuit Protection
Overload Protection
Short Circuit Current at 24 V (until cut-off)
Readable Outputs
Max. 5 µs
Max. 100 kHz
Yes
Yes
Approx. 0.3 A
Yes
Analog Inputs
Number of Inputs
Design
Electrical Isolation
Input - ACOPOS
Input - Input
Input Signal
Nominal
Maximum
Operating mode
Digital Converter Resolution
Max. 2
Differential input or single ended input
Yes
No
-10 V to +10 V
-15 V to +15 V
Cyclic measurement synchronous to 50 µs ACOPOS clock
12-bit
Non-Linearity
±1 LSB
Output Format
INT16 $8000 - $7FF01
LSB = $0010 = 4.883 mV
Conversion Procedure
Successive approximation
Conversion Time for both Inputs
< 50 µs
Differential Input Impedance
>10 MΩ
Input Filter
Basic Accuracy at 25 °C
Analog low pass 3rd order / cut-off frequency: 10 kHz
±0.05 % 1)
Offset Drift
Max. ±0.0005 % / °C 1)
Gain Drift
Max. ±0.006 % / °C 1)
Cross-talk between the Analog Inputs
Common-Mode Rejection
DC
50 Hz
Min. -90 dB at 1kHz
Min. -73 dB
Min. -73 dB
Table 32: Technical data for AC131 (cont.)
64
ACOPOS User's Manual
Technical Data • ACOPOS Plug-in Modules
Product ID
8AC131.60-1
Modulation Compared to Ground
Potential
Max. ±50 V
Modulation between the Analog Input
Channels
Max. ±5 V
Operational Conditions
Environment Temperature during
Operation
0 to +50 °C
5 to 95 %, non-condensing
Chapter 2
Technical Data
Relative Humidity during Operation
Storage and Transport Conditions
Storage Temperature
-25 to +55 °C
Relative Humidity during Storage
5 to 95 %, non-condensing
Transport Temperature
-25 to +70 °C
Relative Humidity during Transport
95 % at +40 °C
Table 32: Technical data for AC131 (cont.)
1) Refers to the measurement range limit.
2.9.4 LEDs
The 24V LED is lit as soon as the supply voltage for the plug-in module goes above 18 VDC.
2.9.5 Firmware
The firmware is part of the operating system for the ACOPOS servo drives. The firmware is
updated by updating the ACOPOS operating system.
ACOPOS User's Manual
65
Technical Data • Cables
3. Cables
3.1 General Information
B&R offers the cables for ACOPOS servo drives in six different lengths. All cables can be used
for drag chain installations. 1)
To prevent disturbances to encoder signals, the holding brake and temperature sensor wires are
in the motor cable and not in the EnDat or resolver cable.
3.1.1 Prefabricated Cables
Using B&R cables guarantees that the EMC limits are not exceeded. The cables are
prefabricated in the EU and are therefore subject to the strictest quality standards.
Information:
If other cables are used, make sure that they have the same wave parameters. If
deviations exist, additional measures are necessary to ensure that EMC guidelines
are met.
1) Custom fabrication of motor cables is available on request. For custom fabrication of motor cables, the plug size must be matched to
the motor used!
66
ACOPOS User's Manual
Technical Data • Cables
3.2 Motor Cables
3.2.1 Order Data
Model Number
Short Description
Image
8CM005.12-1
Motor cable, length 5m, 4 x 1.5mm² + 2 x 2 x 0.75mm², Motor connector
8pin Intercontec socket, can be used in cable drag chains, UL/CSA listed
8CM007.12-1
Motor cable, length 7m, 4 x 1.5mm² + 2 x 2 x 0.75mm², Motor connector
8pin Intercontec socket, can be used in cable drag chains, UL/CSA listed
8CM010.12-1
Motor cable, length 10m, 4 x 1.5mm² + 2 x 2 x 0.75mm², Motor connector
8pin Intercontec socket, can be used in cable drag chains, UL/CSA listed
8CM015.12-1
Motor cable, length 15m, 4 x 1.5mm² + 2 x 2 x 0.75mm², Motor connector
8pin Intercontec socket, can be used in cable drag chains, UL/CSA listed
8CM020.12-1
Motor cable, length 20m, 4 x 1.5mm² + 2 x 2 x 0.75mm², Motor connector
8pin Intercontec socket, can be used in cable drag chains, UL/CSA listed
8CM025.12-1
Motor cable, length 25m, 4 x 1.5mm² + 2 x 2 x 0.75mm², Motor connector
8pin Intercontec socket, can be used in cable drag chains, UL/CSA listed
Chapter 2
Technical Data
Motor Cables 1.5 mm² 1)
Motor Cables 4 mm² 2)
8CM005.12-3
Motor cable, length 5m, 4 x 4mm² + 2 x 2 x 1mm², Motor connector
8pin Intercontec socket, can be used in cable drag chains, UL/CSA listed
8CM007.12-3
Motor cable, length 7m, 4 x 4mm² + 2 x 2 x 1mm², Motor connector
8pin Intercontec socket, can be used in cable drag chains, UL/CSA listed
8CM010.12-3
Motor cable, length 10m, 4 x 4mm² + 2 x 2 x 1mm², Motor connector
8pin Intercontec socket, can be used in cable drag chains, UL/CSA listed
8CM015.12-3
Motor cable, length 15m, 4 x 4mm² + 2 x 2 x 1mm², Motor connector
8pin Intercontec socket, can be used in cable drag chains, UL/CSA listed
8CM020.12-3
Motor cable, length 20m, 4 x 4mm² + 2 x 2 x 1mm², Motor connector
8pin Intercontec socket, can be used in cable drag chains, UL/CSA listed
8CM025.12-3
Motor cable, length 25m, 4 x 4mm² + 2 x 2 x 1mm², Motor connector
8pin Intercontec socket, can be used in cable drag chains, UL/CSA listed
Motor Cables 10 mm² 3)
8CM005.12-5
Motor cable, length 5m, 4 x 10mm² + 2 x 2 x 1.5mm², Motor connector
8pin Intercontec socket, can be used in cable drag chains, UL/CSA listed
8CM007.12-5
Motor cable, length 7m, 4 x 10mm² + 2 x 2 x 1.5mm², Motor connector
8pin Intercontec socket, can be used in cable drag chains, UL/CSA listed
8CM010.12-5
Motor cable, length 10m, 4 x 10mm² + 2 x 2 x 1.5mm², Motor connector
8pin Intercontec socket, can be used in cable drag chains, UL/CSA listed
8CM015.12-5
Motor cable, length 15m, 4 x 10mm² + 2 x 2 x 1.5mm², Motor connector
8pin Intercontec socket, can be used in cable drag chains, UL/CSA listed
8CM020.12-5
Motor cable, length 20m, 4 x 10mm² + 2 x 2 x 1.5mm², Motor connector
8pin Intercontec socket, can be used in cable drag chains, UL/CSA listed
8CM025.12-5
Motor cable, length 25m, 4 x 10mm² + 2 x 2 x 1.5mm², Motor connector
8pin Intercontec socket, can be used in cable drag chains, UL/CSA listed
Table 33: Order data for motor cables
ACOPOS User's Manual
67
Technical Data • Cables
Model Number
Short Description
Image
Motor Cables 35 mm²
8CM005.12-8
Motor cable, length 5m, 4 x 35mm² + 2 x 2 x 1.5mm², can be used in cable
drag chains, UL/CSA listed
8CM007.12-8
Motor cable, length 7m, 4 x 35mm² + 2 x 2 x 1.5mm², can be used in cable
drag chains, UL/CSA listed
8CM010.12-8
Motor cable, length 10m, 4 x 35mm² + 2 x 2 x 1.5mm², can be used in cable
drag chains, UL/CSA listed
8CM015.12-8
Motor cable, length 15m, 4 x 35mm² + 2 x 2 x 1.5mm², can be used in cable
drag chains, UL/CSA listed
8CM020.12-8
Motor cable, length 20m, 4 x 35mm² + 2 x 2 x 1.5mm², can be used in cable
drag chains, UL/CSA listed
8CM025.12-8
Motor cable, length 25m, 4 x 35mm² + 2 x 2 x 1.5mm², can be used in cable
drag chains, UL/CSA listed
Table 33: Order data for motor cables (cont.)
1) Standard fabrication; designed for use with ACOPOS servo drives 8V1022.00-x, 8V1045.00-x and 8V1090.00-x and motor sizes 2 to 7.
2) Standard fabrication; designed for use with ACOPOS servo drives 8V1180.00-x and 8V1320.00-x and motor sizes 2 to 7.
3) Standard fabrication; designed for use with ACOPOS servo drives 8V1640.00-x and 8V128M.00-x and motor size 8.
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ACOPOS User's Manual
Technical Data • Cables
3.2.2 Technical Data
1.5 and 4 mm² motor cables
Description
Motor Cables 1.5 mm²
Motor Cables 4 mm²
4 x 1.5 mm² + 2 x 2 x 0.75 mm²
4 x 4 mm² + 2 x 2 x 1 mm²
General Information
Cable Cross Section
Durability
Oil resistant according to VDE 0472 part 803, as well as standard hydraulic oil
Certification
UL AWM Style 20669, 90 °C, 600 V, E63216 and CSA AWM I/II A/B, 90 °C, 600 V, FT1 LL46064
Power Lines
1.5 mm², tinned Cu wire
Wire Insulation
Wire Colors
Chapter 2
Technical Data
Conductor
4 mm², tinned Cu wire
Special thermoplastic material
Black, brown, blue, yellow/green
Signal Lines
0.75 mm², tinned Cu wire
Wire Insulation
Wire Colors
1 mm², tinned Cu wire
Special thermoplastic material
White, white/red, white/blue, white/green
Cable Structure
Power Lines
Stranding
Shield
No
No
Signal Lines
Stranding
Shield
White with white/red and white/blue with white/green
Separate shielding for pairs, tinned Cu mesh, optical coverage > 85 % and foil banding
Cable Stranding
With filler elements and foil banding
Cable Shielding
Tinned Cu mesh, optical coverage > 85 % and wrapped in isolating fabric
Outer Sheathing
Material
Color
PUR
Orange, similar to RAL 2003 flat
Labeling
BERNECKER + RAINER 4x1.5+2x2x0.75 FLEX
BERNECKER + RAINER 4x4.0+2x2x1.5 FLEX
≤ 14 Ω/km
≤ 29 Ω/km
≤ 5.2 Ω/km
≤ 14 Ω/km
Electrical Characteristics
Conductor Resistance
Power Lines
Signal Lines
Insulation Resistance
> 200 MΩ per km
Isolation Voltage
Wire/Wire
Wire/Shield
3 kV
1 kV
Operating Voltage
Max. 600 V
Mechanical Characteristics
Temperature Range
Moving
Static
-10 °C to +70 °C
-20 °C to +90 °C
Outer Diameter
12.8 mm ± 0.4 mm
Flex Radius
15.8 mm ± 0.5 mm
> 96 mm
> 118.5 mm
≤ 4 m/s
Speed
Acceleration
< 60 m/s²
Flex Cycles
≥ 3,000,000
Weight
0.26 kg/m
0.45 kg/m
Table 34: Technical data for motor cables 1.5 and 4 mm²
ACOPOS User's Manual
69
Technical Data • Cables
10 and 35 mm² motor cables
Description
Motor Cables 10 mm²
Motor Cables 35 mm²
4 x 10 mm² + 2 x 2 x 1.5 mm²
4 x 35 mm² + 2 x 2 x 1.5 mm²
General Information
Cable Cross Section
Durability
Certification
Oil resistant according to VDE 0472 part 803, as well as standard hydraulic oil
UL AWM Style 20669, 90 °C, 600 V, E63216 and CSA AWM I/II A/B, 90 °C, 600 V, FT1 LL46064
Conductor
Power Lines
10 mm², tinned Cu wire
Wire Insulation
Wire Colors
35 mm², tinned Cu wire
Special thermoplastic material
Black, brown, blue, yellow/green
Signal Lines
Wire Insulation
Wire Colors
1.5 mm², tinned Cu wire
Special thermoplastic material
White, white/red, white/blue, white/green
Cable Structure
Power Lines
Stranding
Shield
No
No
Signal Lines
Stranding
Shield
White with white/red and white/blue with white/green
Separate shielding for pairs, tinned Cu mesh, optical coverage > 85 % and foil banding
Cable Stranding
With filler elements and foil banding
Cable Shielding
Tinned Cu mesh, optical coverage > 85 % and wrapped in isolating fabric
Outer Sheathing
Material
Color
PUR
Orange, similar to RAL 2003 flat
Labeling
BERNECKER + RAINER 4x10.0+2x2x1.5 FLEX
BERNECKER + RAINER 4x35.0+2x2x1.5 FLEX
≤ 2.1 Ω/km
≤ 14 Ω/km
≤ 0.6 Ω/km
≤ 14 Ω/km
Electrical Characteristics
Conductor Resistance
Power Lines
Signal Lines
Insulation Resistance
> 200 MΩ per km
Isolation Voltage
Wire/Wire
Wire/Shield
3 kV
1 kV
Operating Voltage
Max. 600 V
Mechanical Characteristics
Temperature Range
Moving
Static
Outer Diameter
Flex Radius
-10 °C to +70 °C
-20 °C to +90 °C
20.1 mm ± 0.7 mm
32.5 mm ± 1 mm
> 150.8 mm
> 243.8 mm
≤ 4 m/s
Speed
Acceleration
< 60 m/s²
Flex Cycles
≥ 3,000,000
Weight
0.77 kg/m
2.2 kg/m
Table 35: Technical data for motor cables 10 and 35 mm²
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ACOPOS User's Manual
Technical Data • Cables
3.3 EnDat Cable
3.3.1 Order Data
Short Description
EnDat cable, length 5m, 10 x 0.14mm² + 2 x 0.5mm², EnDat connector 17pin Intercontec socket, servo connector 15-pin DSUB plug, can be used in
cable drag chains, UL/CSA listed
Image
8CE007.12-1
EnDat cable, length 7m, 10 x 0.14mm² + 2 x 0.5mm², EnDat connector 17pin Intercontec socket, servo connector 15-pin DSUB plug, can be used in
cable drag chains, UL/CSA listed
8CE010.12-1
EnDat cable, length 10m, 10 x 0.14mm² + 2 x 0.5mm², EnDat connector 17pin Intercontec socket, servo connector 15-pin DSUB plug, can be used in
cable drag chains, UL/CSA listed
8CE015.12-1
EnDat cable, length 15m, 10 x 0.14mm² + 2 x 0.5mm², EnDat connector 17pin Intercontec socket, servo connector 15-pin DSUB plug, can be used in
cable drag chains, UL/CSA listed
8CE020.12-1
EnDat cable, length 20m, 10 x 0.14mm² + 2 x 0.5mm², EnDat connector 17pin Intercontec socket, servo connector 15-pin DSUB plug, can be used in
cable drag chains, UL/CSA listed
8CE025.12-1
EnDat cable, length 25m, 10 x 0.14mm² + 2 x 0.5mm², EnDat connector 17pin Intercontec socket, servo connector 15-pin DSUB plug, can be used in
cable drag chains, UL/CSA listed
Chapter 2
Technical Data
Model Number
8CE005.12-1
Table 36: Order data for EnDat cables
3.3.2 Technical Data
Description
EnDat Cables
General Information
Cable Cross Section
Durability
Certification
10 x 0.14 mm² + 2 x 0.50 mm²
Oil resistant according to VDE 0472 part 803, as well as standard hydraulic oil
UL AWM Style 20963, 80 °C, 30 V, E63216 and CSA AWM I/II A/B, 90 °C, 30 V, FT1 LL46064
Conductor
Signal Lines
Wire Insulation
Wire Colors
0.14 mm², tinned Cu wire
Special thermoplastic material
Blue, brown, yellow, gray, green, pink, red, black, violet, white
Supply Lines
Wire Insulation
Wire Colors
0.5 mm², tinned Cu wire
Special thermoplastic material
White/green, white/red
Cable Structure
Signal Lines
Stranding
Shield
No
No
Supply Lines
Stranding
Shield
White/red with white/green and filler elements
No
Cable Stranding
With foil banding
Table 37: Technical data for EnDat cables
ACOPOS User's Manual
71
Technical Data • Cables
Description
EnDat Cables
Cable Shielding
Cu mesh, optical coverage > 85 % and wrapped in isolating fabric
Outer Sheathing
Material
Color
Labeling
PUR
Orange, similar to RAL 2003 flat
BERNECKER + RAINER 10x0.14+2x0.50 FLEX
Electrical Characteristics
Conductor Resistance
Signal Lines
Supply Lines
≤ 140 Ω/km
≤ 40 Ω/km
Insulation Resistance
> 200 MΩ per km
Isolation Voltage
Wire/Wire
Wire/Shield
1.5 kV
0.8 kV
Operating Voltage
Max. 30 V
Mechanical Characteristics
Temperature Range
Moving
Static
Outer Diameter
Flex Radius
-10 °C to +70 °C
-20 °C to +90 °C
7.3 mm ± 0.25 mm
> 55 mm
Speed
≤ 4 m/s
Acceleration
< 60 m/s²
Flex Cycles
≥ 3,000,000
Weight
0.08 kg/m
Table 37: Technical data for EnDat cables (cont.)
72
ACOPOS User's Manual
Technical Data • Cables
3.4 Resolver Cable
3.4.1 Order Data
Short Description
Resolver cable, length 5m, 3 x 2 x 24 AWG/19, resolver plug 12pin Intercontec socket, servo plug 9-pin DSUB plug, can be used in cable
drag chains, UL/CSA listed
Image
8CR007.12-1
Resolver cable, length 7m, 3 x 2 x 24 AWG/19, resolver plug 12pin Intercontec socket, servo plug 9-pin DSUB plug, can be used in cable
drag chains, UL/CSA listed
8CR010.12-1
Resolver cable, length 10m, 3 x 2 x 24 AWG/19, resolver plug 12pin Intercontec socket, servo plug 9-pin DSUB plug, can be used in cable
drag chains, UL/CSA listed
8CR015.12-1
Resolver cable, length 15m, 3 x 2 x 24 AWG/19, resolver plug 12pin Intercontec socket, servo plug 9-pin DSUB plug, can be used in cable
drag chains, UL/CSA listed
8CR020.12-1
Resolver cable, length 20m, 3 x 2 x 24 AWG/19, resolver plug 12pin Intercontec socket, servo plug 9-pin DSUB plug, can be used in cable
drag chains, UL/CSA listed
8CR025.12-1
Resolver cable, length 25m, 3 x 2 x 24 AWG/19, resolver plug 12pin Intercontec socket, servo plug 9-pin DSUB plug, can be used in cable
drag chains, UL/CSA listed
Chapter 2
Technical Data
Model Number
8CR005.12-1
Table 38: Order data for resolver cables
3.4.2 Technical Data
Description
Resolver Cables
General Information
Cable Cross Section
Durability
Certification
3 x 2 x 24 AWG/19
Oil resistant according to VDE 0472 part 803, as well as standard hydraulic oil
UL AWM Style 20671, 90 °C, 30 V, E63216 and CSA AWM, 90 °C, 30 V, I/II A/B FT1 LL46064
Conductor
Signal Lines
Wire Insulation
Wire Colors
24 AWG/19, tinned Cu wire
Special thermoplastic material
White, brown, green, yellow, gray, pink
Cable Structure
Signal Lines
Stranding
Shield
White with brown, green with yellow, gray with pink
No
Cable Stranding
The 3 pairs together covered by foil banding
Cable Shielding
Cu mesh, optical coverage ≥ 90 % and wrapped in isolating fabric
Outer Sheathing
Material
Color
Labeling
PUR
Orange, similar to RAL 2003 flat
BERNECKER + RAINER 3x2x24 AWG FLEX
Table 39: Technical data for resolver cables
ACOPOS User's Manual
73
Technical Data • Cables
Description
Resolver Cables
Electrical Characteristics
Conductor Resistance 24 AWG
Insulation Resistance
≤ 86 Ω/km
> 200 MΩ per km
Isolation Voltage
Wire/Wire
Wire/Shield
1.5 kV
0.8 kV
Operating Voltage
Max. 30 V
Mechanical Characteristics
Temperature Range
Moving
Static
-10 °C to +80 °C
-40 °C to +90 °C
Outer Diameter
6.5 mm ± 0.2 mm
Flex Radius
≥ 50 mm
Speed
≤ 4 m/s
Acceleration
< 60 m/s²
Flex Cycles
≥ 3,000,000
Weight
0.07 kg/m
Table 39: Technical data for resolver cables (cont.)
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ACOPOS User's Manual
Technical Data • Connectors
4. Connectors
B&R offers five different motor/encoder connectors for AC servo motors. All connectors have
IP67 protection. The metallic housing provides a protective ground connection on the housing
according to VDE 0627. All plastic used in the connector is UL94/V0 listed. High quality, gold
plated cage connector contacts guarantee a high level of contact security even when reinserted
many times.
Using B&R connectors guarantees that the EMC limits for the connection are not exceeded.
Make sure that connectors are put together correctly including a proper shield connection.
