Start-Up 09/2004 Edition Start-Up 09/2004 Edition simodrive SIMODRIVE base line A Introduction Installation SIMODRIVE base line A Start-Up Technical description Technical Manual Servomotor Valid for Servo Drive SIMODRIVE base line A 09 2004 Edition SIMODRIVE base line A ® Documentation Key to editions The editions listed below have been published prior to the current edition The column headed "Note" lists the amended sections, with reference to the previous edition Marking of edition in the "Note" column: A New documentation B Unrevised reprint with new order number C Revised edition of new issue Edition 2003.09 2004.09 Order No 6SN1197-0AB21-0BP0 6SN1197-0AB21-0BP1 Note C C Trademarks SIMATIC®, SIMATIC HMI®, SIMATIC NET®, SIMODRIVE®, SINUMERIK® and SIMOTION® are registered trademarks of SIEMENS AG Other names in this publication might be trademarks whose use by a third party for his own purposes may violate the rights of the registered holder Copyright Siemens AG 2004 All right reserved Exclusion of liability The reproduction, transmission or use of this document or its contents is not permitted without express written authority Offenders will be liable for damages All rights, including rights created by patent grant or registration of a utility model, are reserved We have checked that the contents of this document correspond to the hardware and software described Nonetheless, differences might exist and we cannot therefore guarantee that they are completely identical The information contained in this document is reviewed regularly and any necessary changes will be included in the next edition We welcome suggestions for improvement © Siemens AG, 2004 Subject to technical changes without notice Siemens-Aktiengesellschaft SIMODRIVE base line A Safety Guidelines This Manual contains notices intended to ensure your personal safety, as well as to protect products and connected equipment against damage Safety notices are highlighted by a warning triangle and presented in the following categories depending on the degree of risk involved: Danger ! Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury or in substantial property damage Warning ! Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury or in substantial property damage Caution ! Used with the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury or in property damage Caution Used without safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage Notice Indicates important information relating to the product or highlights part of the documentation for special attention Qualified Person The unit may only be started up and operated by a qualified person or persons Qualified persons as referred to in the safety guidelines in this document are those who are authorized to start up, earth and label units, systems and circuits in accordance with relevant safety standards Proper use Please note the following: Warning ! The unit may be used only for the applications described in the catalog or the technical description, and only in combination with the equipment, components and devices of other manufactures as far as this is recommended or permitted by Siemens This product must be transported, stored and installed, and maintained and operated with care to ensure that it functions correctly and safely Contents Contents INTRODUCTION 1-1 1.1 1.2 1.3 Components of SIMODRIVE base line A 1-1 Technical data 1-3 Order number 1-5 INSTALLATION 2-1 2.1 Installation of SIMODRIVE base line A 2-1 2.2 Installation of accessories 2-4 2.3 Commissioning of SIMODRIVE base line A 2-5 2.4 Interfaces and cabling 2-7 2.5 Cable connection 2-10 2.6 Interface description 2-11 2.6.1 Control module interface 2-11 2.6.1.1 2.6.1.2 2.6.1.3 2.6.1.4 2.6.1.5 2.6.1.6 2.6.1.7 2.6.1.8 2.6.1.9 2.6.2 Pole pair numbers 2-12 Current controller settings 2-12 Position feedback interface - X391/X392 2-13 Encoder interface - X311/X312 2-13 Drift compensation － Drift potentiometer 2-14 Tachometer －Potentiometer 2-14 Proportional gain － KP potentiometer 2-15 Integral action time － TN potentiometer 2-15 Speed setpoint & controller enable interface - X321/X322 2-16 Infeed module interface 2-17 2.6.2.1 Grounding of electronics power supply - X131 2-17 2.6.2.2 Enable interface terminals - X141A 2-17 2.7 2.8 TECHNICAL DESCRIPTION 3-1 3.1 3.2 3.3 Power supply 2-18 Grounding 2-26 Closed-loop control with resolver 3-1 Infeed module 3-2 Control module 3-4 SERVOMOTOR 4-1 Introduction 1.1 Components of SIMODRIVE base line A What is SIMODRIVE base line A SIMODRIVE base line A is a compact AC servo drive It applies to economical CNC lathe, milling machine and drilling machine It can also be adapted to control diverse production machines Components SIMODRIVE base line A is designed in a compact structure The internal parts include following modules: ● Control module ● Infeed module ● Power module Fig.1-1 SIMODRIVE base line A (1-axis/2-axes module, V1/V2) SIMODRIVE base line A SIMODRIVE base line A can be ordered with the following two versions: versions: ● V1: 1-axis version, motor static torque of 6Nm, 11Nm, 8Nm, 16Nm; ● V2: 2-axes version, motor static torque of 3+3Nm, 3+6Nm, 3+8Nm, 6Nm+8Nm, 6+6