ACOPOS User's Manual
75
Chapter 2
Technical Data
4.1 General Information
Technical Data • Connectors
4.2 Motor Connectors
4.2.1 Order Data
Model Number
Short Description
Image
Cable Diameter 9 - 17 mm
8PM001.00-1
Motor plug 8-pin Intercontec socket, crimp range 4 x 0.5-2.5mm² +
4 x 0.06-1.0mm², for cable ø 9-14mm, IP67, UL/CSA listed
8PM002.00-1
Motor plug 8-pin Intercontec socket, crimp range 4 x 2.5-4.0mm² +
4 x 0.06-1.0mm², for cable ø 14-17mm, IP67, UL/CSA listed
Cable Diameter 17 -26 mm
8PM003.00-1
Motor plug 8-pin Intercontec socket, crimp
range 4 x 1.5-10mm² + 4 x 0.5-2.5mm², for cable ø 17-26mm, IP67,
UL/CSA listed
Table 40: Order data for motor connectors
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ACOPOS User's Manual
Technical Data • Connectors
4.2.2 Technical Data for 8PM001.00-1 and 8PM002.00-1
Product ID
8PM001.00-1
8PM002.00-1
General Information
Connector Size
Size 1
8 (4 power and 4 signal contacts)
Degree of Pollution
3
Installation Altitude
Up to 2,000 m
Insulator
Chapter 2
Technical Data
Contacts
PA 6.6 / PBT, UL94/V0 listed
Contacts
Gold plated brass
Protective Ground Connection on Housing
According to VDE 0627
Protection according to DIN 40050
IP67 when connected
Certifications
UL/CSA
Electrical Characteristics
Overvoltage Category
3
Power Contacts
Nominal Current
Nominal Voltage
Isolation Voltage (L-L)
Contact Resistance
30 A
630 VAC / VDC
6000 V
< 3 mΩ
Signal Contacts
Nominal Current
Nominal Voltage
Isolation Voltage (L-L)
Contact Resistance
10 A
250 VAC / VDC
2500 V
< 5 mΩ
Mechanical Characteristics
Temperature Range
-20 °C to +130 °C
Housing Material
Zinc die cast / brass, nickel plated
Gaskets
FPM / HNBR
Mating Cycles
> 50
Crimp Range
Cable ø
4 x 0.5 - 2.5 mm² + 4 x 0.06 - 1 mm²
4 x 0.5 -4 mm² + 4 x 0.06 - 1 mm²
9.5 -14.5 mm
14 -17 mm
Manufacturer Information
Manufacturer
Internet Address
Manufacturer’s Product ID
INTERCONTEC
www.intercontec.biz
BSTA 108 FR 19 58 0036 000
BSTA 108 FR 35 59 0036 000
Table 41: Technical data for motor connectors 8PM001.00-1 and 8PM002.00-1
ACOPOS User's Manual
77
Technical Data • Connectors
4.2.3 Technical Data for 8PM003.00-1
Product ID
8PM003.00-1
General Information
Connector Size
Size 1.5
Contacts
8 (4 power and 4 signal contacts)
Degree of Pollution
3
Installation Altitude
Up to 2,000 m
Insulator
PA 6.6 / PBT, UL94/V0 listed
Contacts
Gold plated brass
Protective Ground Connection on
Housing
According to VDE 0627
Protection according to DIN 40050
IP67 when connected
Certifications
UL/CSA
Electrical Characteristics
Overvoltage Category
3
Power Contacts
Nominal Current
Nominal Voltage
Isolation Voltage (L-L)
Contact Resistance
75 A
630 VAC / VDC
6000 V
< 1 mΩ
Signal Contacts
Nominal Current
Nominal Voltage
Isolation Voltage (L-L)
Contact Resistance
30 A
630 VAC / VDC
4000 V
< 3 mΩ
Mechanical Characteristics
Temperature Range
Housing Material
Gaskets
-20 °C to +130 °C
Magnesium die cast / aluminum, nickel plated
FPM / HNBR
Mating Cycles
> 50
Crimp Range
4 x 1.5 - 10 mm² + 4 x 0.5 - 2.5 mm²
Cable ø
17 -26 mm
Manufacturer Information
Manufacturer
Internet Address
Manufacturer’s Product ID
INTERCONTEC
www.intercontec.biz
CSTA 264 FR 48 25 0001 000
Table 42: Technical data for motor connector 8PM003.00-1
78
ACOPOS User's Manual
Technical Data • Connectors
4.3 Encoder Connectors
4.3.1 Order Data
Model Number
Short Description
Image
EnDat Connector
EnDat Connector 17 pin Intercontec socket, crimp range 17 x 0.06-1,0mm²,
for cable ø 9-12mm, IP67, UL/CSA listed
Chapter 2
Technical Data
8PE001.00-1
Resolver Connector
8PR001.00-1
Resolver connector 12 pin Intercontec socket, crimp range 12 x
0.06-1,0mm², for cable ø 5.5-10.5mm, IP67, UL/CSA listed
Table 43: Order data for encoder connectors
ACOPOS User's Manual
79
Technical Data • Connectors
4.3.2 Technical Data for EnDat Connector 8PE001.00-1
Product ID
8PE001.00-1
General Information
Connector Size
Size 1
Contacts
17 signal contacts
Degree of Pollution
3
Installation Altitude
Up to 2,000 m
Insulator
PA 6.6 / PBT, UL94/V0 listed
Contacts
Gold plated brass
Protective Ground Connection on Housing
Protection according to DIN 40050
Certifications
According to VDE 0627
IP67 when connected
UL/CSA
Electrical Characteristics
Overvoltage Category
Signal Contacts
Nominal Current
Nominal Voltage
Isolation Voltage (L-L)
Contact Resistance
3
9A
125 V
2500 V
< 5 mΩ
Mechanical Characteristics
Temperature Range
Housing Material
Gaskets
-20 °C to +130 °C
Zinc die cast / brass, nickel plated
FPM / HNBR
Mating Cycles
> 50
Crimp Range
17 x 0.06 - 1 mm²
Cable ø
9 -12 mm
Manufacturer Information
Manufacturer
Internet Address
Manufacturer’s Product ID
INTERCONTEC
www.intercontec.biz
ASTA 035 FR 11 12 0035 000
Table 44: Technical data for EnDat connector 8PE001.00-1
80
ACOPOS User's Manual
Technical Data • Connectors
4.3.3 Technical Data for Resolver Connector 8PR001.00-1
Product ID
8PR001.00-1
General Information
Connector Size
Size 1
12 signal contacts
Degree of Pollution
3
Installation Altitude
Up to 2,000 m
Insulator
Chapter 2
Technical Data
Contacts
PA 6.6 / PBT, UL94/V0 listed
Contacts
Gold plated brass
Protective Ground Connection on Housing
Protection according to DIN 40050
Certifications
According to VDE 0627
IP67 when connected
UL/CSA
Electrical Characteristics
Overvoltage Category
3
Signal Contacts
Nominal Current
Nominal Voltage
Isolation Voltage (L-L)
Contact Resistance
9A
160 V
2500 V
< 5 mΩ
Mechanical Characteristics
Temperature Range
-20 °C to +130 °C
Housing Material
Zinc die cast / brass, nickel plated
Gaskets
FPM / HNBR
Mating Cycles
> 50
Crimp Range
12 x 0.06 - 1 mm²
Cable ø
5.5 -10.5 mm
Manufacturer Information
Manufacturer
Internet Address
INTERCONTEC
www.intercontec.biz
Manufacturer’s Product ID
ASTA 021 FR 11 10 0035 000
Table 45: Technical data for resolver connector 8PR001.00-1
ACOPOS User's Manual
81
Technical Data • Connectors
82
ACOPOS User's Manual
Installation • General Information
Chapter 3 • Installation
1. General Information
Make sure that installation takes place on a flat surface which is correctly dimensioned. The
dimensional diagram lists the number and type of mounting screws to be used.
Chapter 3
Installation
The eye bolt contained in the delivery can be attached to the device to lift ACOPOS 1640 and
ACOPOS 128M drives:
Figure 12: Attaching the eye bolt contained in the delivery to ACOPOS 1640 and 128M drives
ACOPOS User's Manual
83
Installation • General Information
ACOPOS servo drives can only be installed in an environment which corresponds to pollution
degree II (non-conductive material). When installing the device, make sure that the maximum
operating temperature (40 °C) is not exceeded and IP20 protection is provided as specified in
the technical data.
For proper air circulation, at least 80 mm has to be left free above and below the ACOPOS servo
drive. ACOPOS servo drives can be mounted directly next to each other; the required distance
between devices can be found in the respective dimensional diagram.
84
ACOPOS User's Manual
Installation • Dimensional Diagrams and Installation Dimensions
2. Dimensional Diagrams and Installation Dimensions
Chapter 3
Installation
2.1 ACOPOS 1022, 1045, 1090
Figure 13: Dimensional diagram and installation dimensions for ACOPOS 1022, 1045, 1090
1) For proper air circulation, at least 80 mm has to be left free above and below the ACOPOS servo drive.
ACOPOS User's Manual
85
Installation • Dimension Diagram and Installation Dimensions
2.2 ACOPOS 1180, 1320
Figure 14: Dimensional diagram and installation dimensions for ACOPOS 1180, 1320
1) For proper air circulation, at least 80 mm has to be left free above and below the ACOPOS servo drive. Approximately 100 mm free
space is required under the ACOPOS servo drive to prevent cabling problems.
86
ACOPOS User's Manual
Installation • Dimension Diagram and Installation Dimensions
Chapter 3
Installation
2.3 ACOPOS 1640
Figure 15: Dimensional diagram and installation dimensions for ACOPOS 1640
1) For proper air circulation, at least 80 mm has to be left free above and below the ACOPOS servo drive. Approximately 160 mm free
space is required under the ACOPOS servo drive to prevent cabling problems.
ACOPOS User's Manual
87
Installation • Dimension Diagram and Installation Dimensions
2.4 ACOPOS 128M
Figure 16: Dimensional diagram and installation dimensions for ACOPOS 128M
1) For proper air circulation, at least 80 mm has to be left free above and below the ACOPOS servo drive. Approximately 160 mm free
space is required under the ACOPOS servo drive to prevent cabling problems.
88
ACOPOS User's Manual
Installation • Installation and Removal of Plug-in Modules
3. Installation and Removal of Plug-in Modules
3.1 General Information
All ACOPOS servo drives are equipped with four slots for plug-in modules. At present, the
following module arrangements must be used:
Plug-in module
Operation possible in
Slot 1
Slot 2
Slot 3
Slot 4
8AC110.60-2
Yes
No
No
No
8AC112.60-1
Yes
No
No
No
8AC120.60-1
No
Yes
Yes
Yes
8AC122.60-2
No
Yes
Yes
Yes
8AC123.60-1
No
Yes
Yes
Yes
8AC130.60-1
No
Yes
Yes
Yes
8AC131.60-1
No
Yes
Yes
Yes
Chapter 3
Installation
Image
Table 46: Slot overview for ACOPOS plug-in modules
Caution!
•
Keep the plug-in modules in the original packaging and only take them out
immediately before installation.
•
Avoid touching the plug-in modules anywhere but on the front cover.
•
Take the necessary steps to protect against electrostatic discharges.
3.2 Installation
1) Disconnect the ACOPOS servo drive from the power mains and prevent reconnection.
2) Switch off 24 VDC supply voltage.
3) Remove screw from the bottom of the slot cover.
4) Loosen screw on the front side.
ACOPOS User's Manual
89
Installation • Installation and Removal of Plug-in Modules
5) Remove slot cover.
Figure 17: Installing ACOPOS plug-in modules
6) Insert plug-in module in the free slot (see figure shown above).
7) Fasten the plug-in module with the two screws.
8) Switch on 24 VDC supply voltage.
9) Connect ACOPOS servo drive to the power mains.
3.3 Removal
1) Disconnect the ACOPOS servo drive from the power mains and prevent reconnection.
2) Switch off 24 VDC supply voltage.
3) Remove screw from the bottom of the plug-in module.
4) Loosen screw on the front side.
5) Remove plug-in module.
6) Insert slot cover in free slot.
7) Fasten the slot cover with the two screws.
8) Switch on 24 VDC supply voltage.
9) Connect ACOPOS servo drive to the power mains.
90
ACOPOS User's Manual
Installation • Installing Various ACOPOS Series Devices Directly Next to Each Other
4. Installing Various ACOPOS Series Devices Directly Next to Each
Other
Chapter 3
Installation
When installing various ACOPOS series devices directly next to each other, we recommend
aligning the vertical position so that the LED displays of the respective devices are lined up.
Figure 18: Installing various ACOPOS series devices directly next to each other
You can see from the image above that the vertical offset of the upper mounting holes is 10 mm.
The distances for the lower mounting holes and the number and size of the screws required can
be taken from the dimensional diagrams for the respective ACOPOS servo drives.
ACOPOS User's Manual
91
Installation • Installing Various ACOPOS Series Devices Directly Next to Each Other
Overview of the vertical offsets:
Installed next to
ACOPOS
1022
1045
1090
1180
1320
1640
128M
1022
1045
1090
ACOPOS
No offset
10 mm
10 mm
No offset
1180
1320
1640
128M
Table 47: Overview of the vertical offsets (ACOPOS - ACOPOS)
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ACOPOS User's Manual
Installation • Using Cooling Aggregates in Switching Cabinets
5. Using Cooling Aggregates in Switching Cabinets
5.1 General Information
To prevent exceeding the required environmental temperatures, it may be necessary to cool the
air inside of a switching cabinet.
Caution!
Incorrect installation of cooling aggregates may cause condensation which can
damage the ACOPOS servo drives installed there!
Condensation can enter the ACOPOS servo drives with the cooled air stream!
During operation with the switching cabinet doors open (e.g. service), the ACOPOS servo drives
are not allowed to be cooler than the air in the switching cabinet at any time after the doors are
closed.
To keep the temperature of the ACOPOS servo drives and the switching cabinet at the same
level, the cooling aggregate must remain in operation even when the system is switched off.
Cooling aggregates must be installed in a way that prevents condensation from dripping into the
ACOPOS servo drives. This should be considered when selecting the switching cabinet (special
construction for use of cooling aggregates on top of the switching cabinet).
Also make sure that condensed water which forms in the cooling aggregate fan when it is
switched off cannot sprinkle into the ACOPOS servo drives.
Make sure the temperature setting of the cooling aggregates is correct!
ACOPOS User's Manual
93
Chapter 3
Installation
Make sure that only well sealed switching cabinets are used (condensation caused by outside
air entering the switching cabinet).
Installation • Using Cooling Aggregates in Switching Cabinets
5.2 Cooling Aggregate on Top of the Switching Cabinet
Figure 19: Cooling aggregate on top of the switching cabinet
94
ACOPOS User's Manual
Installation • Using Cooling Aggregates in Switching Cabinets
Chapter 3
Installation
5.3 Placing a Cooling Aggregate on the Front of the Switching Cabinet
Figure 20: Placing a cooling aggregate on the front of the switching cabinet
ACOPOS User's Manual
95
Installation • Using Cooling Aggregates in Switching Cabinets
96
ACOPOS User's Manual
Dimensioning • Power Mains Connection
Chapter 4 • Dimensioning
1. Power Mains Connection
1.1 General Information
1.1.1 System Configuration
The power mains connection is made using terminals X3 / L1, L2, L3 and PE. The ACOPOS
servo drives can be directly connected to TT and TN systems (these are three-phase systems
with grounded neutral).
Danger!
The ACOPOS servo drives are only allowed to be operated directly on grounded,
three-phase industrial mains (TN, TT systems). When using the servo drives in living
areas, shops and small businesses, additional filtering measures must be
implemented by the user.
1.1.2 Supply Voltage Range
The permissible supply voltage range for ACOPOS servo drives is 3 x 400 VAC to
3 x 480 VAC ±10 %. Respective intermediate transformers must be used for other supply
voltages. With grounded power mains, autotransformers can also be used to adjust the voltage.
Neutral does not have to be connected for this type of transformer.
ACOPOS User's Manual
97
Chapter 4
Dimensioning
When using ungrounded IT systems (three-phase systems without grounded neutral), isolation
transformers must be used. The secondary neutral must be grounded and connected to the
ACOPOS protective ground conductor. In this way, it is possible to prevent overvoltages
between external conductors and the ACOPOS housing. Three-phase isolation transformers
with the corresponding input and output voltages and a vector group with secondary neutral can
be used (e.g. 3 x 400 V / 3 x 400 V, Dyn3).
Dimensioning • Power Mains Connection
1.1.3 Protective Ground Connection (PE)
The following information concerning the protective ground connection corresponds to
IEC 61800-5 (draft), Item 3.2.5.3 "Connection elements for the protective ground conductor" and
must be followed.
Wire Cross Section
The wire cross section for the protective ground conductor is oriented to the external conductors
and must be selected according to the following table:
Wire Cross Section for External Line A
[mm²]
Minimum Wire Cross Section for Protective Ground Connection APE
[mm²]
A ≤ 16
A
16 < A ≤ 35
16
35 < A
A/2
Table 48: Selection of the protective ground conductor cross section
Increased Discharge Current
ACOPOS servo drives are devices with increased discharge current (larger than 3.5 mA AC or
10 mA DC). Therefore a fixed (immobile) protective ground connection is required on the servo
drives.
The following conditions must be met, depending on the ACOPOS device being used:
ACOPOS
1022
1045
1090
Conditions
Image
In addition to the connection of the first protective ground
conductor on terminal X3 / PE, a second protective ground
conductor with the same cross section must be connected on
the designated terminal (threaded bolt M5).
Table 49: Protective ground conditions according to ACOPOS device
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ACOPOS User's Manual
Dimensioning • Power Mains Connection
ACOPOS
Conditions
1180
1320
In addition to the connection of the first protective ground
conductor on terminal X3 / PE, a second protective ground
conductor with the same cross section must be connected on
the designated terminal (threaded bolt M5).
1640
128M
The cross section of the protective ground conductor
connected to terminal X3 / PE must be at least 10 mm² Cu.
Image
Table 49: Protective ground conditions according to ACOPOS device (cont.)
1.2 Dimensioning
1.2.1 Individual ACOPOS Power Mains Connections
The structure of an individual power mains connection with line contactor and circuit breaker can
be seen in the following diagram:
Figure 21: Circuit diagram for ACOPOS X3, individual power mains connection
ACOPOS User's Manual
99
Chapter 4
Dimensioning
In general, dimensioning the power mains, the overcurrent protection and the line contactors
depend on the structure of the power mains connection. The ACOPOS servo drives can be
connected individually (each drive has separate overcurrent protection and, if necessary, a
separate line contactor) or together in groups.
Dimensioning • Power Mains Connection
Dimensioning the Power Mains and Overcurrent Protection
The cross section of the power mains and the rated current for overcurrent protection should be
dimensioned for the average current load to be expected.
The power mains are to be equipped with overcurrent protection in the form of a circuit breaker
or a fuse. Circuit breakers (time lag) with type C tripping characteristics (according to IEC 60898)
or fuses (time lag) with type gM tripping characteristics (according to IEC 60269-1) are to be
used. 1)
The average current load to be expected can be calculated as follows:
S [ VA ]
I mains [ A ] = -------------------------------------3 ⋅ U mains [ V ]
The apparent power S can be calculated as follows: 2)
2 ⋅ π ⋅ n aver [ min –1 ]
S [ VA ] = M eff [ Nm ] ⋅ k ⋅ -------------------------------------------------60
The constant k for each of the various ACOPOS servo drives can be taken from the following
table:
Description
ACOPOS
1022
Constant k
1045
2.8
1090
2.4
1180
1320
1640
128M
2.1
1.9
1.7
1.5
Table 50: Constant k
1) Circuit breakers are available on the market with rated currents from 6 A to 63 A.
Outside of this range, fuses must be used.
2) If information concerning load torque, inertia and friction are available, the effective torque is calculated using the following formula (the
nominal torque of the motor can also be used here if the motor is dimensioned correctly):
M eff [ Nm ] =
1
2
----------------------- ⋅∑ Mi [ Nm ] ⋅ t i [ s ]
T cycle [ s ]
i
To calculate nave, information concerning the positioning cycle must be available.
nave is calculated using the following formula:
1
–1
n a ver [ min –1 ] = ----------------------- ⋅ ∑ n i [ min ] ⋅ t i [ s ]
T cycle [ s ]
i
100
ACOPOS User's Manual
Dimensioning • Power Mains Connection
The cross section of the power mains and the rated current of the overcurrent protection used
are chosen according to table 51 "Maximum current load for PVC insulated three-phase cables
or individual wires", on page 101 so that the maximum current load for the cable cross section
selected is greater than or equal to the calculated mains current.
IZ ≥ Imains
The rated current of the overcurrent protection must be less than or equal to the maximum
current load for the cable cross section selected (see table 51 "Maximum current load for PVC
insulated three-phase cables or individual wires", on page 101).
IB ≤ I Z
The following table shows the maximum current load of PVC insulated three-phase cables (or
three current-carrying wires) according to IEC 60204-1 at 40 °C environmental temperature 1)
and 70 °C maximum conductor temperature (maximum current load for installation type F and
cross sections greater than 35 mm², IEC 60364-5-523 is used for installation types B1 and B2).
Line cross section
[mm²]
Maximum current load for the cable cross section IZ / rated current for the overcurrent protection IR [A] depending
on the type of installation
Three-phase cable
in insulating
conduit or cable
duct
Three-phase cable
on walls
Three-phase cable
in a cable tray
Three individual
wires in a cable tray
B1
B2
C
E
F
1.5
13.5 / 13
12.2 / 10
15.2 / 13
16.1 / 16
---
2.5
18.3 / 16
16.5 /16
21 / 20
22 / 20
---
4
25 / 25
23 / 16
28 / 25
30 / 25
---
6
32 / 32
29 / 25
36 / 32
37 / 32
---
10
44 / 32
40 / 32
50 / 50
52 / 50
---
16
60 / 50
53 / 63
66 / 63
70 / 63
---
25
77 / 63
67 / 63
84 / 80
88 / 80
96 / 80
35
97 / 80
83 / 80
104 / 100
114 / 100
119 / 100
50
117 / 100
103 / 100
123 / 100
123 / 100
145 / 125
70
149 / 125
130 / 125
155 / 125
155 / 125
188 / 160
95
180 / 160
156 / 125
192 / 160
192 / 160
230 / 200
Chapter 4
Dimensioning
Three individual
wires in insulating
conduit or cable
duct
Table 51: Maximum current load for PVC insulated three-phase cables or individual wires
When determining the cross section for the power mains, make sure that the cross section
selected is within the range that can be used with power mains terminal X3 (see table 60
"Terminal cross sections for ACOPOS servo drives", on page 138).
1) The maximum current load value in IEC 60204-1 is for an environmental temperature of 40 °C. In IEC 60364-5-523, this reference
temperature is 30 °C. The values in table 51 "Maximum current load for PVC insulated three-phase cables or individual wires", on
page 101 from IEC 60364-5-523 are calculated with the factor kTemp = 0.87 given in the standard and also at 40 °C.
ACOPOS User's Manual
101
Dimensioning • Power Mains Connection
Dimensioning the Line Contactor
The rated current of the line contactor is oriented to the overcurrent protection for the power
mains connection. The line contactor is set up so that nominal operating current specified by the
manufacturer of the line contactor for category AC-1 is approximately 1.3 times the rated current
of the overcurrent protection.
1.2.2 Implementing ACOPOS Power Mains Connections for Drive Groups
The structure of the power mains connection for a drive group with line contactor and circuit
breaker can be seen in the following diagram:
Figure 22: Circuit diagram for ACOPOS X3, power mains connection for a drive group
Dimensioning the Power Mains and Overcurrent Protection
The cross section of the distribution point and all power mains connections are chosen according
to table 51 "Maximum current load for PVC insulated three-phase cables or individual wires", on
page 101 so that the maximum current load for the cable cross section selected 1) is greater than
or equal to the sum of the calculated mains current.
I Z ≥ ∑ I mains
The rated current of the overcurrent protection must be less than or equal to the maximum
current load for the cable cross section selected (see table 51 "Maximum current load for PVC
insulated three-phase cables or individual wires", on page 101).
IB ≤ I Z
1) When determining a common cross section for several drives (especially with different sized ACOPOS modules), make sure that the
cross section selected is within the range that can be used with the power mains terminals (see table 60 "Terminal cross sections for
ACOPOS servo drives", on page 138).
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ACOPOS User's Manual
Dimensioning • Power Mains Connection
Dimensioning the Line Contactor
The rated current of a common line contactor is oriented to the overcurrent protection for the
power mains connection. The line contactor is set up so that nominal operating current specified
by the manufacturer of the line contactor for category AC-1 is approximately 1.3 times the rated
current of the overcurrent protection.
1.3 Fault Current Protection
Fault current protection (RCD - residual current-operated protective device) can be used with
ACOPOS servo drives. However the following points must be noted:
ACOPOS servo drives have a power rectifier. If a short-circuit to the frame occurs, a flat DC fault
current can be created which prevents an AC current or pulse current sensitive RCD (Type A or
AC) from being activated, therefore canceling the protective function for all connected devices.
Danger!
If used for protection during direct or indirect contact of the fault current protection
(RCD), only a Type B RCD (AC-DC sensitive, according to IEC 60755) can be used
for the ACOPOS power mains connection. Otherwise additional protective
measures must be used, such as neutralization or isolation from the power mains
using an isolation transformer.
On ACOPOS servo drives, fault current protection with a rated fault current 1) of ≥ 100 mA can
be used. However, errors can occur:
•
When connecting servo drives to the power mains (short-term single-phase or two-phase
operation because of contact chatter on the line contactor).
•
Because of high frequency discharge currents occurring during operation when using
long motor cables.
•
Because of an extreme unbalance factor for the three-phase system.
1) The rated fault current listed by the manufacturer are maximum values which will definitely trip the protective device. Normally, the
protective device is tripped at approximately 60 % of the rated fault current.
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103
Chapter 4
Dimensioning
1.3.1 Rated Fault Current
Dimensioning • Power Mains Connection
1.3.2 Estimating the Discharge Current
Depending on the connection of the ACOPOS servo drive, different discharge currents flow to
ground on the protective ground conductor (PE):
Single-phase or two-phase operation (as intermediate state when switching on the line
contactor):
U mains [ V ] ⋅ 2 ⋅ π ⋅ f mains [ Hz ] ⋅ C A [ F ]
IA [ A ] = -----------------------------------------------------------------------------------------------3
Single-phase operation with neutral (lab or test operation):
U mains [ V ] ⋅ 2 ⋅ π ⋅ f mains [ Hz ] ⋅ C A [ F ]
IA [ A ] = -----------------------------------------------------------------------------------------------2⋅ 3
The discharge capacitance CD the various ACOPOS servo drives can be taken from the
following table:
Description
ACOPOS
1022
Discharge capacitance CD
1045
1090
1180
660 nF
1320
3.1 µF
1640
128M
--- 1)
Table 52: Discharge capacitance CD
1) Integrated line filter in preparation.
1.3.3 Manufacturer Used
For example, the AC-DC sensitive, 4 pole fault current protective device F 804 from ABB (fault
current: 300 mA; nominal current: 63 A) can be used. Using this fault current protective device,
approximately 5 ACOPOS 1022 (or 1045, 1090) can be connected in parallel.
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ACOPOS User's Manual
Dimensioning • DC Bus
2. DC Bus
2.1 General Information
With ACOPOS servo drives, it is possible to connect several servo drives via the DC bus. This
connection allows compensation of braking and drive energy of several axes or the distribution
of braking energy to several braking resistors.
The connection is made using terminals X2 / +DC and -DC. The structure of the DC bus
connections can be seen in the following diagram:
Caution!
To prevent excessively high discharge currents from flowing over the individual
servo drives, make sure that smaller servo drives are not connected between two
larger servo drives.
ACOPOS User's Manual
105
Chapter 4
Dimensioning
Figure 23: ACOPOS X2 circuit diagram, DC bus connections
Dimensioning • DC Bus
2.2 Wiring
The DC bus connections on the ACOPOS servo drives do not have short circuit and ground fault
protection and are not protected against reverse polarity. Therefore the DC bus connections
must be wired correctly.
Caution!
The DC bus connections must be wired correctly (no short circuits, ground faults or
reverse polarity).
A suitable measure to ensure that the wiring is secure against short circuits and ground faults 1)
is the use of corresponding cabling. Special rubber-insulated wires with increased resistance to
heat (90 °C) of types
•
NSGAÖU
•
NSGAFÖU
•
NSGAFCMÖU
with a nominal voltage Uo/U of at least 1.7/3 kV are considered to be secure against short circuits
and ground faults in switchgear and distribution systems up to 1000 V 2) .
1) Cabling e.g. according to DIN VDE 0100, part 200 "Electrical systems for buildings - terms", item A.7.6.
2) See e.g. DIN VDE 0298, part 3 "Use of cables and insulated wires for high-voltage systems", item 9.2.8.
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Dimensioning • DC Bus
2.3 Equal Distribution of the Applied Power via the Power Rectifiers
When creating a DC bus connection between several servo drives, it is possible that the parallel
connection of the power rectifiers causes incorrect distribution of the applied power. To prevent
this undesired effect, appropriately dimensioned shunt resistors are integrated in the ACOPOS
servo drives.
The following rules must be observed so that the effect of these shunt resistors is not cancelled
out:
•
The length of the DC bus wiring is not allowed to exceed a total length of 3 m and must
be within a single switching cabinet.
•
Dimensioning the cross section of the ACOPOS servo drive power mains must be done
according to section “Dimensioning the Power Mains and Overcurrent Protection" on
page 100.
•
The cross section of the DC bus wiring 1) on the respective ACOPOS servo drives must
be less than or equal to the cross section of the servo drive power mains.
•
The selected cross section must be within the range possible for the DC bus connection
terminal X2 (see table 60 "Terminal cross sections for ACOPOS servo drives", on
page 138).
The braking resistors integrated in the ACOPOS servo drives as well as braking resistors which
can be connected externally are controlled using a specially developed procedure. This
guarantees that the brake power is optimally and equally distributed on the braking resistors
when a DC bus connection is made between several units.
When using the integrated braking resistors, additional configuration is not required.
When using external braking resistors, the corresponding parameters must be defined
(see section 4.4 "Setting Brake Resistor Parameters", on page 115).
1) The cross section of the individual segments of the DC bus wiring must be dimensioned for the thermal equivalent effective value of
the respective compensation current. If information concerning the flow of the compensation current is available, calculate the thermal
equivalent effective value of the compensation current using
Iq [ A ] =
1
----------------------- ⋅
I [ A ] 2 ⋅ ti [ s ]
Tcycle [ s ] ∑ i
i
The cross section of the DC bus connection should then also be selected as described in table 60 "Terminal cross sections for
ACOPOS servo drives", on page 138, so that the maximum current load of the cable cross section is greater than or equal to the
thermal equivalent effective value of the compensation current (IZ ≥ Iq).
ACOPOS User's Manual
107
Chapter 4
Dimensioning
2.4 Equal Distribution of the Brake Power on the Braking Resistors
Dimensioning • DC Bus
2.5 Connection of External DC Bus Power Supplies
The ACOPOS servo drives recognize a power failure and can immediately initiate active braking
of the motor. The brake energy that occurs when braking is returned to the DC bus and the DC
bus power supply can use it to create the 24 VDC supply voltage. In this way, the ACOPOS servo
drives as well as encoders, sensors and possible safety circuit can be supplied with 24 VDC
while braking. 1)
An external DC bus power supply must be used for ACOPOS servo drives 8V1022 to 8V1090.
A DC bus power supply is integrated in ACOPOS servo drives 8V1180 to 8V128M.
Figure 24: B&R power supply 0PS320.1 as DC bus power supply for ACOPOS servo drives
1) WARNING: In some applications, there is not enough brake energy provided to guarantee that the 24 VDC supply voltage remains
active until the system is stopped.
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ACOPOS User's Manual
Dimensioning • Motor Connection
3. Motor Connection
On B&R motors, the power connections, the connections for the holding brake and the
connections for the motor temperature sensor are all made using the same motor plug.
On the servo drive, the motor connection is made using terminals X5 / U, V, W and PE as well
as terminals X4b / B+, B-, T+ and T-. The motor connection must be shieled correctly (see
section 1.1 "Electromagnetic Compatibility of the Installation", on page 121).
Chapter 4
Dimensioning
The structure of the motor connection can be seen in the following diagram:
Figure 25: ACOPOS X4/X5 circuit diagram, motor connection
The cross section of the motor cable must be dimensioned for the thermal equivalent effective
value of the motor current. 1)
The cross section of the motor cable is chosen for B&R motor cables according to the following
table so that the maximum current load for the cable cross section selected is greater than or
equal to the thermal equivalent effective value of the motor current:
I Z ≥ Iq
1) If information concerning load torque, inertia and friction are available, the thermal equivalent effective value for the motor current of
the motor used is calculated as follows:
Iq [ A ] =
1
----------------------- ⋅
I [ A ] 2 ⋅ ti [ s ]
Tcycle [ s ] ∑ i
i
ACOPOS User's Manual
109
Dimensioning • Motor Connection
The following table shows the maximum current load for special insulated three-phase cables
according to IEC 60364-5-523 at 40 °C environmental temperature 1) and 90 °C maximum cable
temperature.
Line cross section [mm²]
Maximum current load on the line IZ [A] depending on type of installation
Three-phase cable in insulating
conduit or cable duct
Three-phase cable on walls
Three-phase cable in a cable
tray
B2
C
E
1.5
17.8
20
20.9
4
31.9
36.4
38.2
10
54.6
64.6
68.3
35
116.5
133.8
143.8
Table 53: Maximum current load for special insulated three-phase cables
When determining the cross section for the motor cable, make sure that the cross section
selected is within the range that can be used with motor connection terminal X5 (see table 60
"Terminal cross sections for ACOPOS servo drives", on page 138).
1) The entry for the maximum current load in IEC 60364-5-523 is for an environmental temperature of 30 °C. The values in table 53
"Maximum current load for special insulated three-phase cables", on page 110 are calculated with the factor kTemp = 0.91 given in the
standard for use at 40 °C environmental temperature.
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ACOPOS User's Manual
Dimensioning • Braking Resistor
4. Braking Resistor
4.1 General Information
When braking servo motors, power is returned to the servo drive. This causes the capacitors in
the DC bus to be charged to higher voltages. Starting with a DC bus voltage of approx. 800 V,
the ACOPOS servo drive links the braking resistor to the DC bus using the brake chopper and
converts the braking energy to heat.
For ACOPOS servo drives, braking resistors are integrated for this purpose or external braking
resistors can be connected. The equipment differences can be found in the following table:
Description
ACOPOS
1022
DC Bus Capacitor
1045
235 µF
1090
1180
1320
1640
128M
470 µF
940 µF
1645 µF
3300 µF
6600 µF
Yes 1)
200 W
7 kW
Yes 1)
240 W
8.5 kW
Integrated Brake Chopper
Yes
Internal Braking Resistor
Continuous Power Output
Maximum Power
Yes
130 W
3.5 kW
Connection of External Braking Resistor Possible 2)
Continuous Power Output
Maximum Power
Minimum braking resistance (RBrmin)
Rated current for the built-in fuse (IB) 3)
Yes
200 W
7 kW
No4)
---------
Yes
400 W
14 kW
Yes
8 kW
40 kW
15 Ω
10 A (fast-acting)
Yes
24 kW
250 kW
2.5 Ω
30 A (fast-acting)
Chapter 4
Dimensioning
Table 54: Braking resistors for ACOPOS servo drives
1) The braking resistor integrated in the ACOPOS servo drives 1640 and 128M is dimensioned so that it is possible to brake to a stop (in
a typical drive situation).
2) The ACOPOS servo drives are designed so that either the integrated braking resistor or the external braking resistor can be activated.
Braking with both braking resistors at the same time is not possible.
Switching takes place using the software and is only possible during the ACOPOS servo drive initialization phase:
ParID 398: Setting for an internal / external braking resistor
0 ... Internal (default)
1 ... External
3) The fuses used must be fast-acting fuses ∅10 x 38 mm for 600 VAC/VDC.
For example, type KLKD0xx (xx is the rated current of the fuse in amperes e.g. KLKD030) from Littelfuse (www.littelfuse.com) can be
used.
4) The braking resistors integrated in ACOPOS servo drives 1022, 1045 and 1090 are optimally dimensioned for the respective sizes.
ACOPOS User's Manual
111
Dimensioning • Braking Resistor
4.2 External Braking Resistor Connection
The external braking resistors are connected using terminals X6 / RB+, RB- and PE. The
structure of the external braking resistor connection can be seen in the following diagram:
Figure 26: Circuit diagram for ACOPOS X6, external braking resistor on ACOPOS 1180/1320/1640/128M
When determining the cross section 1) for wiring the external braking resistor, make sure that the
cross section selected is within the range that can be used with braking resistor connection
terminal X6 (see table 60 "Terminal cross sections for ACOPOS servo drives", on page 138).
1) The cross section of the braking resistor cable must be dimensioned for the thermal equivalent effective value of the respective brake
current. If information concerning the flow of the brake current is available, calculate the thermal equivalent effective value of the brake
current using
Iq [ A ] =
1
----------------------- ⋅ ∑ I i [ A ] 2 ⋅ t i [ s ]
T cycle [ s ]
i
The cross section of the braking resistor connection should then be selected as described in table 51 "Maximum current load for PVC
insulated three-phase cables or individual wires", on page 101, so that the maximum current load of the cable cross section is greater
than or equal to the thermal equivalent effective value of the brake current (IZ ≥ Iq).
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ACOPOS User's Manual
Dimensioning • Braking Resistor
4.3 Dimensioning the Braking Resistor
Like other drive components, the externally connected braking resistors must be dimensioned
according to the requirements of the application.
To determine the required braking power (PBrmax and PBrave), the mechanical values M(t), ω(t)
and Tcycle must be known. The following formulas are used to determine the drive power curve:
P ( t ) [ W ] = M ( t ) [ Nm ] ⋅ ω ( t ) [ rad ⋅ s – 1 ]
Chapter 4
Dimensioning
n ( t ) [ min –1 ]ω ( t ) [ rad ⋅ s –1 ] = 2 ⋅ π ⋅ ---------------------------------60 [ s ⋅ min – 1 ]
Figure 27: Diagram of a typical movement with the brake power curve PBr(t) 1)
1) If - as shown - a typical triangular brake power curve occurs, then the average brake power can be calculated directly with the following
formula:
P BR
aver
P Br ⋅ t Br
1
max
[ W ] = ----------------------- ⋅ -------------------------T cycle [ s ]
2
The calculation is continued by deriving the brake power curve PBr(t) from the drive power curve.
The power must be set to zero in areas where it is positive (P(t) > 0). This results in the following
maximum brake power
P Br
ACOPOS User's Manual
max
[ W ] = abs ( max ( P Br ( t ) [ W ] ) )
113
Dimensioning • Braking Resistor
Then the average brake power is calculated over the given cycle
P Br
aver
1
[ W ] = ------------------------ ⋅ ∑ P Br ( t ) [ W ] ⋅ ti [ s ]
i
Tcycle [ s ]
i
In order to use an external braking resistor
•
the resistance (RBr)
•
the maximum power (PBrmax)
•
the nominal power (PRBrN)
1)
, the following parameters must be calculated:
4.3.1 Resistance of the External Braking Resistor
The resistance of the external braking resistor RBr can be calculated as follows:
U DC [ V ] 2
800 [ V ] 2
- = --------------------------R Br [ Ω ] = -------------------------P Br [ W ]
PBr [ W ]
max
ma x
The selected resistance is not allowed to be less than the minimum resistance for the
respective ACOPOS servo drive (see table 54 "Braking resistors for ACOPOS servo drives", on
page 111).
R Br [ Ω ] ≥ R Br
min
[Ω]
If this condition is not met, the maximum brake power required cannot be reached! Typical
resistances are between 4 and 50 Ω depending on the size of the ACOPOS device.
Caution!
If a resistance less than the minimum resistance is used, the brake chopper built
into the ACOPOS device could be destroyed!
Then the following calculation
P Br
aver
[ W ] ≤ R Br [ Ω ] ⋅I B [ A ] 2
must be made to check if the average continuous power for the brake can be reached with the
selected braking resistor on the ACOPOS servo drive. The brake power which can be continually
output by the ACOPOS device is limited by the built-in fuse (rated current of the built-in fuse, see
table 54 "Braking resistors for ACOPOS servo drives", on page 111).
1) Reliable braking resistors are available from Danotherm (www.danotherm.com).
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ACOPOS User's Manual
Dimensioning • Braking Resistor
4.3.2 Power Data for the External Braking Resistor
The maximum power that the external braking resistor must be able to dissipate is calculated as
follows:
PR
Br
ma x
[ W ] ≥ P Br
ma x
[W]
The nominal power (the power which can be continually dissipated) for the external braking
resistor is calculated using the following formulas:
PR
PR
Br
N
Br
N
[ W ] ≥ PBr
ave r
1
[ W ] ≥ ------ ⋅ P R
[W]
Br
30
max
The second condition depends on ACOPOS internal relationships.
4.3.3 Nominal Voltage of the External Braking Resistor
The external braking resistor must be selected so that it can handle the maximum voltage that
can occur during operation.
Danger!
During braking, voltages up to 900 VDC can occur on the external braking resistor.
The external braking resistor must be able to handle these voltages.
4.4 Setting Brake Resistor Parameters
The braking resistors integrated in the ACOPOS servo drives as well as braking resistors which
can be connected externally are controlled using a specially developed procedure. This
guarantees that the brake power is optimally and equally distributed on the braking resistors
when a DC bus connection is made between several units.
4.4.1 Using the Integrated Braking Resistors
No settings or configuration is required by the user.
ACOPOS User's Manual
115
Chapter 4
Dimensioning
During braking, voltages up to 900 VDC can occur.
Dimensioning • Braking Resistor
4.4.2 Using External Braking Resistors
When using external braking resistors, the following parameters must be set on the ACOPOS
servo drive using B&R Automation Studio™:
ParID
Formula Symbols
10
R Br
11
T Br
12
R Br
13
C Br
m ax
Description
Unit
Ohmic resistance
[Ω]
Maximum over-temperature on the external braking resistor
[°C]
Th
Thermal resistance between braking resistor and the environment 1)
[°C/W]
Th
Heat capacitance of the filament 2)
[Ws/°C]
Table 55: ParIDs for setting external braking resistor parameters
1) Total thermal resistance for series or parallel connections of several (nBr) of the same braking resistors:
R Br
Th
total
R Br
Th
= -----------n Br
2) Total heat capacitance of the filament for series or parallel connections of several (nBr) of the same braking resistors:
C Br
Th
tota l
= C Br ⋅ n Br
Th
The parameters can normally be found on the data sheet from the manufacturer. 1)
The parameters are based on the following thermal equivalent circuit for the external braking
resistor:
Figure 28: Thermal equivalent circuit for the external braking resistor
If a value for the maximum over-temperature of the external braking resistor is not given, it can
be determined using the following formula:
TBr
max
= PR
Br
N
⋅ RBr
Th
1) An example of reliable braking resistors are Σ SIGMA type braking resistors from Danotherm (www.danotherm.com).
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ACOPOS User's Manual
Dimensioning • Configuration of ACOPOS Servo Drives
5. Configuration of ACOPOS Servo Drives
The plug-in modules for ACOPOS servo drives allow each servo drive to be individually
configured according to the requirements of the application. When putting together plug-in
module combinations, the power consumption must be checked. This then results in the current
requirements of the ACOPOS servo drive configuration.
5.1 Maximum Power Output via the Four ACOPOS Servo Drive Slots
The maximum power output for all four slots is 22 W. The total power consumption for all plugin modules must be less than or equal to the maximum power output.
P max = 22W ≥ ∑ P module [ W ]
The power consumption of the individual modules can be found in table 56 "Power consumption
of the ACOPOS plug-in modules" or the technical data for the modules (see chapter 2 "Technical
Data"):
Plug-in module
Power Consumption
8AC110.60-2
Max. 0.7 W
Max. 2.5 W
8AC120.60-1
E0 ... EnDat single-turn, 512 lines
E1 ... EnDat multi-turn, 512 lines
E2 ... EnDat single-turn, 32 lines (inductive)
E3 ... EnDat multi-turn, 32 lines (inductive)
E4 ... EnDat single-turn, 512 lines
E5 ... EnDat multi-turn, 512 lines
Depends on the EnDat encoder connected
Max. 1.8 W
Max. 2.5 W
Max. 2.2 W
Max. 1.9 W
Max. 1.7 W
Max. 2.2 W
8AC122.60-2
Max. 1.2 W
8AC123.60-1
Max. 7.5 W
Depends on the current requirements for the encoder connected 1)
8AC130.60-1
Max. 0.8 W
8AC131.60-1
Chapter 4
Dimensioning
8AC112.60-1
Max. 1 W
Table 56: Power consumption of the ACOPOS plug-in modules
1) The power consumption of the plug-in module can be approximated using the following formula:
PModule [W] = PEncoder [W] . k + 0.6 W
The power consumed by the encoder PEncoder is calculated from the selected encoder supply voltage (5 V / 15 V) and the current
required:
PEncoder [W] = UEncoder [V] . IEncoder [A]
The following values must be used for k:
k = 1.2 (with 15 V encoder supply)
k = 1.75 (with 5 V encoder supply)
ACOPOS User's Manual
117
Dimensioning • Configuration of ACOPOS Servo Drives
5.2 24 VDC Current Requirements for the ACOPOS Servo Drive
The 24 VDC current requirements has to be regarded differently depending on the size of the
ACOPOS servo drive.
•
The following estimation can always be used for the ACOPOS 1022, 1045 and 1090:
I 24VDC [ A ] = I 24VDC
•
max
1, 1
[ A ] – ------------------ ⋅ ( 22W – ∑ P module [ W ] )
24V ⋅ k
This estimation can also be used for the ACOPOS 1180, 1320, 1640 and 128M as long
as a mains input voltage is not applied. As soon as a mains input voltage is applied to
these servo drives, the 24 VDC supply voltage is created via the integrated DC bus power
supply; the 24 VDC current requirements (I24VDC) is then reduced to 0.
The 24 VDC maximum current requirements for the ACOPOS servo drives can be found in
table 57 "Maximum current requirements and constant k" or the technical data for the ACOPOS
servo drives (see chapter 2 "Technical Data").
Description
ACOPOS
1022
I 24VDC
max
k
1045
1090
1180
1320
1640
128M
2.5
2.8
--- 1)
0.64
0.63
--- 1)
Table 57: Maximum current requirements and constant k
1) In preparation.
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ACOPOS User's Manual
Dimensioning • Formula Variables Used
6. Formula Variables Used
Symbol
Unit
CD
F
Th
Ws/°C
Heat capacitance of the filament
k
---
General constants
fmains
Hz
Mains frequency
I24VDC
A
24 VDC current requirements
A
24 VDC maximum current requirements
IA
A
Discharge current via protective ground conductor (PE)
IB
A
Rated current for overcurrent protection
Imains
A
Mains current (phase current)
Thermal equivalent current effective value
I 24VDC
max
Iq
A
IZ
A
M
Nm
Torque (general)
Meff
Nm
Effective load torque for a cycle
Maximum current load on a cable
-1
Speed (general)
n
min
naver
min-1
Average speed for a cycle
ω
rad/s
Rotational Speed
P
W
Power or true power (general)
PBr
W
Brake power
W
Maximum brake power
W
Average brake power
W
Maximum load on the external braking resistor
P Br
max
P Br
a ver
PR
Br max
PR
W
Nominal power of the external braking resistor
W
Maximum power
Pmodule
W
Power consumption of the plug-in modules
p
---
Pi (3.1415)
RBr
W
Braking resistor
W
Minimum braking resistance
Br N
Pmax
R Br
min
R Br
Th
S
°C/W
VA
Thermal resistance between braking resistor and the environment
Apparent power
t
s
Time (general)
tBr
s
Braking time
°C
Maximum over-temperature of the resistor
s
Cycle time
T Br
m ax
Tcycle
Chapter 4
Dimensioning
C Br
Description
Discharge capacitance
UDC
V
DC bus voltage
Umains
V
Supply voltage (phase to phase)
Table 58: Formula variables used
ACOPOS User's Manual
119
Dimensioning • Formula Variables Used
120
ACOPOS User's Manual
Wiring • General Information
Chapter 5 • Wiring
1. General Information
1.1 Electromagnetic Compatibility of the Installation
1.1.1 General Information
If the guidelines for elecromagnetic compatibility of the installation are followed, ACOPOS servo
drives meet EMC guidelines 89/336/EWG and low-voltage guidelines 73/23/EWG. They meet
the requirements for harmonized EMC product standard IEC 61800-3:1996 + A11:2000 for
industry (second environment).
Additional EMC measures must be implemented by the manufacturer of machines or systems if
the product standards for the machine has lower limits or if the machine should conform to
generic standard IEC 61000-6-4. Additional EMC measures may also be needed for machines
with a large number of ACOPOS servo drives. The installation of a central line filter is mostly
sufficient in such cases. Proof of conformity to the necessary limits must be provided according
to the documentation for use of the EMC guidelines from the manufacturer or distributor of the
machine or system.
Chapter 5
Wiring
Additional EMC measures are needed when operating ACOPOS servo drives in living area or
when connecting ACOPOS servo drives to a low voltage system which supplies buildings in
living areas without an intermediate transformer (first environment).
ACOPOS User's Manual
121
Wiring • General Information
1.1.2 Installation Notes
1) The switching cabinet or the system must be constructed appropriately.
2) To prevent the effects of disturbances, the following lines must be properly shielded:
•
motor lines
•
encoder cables
•
control lines
•
data cables
3) Inductive switching elements such as contactors or relays are to be equipped with
corresponding suppressor elements such as varistors, RC elements or damping diodes.
4) All electrical connections are to be kept as short as possible.
5) Cable shields are to be attached to the designated shield terminals and the plug housing.
6) Shielded cables with copper mesh or tinned copper mesh are to be used. Twisting or
extending the protective mesh using single conductors is not allowed.
7) Unused cable conductors are to be grounded on both sides if possible.
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ACOPOS User's Manual
Wiring • General Information
Chapter 5
Wiring
The ground connections and shield connections have to be made as illustrated in the following
diagram.
Figure 29: Connection diagram for ground and shield connections
ACOPOS User's Manual
123
Wiring • General Information
➊ The protective ground conductors (PE) for the power mains, the motor lines and external
braking resistor connection are internally connected with the housing of the ACOPOS servo
drive.
o The second protective ground conductor connection is required because of the increased
discharge current (> 3.5 mA) on ACOPOS servo drives 1022, 1045, 1090, 1180 and 1320.
The same cross section as the power mains protective ground conductor must be used.
p Both trigger inputs are only filtered internally with approx. 50 µs. Make sure the cable shield
is grounded properly.
q The cable shield must be attached to the shield connector.
r On all plug-in modules, the two screws used to fasten the module must be tightened so that
the mounting bracket is connected to ground.
s Using a DSUB connector:
The cable shield must be connected to the designated clamp in the metallic or metal plated
plug housing. The fastening screws must be tightened.
Cable connection via terminals:
The cable shield must be attached to the shield connection terminal.
Cable connection via RJ45 plug:
Also grounding the cable shield provides an improvement in EMC properties. Grounding
should take place on both sides, extensively and near to the connector.
Figure 30: Cable shield grounding for the ETHERNET Powerlink cable
124
ACOPOS User's Manual
Wiring • General Information
t The cable shield for the motor line or the connection cable for the external braking resistor is
connected with the housing of the ACOPOS servo drive via the grounding plate using the
grounding clamp provided:
Shield connection for the motor cable using grounding clamps
1022, 1045, 1090
1180, 1320
1640, 128M
Table 59: Grounding the motor cable
u On the motor side, the cable shield for the motor line is connected to the motor housing using
the motor plug and connected to ground via the machine.
The cable shield on the connection cable for the external braking resistor must be connected
with the housing of the braking resistor.
v On the motor side, the encoder cable shield is connected to the motor housing using the
Chapter 5
Wiring
encoder plug and connected to ground via the machine.
ACOPOS User's Manual
125
Wiring • Secure Restart Inhibit
1.2 Secure Restart Inhibit
1.2.1 General Information
ACOPOS servo drives have a built-in secure restart inhibit to guarantee that the device is
stopped securely and to prevent it from restarting unexpectedly. It is designed to correspond to
safety category 3 according to EN 954-1. 1)
In addition to preventing the device from restarting unexpectedly according to EN 1037, this
safety function also meets the requirements of EN 60204-1 regarding the stop function for
categories 0 and 1. Both stop functions require the supply to the machine drives to be switched
off (immediately for category 0 and after stopping for category 1).
The secure restart inhibit interrupts the supply to the motor by preventing the pulses to the
IGBTs. In this way, a rotating field can no longer be creating in synchronous and asynchronous
motors controlled by the ACOPOS servo drives. This fulfills the requirements of EN 1037
regarding preventing the device from starting unexpectedly and IEC 60204-1 regarding the stop
function for categories 0 and 1. 2)
Danger!
Take note that multiple errors in the IGBT bridge can cause a short advancing
movement. The maximum rotary angle of the advancing movement ϕ on the motor
shaft depends on the motor used. For permanently excited synchronous motors,
ϕ = 360°/2p (for B&R standard motors, p = 3 and the angle is therefore 60°). For
three-phase current asynchronous motors, there is a relatively small angle of
rotation, between 5° and 15°.
For applications, where this can be dangerous, the goal for protection cannot be
obtained.
1) TÜV: Sample test for secure restart inhibit according to EN 954-1 category 3 is in preparation.
2) A detailed explanation of the standards and categories can be found in chapter 7 "Standards and Certifications".
126
ACOPOS User's Manual
Wiring • Secure Restart Inhibit
1.2.2 Principle - Realization of the Safety Function
Chapter 5
Wiring
Secure restart inhibit is obtained by removing the IGBT driver supply. Terminals X1 / Enable and
X1 / COM(8, 9) are used to supply an integrated DC-DC converter with 24 VDC. The converter
creates the supply voltage for the IGBT driver from this voltage.
Figure 31: Block diagram of secure restart inhibit
If the 24 VDC voltage supply for the DC-DC converter is interrupted, the IGBT driver is also no
longer supplied. Then it is no longer possible to transfer the modulation pattern needed to
generate the rotating field on the IGBT output stage.
ACOPOS User's Manual
127
Wiring • Secure Restart Inhibit
Additional Function
The availability of the DC-DC converter output voltage can be requested from the
microprocessor. If a voltage is not present, the generation of the modulation pattern is
suppressed by the microprocessor.
Danger!
After activating the secure restart inhibit using terminals X1 / Enable and X1 /
COM(8, 9), the motor is de-energized and therefore torque-free. If the motor was
moving before activation of the secure restart inhibit, it is only stopped by an
operational brake which is sometimes available or from the friction of the entire
system. Therefore, the motor is not able to hold hanging loads. Holding brakes must
be used for this purpose.
For applications, where this can be dangerous, the goal for protection cannot be
obtained.
1.2.3 External Wiring
The following section contains four wiring suggestions for the external wiring of the secure restart
inhibit. They are divided corresponding to the three stop functions (categories 0, 1 and 2)
according to IEC 60204-1.
With the wiring shown, you can obtain safety category 3 according to EN 954-1 for the
emergency stop function (for regular checks of the emergency stop function) and for secure
restart inhibit.
In order for the wiring to meet the requirements of the respective application and the listed safety
category according to EN 954-1, suitable switching devices – one or two pin e-stop switching
devices from safety category 2 (reliable switching devices) - and cabling concepts must be used.
Danger!
To set up the e-stop function, one or two pin switching devices from safety category
2 (reliable switching devices) must be used in the e-stop chain. To obtain safety
category 3 according to EN 954-1, the e-stop function must be checked once a day.
For applications where this is not possible, the goal for protection cannot be
obtained.
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Wiring • Secure Restart Inhibit
Chapter 5
Wiring
Stop Function for Category 0 – Safety Category 3
Figure 32: External wiring for the stop function in category 0 – safety category 3
1) The network connection is used for diagnosis and setting parameters.
2) For servo drives which have no 24 VDC output (ACOPOS 1022/1045/1090), the control voltage must be provided externally.
ACOPOS User's Manual
129
Wiring • Secure Restart Inhibit
Description
By pressing the e-stop switch S1 (cat. 0 stop function) or the stop switch S2 (cat. 0 stop function),
the drive has no torque and spins out.
This guarantees that the energy feed to the motor is immediately switched off.
If you open and lock stop switch S2, restart is inhibited.
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Stop Function for Category 1 – Safety Category 3
Chapter 5
Wiring
Type 1 – Starting active braking over the network
Figure 33: Type 1 – Starting active braking over the network
1) The drop-out time lag corresponds to the requirements of the application. The K3 auxiliary relay with drop-out time lag is a part of the
safety function. Therefore K3 must meet safety category 3.
2) The network connection is used to transfer the interruption command for active braking, for diagnosis and setting parameters.
3) For servo drives which have no 24 VDC output (ACOPOS 1022/1045/1090), the control voltage must be provided externally.
ACOPOS User's Manual
131
Wiring • Secure Restart Inhibit
Description
When the e-stop switch S1 (cat. 1 stop function) is pressed, the "EmergencyStop" control input
on the controller triggers active braking (see following example code).
If the controller, the network, the drive, etc. is faulty, then auxiliary relay K3 is released after a
defined delay and causes the energy feed to the motor to be cut off.
Pressing stop switch S2 (cat. 1 stop function) basically triggers the same procedure, but is
handled differently by the software (separate digital input "Stop").
This guarantees that the energy feed to the motor is definitely switched off afterwards.
If you open and lock stop switch S2, restart is inhibited.
Example Code
Trigger the stop command (via CAN bus or ETHERNET Powerlink).
if ( ! stop_active )
{
/* Movement stop not active: Test stop inputs */
if ( EmergencyStop == ncLOW )
{
/* Movement stop with parameter set for "emergency stop" activated */
stop_index = E_STOP_INDEX;
step = MOV_STOP;
stop_active = 1;
}
else if ( Stop == ncLOW )
{
/* Movement stop with parameter set for "stop" activated */
stop_index = STOP_INDEX;
step = MOV_STOP;
stop_active = 1;
}
}
else
{
/* Movement stop was activated */
if ( EmergencyStop == ncHIGH && Stop == ncHIGH && step!= W_MOV_STOP )
{
/* Movement stop completed */
stop_active = 0;
}
}
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Wiring • Secure Restart Inhibit
switch(step)
{
...
case MOV_STOP:
/* Call NC action for movement stop */
p_ax_dat->move.stop.index.command = stop_index;
action_status = ncaction(ax_obj,ncMOVE,ncSTOP);
if ( action_status == ncOK )
{
step = W_MOVE_STOP;
}
break;
case W_MOVE_STOP:
/* Wait for completion of movement stop */
if (p_ax_dat->move.mode == ncOFF)
{
/* Movement stop completed */
step = <NEXT_STEP>
}
break;
...
Chapter 5
Wiring
}
ACOPOS User's Manual
133
Wiring • Secure Restart Inhibit
Type 2 – Starting active braking using the Quickstop input on the ACOPOS
Figure 34: Type 2 – Starting active braking using the Quickstop-input on the ACOPOS
1) The drop-out time lag corresponds to the requirements of the application. The K3 auxiliary relay with drop-out time lag is a part of the
safety function. Therefore K3 must meet safety category 3.
2) The network connection is used for diagnosis and setting parameters.
3) For servo drives which have no 24 VDC output (ACOPOS 1022/1045/1090), the control voltage must be provided externally.
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Wiring • Secure Restart Inhibit
Description
Pressing e-stop switch S1 (cat. 1 stop function) causes relay K2 to be released. In this way, the
ACOPOS input "Quickstop" triggers active braking.
If the drive, etc. is faulty, then auxiliary relay K3 is released after a defined delay and causes the
energy feed to the motor to be cut off.
Pressing stop switch S2 (cat. 1 stop function) starts the same procedure as for type 1.
This guarantees that the energy feed to the motor is definitely switched off afterwards.
Chapter 5
Wiring
If you open and lock stop switch S2, restart is inhibited.
ACOPOS User's Manual
135
Wiring • Secure Restart Inhibit
Stop Function for Category 2 – Safety Category 3
Figure 35: External wiring for the stop function in category 2 – safety category 3
1) The drop-out time lag corresponds to the requirements of the application. The K3 auxiliary relay with drop-out time lag is a part of the
safety function. Therefore K3 must meet safety category 3.
2) The network connection is used to transfer the interruption command for active braking, for diagnosis and setting parameters.
3) For servo drives which have no 24 VDC output (ACOPOS 1022/1045/1090), the control voltage must be provided externally.
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Wiring • Secure Restart Inhibit
Description
When the e-stop switch S1 (cat. 1 stop function) is pressed, the "EmergencyStop" control input
on the controller triggers active braking (see “Example Code" on page 132).
If the controller, the network, the drive, etc. is faulty, then auxiliary relay K3 is released after a
defined delay and causes the energy feed to the motor to be cut off.
Pressing stop switch S2 (cat. 2 stop function) basically triggers the same procedure, but is
handled differently by the software (separate digital input "Stop"). However, the energy feed to
the motor is not switched off after stopping.
Chapter 5
Wiring
If you open and lock e-stop switch S1, restart is inhibited.
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137
Wiring • Overview of the Terminal Cross Sections
1.3 Overview of the Terminal Cross Sections 1)
Terminal Cross Sections
8V1022.00-2
8V1045.00-2
8V1180.00-2
8V1320.00-2
8V1640.00-2
8V128M.00-2
8V1090.00-2
[mm²]
0.5 - 1.5
[AWG]
Solid core/multiple conductor lines
20 - 14
Flexible and fine wire lines
without Wire Tip Sleeves
0.5 - 1.5 20 - 14
X1
with Wire Tip Sleeves
0.5 - 1.5 20 - 14
Approbation Data
26 - 14
UL/C-UL-US
--26 - 14
CSA
--Holding Torque for the Terminal Screws [Nm]
0.2 ... 0.25
Solid core/multiple conductor lines
0.2 - 4
24 - 10
Flexible and fine wire lines
X2
24 - 10
without Wire Tip Sleeves
0.2 - 4
23 - 10
with Wire Tip Sleeves
0.25 - 4
DC Bus
Approbation Data
UL/C-UL-US
--30 - 10
CSA
--28 - 10
Holding Torque for the Terminal Screws [Nm]
0.5 ... 0.6
Solid core/multiple conductor lines
0.2 - 4
24 - 10
Flexible and fine wire lines
without Wire Tip Sleeves
0.2 - 4
X3
24 - 10
with Wire Tip Sleeves
0.25 - 4
23 - 10
Power mains Approbation Data
30 - 10
UL/C-UL-US
--28 - 10
CSA
--Holding Torque for the Terminal Screws [Nm]
0.5 ... 0.6
Solid core/multiple conductor lines 0.2 - 2.5 24 - 12
X4a, X4b
Flexible and fine wire lines
Motor
without Wire Tip Sleeves
0.2 - 2.5 24 - 12
(holding
with Wire Tip Sleeves
0.25 - 2.5 23 - 12
brake.
Approbation Data
temperature
UL/C-UL-US
--30 - 12
sensor)
CSA
--28 - 12
Holding Torque for the Terminal Screws [Nm]
0.5 ... 0.6
Solid core/multiple conductor lines
0.2 - 4
24 - 10
Flexible and fine wire lines
X5
24 - 10
without Wire Tip Sleeves
0.2 - 4
23 - 10
with Wire Tip Sleeves
0.25 - 4
Motor
Approbation Data
(power)
UL/C-UL-US
--30 - 10
CSA
--28 - 10
Holding Torque for the Terminal Screws [Nm]
0.5 ... 0.6
--Solid core/multiple conductor lines
--Flexible and fine wire lines
X6
--without Wire Tip Sleeves
----with Wire Tip Sleeves
--External
Brake
Approbation Data
Resistor
UL/C-UL-US
----CSA
----Holding Torque for the Terminal Screws [Nm]
---
[mm²]
0.5 - 1.5
[AWG]
20 - 14
[mm²]
0.5 - 1.5
[AWG]
20 - 14
[mm²]
0.5 - 1.5
[AWG]
20 - 14
0.5 - 1.5
0.5 - 1.5
20 - 14
20 - 14
0.5 - 1.5
0.5 - 1.5
20 - 14
20 - 14
0.5 - 1.5
0.5 - 1.5
20 - 14
20 - 14
--26 - 14
--26 - 14
0.2 ... 0.25
0.5 - 10
20 - 7
--26 - 14
--26 - 14
0.2 ... 0.25
10 - 50
7-0
--26 - 14
--26 - 14
0.2 ... 0.25
16 - 95
6 - 3/0
0.5 - 6
0.5 - 6
10 - 35
10 - 35
7-2
7-2
10 - 70
10 - 70
-----
10 - 2
12 - 2
-----
20 - 9
20 - 9
-----
7 - 2/0
7 - 2/0
20 - 8
20 - 8
1.2 ... 1.5
0.5 - 10
20 - 7
3 ... 4
10 - 50
7-0
6 - 2/0
6 - 2/0
6 ... 10
16 - 95
6 - 3/0
0.5 - 6
0.5 - 6
10 - 35
10 - 35
7-2
7-2
10 - 70
10 - 70
-----
10 - 2
12 - 2
-----
20 - 9
20 - 9
-----
7 - 2/0
7 - 2/0
20 - 8
20 - 8
1.2 ... 1.5
0.2 - 2.5 24 - 12
3 ... 4
0.2 - 2.5 24 - 12
6 - 2/0
6 - 2/0
6 ... 10
0.2 - 2.5 24 - 12
0.2 - 2.5
0.25 - 2.5
0.2 - 2.5
0.25 - 2.5
0.2 - 2.5
0.25 - 2.5
24 - 12
23 - 12
-----
24 - 12
23 - 12
30 - 12
28 - 12
0.5 ... 0.6
0.5 - 10
20 - 7
30 - 12
28 - 12
0.5 ... 0.6
10 - 50
7-0
30 - 12
28 - 12
0.5 ... 0.6
16 - 95
6 - 3/0
0.5 - 6
0.5 - 6
10 - 35
10 - 35
7-2
7-2
10 - 70
10 - 70
-----
10 - 2
12 - 2
-----
20 - 9
20 - 9
-----
-----
24 - 12
23 - 12
-----
7 - 2/0
7 - 2/0
20 - 8
20 - 8
1.2 ... 1.5
0.2 - 4
24 - 10
3 ... 4
0.5 - 10
20 - 7
6 - 2/0
6 - 2/0
6 ... 10
0.5 - 10
20 - 7
0.2 - 4
0.25 - 4
0.5 - 6
0.5 - 6
0.5 - 6
0.5 - 6
-----
24 - 10
23 - 10
30 - 10
28 - 10
0.5 ... 0.6
-----
20 - 9
20 - 9
20 - 8
20 - 8
1.2 ... 1.5
-----
20 - 9
20 - 9
20 - 8
20 - 8
1.2 ... 1.5
Table 60: Terminal cross sections for ACOPOS servo drives
1) ACOPOS 1022/1045/1090 revision I0 and up; ACOPOS 1180/1320 revision F0 and up; ACOPOS 1640/128M revision K0 and up.
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Wiring • Pin Assignments ACOPOS 1022, 1045, 1090
Chapter 5
Wiring
2. Pin Assignments ACOPOS 1022, 1045, 1090 1)
Figure 36: Pin assignment overview ACOPOS 1022, 1045, 1090
1) Starting with revision I0.
ACOPOS User's Manual
139
Wiring • Pin Assignments ACOPOS 1022, 1045, 1090
2.1 Pin Assignments for Plug X1
X1
Pin
Description
Function
1
Trigger1
Trigger 1
2
Quickstop/Trigger2
Quickstop/Trigger 2
3
COM (1, 2)
Trigger 1, Quickstop/Trigger 2 - 0 V
4
Shield
Shield
5
End+
Positive HW limit
6
End-
Negative HW limit
7
Ref
Reference switch
8
Enable
Enable
9
Enable
Enable
10
COM (8, 9)
Enable 0 V
11
COM (8, 9)
Enable 0 V
12
---
---
13
---
---
14
+24V
Supply +24 V
15
+24V
Supply +24 V
16
COM (5-7, 14, 15)
Supply 0 V
17
COM (5-7, 14, 15)
Supply 0 V
18
COM (5-7, 14, 15)
Supply 0 V
Terminal Cross Sections see table 60 "Terminal cross sections for ACOPOS servo drives",
on page 138
Table 61: Pin assignments for plug X1 ACOPOS 1022, 1045, 1090
2.2 Pin Assignments for Plug X2
X2
Pin
Description
Function
1
-DC1
U DC bus -
2
+DC1
U DC bus +
3
+DC2
U DC bus +
4
-DC2
U DC bus -
Terminal Cross Sections see table 60 "Terminal cross sections for ACOPOS servo drives",
on page 138
Table 62: Pin assignments for plug X2 ACOPOS 1022, 1045, 1090
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Wiring • Pin Assignments ACOPOS 1022, 1045, 1090
2.3 Pin Assignments for Plug X3
X3
Pin
Description
Function
1
L1
Power mains connection L1
2
L2
Power mains connection L2
3
L3
Power mains connection L3
4
PE
Protective ground conductor
Terminal Cross Sections see table 60 "Terminal cross sections for ACOPOS servo drives",
on page 138
Table 63: Pin assignments for plug X3 ACOPOS 1022, 1045, 1090
2.4 Pin assignments for plugs X4a, X4b
X4a
Pin
Description
Function
1
S2
Activation, supply for the external holding
brake (+)
2
S1
Activation for the external holding brake (+)
3
S4
Activation, supply for the external holding
brake (-)
4
S3
Activation for the external holding brake (-)
Terminal Cross Sections see table 60 "Terminal cross sections for ACOPOS servo drives",
on page 138
X4b
Pin
Description
Function
1
T-
Temperature Sensor -
2
T+
Temperature Sensor +
3
B-
Brake -
4
B+
Brake +
Terminal Cross Sections see table 60 "Terminal cross sections for ACOPOS servo drives",
on page 138
Table 65: Pin assignments for plug X4b ACOPOS 1022, 1045, 1090
2.4.1 Wiring the Output for the Motor Holding Brake
The supply, activation and monitoring of the output for the motor holding brake can take place
via the the X4a connector in three different ways:
ACOPOS User's Manual
141
Chapter 5
Wiring
Table 64: Pin assignments for plug X4a ACOPOS 1022, 1045, 1090
Wiring • Pin Assignments ACOPOS 1022, 1045, 1090
Image
Description
• Supply:
Internally by the ACOPOS servo drive
• Activation:
Internally by the ACOPOS servo drive
1
• Monitoring:
Internally by the ACOPOS servo drive
A jumper must be placed between S1 and S2 as well as S3 and
S4 on the X4a connector. 1)
• Supply:
Internally by the ACOPOS servo drive
• Activation:
Internally by the ACOPOS servo drive and also possible
externally using potential free contacts 2)
2
• Monitoring:
Internally by the ACOPOS servo drive
Information:
The parameters for ACOPOS internal monitoring must be set
according to the requirements of the application. 3)
• Supply:
External
• Activation:
External
3
• Monitoring:
External
Information:
ACOPOS internal monitoring cannot be used here; therefore it
must be deactivated using software. 4)
Table 66: Activation for the external holding brake
1) Both jumpers are already on the X4a connector delivered with the ACOPOS servo drives.
2) External potential free contacts can be connected between S1 and S2 as well as between S3 and S4. This makes it possible to activate the
holding brake using an external safety circuit independent of the control integrated in the ACOPOS servo drive.
3) The parameters are set using ParID 90 (1 ... internal monitoring active; 5 ... internal monitoring not active).
4) Deactivation takes place using ParID 90 (5 ... internal monitoring not active).
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Wiring • Pin Assignments ACOPOS 1022, 1045, 1090
2.5 Pin Assignments for Plug X5
X5
Pin
Description
Function
1
PE
Protective ground conductor
2
W
Motor connection W
3
V
Motor connection V
4
E
Motor connection U
Terminal Cross Sections see table 60 "Terminal cross sections for ACOPOS servo drives",
on page 138
Table 67: Pin assignments for plug X5 ACOPOS 1022, 1045, 1090
2.6 Protective Ground Connection (PE)
Image
Terminal Cross Sections
Cable lug for threaded bolt M5
Pin
Description
Function
---
PE
Protective ground conductor
[mm²]
AWG
0.25 - 16
23 - 5
Chapter 5
Wiring
The protective ground conductor is connected to the threaded bolt M5 provided using a cable
lug. For information concerning dimensioning see section 1.1.3 "Protective Ground Connection
(PE)", on page 98.
Table 68: Protective ground conductor (PE) ACOPOS 1022, 1045, 1090
Danger!
Before turning on the servo drive, make sure that the housing is properly connected
to ground (PE rail). The ground connection must be made, even when testing the
servo drive or when operating it for a short time!
ACOPOS User's Manual
143
Wiring • Pin Assignments ACOPOS 1180, 1320
3. Pin Assignments ACOPOS 1180, 1320 1)
Figure 37: Pin assignment overview ACOPOS 1180, 1320
1) Starting with revision F0.
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Wiring • Pin Assignments ACOPOS 1180, 1320
3.1 Pin Assignments for Plug X1
X1
Pin
Description
Function
1
Trigger1
Trigger 1
2
Quickstop/Trigger2
Quickstop/Trigger 2
3
COM (1, 2)
Trigger 1, Quickstop/Trigger 2 - 0 V
4
Shield
Shield
5
End+
Positive HW limit
6
End-
Negative HW limit
7
Ref
Reference switch
8
Enable
Enable
9
Enable
Enable
10
COM (8, 9)
Enable 0 V
11
COM (8, 9)
Enable 0 V
12
---
---
13
+24V out / 0.5A
+24 V output / 0.5 A
14
+24V
Supply +24 V
15
+24V
Supply +24 V
16
COM (5-7, 13-15)
Supply 0 V
17
COM (5-7, 13-15)
Supply 0 V
18
COM (5-7, 13-15)
Supply 0 V
Terminal Cross Sections see table 60 "Terminal cross sections for ACOPOS servo drives",
on page 138
Table 69: Pin assignments for plug X1 ACOPOS 1180, 1320
X2
Pin
Description
Function
1
-DC1
U DC bus -
2
+DC1
U DC bus +
3
+DC2
U DC bus +
4
-DC2
U DC bus -
Chapter 5
Wiring
3.2 Pin Assignments for Plug X2
Terminal Cross Sections see table 60 "Terminal cross sections for ACOPOS servo drives",
on page 138
Table 70: Pin assignments for plug X2 ACOPOS 1180, 1320
ACOPOS User's Manual
145
Wiring • Pin Assignments ACOPOS 1180, 1320
3.3 Pin Assignments for Plug X3
X3
Pin
Description
Function
1
L1
Power mains connection L1
2
L2
Power mains connection L2
3
L3
Power mains connection L3
4
PE
Protective ground conductor
Terminal Cross Sections see table 60 "Terminal cross sections for ACOPOS servo drives",
on page 138
Table 71: Pin assignments for plug X3 ACOPOS 1180, 1320
3.4 Pin Assignments for Plugs X4a, X4b
X4a
Pin
Description
Function
1
S2
Activation, supply for the external holding
brake (+)
2
S1
Activation for the external holding brake (+)
3
S4
Activation, supply for the external holding
brake (-)
4
S3
Activation for the external holding brake (-)
Terminal Cross Sections see table 60 "Terminal cross sections for ACOPOS servo drives",
on page 138
Table 72: Pin assignments for plug X4a ACOPOS 1180, 1320
X4b
Pin
Description
Function
1
T-
Temperature Sensor -
2
T+
Temperature Sensor +
3
B-
Brake -
4
B+
Brake +
Terminal Cross Sections see table 60 "Terminal cross sections for ACOPOS servo drives",
on page 138
Table 73: Pin assignments for plug X4b ACOPOS 1180, 1320
3.4.1 Wiring the Output for the Motor Holding Brake
The supply, activation and monitoring of the output for the motor holding brake can take place
via the the X4a connector in three different ways:
146
ACOPOS User's Manual
Wiring • Pin Assignments ACOPOS 1180, 1320
Image
Description
• Supply:
Internally by the ACOPOS servo drive
• Activation:
Internally by the ACOPOS servo drive
1
• Monitoring:
Internally by the ACOPOS servo drive
A jumper must be placed between S1 and S2 as well as S3 and
S4 on the X4a connector. 1)
• Supply:
Internally by the ACOPOS servo drive
• Activation:
Internally by the ACOPOS servo drive and also possible
externally using potential free contacts 2)
2
• Monitoring:
Internally by the ACOPOS servo drive
Information:
The parameters for ACOPOS internal monitoring must be set
according to the requirements of the application. 3)
• Supply:
External
• Activation:
External
Chapter 5
Wiring
• Monitoring:
External
3
Information:
ACOPOS internal monitoring cannot be used here; therefore it
must be deactivated using software. 4)
Table 74: Activation for the external holding brake
1) Both jumpers are already on the X4a connector delivered with the ACOPOS servo drives.
2) External potential free contacts can be connected between S1 and S2 as well as between S3 and S4. This makes it possible to activate the
holding brake using an external safety circuit independent of the control integrated in the ACOPOS servo drive.
3) The parameters are set using ParID 90 (1 ... internal monitoring active; 5 ... internal monitoring not active).
4) Deactivation takes place using ParID 90 (5 ... internal monitoring not active).
ACOPOS User's Manual
147
Wiring • Pin Assignments ACOPOS 1180, 1320
3.5 Pin Assignments for Plug X5
X5
Pin
Description
Function
1
PE
Protective ground conductor
2
W
Motor connection W
3
V
Motor connection V
4
E
Motor connection U
Terminal Cross Sections see table 60 "Terminal cross sections for ACOPOS servo drives",
on page 138
Table 75: Pin assignments for plug X5 ACOPOS 1180, 1320
3.6 Pin Assignments for Plug X6
X6
Pin
Description
Function
1
PE
Protective ground conductor
2
RB-
Brake Resistance -
3
RB+
Brake Resistance +
Terminal Cross Sections see table 60 "Terminal cross sections for ACOPOS servo drives",
on page 138
Table 76: Pin assignments for plug X6 ACOPOS 1180, 1320
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Wiring • Pin Assignments ACOPOS 1180, 1320
3.7 Protective Ground Connection (PE)
The protective ground conductor is connected to the threaded bolt M5 provided using a cable
lug. For information concerning dimensioning see section 1.1.3 "Protective Ground Connection
(PE)", on page 98.
Image
Terminal Cross Sections
Cable lug for threaded bolt M5
Pin
Description
Function
---
PE
Protective ground conductor
[mm²]
AWG
0.25 - 16
23 - 5
Table 77: Protective ground conductor (PE) ACOPOS 1180, 1320
Danger!
Chapter 5
Wiring
Before turning on the servo drive, make sure that the housing is properly connected
to ground (PE rail). The ground connection must be made, even when testing the
servo drive or when operating it for a short time!
ACOPOS User's Manual
149
Wiring • Pin Assignments ACOPOS 1640, 128M
4. Pin Assignments ACOPOS 1640, 128M 1)
Figure 38: Pin assignment overview ACOPOS 1640, 128M
1) Starting with revision K0.
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ACOPOS User's Manual
Wiring • Pin Assignments ACOPOS 1640, 128M
4.1 Pin Assignments for Plug X1
X1
Pin
Description
Function
1
Trigger1
Trigger 1
2
Quickstop/Trigger2
Quickstop/Trigger 2
3
COM (1, 2)
Trigger 1, Quickstop/Trigger 2 - 0 V
4
Shield
Shield
5
End+
Positive HW limit
6
End-
Negative HW limit
7
Ref
Reference switch
8
Enable
Enable
9
Enable
Enable
10
COM (8, 9)
Enable 0 V
11
COM (8, 9)
Enable 0 V
12
---
---
13
+24V out / 0.5A
+24 V output / 0.5 A
14
+24V
Supply +24 V
15
+24V
Supply +24 V
16
COM (5-7, 13-15)
Supply 0 V
17
COM (5-7, 13-15)
Supply 0 V
18
COM (5-7, 13-15)
Supply 0 V
Terminal Cross Sections see table 60 "Terminal cross sections for ACOPOS servo drives",
on page 138
Table 78: Pin assignments for plug X1 ACOPOS 1640, 128M
X2
Pin
Description
Function
1
+DC2
U DC bus +
2
+DC1
U DC bus +
3
-DC2
U DC bus -
4
-DC1
U DC bus -
Chapter 5
Wiring
4.2 Pin Assignments X2
Terminal Cross Sections see table 60 "Terminal cross sections for ACOPOS servo drives",
on page 138
Table 79: Pin assignments for X2 ACOPOS 1640, 128M
ACOPOS User's Manual
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Wiring • Pin Assignments ACOPOS 1640, 128M
4.3 Pin Assignments X3
X3
Pin
Description
Function
1
L1
Power mains connection L1
2
L2
Power mains connection L2
3
L3
Power mains connection L3
4
Protective ground conductor
Terminal Cross Sections see table 60 "Terminal cross sections for ACOPOS servo drives",
on page 138
Table 80: Pin assignments for X3 ACOPOS 1640, 128M
4.4 Pin Assignments for Plugs X4a, X4b
X4a
Pin
Description
Function
1
S2
Activation, supply for the external holding
brake (+)
2
S1
Activation for the external holding brake (+)
3
S4
Activation, supply for the external holding
brake (-)
4
S3
Activation for the external holding brake (-)
Terminal Cross Sections see table 60 "Terminal cross sections for ACOPOS servo drives",
on page 138
Table 81: Pin assignments for plug X4a ACOPOS 1640, 128M
X4b
Pin
Description
Function
1
T-
Temperature Sensor -
2
T+
Temperature Sensor +
3
B-
Brake -
4
B+
Brake +
Terminal Cross Sections see table 60 "Terminal cross sections for ACOPOS servo drives",
on page 138
Table 82: Pin assignments for plug X4b ACOPOS 1640, 128M
4.4.1 Wiring the Output for the Motor Holding Brake
The supply, activation and monitoring of the output for the motor holding brake can take place
via the the X4a connector in three different ways:
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Wiring • Pin Assignments ACOPOS 1640, 128M
Image
Description
• Supply:
Internally by the ACOPOS servo drive
• Activation:
Internally by the ACOPOS servo drive
1
• Monitoring:
Internally by the ACOPOS servo drive
A jumper must be placed between S1 and S2 as well as S3 and
S4 on the X4a connector. 1)
• Supply:
Internally by the ACOPOS servo drive
• Activation:
Internally by the ACOPOS servo drive and also possible
externally using potential free contacts 2)
2
• Monitoring:
Internally by the ACOPOS servo drive
Information:
The parameters for ACOPOS internal monitoring must be set
according to the requirements of the application. 3)
• Supply:
External
• Activation:
External
Chapter 5
Wiring
• Monitoring:
External
3
Information:
ACOPOS internal monitoring cannot be used here; therefore it
must be deactivated using software. 4)
Table 83: Activation for the external holding brake
1) Both jumpers are already on the X4a connector delivered with the ACOPOS servo drives.
2) External potential free contacts can be connected between S1 and S2 as well as between S3 and S4. This makes it possible to activate the
holding brake using an external safety circuit independent of the control integrated in the ACOPOS servo drive.
3) The parameters are set using ParID 90 (1 ... internal monitoring active; 5 ... internal monitoring not active).
4) Deactivation takes place using ParID 90 (5 ... internal monitoring not active).
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Wiring • Pin Assignments ACOPOS 1640, 128M
4.5 Pin Assignments X5
X5
Pin
Description
Function
1
PE
Protective ground conductor
2
W
Motor connection W
3
V
Motor connection V
4
E
Motor connection U
Terminal Cross Sections see table 60 "Terminal cross sections for ACOPOS servo drives",
on page 138
Table 84: Pin assignments for X5 ACOPOS 1640, 128M
4.6 Pin Assignments X6
X6
Pin
Description
Function
1
PE
Protective ground conductor
2
RB-
Brake Resistance -
3
RB+
Brake Resistance +
Terminal Cross Sections see table 60 "Terminal cross sections for ACOPOS servo drives",
on page 138
Table 85: Pin assignments for X6 ACOPOS 1640, 128M
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ACOPOS User's Manual
Wiring • Pin Assignments Plug-in Modules
5. Pin Assignments Plug-in Modules
5.1 AC110 - CAN Interface
5.1.1 Pin Assignments
Image
X1
Pin
1
Description
Function
---
---
2
CAN_L
CAN Low
3
COM (2, 7)
CAN 0 V
4
---
---
5
---
---
6
---
---
7
CAN_H
CAN High
8
---
---
9
---
---
Chapter 5
Wiring
Table 86: Pin assignments for AC110 - CAN Interface
ACOPOS User's Manual
155
Wiring • Plug-in Module Pin Assignments
5.2 AC112 - ETHERNET Powerlink Interface
5.2.1 Pin Assignments
Image
X1
X2
Pin
Description
Function
1
RXD
Receive Signal
2
RXD
Receive Signal Inverted
3
TXD
Transmit Signal
4
Shield
Shield
5
Shield
Shield
6
TXD
Transmit Signal Inverted
7
Shield
Shield
8
Shield
Shield
Description
Function
Pin
1
RXD
Receive Signal
2
RXD
Receive Signal Inverted
3
TXD
Transmit Signal
4
Shield
Shield
5
Shield
Shield
6
TXD
Transmit Signal Inverted
7
Shield
Shield
8
Shield
Shield
Table 87: Pin assignments for AC112 - ETHERNET Powerlink Interface
Information:
In general, crossover Ethernet cables must be used for ETHERNET Powerlink
connections!
Take care when plugging the cable in and out because otherwise the shield
connection could break between the RJ45 plug and the cable shield which could
then cause connection disturbances!
Information:
ETHERNET Powerlink cables must have crossover pin assignments. Unassigned
wires cannot be omitted.
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5.3 AC120 - EnDat Encoder Interface
5.3.1 Pin Assignments
Image
X1
Pin
Description
Function in
EnDat mode
1
A
2
COM (1, 3 - 9, 11, 13 - 15)
3
B
4
+5V out / 0.25A
5
D
6
---
7
R
---
8
T
Clock output
9
A
10
Sense COM
11
B
12
Sense +5V
13
D
14
15
Function in
Incremental mode
Channel A
Encoder supply 0 V
Channel B
Encoder supply +5 V
Data input
----Reference pulse
inverted
---
Channel A inverted
Sense input 0 V
Channel B inverted
Sense input +5 V
Data inverted
---
R
---
Reference Pulse
T
Clock output
inverted
---
Chapter 5
Wiring
Table 88: Pin assignments for AC120 - EnDat encoder interface
ACOPOS User's Manual
157
Wiring • Plug-in Module Pin Assignments
5.4 AC122 - Resolver Interface
5.4.1 Pin Assignments
Image
X1
Pin
Description
Function
1
---
---
2
---
---
3
Cos
Cosine input
4
Sin
Sine input
5
Ref
Reference output
6
---
---
7
Cos
Cosine input inverted
8
Sin
Sine input inverted
9
Ref 
Reference output inverted
Table 89: Pin assignments for AC122 - resolver interface
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Wiring • Plug-in Module Pin Assignments
5.5 AC123 - Incremental Encoder and SSI Absolute Encoder Interface
5.5.1 Pin Assignments
Image
X1
Pin
Description
Function in
Incremental mode
Function in
SSI mode
1
A
Channel A
---
2
A
Channel A inverted
---
3
B
Channel B
---
4
B
Channel B inverted
---
5
RD
Reference Pulse
Data input
6
RD
Reference pulse
inverted
Data input
inverted
7
T
---
Clock output
8
T
---
Clock output
inverted
9
+5V out / 0.35A
10
Sense +5V
11
Sense COM
12
COM (7 - 9, 13)
Encoder supply 0 V
13
+15V out / 0.35A
Encoder supply +15 V
14
A1
Activate encoder supply
A2
Activate encoder supply 1)
15
Encoder supply +5 V
Sense +5 V
Sense 0 V
1)
Table 90: Pin assignments AC123 - incremental encoder and SSI absolute encoder interface
Chapter 5
Wiring
1) To activate the encoder supply, pins 14 and 15 must be connected in the encoder cable plug.
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Wiring • Plug-in Module Pin Assignments
5.6 AC130 - Digital Mixed Module
5.6.1 Pin Assignments
Image
X1
Terminal Cross Sections
Pin
Description
Function
1
Digital I/O 1
Digital input / output 1
2
Digital I/O 2
Digital input / output 2
3
Digital I/O 3
Digital input / output 3
4
Digital I/O 4
Digital input / output 4
5
Digital I/O 5
Digital input / output 5
6
Digital I/O 6
Digital input / output 6
7
Digital I/O 7
Digital input / output 7
8
Digital I/O 8
Digital input / output 8
9
Digital O 9
Digital output 9
10
Digital O 10
Digital output 10
11
+24V
Supply +24 V
12
COM (1-11)
Supply 0 V
[mm²]
[AWG]
Solid Core / Multiple Conductor Lines
0.5 - 1.5
20 - 14
Flexible, Multiple Conductor Line
without Wire Tip Sleeves
with Wire Tip Sleeves
0.5 - 1.5
0.5 - 1.5
20 - 14
20 - 14
-----
26 - 14
26 - 14
Approbation Data (UL/C-UL-US- and CSA)
UL/C-UL-US
CSA
Holding Torque for the Terminal Screws [Nm]
0.2 ... 0.25
Table 91: Pin assignments AC130 - digital mixed module
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Wiring • Plug-in Module Pin Assignments
5.7 AC131 - Mixed Module
5.7.1 Pin Assignments
Image
X1
Terminal Cross Sections
Pin
Description
Function
1
Analog I 1 +
Analog input 1 plus
2
Analog I 1 -
Analog input 1 minus
3
COM (1, 2, 5, 6)
Analog input 0 V
4
Shield
Shield
5
Analog I 2 +
Analog input 2 plus
6
Analog I 2 -
Analog input 2 minus
7
COM (1, 2, 5, 6)
Analog input 0 V
8
Shield
Shield
9
Digital I/O 1
Digital input / output 1
10
Digital I/O 2
Digital input / output 2
11
+24V
Supply +24 V
12
COM (9-11)
Supply 0 V
[mm²]
[AWG]
Solid Core / Multiple Conductor Lines
0.5 - 1.5
20 - 14
Flexible, Multiple Conductor Line
without Wire Tip Sleeves
with Wire Tip Sleeves
0.5 - 1.5
0.5 - 1.5
20 - 14
20 - 14
-----
26 - 14
26 - 14
Approbation Data (UL/C-UL-US- and CSA)
UL/C-UL-US
CSA
Holding Torque for the Terminal Screws [Nm]
0.2 ... 0.25
Chapter 5
Wiring
Table 92: Pin assignments AC131 - digital mixed module
ACOPOS User's Manual
161
Wiring • Plug-in Module Pin Assignments
5.8 Connecting Cables to Plug-in Modules
Figure 39: Connecting Cables to Plug-in Modules
Stress relief for the cable is implemented using a cable tie. The cable tie is to be run through the
eye on the bottom of the plug-in module.
Make sure that the ventilation slots on the bottom of the ACOPOS drive are not blocked.
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Wiring • Cables
6. Cables
6.1 Motor Cable
6.1.1 Motor Cable Construction
Pos.
Amount
Description
Remark
1
1
Motor lines
4 x 1.5 mm² + 2 x 2 x 0.75 mm²
4 x 4 mm² + 2 x 2 x 1 mm²
4 x 10 mm² + 2 x 2 x 1.5 mm²
4 x 35 mm² + 2 x 2 x 1.5 mm² (not prefabricated)
2
1
Circular connector
BSTA 108 FR 19 58 0036 000 (for 8CMxxx.12-1)
BSTA 108 FR 35 59 0036 000 (for 8CMxxx.12-3)
CSTA 264 FR 48 25 0001 000 (for 8CMxxx.12-5)
3
1
Heat shrink tubing
4
8
Wire tip sleeve
Chapter 5
Wiring
Table 93: Motor cable construction
ACOPOS User's Manual
163
Wiring • Cables
6.1.2 Pin Assignments for 8CMxxx.12-1, 8CMxxx.12-3
Circular Connector
Pin
Description
Function
1
U
Motor connection U
4
V
Motor connection V
3
W
Motor connection W
2
PE
Protective ground conductor
A
T+
Temperature +
Temperature -
B
T-
C
B+
Brake +
D
B-
Brake -
Table 94: Pin assignments for motor cable 8CMxxx.12-1, 8CMxxx.12-3
6.1.3 Cable Schematic for 8CMxxx.12-1, 8CMxxx.12-3
Figure 40: Cable schematic for motor cable 8CMxxx.12-1, 8CMxxx.12-3
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Wiring • Cables
6.1.4 Pin Assignments for 8CMxxx.12-5
Circular Connector
Pin
U
Description
Function
U
Motor connection U
V
V
Motor connection V
W
W
Motor connection W
PE
Protective ground conductor
1
T+
Temperature +
Temperature -
2
T-
+
B+
Brake +
-
B-
Brake -
Table 95: Pin assignments for motor cables 8CMxxx.12-5
Chapter 5
Wiring
6.1.5 Cable Schematic for 8CMxxx.12-5
Figure 41: Cable schematic for motor cables 8CMxxx.12-5
ACOPOS User's Manual
165
Wiring • Cables
6.2 EnDat Encoder Cables
6.2.1 EnDat Encoder Cable Construction
Pos.
Amount
1
1
Description
Encoder cable
Remark
10 x 0.14 mm² + 2 x 0.50 mm²
2
1
Circular connector, 17 pin socket
ASTA 035 FR 11 12 0035 000
3
1
DSUB housing 45°, metal plated, 15-pin plug
4
1
Heat shrink tubing
Table 96: EnDat encoder cable construction
6.2.2 Pin Assignments
Circular Connector
Pin
Description
Function
Pin
15
A
Channel A
1
10
COM (1, 3 - 9, 11, 13 - 15)
Encoder supply 0 V
2
12
B
Channel B
3
7
+5V out / 0.25A
Encoder supply +5 V
4
14
D
Data input
5
8
T
Clock output
8
16
A
Channel A inverted
9
10
4
Sense COM
Sense input 0 V
13
B
Channel B inverted
11
1
Sense +5V
Sense input +5 V
12
17
D
Data inverted
13
9
T
Clock output inverted
15
DSUB Plug
Table 97: Pin assignments for EnDat encoder cables
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Wiring • Cables
6.2.3 Cable Schematic
Chapter 5
Wiring
Figure 42: Cable schematic for EnDat encoder cables
ACOPOS User's Manual
167
Wiring • Cables
6.3 Resolver Cables
6.3.1 Resolver Cable Construction
Pos.
Amount
1
1
Description
Encoder cable
Remark
3 x 2 x 24 AWG/19
2
1
Circular connector, 12 pin socket
ASTA 021 FR 11 10 0035 000
3
1
DSUB housing 45°, metal plated, 9 pin plug
4
1
Kink protection
Table 98: Resolver cable construction
6.3.2 Pin Assignments
Circular Connector
Pin
Description
Function
Pin
1
---
2
---
3
Cos
Cosine input
4
Sin
Sine input
4
5
Ref
Reference output
5
6
---
7
Cos
Cosine input inverted
7
8
Sin
Sine input inverted
8
Reference output inverted
9
9
Ref 
10
---
11
---
12
---
DSUB Plug
3
Table 99: Pin assignments for resolver cable
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ACOPOS User's Manual
Wiring • Cables
6.3.3 Cable Schematic
Chapter 5
Wiring
Figure 43: Cable schematic for resolver cables
ACOPOS User's Manual
169
Wiring • Cables
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Getting Started • Preparation
Chapter 6 • Getting Started
1. Preparation
1.1 Unpacking the ACOPOS Servo Drive
Remove the protective packaging from the ACOPOS servo drive. Check the ACOPOS servo
drive for obvious mechanical damage.
Danger!
Do not operate the ACOPOS servo drive if it is damaged. This can cause severe
personal injury or damage to property!
1.2 Installing and Connecting the ACOPOS Servo Drive
The guidelines and specifications for installing and wiring the respective ACOPOS servo drive
can be found in chapter 3 "Installation", chapter 4 "Dimensioning" and chapter 5 "Wiring".
1.3 Connecting the ACOPOS Servo Drive with a B&R PLC
Chapter 6
Getting Started
Depending on the configuration, ACOPOS servo drives are equipped with a CAN (AC110) or
ETHERNET Powerlink (AC112) interface which can be used to connect to a B&R PLC.
The connection is made using a a CAN cable (AC110) or an Ethernet cable 1) (AC112)
(pin assignments can be found in chapter 5 "Wiring" and in the User's Manual for the PLC).
1) Caution: In general, crossover Ethernet cables must be used for ETHERNET Powerlink connections!
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171
Getting Started • Starting Up an ACOPOS Servo Drive
2. Starting Up an ACOPOS Servo Drive
The goal of the following example is move the shaft of a motor connected to an ACOPOS servo
drive 5000 units. In order to emphasize the important points of starting up the hardware, this will
be done using an sample project contained in B&R Automation Studio™.
Danger!
Incorrect control of motors or mechanical parts connected to the motor shaft can
cause unwanted and dangerous movements!
2.1 General Information
The start-up procedure described here is based on the following configuration: 1)
Model number
Short description
Servo Drives
8V1045.00-1
Servo drive 3 x 400-480V 4.4A 2kW, line filter and braking resistor integrated
Plug-in Modules
8AC110.60-1
ACOPOS plug-in module, CAN interface
8AC120.60-1
ACOPOS plug-in module, EnDat encoder interface
Motor
8MSA4L.E0-B4
Motor MSA4 series with EnDat encoder
Accessories
7AC911.9
Bus connector, CAN (2 pcs.)
8CE005.12-1
EnDat cable, length 5m, 10 x 0.14mm² + 2 x 0.5mm², EnDat connector 17-pin Intercontec socket, servo
connector 15-pin DSUB plug, can be used in cable drag chains, UL/CSA listed
8CM005.12-1
Motor cable, length 5m, 4 x 1.5mm² + 2 x 2 x 0.75mm², motor connector 8 pin Intercontec socket, can be used in
cable drag chains, UL/CSA listed
0G0001.00-090
Cable PC <--> PLC/PW, RS232, Online cable
PLC CPU
7CP476.60-1
2003 CPU, 750 KB SRAM, 1.5 MB FlashPROM, 24 VDC, 12.5 W supply, 1 RS232 interface, 1 CAN interface,
CAN: electrically isolated, network capable, 4 slots for screw-in modules, system bus for expansion modules,
max. 272 digital / 80 analog I/O points
B&R Automation Studio™
1A4000.Lx
B&R AutomationSoftware™ CD, full version
Table 100: Configuration for the start-up example
1) The procedure can change slightly depending on the hardware configuration. The procedure does not change using an 8V1045.00-2.
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Getting Started • Starting Up an ACOPOS Servo Drive
The hardware configuration will be called the "target system" in the following sections. A PC with
B&R Automation Studio™ installed will also be needed.
2.1.1 Sample project
Several sample projects are available in B&R Automation Studio™ which can be used to test
ACOPOS servo drives. They are found in the directory "...BR_AS_xxxSAMPLESMOTION" in the
B&R Automation Studio™ installation directory (xxx indicates the B&R Automation Studio™
version number).
"...BR_AS_xxxSAMPLESMOTIONDEUTSCHACP10CANM68KCACP10.PGPACP10.GDM" is the
sample project referred to in this section, starting with ACOPOS operating system version
V 0.472 (xxx indicates the B&R Automation Studio™ version number).
Figure 44: Open sample project
Information:
During start-up, changes will be made to the sample project. We recommend that
you make a copy of the sample project (entire ACP10.PGP directory, see figure 44
"Open sample project") in a different project directory and use it for the start-up.
•
Check the wiring of the ACOPOS servo drive connections
(also see chapter 5 "Wiring").
•
Set node number 1 on the AC110 plug-in module
(see chapter 2 "Technical Data").
•
Connect the PC with the PLC using the online cable
(see user's manual for the PLC for information concerning the online cable connection to
the PLC).
•
Apply power to the PLC and the ACOPOS servo drive (24 VDC, 400 VAC). You can
make sure the ACOPOS servo drive boots correctly by watching the blink code (see
chapter 2 "Technical Data").
ACOPOS User's Manual
173
Chapter 6
Getting Started
2.1.2 Preparing the Hardware for Sample Project acp10.gdm
Getting Started • Starting Up an ACOPOS Servo Drive
2.2 Start-Up
2.2.1 Load Sample Project
Start B&R Automation Studio™:
Figure 45: B&R Automation Studio™ Start-up Screen
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ACOPOS User's Manual
Getting Started • Starting Up an ACOPOS Servo Drive
Open the project (recommended: make a copy of sample project ACP10.GDM in the respective
project path):
•
Click Open Project ... in the File menu.
Figure 46: Open project
•
Select ...ACP10.PGPACP10.GDM.
•
Load the project by clicking on the Open button.
Chapter 6
Getting Started
Figure 47: Selecting the project
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175
Getting Started • Starting Up an ACOPOS Servo Drive
The selected project is then opened in the project window:
Figure 48: Project window with representation of the hardware and software configuration
The left part of the window contains the hardware configuration for the project and the right part
of the window contains the software configuration for the hardware component selected in the
left part of the window.
Information:
When loading the project, a connection is automatically established between the PC
and the PLC.
If the connection is active, the CPU type and "RUN" are shown to the right below the
status bar (see figure 48 "Project window with representation of the hardware and
software configuration").
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Getting Started • Starting Up an ACOPOS Servo Drive
2.2.2 Preset Values for the Sample Project
A few preset values must be defined on the target system before downloading the project.
CPU
The sample project was originally created for a different PLC CPU (7CP474.60-1).
This must be changed to the CPU used on the target system (shown to the right under the status
bar):
•
In the left part of the window, position the mouse pointer on the CPU (7CP474.60-1).
Chapter 6
Getting Started
Figure 49: Select the CPU in the left part of the window
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177
Getting Started • Starting Up an ACOPOS Servo Drive
•
Open the shortcut menu with the right mouse button.
•
Position the mouse pointer on Replace with 7CP476.60-1.
•
Select this menu item with the left mouse button.
Figure 50: Select the command used to replace the CPU from the shortcut menu
•
Acknowledge the change of the CPU by clicking on the OK button.
Figure 51: Acknowledge the change of the CPU
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ACOPOS User's Manual
Getting Started • Starting Up an ACOPOS Servo Drive
User Memory
Before downloading the sample project, we recommend clearing the user memory on the PLC:
•
In the Project menu, select Services and then Clear Memory ....
Figure 52: Clearing user memory on the PLC
•
Activate the checkbox Erase USER ROM.
•
Acknowledge the selection by clicking the OK button.
Chapter 6
Getting Started
Figure 53: Selecting the user memory on the PLC
ACOPOS User's Manual
179
Getting Started • Starting Up an ACOPOS Servo Drive
•
The user memory is erased.
Figure 54: Erasing the user memory
After clearing the user memory, the project window will be shown again.
Operating System Download
The first time an ACOPOS servo drive is started up, the ACOPOS operating system ACP10SYS
must also be transferred to the target system. In the sample project, transferring ACP10SYS is
deactivated (shown in gray in the right part of the window). Transferring ACP10SYS must be
activated separately in the sample project:
•
Position the mouse pointer on ACP10SYS in the right part of the window.
Figure 55: Place mouse pointer on ACOPOS operating system ACP10SYS
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Getting Started • Starting Up an ACOPOS Servo Drive
•
Open the shortcut menu with the right mouse button.
•
Position the mouse pointer on Disable.
•
Click on Disable with the left mouse button to cancel deactivation.
Chapter 6
Getting Started
Figure 56: Enable transferring the ACOPOS operating system
ACOPOS User's Manual
181
Getting Started • Starting Up an ACOPOS Servo Drive
ACP10SYS is now enabled (shown in black instead of gray) and is also transferred the next time
the project is downloaded.
Figure 57: The operating system is also transferred the next time the project is downloaded
Information:
After successfully downloading the operating system the first time, "Disable" can
be set again which shortens the download time for projects.
2.2.3 Preset Values Concerning Wiring
The further procedure depends on the wiring of the digital control inputs on the ACOPOS servo
drives.
End Switch and Quickstop are Wired
If the hardware end switches (normally closed) are wired to X1 / End+ and X1 / End- and a
quickstop switch (normally closed) is wired to X1 / Quickstop/Trigger2 according to section 2 "Pin
Assignments ACOPOS 1022, 1045, 1090", on page 139, then start-up can be continued with
section 2.2.4 "Downloading the Project", on page 188.
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Getting Started • Starting Up an ACOPOS Servo Drive
End Switch and Quickstop are not Wired
If the hardware end switches and quickstop are not wired, it is possible to change the parameters
so that the motor shaft can still be moved.
Danger!
When moving the motor shaft without the hardware end switches connected,
movements of mechanical parts mounted on the motor shaft must be considered.
Otherwise severe personal injury or damage to property can occur!
•
Position the cursor on the initial parameter module AX1_PAR.
•
Open the object by double-clicking with the left mouse button.
Chapter 6
Getting Started
Figure 58: Open initial parameter module AX1_PAR
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183
Getting Started • Starting Up an ACOPOS Servo Drive
•
Position the mouse pointer on "dig_in".
Figure 59: Place the mouse pointer on "dig_in"
•
Expand the view by clicking on "+".
Figure 60: Expand the view
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Getting Started • Starting Up an ACOPOS Servo Drive
•
Position the mouse pointer on "level". The parameters are now shown in the right part of
the window.
Figure 61: Displaying the level parameters
To allow movement of the motor shaft, the following parameters must be changed to the value
"ncACTIV_HI":
•
pos_hw_end
•
neg_hw_end
•
trigger2 (quickstop)
"ncACTIV_HI" means that the inputs for both hardware end switches and the quickstop are
activated (logical "1"). This allows the motor shaft to be moved without wiring the hardware end
switches and a quickstop.
The procedure is shown here in an example for pos_hw_end:
In the right part of the window, position the mouse pointer on level "ncACTIV_LO" for the
shaft parameter pos_hw_end.
Chapter 6
Getting Started
•
Figure 62: Place mouse pointer on level "ncACTIV_LO"
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185
Getting Started • Starting Up an ACOPOS Servo Drive
•
Open the selection list by clicking with the left mouse button.
•
Select "ncACTIV_HI" by clicking with the left mouse button.
Figure 63: Change the level for the positive hardware end switch
•
Acknowledge the selection by pressing the ENTER key.
Figure 64: Acknowledge level change
Use the same procedure for the other two parameters, neg_hw_end and trigger2 (quickstop).
When all changes are made, the value list looks like this:
Figure 65: Levels after all changes are made
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Getting Started • Starting Up an ACOPOS Servo Drive
Now the object window can be closed.
•
In the File menu, click on Close.
Figure 66: Closing the object window
•
Acknowledge the changes by clicking the Yes button.
Figure 67: Acknowledge level changes
Chapter 6
Getting Started
The project window will be shown again.
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Getting Started • Starting Up an ACOPOS Servo Drive
2.2.4 Downloading the Project
After making the preparations, the project can now be transferred to the target system:
•
In the Project menu, click on Transfer To Target.
Figure 68: Click on the command to transfer the project to the target system
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Getting Started • Starting Up an ACOPOS Servo Drive
If an operating system has already been transferred to the PLC, a version conflict could occur.
In this case, the operating system on the PLC is to be replaced by the operating system in the
sample project:
•
Select Replace operating system ... option field.
Figure 69: Operating system version conflict
•
Acknowledge by clicking the Continue button.
Chapter 6
Getting Started
Figure 70: Acknowledge selection of conflict resolution
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Getting Started • Starting Up an ACOPOS Servo Drive
•
A message will be displayed by B&R Automation Studio™. Acknowledge this message
by clicking Yes.
Figure 71: Acknowledge message from B&R Automation Studio™ with Yes
•
The project is transferred.
Figure 72: The project is transferred
•
The following message is given after the project has been successfully transferred:
Figure 73: The project was transferred successfully
•
190
Acknowledge the message by clicking the OK button.
ACOPOS User's Manual
Getting Started • Starting Up an ACOPOS Servo Drive
2.2.5 Test Function
Now control of the motor shaft can be taken over using the test function (ACP10 - real axis):
•
Position the cursor on the initial parameter module AX1_PAR.
Chapter 6
Getting Started
Figure 74: Select initial parameter module AX1_PAR
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Getting Started • Starting Up an ACOPOS Servo Drive
•
In the Open menu, click on Test.
Figure 75: Command to open the test window
The test window is shown:
Action area
Watch window
NC object parameter area
Trace window
Figure 76: Test window for ACOPOS servo drives
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Getting Started • Starting Up an ACOPOS Servo Drive
2.2.6 Starting the Motor Movement
Danger!
The traverse path must be adjusted for the conditions present (installed mechanical
parts, etc.).
Incorrect control of motors or mechanical parts connected to the motor shaft can
cause unwanted and dangerous movements. This can cause severe personal injury
or damage to property!
If mechanical parts are mounted on the motor, the number of encoder units per motor revolution
must be adjusted to the mechanical characteristics (possible traverse path, etc.).
The number of encoder units per motor revolution (units, rev_motor) can be set as follows:
•
Position the mouse pointer on "encoder_if"
•
Expand the view by clicking on "+"
•
Position the mouse pointer on "parameter"
•
Expand the view by clicking on "+"
•
Position the mouse pointer on "scaling"
•
Expand the view by clicking on "+"
•
Position the mouse pointer on "load"
The parameters are now shown in the right part of the window:
Figure 77: Setting the encoder resolution
Now the values can be adjusted to the mechanical parts used and acknowledged by pressing
the ENTER key.
•
Action window:
Position the mouse pointer on the action ncENCODER_IF, ncINIT
•
Initialize the new values on the encoder by pressing the
ACOPOS User's Manual
Chapter 6
Getting Started
The new encoder parameters now have to be initialized:
button.
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Getting Started • Starting Up an ACOPOS Servo Drive
For additional safety, the traverse path can be limited using software end switches (pos_sw_end,
neg_sw_end).
The software end switches can be defined as follows:
•
Position the mouse pointer on "limit"
•
Expand the view by clicking on "+"
•
Position the mouse pointer on "parameter"
The parameters are now shown in the right part of the window:
Figure 78: Defining the software end switches
Now the values can be adjusted to the mechanical parts used and acknowledged by pressing
the ENTER key.
The new limit values now have to be initialized:
•
Action window:
Position the mouse pointer on the action ncLIMITS, ncINIT
•
Initialize the new limit values by pressing the
194
button.
ACOPOS User's Manual
Getting Started • Starting Up an ACOPOS Servo Drive
Entering the Traverse Path
•
Position the mouse pointer on the action "ncSTART" for the subject "ncREL_MOVE" in
the action window.
Figure 79: Place mouse pointer on the action "ncSTART"
Enter the value (e.g. 5000) for s (target position or relative traverse path) in the
parameter object , value column.
•
Acknowledge by pressing the ENTER key.
The value is entered in the axis data structure.
Chapter 6
Getting Started
•
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Getting Started • Starting Up an ACOPOS Servo Drive
Enabling the Trace Function
•
Position the mouse pointer on the Trace enabled checkbox in the action window.
•
Activate the checkbox by clicking on it with the left mouse button.
Figure 80: Enable trace function
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Getting Started • Starting Up an ACOPOS Servo Drive
Start the Motor Movement
•
Position the mouse pointer on the action "ncSTART" for the subject "ncREL_MOVE" in
the action window.
Figure 81: Place mouse pointer on the action "ncSTART"
•
Click on the
button on the toolbar:
Chapter 6
Getting Started
The motor shaft now moves according to the traverse path (s) defined and the Trace
function starts.
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Getting Started • Starting Up an ACOPOS Servo Drive
Display and Evaluation of the Trace Function
Figure 82: During the movement of the shaft, the traverse path already completed is shown in the Watch
window
Figure 83: The defined traverse path was completed and the Trace data is loaded
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Figure 84: The data recorded is shown in the Trace window
The current position of the motor shaft is shown in the Watch window:
Display of the current position of the motor shaft
Before the shaft movement
During the shaft movement
After the shaft movement
Chapter 6
Getting Started
Table 101: Display of the current position of the motor shaft in the Watch window
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Getting Started • Starting Up an ACOPOS Servo Drive
The following data concerning shaft movement is displayed in the Trace window:
Set Speed
The acceleration phase, the constant speed phase and the braking phase of the shaft movement can be evaluated here.
Lag Error
• the lag error increases in the acceleration phase of the motor axis
• the lag error remains constant at a constant speed
• the lag error decreases in the braking phase
Actual stator current quadrature component
The various movement phases are represented here:
• in the acceleration phase of the motor axis: high current
• at constant speed: current is reduced
• in the braking phase: negative current
Table 102: Output of the recorded data in the Trace window
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Chapter 7
Standards and
Certifications
Standards and Certifications • Valid European Guidelines
Chapter 7 • Standards and Certifications
1. Valid European Guidelines
•
EMC guidelines 89/336/EWG
•
Low-voltage guidelines 73/23/EWG
•
Machine guidelines 98/37/EG
2. Valid Standards
Standard
Description
IEC/EN 61800-2
Adjustable speed electrical power drive systems
• Part 2: General requirements; Rating specifications for low voltage adjustable frequency AC power drive
systems
IEC/EN 61800-3
Adjustable speed electrical power drive systems
IEC 61800-5 (draft)
Adjustable speed electrical power drive systems
• Part 3: EMC product standard including specific test methods
• Part 5: Electrical, thermal and functional safety aspects; drive systems with electrically adjustable speed
(IEC 22G/CD:1998)
IEC/EN 61131-2
Programmable logic controllers
IEC 60204-1
Safety of machinery - electrical equipment on machines
EN 1037
Safety of machinery - prevention of unexpected start-up
• Part 2: Equipment requirements and tests
• Part 1: General requirements
IEC 61508
Functional safety of electrical, electronic, programmable electronic systems
EN 954-1
Safety of machinery - safety-related parts of control systems
UL 508 C
Industrial control equipment
• Part 1: General design principles 1)
• Part 6: Solid-state AC Motor Controllers
Table 103: Valid Standards for ACOPOS Servo Drives
1) TÜV: Sample test for secure restart inhibit according to EN 954-1 category 3 is in preparation.
The limit values specified from section 3 "Environmental Limits" to section 6 "Other
Environmental Limit Values according to IEC 61800-2" are taken from product standard
IEC 61800 for servo drives in industrial environments (2nd environment). Stricter test procedures
and limit values are used during the type tests for ACOPOS servo drives. Additional information
is available from B&R.
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Standards and Certifications • Environmental Limits
3. Environmental Limits
3.1 Mechanical Conditions according to IEC 61800-2
3.1.1 Operation
IEC 60721-3-3, class 3M1
IEC 61800-2
Vibration during operation
2 ≤ f < 9 Hz
9 ≤ f < 200 Hz
0.3 mm amplitude
1 m/s² acceleration
Table 104: Mechanical conditions during operation
3.1.2 Transport
IEC 60721-3-2, class 2M1
IEC 61800-2
Vibration during transport
2 ≤ f < 9 Hz
9 ≤ f < 200 Hz
200 ≤ f < 500 Hz
3.5 mm amplitude
10 m/s² acceleration
15 m/s² acceleration
Table 105: Mechanical conditions during transport
3.2 Climate Conditions according to IEC 61800-2
3.2.1 Operation
IEC 60721-3-3, class 3K3
IEC 61800-2
Environmental temperature during operation
5 to 40 °C
Relative humidity during operation
5 -85 %, non-condensing
Table 106: Climate conditions during operation
3.2.2 Storage
IEC 60721-3-1, class 1K4
IEC 61800-2
Storage temperature
-25 to +55 °C
Table 107: Climate conditions (temperature) during storage
IEC 60721-3-1, class 1K3
IEC 61800-2
Relative humidity during storage
5 - 95 %, non-condensing
Table 108: Climate conditions (humidity) during storage
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Standards and Certifications • Environmental Limits
Chapter 7
Standards and
Certifications
3.2.3 Transport
IEC 60721-3-2, class 2K3
IEC 61800-2
Transport temperature
Humidity during transport
-25 to +70 °C
95 % at +40 °C
Table 109: Climate conditions during transport
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Standards and Certifications • Requirements for Immunity to Disturbances (EMC)
4. Requirements for Immunity to Disturbances (EMC)
4.1 Evaluation Criteria (performance criteria)
Criteria A ...... Test object not influenced during test.
Criteria B ...... Test object only temporarily influenced during test.
Criteria C ...... The system does not reboot automatically (reset required).
4.2 Low Frequency Disturbances according to IEC 61800-3
The following limits are valid for industry (2nd environment).
4.2.1 Power Mains Harmonics and Commutation Notches / Voltage Distortions
IEC 61000-2-4, class 3
IEC 61800-3
Performance Criteria
THD = 10 %
A
1.5x continuous level
B
Harmonics
Short harmonics (< 15 s)
Table 110: Limits for power mains harmonics
IEC 60146-1-1, class 3
Commutation notches
IEC 61800-3
Performance Criteria
Depth = 40 %,
total area = 250 % x degree
A
Table 111: Limit values for commutation notches / voltage distortions
4.2.2 Voltage Changes, Deviations, Dips and Short-term Interruptions
IEC 61000-2-4, class 3
IEC 61800-3
Voltage changes and deviations
Performance Criteria
± 10 %
A
Voltage changes and deviations (< 1 min)
+10 % to -15 %
Table 112: Limit values for voltage changes and deviations
IEC 61000-2-1
Voltage dips and short-term interruptions
IEC 61800-3
Performance Criteria
10 % to 100 %
C
Table 113: Limit values for voltage dips and short-term interruptions
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Standards and Certifications • Requirements for Immunity to Disturbances (EMC)
Chapter 7
Standards and
Certifications
4.2.3 Asymmetric Voltage und Frequency Changes
IEC 61000-2-4, class 3
IEC 61800-3
Asymmetric voltages
Performance Criteria
3 % negative component
Frequency change and change rate
± 2 %, 1 % / s
(+-4%, 2%/s if the power supply is
isolated from general power mains)
A
Table 114: Limit values for asymmetric voltages and frequency changes
4.3 High Frequency Disturbances according to IEC 61800-3
These immunity tests are valid for industrial environments (2nd environment).
4.3.1 Electrostatic Discharge
Tests according to IEC 61000-4-2
IEC 61800-3
Contact discharge to powder-coated and bare metal housing parts
6 kV
Discharge through the air to plastic housing parts
8 kV
Performance Criteria
B
Table 115: Limits for electrical discharge
4.3.2 Electromagnetic Fields
Tests according to IEC 61000-4-3
Housing, completely wired
IEC 61800-3
Performance Criteria
80 MHz - 1 GHz, 10 V/m,
80 % amplitude modulation
at 1 kHz
A
Table 116: Limits for electromagnetic fields
4.3.3 Burst
Tests according to IEC 61000-4-4
IEC 61800-3
Power connection
Performance Criteria
2 kV, 1 min, direct coupling
Lines for measurement and control functions in the process
environment
2 kV, 1 min
Signal interfaces, other lines
1 kV, 1 min
B
Table 117: Limits for burst
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Standards and Certifications • Requirements for Immunity to Disturbances (EMC)
4.3.4 Surge
Tests according to IEC 61000-4-5
Power connection
IEC 61800-3
Performance Criteria
1 kV (2 Ω) 1) , DM, symmetrical
2 kV (12 Ω) 1) , CM, unsymmetrical
B
Table 118: Limits for surge
1) The impedance was added from IEC 61000-4-5 because it is not defined in IEC 61800-3.
4.3.5 High Frequency Conducted Disturbances
Tests according to IEC 61000-4-6
IEC 61800-3
Performance Criteria
0.15 - 80 MHz, 10 V,
80 % amplitude modulation
at 1 kHz
A
Power connection
Lines for measurement and control functions in the process
environment
Signal interfaces, other lines
Table 119: Limits for conducted disturbances (radio frequency)
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Standards and Certifications • Requirements for Emissions (EMC)
Chapter 7
Standards and
Certifications
5. Requirements for Emissions (EMC)
5.1 High Frequency Emissions according to IEC 61800-3
These emissions tests are valid for industrial environments (2nd environment).
5.1.1 Emissions on the Power Connections
Tests according to IEC 55011
Continuous Current on
Motor
Frequency Range [MHz]
Quasi-peak Value
Average
0,15 ≤ f < 0.5
100 dB (µV)
90 dB (µV)
0,5 ≤ f < 5
86 dB (µV)
76 dB (µV)
I ≤ 100 A
100 A < I
5 ≤ f < 30
90 dB (µV)
80 dB (µV)
0,15 ≤ f < 0.5
130 dB (µV)
120 dB (µV)
0,5 ≤ f < 5
125 dB (µV)
115 dB (µV)
5 ≤ f < 30
115 dB (µV)
105 dB (µV)
Table 120: Limits for emissions on the power connections
5.1.2 Electromagnetic Emissions
Tests according to IEC 55011
Frequency Range [MHz]
Quasi-peak Value
30 ≤ f ≤ 230
40 dB (µV/m), measured at distance of 30 m 1)
230 < f ≤ 1000
50 dB (µV/m), measured at distance of 30 m 1)
Table 121: Limits for electromagnetic emissions
1) The limit values were increased by 10 dB (µV/m) when measuring from distances of 10 m.
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Standards and Certifications • Other Environmental Limit Values according to
6. Other Environmental Limit Values according to IEC 61800-2
IEC 61800-2
Degree of pollution according to IEC 61800-2, 4.1.2.1.
2
Over-voltage category according to
IEC 60364-4-443:1999
II
Protection according to IEC 60529
IP20
Reduction of the continuous current at installation
altitudes over 500 m above sea level
10 % per 1000 m
2000 m 1)
Maximum Installation Altitude
Table 122: Additional environmental limits
1) Additional requirements are to be arranged with B&R.
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Standards and Certifications • International Certifications
B&R products and services comply with the applicable standards. They are international
standards from organizations such as ISO, IEC and CENELEC, as well as national standards
from organizations such as UL, CSA, FCC, VDE, ÖVE, etc. We give special consideration to the
reliability of our products in an industrial environment.
Certifications
USA and Canada
Europe
Russian Federation
All important B&R products are tested and listed by Underwriters Laboratories and are
checked quarterly by a UL inspector.
This mark is valid for the USA and Canada and eases certification of your machines and
systems in these areas.
All harmonized EN standards for the valid guidelines are met.
GOST-R certification is available for the export of all B&R ACOPOS servo drives in the
Russian Federation.
Table 123: International Certifications
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Chapter 7
Standards and
Certifications
7. International Certifications
Standards and Certifications • Standards, Definitions for Safety Techniques
8. Standards, Definitions for Safety Techniques
Stop Functions according to IEC 60204-1/11.98 (electrical equipment for machines,
part 1: general requirements)
The following three stop function categories exist:
Category
Description
0
Stop by immediately switching off the power to the machine drive elements (i.e. uncontrolled stop).
1
A controlled stop, the power to the machine drive elements remains on until the stop procedure is completed. The power is switched
off after the stop is complete.
2
A controlled stop, the power to the machine drive elements is not switched off.
Table 124: Overview of stop function categories
The necessary stop functions must be determined based on a risk evaluation for the machine.
Stop functions in category 0 and category 1 must be able to function regardless of the operating
mode. A category 0 stop must have priority. Stop functions must have priority over assigned start
functions. Resetting the stop function is not allowed to cause a dangerous state.
Emergency stops according to IEC 60204-1/11.98 (electrical equipment for machines,
part 1: general requirements)
The following requirements are valid for emergency stops in addition to the requirements for the
stop functions:
•
It must have priority over all other functions and operations in all operating modes.
•
The power to the machine drive elements which can cause a dangerous state must be
switched off as quickly as possible without creating other dangers.
•
Resetting is not allowed to cause a restart.
Emergency stops must be category 0 or category 1 stop functions. The necessary stop function
must be determined based on a risk evaluation for the machine.
For emergency stop function in stop category 0, only hard wired, electromechanical equipment
can be used. Additionally, the function is not allowed to depend on electronic switching logic
(hardware or software) or the transfer of commands via a communication network or data
connection. 1)
When using a category 1 stop function for the emergency stop function, it must be guaranteed
that the power to the machine drive elements is completely switched off. These elements must
be switched off using electromechanical equipment. 1)
1) In accordance to the national foreword for the valid German version of IEC 60204-1/11.98, it is determined that electronic equipment
(and also especially for emergency stop systems) can be used regardless of the stop category, if e.g. it provides the same safety using
the standards EN 954-1 and/or IEC 61508 as required by IEC 60204-1.
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Safety category according to EN 954-1/03.97 (safety of machines - safety related parts of
control systems, part 1: general design principles) 1)
The safety related parts of control systems must meet one or more of the requirements for five
defined safety categories. The safety categories define the required behavior of safety related
controller parts regarding their resistance to errors.
Safety Category
(according to EN 9541)
Safety Integrity
Level - SIL
(according to
IEC 61508-2)
B
---
Short Description
System Behavior
Safety related parts must be designed and
built so that they can meet the expected
operational requirements.
Caution!
An error can cause the safety function to
fail.
(No specific safety measures are
implemented.)
1
1
Safety related parts must be designed and
built so that only reliable components and
safety principles are used.
Caution!
An error can cause the safety function to
fail.
(e.g. preventing short circuits by using
sufficient distances, reducing the probability
of errors by over-dimensioning components,
defining the failure route - closed-circuit
current principle, etc.)
2
1
Safety related parts must be designed so
that their safety functions are checked in
suitable intervals by the machine controller.
(e.g. automatic or manual check during startup)
3
4
2
3
Caution!
An error between checks can cause the
safety function to fail. If the safety
function fails, it will be recognized during
the check.
Safety related parts must be designed so
that individual errors do not cause the safety
function to fail. Individual errors should - if
possible - be recognized the next time (or
before) the safety function is required.
Caution!
Safety related parts must be designed so
that individual errors do not cause the safety
function to fail. Individual errors must be
recognized the next time (or before) the
safety function is required. If this type of
recognition is not possible, a buildup of
errors is not allowed to cause the safety
function to fail.
Information:
The safety function remains active when
an error occurs. Some, but not all errors
are recognized. A buildup of errors can
cause the safety function to fail.
The safety function remains active when
an error occurs. Errors are recognized in
time to prevent the safety function from
failing.
Table 125: Safety category overview
Selecting the suitable safety category must be done separately for each ACOPOS servo drive
(or for each shaft) based on a risk evaluation. This risk evaluation is a part of the total risk
evaluation for the machine.
1) To prevent confusing EN 951-1 categories with IEC 60204-1 stop categories, the term "safety categories" was used in the text shown
above for EN 954-1 categories.
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Chapter 7
Standards and
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Standards and Certifications • Standards, Definitions for Safety Techniques
Standards and Certifications • Standards, Definitions for Safety Techniques
The following risk graph (according to EN 954-1, Appendix B) provides a simplified procedure
for risk evaluation:
Figure 85: Risk graph according to EN 954-1, Appendix B
Begin at the starting point shown and follow the parameters S, F and P to the safety category to
be used.
Parameter S ... Seriousness of injury
S1
Light (usually reversible) injury.
S2
Serious (usually irreversible) injury.
F1
Seldom to slightly more frequent and/or short exposure duration.
F2
Frequent to continuous and/or long exposure duration.
P1
Possible under some conditions.
P2
Nearly impossible.
Parameter F ... Frequency and/or duration of the danger exposure
Parameter P ... Possibility to prevent danger
Table 126: Parameters S, F and P lead you to the safety category to be used
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ACOPOS User's Manual
Restart inhibit according to EN 1037/04.96 (Safety of machinery - prevention of
unexpected start-up)
Keeping a machine in an idle state when people are working in the danger zone is one of the
most important requirements for safe operation of machines.
Starting refers to the transition of a machine or its parts from an idle state to moving state. Any
start is unexpected if it is caused by:
•
A start command sent because of a controller failure or because of external influences on
the controller.
•
A start command sent because of incorrect operation of a start element or another part
of the machine.
•
Restoration of power supply after an interruption.
•
External/internal influences on parts of the machine.
To prevent unexpected starting of machines or parts of machines, power should be removed and
dissipated. If this is not practical (e.g. frequent, short work in danger zone), other measures must
be taken:
•
Measures to prevent random start commands.
•
Measures to prevent that random start commands cause unexpected starting.
•
Measures to automatically stop dangerous parts of the machine before a dangerous
situation can be caused by unexpected starting.
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Standards and
Certifications
Standards and Certifications • Standards, Definitions for Safety Techniques
Standards and Certifications • Standards, Definitions for Safety Techniques
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Figure 1:
Figure 2:
Figure 3:
Figure 4:
Figure 5:
Figure 6:
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Figure 8:
Figure 9:
Figure 10:
Figure 11:
Figure 12:
Figure 13:
Figure 14:
Figure 15:
Figure 16:
Figure 17:
Figure 18:
Figure 19:
Figure 20:
Figure 21:
Figure 22:
Figure 23:
Figure 24:
Figure 25:
Figure 26:
Figure 27:
Figure 28:
Figure 29:
Figure 30:
Figure 31:
Figure 32:
Figure 33:
Figure 34:
Figure 35:
Figure 36:
Figure 37:
Figure 38:
Figure 39:
Figure 40:
Secure operation ..........................................................................................15
Individual I/O configurations .........................................................................17
Software and hardware as a unit ..................................................................18
Simple function test ......................................................................................19
Control trigger ...............................................................................................20
Cam profiles for everyone.............................................................................21
CAN configuration 1......................................................................................22
CAN configuration 2......................................................................................23
Powerlink configuration 1 - star topology......................................................24
Powerlink configuration 2 - line topology ......................................................25
Status LEDs AC112 ......................................................................................47
Attaching the eye bolt contained in the delivery to
ACOPOS 1640 and 128M drives..................................................................83
Dimensional diagram and installation dimensions for
ACOPOS 1022, 1045, 1090 .........................................................................85
Dimensional diagram and installation dimensions for
ACOPOS 1180, 1320 ...................................................................................86
Dimensional diagram and installation dimensions for ACOPOS 1640 .........87
Dimensional diagram and installation dimensions for ACOPOS 128M ........88
Installing ACOPOS plug-in modules.............................................................90
Installing various ACOPOS series devices directly next to each other.........91
Cooling aggregate on top of the switching cabinet .......................................94
Placing a cooling aggregate on the front of the switching cabinet ................95
Circuit diagram for ACOPOS X3, individual power mains connection ..........99
Circuit diagram for ACOPOS X3, power mains connection
for a drive group..........................................................................................102
ACOPOS X2 circuit diagram, DC bus connections ....................................105
B&R power supply 0PS320.1 as DC bus power supply for
ACOPOS servo drives ................................................................................108
ACOPOS X4/X5 circuit diagram, motor connection....................................109
Circuit diagram for ACOPOS X6, external braking resistor on
ACOPOS 1180/1320/1640/128M ...............................................................112
Diagram of a typical movement with the brake power curve PBr(t) ...........113
Thermal equivalent circuit for the external braking resistor ........................116
Connection diagram for ground and shield connections.............................123
Cable shield grounding for the ETHERNET Powerlink cable .....................124
Block diagram of secure restart inhibit........................................................127
External wiring for the stop function in category 0 – safety category 3.......129
Type 1 – Starting active braking over the network......................................131
Type 2 – Starting active braking using the Quickstop-input
on the ACOPOS .........................................................................................134
External wiring for the stop function in category 2 – safety category 3.......136
Pin assignment overview ACOPOS 1022, 1045, 1090...............................139
Pin assignment overview ACOPOS 1180, 1320.........................................144
Pin assignment overview ACOPOS 1640, 128M........................................150
Connecting Cables to Plug-in Modules.......................................................162
Cable schematic for motor cable 8CMxxx.12-1, 8CMxxx.12-3 ...................164
ACOPOS User's Manual
215
Figure Index
Figure Index
Figure Index
Figure 41:
Figure 42:
Figure 43:
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Figure 83:
216
Cable schematic for motor cables 8CMxxx.12-5 ........................................165
Cable schematic for EnDat encoder cables................................................167
Cable schematic for resolver cables...........................................................169
Open sample project...................................................................................173
B&R Automation Studio™ Start-up Screen ................................................174
Open project ...............................................................................................175
Selecting the project ...................................................................................175
Project window with representation of the hardware and software
configuration ...............................................................................................176
Select the CPU in the left part of the window .............................................177
Select the command used to replace the CPU from the shortcut menu.....178
Acknowledge the change of the CPU .........................................................178
Clearing user memory on the PLC .............................................................179
Selecting the user memory on the PLC ......................................................179
Erasing the user memory............................................................................180
Place mouse pointer on ACOPOS operating system ACP10SYS..............180
Enable transferring the ACOPOS operating system...................................181
The operating system is also transferred the next time the project
is downloaded.............................................................................................182
Open initial parameter module AX1_PAR ..................................................183
Place the mouse pointer on "dig_in" ...........................................................184
Expand the view .........................................................................................184
Displaying the level parameters..................................................................185
Place mouse pointer on level "ncACTIV_LO" .............................................185
Change the level for the positive hardware end switch ..............................186
Acknowledge level change .........................................................................186
Levels after all changes are made ..............................................................186
Closing the object window ..........................................................................187
Acknowledge level changes .......................................................................187
Click on the command to transfer the project to the target system.............188
Operating system version conflict ...............................................................189
Acknowledge selection of conflict resolution ..............................................189
Acknowledge message from B&R Automation Studio™ with Yes..............190
The project is transferred............................................................................190
The project was transferred successfully....................................................190
Select initial parameter module AX1_PAR .................................................191
Command to open the test window ............................................................192
Test window for ACOPOS servo drives......................................................192
Setting the encoder resolution ....................................................................193
Defining the software end switches ............................................................194
Place mouse pointer on the action "ncSTART" ..........................................195
Enable trace function ..................................................................................196
Place mouse pointer on the action "ncSTART" ..........................................197
During the movement of the shaft, the traverse path already
completed is shown in the Watch window ..................................................198
The defined traverse path was completed and the Trace data
is loaded .....................................................................................................198
ACOPOS User's Manual
Figure Index
The data recorded is shown in the Trace window ......................................199
Risk graph according to EN 954-1, Appendix B .........................................212
Figure Index
Figure 84:
Figure 85:
ACOPOS User's Manual
217
Figure Index
218
ACOPOS User's Manual
Table 1:
Table 2:
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Table 42:
Table 43:
Table 44:
Table 45:
Table 46:
Description of the safety guidelines .................................................................... 29
General description of the ACOPOS servo drive series...................................... 32
Status LEDs ACOPOS servo drives ................................................................... 33
LED status........................................................................................................... 34
Status changes when booting the operating system loader................................ 34
Error status with reference to the CAN plug-in module AC110 ........................... 35
Error status with reference to the ETHERNET Powerlink
plug-in module AC112......................................................................................... 35
Order data for ACOPOS 1022, 1045 and 1090 .................................................. 36
Technical data for ACOPOS 1022, 1045 and 1090 ............................................ 36
Order data for ACOPOS 1180, 1320 .................................................................. 38
Technical data for ACOPOS 1180, 1320 ............................................................ 38
Order data for ACOPOS 1640, 128M ................................................................. 40
Technical data for ACOPOS 1640, 128M ........................................................... 40
Order data for plug-in modules ........................................................................... 42
Order data for AC110 .......................................................................................... 43
Technical Data for AC110 ................................................................................... 43
Setting the CAN node number with the two HEX code switches ........................ 44
Order data for AC112 .......................................................................................... 45
Technical data for AC112.................................................................................... 45
Setting the Powerlink node number with the two HEX code switches ................ 46
Indication diagram for the AC112 status LEDs ................................................... 47
System stop error codes ..................................................................................... 48
Order data for AC120 .......................................................................................... 50
Technical data for AC120.................................................................................... 50
Order data for AC122 .......................................................................................... 52
Technical data for AC122.................................................................................... 53
Order data for AC123 .......................................................................................... 55
Technical data for AC123.................................................................................... 56
Order data for AC130 .......................................................................................... 58
Technical data for AC130.................................................................................... 59
Order data for AC131 .......................................................................................... 62
Technical data for AC131.................................................................................... 63
Order data for motor cables ................................................................................ 67
Technical data for motor cables 1.5 and 4 mm² .................................................. 69
Technical data for motor cables 10 and 35 mm² ................................................. 70
Order data for EnDat cables ............................................................................... 71
Technical data for EnDat cables ......................................................................... 71
Order data for resolver cables............................................................................. 73
Technical data for resolver cables ...................................................................... 73
Order data for motor connectors ......................................................................... 76
Technical data for motor connectors 8PM001.00-1 and 8PM002.00-1............... 77
Technical data for motor connector 8PM003.00-1 .............................................. 78
Order data for encoder connectors ..................................................................... 79
Technical data for EnDat connector 8PE001.00-1 .............................................. 80
Technical data for resolver connector 8PR001.00-1........................................... 81
Slot overview for ACOPOS plug-in modules ....................................................... 89
ACOPOS User's Manual
219
Table Index
Table Index
Table Index
Table 47:
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220
Overview of the vertical offsets (ACOPOS - ACOPOS) ...................................... 92
Selection of the protective ground conductor cross section................................ 98
Protective ground conditions according to ACOPOS device .............................. 98
Constant k ......................................................................................................... 100
Maximum current load for PVC insulated three-phase cables
or individual wires.............................................................................................. 101
Discharge capacitance CD................................................................................ 104
Maximum current load for special insulated three-phase cables ...................... 110
Braking resistors for ACOPOS servo drives...................................................... 111
ParIDs for setting external braking resistor parameters .................................... 116
Power consumption of the ACOPOS plug-in modules ...................................... 117
Maximum current requirements and constant k ................................................ 118
Formula variables used..................................................................................... 119
Grounding the motor cable................................................................................ 125
Terminal cross sections for ACOPOS servo drives........................................... 138
Pin assignments for plug X1 ACOPOS 1022, 1045, 1090 ................................ 140
Pin assignments for plug X2 ACOPOS 1022, 1045, 1090 ................................ 140
Pin assignments for plug X3 ACOPOS 1022, 1045, 1090 ................................ 141
Pin assignments for plug X4a ACOPOS 1022, 1045, 1090 .............................. 141
Pin assignments for plug X4b ACOPOS 1022, 1045, 1090 .............................. 141
Activation for the external holding brake ........................................................... 142
Pin assignments for plug X5 ACOPOS 1022, 1045, 1090 ................................ 143
Protective ground conductor (PE) ACOPOS 1022, 1045, 1090........................ 143
Pin assignments for plug X1 ACOPOS 1180, 1320 .......................................... 145
Pin assignments for plug X2 ACOPOS 1180, 1320 .......................................... 145
Pin assignments for plug X3 ACOPOS 1180, 1320 .......................................... 146
Pin assignments for plug X4a ACOPOS 1180, 1320 ........................................ 146
Pin assignments for plug X4b ACOPOS 1180, 1320 ........................................ 146
Activation for the external holding brake ........................................................... 147
Pin assignments for plug X5 ACOPOS 1180, 1320 .......................................... 148
Pin assignments for plug X6 ACOPOS 1180, 1320 .......................................... 148
Protective ground conductor (PE) ACOPOS 1180, 1320.................................. 149
Pin assignments for plug X1 ACOPOS 1640, 128M ......................................... 151
Pin assignments for X2 ACOPOS 1640, 128M ................................................. 151
Pin assignments for X3 ACOPOS 1640, 128M ................................................. 152
Pin assignments for plug X4a ACOPOS 1640, 128M ....................................... 152
Pin assignments for plug X4b ACOPOS 1640, 128M ....................................... 152
Activation for the external holding brake ........................................................... 153
Pin assignments for X5 ACOPOS 1640, 128M ................................................. 154
Pin assignments for X6 ACOPOS 1640, 128M ................................................. 154
Pin assignments for AC110 - CAN Interface ..................................................... 155
Pin assignments for AC112 - ETHERNET Powerlink Interface......................... 156
Pin assignments for AC120 - EnDat encoder interface..................................... 157
Pin assignments for AC122 - resolver interface ................................................ 158
Pin assignments AC123 - incremental encoder and SSI absolute encoder
interface ............................................................................................................ 159
Pin assignments AC130 - digital mixed module ................................................ 160
ACOPOS User's Manual
Table 92:
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Pin assignments AC131 - digital mixed module ................................................ 161
Motor cable construction ................................................................................... 163
Pin assignments for motor cable 8CMxxx.12-1, 8CMxxx.12-3.......................... 164
Pin assignments for motor cables 8CMxxx.12-5............................................... 165
EnDat encoder cable construction .................................................................... 166
Pin assignments for EnDat encoder cables ...................................................... 166
Resolver cable construction .............................................................................. 168
Pin assignments for resolver cable ................................................................... 168
Configuration for the start-up example.............................................................. 172
Display of the current position of the motor shaft in the Watch window ............ 199
Output of the recorded data in the Trace window ............................................. 200
Valid Standards for ACOPOS Servo Drives...................................................... 201
Mechanical conditions during operation ............................................................ 202
Mechanical conditions during transport............................................................. 202
Climate conditions during operation .................................................................. 202
Climate conditions (temperature) during storage .............................................. 202
Climate conditions (humidity) during storage .................................................... 202
Climate conditions during transport................................................................... 203
Limits for power mains harmonics..................................................................... 204
Limit values for commutation notches / voltage distortions ............................... 204
Limit values for voltage changes and deviations............................................... 204
Limit values for voltage dips and short-term interruptions................................. 204
Limit values for asymmetric voltages and frequency changes .......................... 205
Limits for electrical discharge ............................................................................ 205
Limits for electromagnetic fields ........................................................................ 205
Limits for burst................................................................................................... 205
Limits for surge.................................................................................................. 206
Limits for conducted disturbances (radio frequency) ........................................ 206
Limits for emissions on the power connections................................................. 207
Limits for electromagnetic emissions ................................................................ 207
Additional environmental limits.......................................................................... 208
International Certifications................................................................................. 209
Overview of stop function categories ................................................................ 210
Safety category overview .................................................................................. 211
Parameters S, F and P lead you to the safety category to be used.................. 212
ACOPOS User's Manual
221
Table Index
Table Index
Table Index
222
ACOPOS User's Manual
Index
AC110 ................................................43, 155
AC112 ................................................45, 156
AC120 ................................................49, 157
AC122 ................................................52, 158
AC123 ................................................55, 159
AC130 ................................................58, 160
AC131 ................................................62, 161
Accessories for
AC110 ....................................................43
AC120 ....................................................50
AC122 ....................................................52
AC130 ....................................................58
AC131 ....................................................62
ACOPOS 1022, 1045, 1090 ...................36
ACOPOS 1180, 1320 .............................38
ACOPOS 1640, 128M ............................40
ACOPOS
1022 ...............................................36, 139
1045 ...............................................36, 139
1090 ...............................................36, 139
1180 ...............................................38, 144
128M ..............................................40, 150
1320 ...............................................38, 144
1640 ...............................................40, 150
see Servo Drives
B
Braking resistor ........................................111
Thermal Equivalent Circuit ...................116
C
Cables
Encoder Cables
EnDat ..........................................71, 166
Resolver ......................................73, 168
General Information ................................66
Motor Cable ....................................67, 163
Cam Editor .................................................21
CAN Bus Interface AC110 .................43, 155
Certifications ............................................209
Configurations
CAN ........................................................22
Powerlink ................................................24
ACOPOS User's Manual
Connectors
Encoder Connectors
EnDat .......................................... 79, 166
Resolver ...................................... 79, 168
General Information ............................... 75
Motor Connectors ........................... 76, 164
Correctly installing cooling aggregates ...... 93
D
Danger Warning ........................................ 26
DC Bus .................................................... 105
Digital Mixed Module AC130 ............. 58, 160
Dimension diagram and
installation dimensions
ACOPOS 1022, 1045, 1090 ................... 85
ACOPOS 1180, 1320 ............................. 86
ACOPOS 128M ...................................... 88
ACOPOS 1640 ....................................... 87
Dimensioning
Braking resistor .................................... 111
Configuration of
ACOPOS Servo Drives ........................ 117
DC Bus ................................................. 105
Formula Symbols ................................. 119
Motor Connection ................................. 109
Power mains connection ........................ 97
Drive Oscilloscope ..................................... 20
Drives
see Servo Drives
E
Electromagnetic Compatibility
of the Installation ..................................... 121
Embedded Parameter Chip ....................... 16
Encoder Cables
EnDat ............................................. 71, 166
Resolver ......................................... 73, 168
Encoder Connectors
EnDat ............................................. 79, 166
Resolver ......................................... 79, 168
Encoder Resolution ................................. 193
Encoder Systems
EnDat Encoder Interface ................ 49, 157
Incremental/SSI Encoder IF ........... 55, 159
223
Index
A
Index
Resolver interface ..........................52, 158
EnDat Cables
Cable Schematic ..................................167
Order Data ..............................................71
Pin Assignments ...................................166
Structure ...............................................166
Technical Data .......................................71
EnDat Connector
Order Data ..............................................79
Pin Assignments ...................................166
Technical Data .......................................80
EnDat Encoder Interface AC120 .............157
ETHERNET Powerlink IF AC112 .......45, 156
Technical Data ....................................... 69
Motor Connection .................................... 109
Motor Connectors
Order Data ............................................. 76
Pin Assignments .......................... 164, 165
Technical Data ................................. 77, 78
Motors
Configurations ........................................ 22
Embedded Parameter Chip .................... 16
General Information ............................... 15
Mounting .............................................. 27, 83
F
NC Objects ................................................ 18
Node Number Setting
CAN ........................................................ 44
ETHERNET Powerlink ........................... 46
Fault Current Protection ...........................103
Formula Symbols .....................................119
Function Test .....................................19, 198
G
Getting Started .........................................171
Guidelines ................................................201
I
Incremental/SSI Encoder IF AC123 ...55, 159
Indication
AC112 ....................................................47
Installation ................................................121
Installation Dimensions ..............................85
L
Line Topology ............................................25
M
Mixed Module AC131 ........................62, 161
Modular Servo Drive Concept ....................31
Motor Cable
Cable Schematic ..........................164, 165
Order Data ..............................................67
Pin Assignments ...........................164, 165
Structure ...............................................163
224
N
O
Order Data
Servo Drives
8V1022.00-2 ....................................... 36
8V1045.00-2 ....................................... 36
8V1090.00-2 ....................................... 36
8V1180.00-2 ....................................... 38
8V128M.00-2 ...................................... 40
8V1320.00-2 ....................................... 38
8V1640.00-2 ....................................... 40
P
Pin Assignments
ACOPOS Servo Drives ........................ 139
Cable and Plug ..................................... 163
Plug-in Modules ................................... 155
Plug-in Modules
AC110 ............................................ 43, 155
AC112 ............................................ 45, 156
AC120 ............................................ 49, 157
AC122 ............................................ 52, 158
AC123 ............................................ 55, 159
AC130 ............................................ 58, 160
AC131 ............................................ 62, 161
General Information ......................... 17, 42
ACOPOS User's Manual
Installation and Removal ........................89
Order Data ..............................................42
Power mains connection ............................97
Programming .............................................17
Protective Ground Connection
(PE) ............................................98, 143, 149
R
Resolver Cables
Cable Schematic ..................................169
Order Data ..............................................73
Pin Assignments ...................................168
Structure ...............................................168
Technical Data .......................................73
Resolver Connector
Order Data ..............................................79
Pin Assignments ...................................168
Technical Data .......................................81
Resolver Interface AC122 ..................52, 158
Restart Inhibit ...................................126, 210
Risk Evaluation ........................................212
S
Safety Categories ....................................211
Safety Guidelines .......................................26
Sample project .........................................172
Secure restart inhibit ........................126, 210
Security ................................................15, 16
Service .......................................................17
Servo Drives
ACOPOS 1022, 1045, 1090 ...................36
ACOPOS 1022, 1045, etc. ...................139
Cables
See Cables
Cam Editor .............................................21
Concept ..................................................31
Configurations
CAN ....................................................22
Powerlink ............................................24
Connectors
see Connectors
Danger Warning .....................................26
Dimensioning ..........................................97
Dimensions .............................................85
ACOPOS User's Manual
Drive Oscilloscope ................................. 20
Function Test ................................. 19, 198
General Information ......................... 15, 31
Indication ................................................ 33
Installation ............................................ 121
Installation Dimensions .......................... 85
Mounting .......................................... 27, 83
NC Objects ............................................. 18
Order Data ............................................. 36
Output for Motor Holding Brake
Wiring ................................ 141, 146, 152
Pin Assignments .................................. 139
Plug-in Modules ................. 17, 42, 89, 155
Programming .......................................... 17
Safety Guidelines ................................... 26
Sample project ..................................... 172
Service ................................................... 17
Software ................................................. 17
Start-Up ................................................ 171
Storage ................................................... 27
Technical Data ....................................... 36
Trace .............................................. 19, 198
Transport ................................................ 27
Trigger .................................................... 20
Wiring ................................................... 121
Shield connection .................................... 123
Software .................................................... 17
Software End Switches ............................ 194
SSI absolute encoder interface
see AC123
Standards ................................................ 201
Star Topology ............................................ 24
Start-Up ................................................... 171
Status LEDs
ACOPOS ................................................ 33
Storage ...................................................... 27
T
Terminal Cross Sections ......................... 138
Terminal Screw Holding Torque .............. 138
Thermal Equivalent Circuit ...................... 116
Trace ................................................. 19, 198
Transport ................................................... 27
Trigger ....................................................... 20
225
Index
Index
Index
W
Wiring .......................................................121
226
ACOPOS User's Manual
0
0AC912.9....................................................43
0AC913.92..................................................43
0PS320.1 ....................................................36
7
7AC911.9....................................................43
7TB712.9 ............................................. 58, 62
7TB712.91 ........................................... 58, 62
7TB712:90-02 ...................................... 58, 62
7TB712:91-02 ...................................... 58, 62
8
8AC110.60-2...............................................43
8AC112.60-1...............................................45
8AC120.60-1...............................................50
8AC122.60-2...............................................52
8AC123.60-1...............................................55
8AC130.60-1...............................................58
8AC131.60-1...............................................62
8CE005.12-1...............................................71
8CE007.12-1...............................................71
8CE010.12-1...............................................71
8CE015.12-1...............................................71
8CE020.12-1...............................................71
8CE025.12-1...............................................71
8CM005.12-1 ..............................................67
8CM005.12-3 ..............................................67
8CM005.12-5 ..............................................67
8CM005.12-8 ..............................................68
8CM007.12-1 ..............................................67
8CM007.12-3 ..............................................67
8CM007.12-5 ..............................................67
ACOPOS User's Manual
8CM007.12-8.............................................. 68
8CM010.12-1.............................................. 67
8CM010.12-3.............................................. 67
8CM010.12-5.............................................. 67
8CM010.12-8.............................................. 68
8CM015.12-1.............................................. 67
8CM015.12-3.............................................. 67
8CM015.12-5.............................................. 67
8CM015.12-8.............................................. 68
8CM020.12-1.............................................. 67
8CM020.12-3.............................................. 67
8CM020.12-5.............................................. 67
8CM020.12-8.............................................. 68
8CM025.12-1.............................................. 67
8CM025.12-3.............................................. 67
8CM025.12-5.............................................. 67
8CM025.12-8.............................................. 68
8CR005.12-1 .............................................. 73
8CR007.12-1 .............................................. 73
8CR010.12-1 .............................................. 73
8CR015.12-1 .............................................. 73
8CR020.12-1 .............................................. 73
8CR025.12-1 .............................................. 73
8PE001.00-1............................................... 79
8PM001.00-1 .............................................. 76
8PM002.00-1 .............................................. 76
8PM003.00-1 .............................................. 76
8PR001.00-1 .............................................. 79
8V1022.00-2 ............................................... 36
8V1045.00-2 ............................................... 36
8V1090.00-2 ............................................... 36
8V1180.00-2 ............................................... 38
8V128M.00-2 .............................................. 40
8V1320.00-2 ............................................... 38
8V1640.00-2 ............................................... 40
227
Model Number Index
Model Number Index
Model Number Index
228
ACOPOS User's Manual
ACOPOS
MAACP2-E
ACOPOS
User´s Manual
U s e r ´s
Manual
Version 1.2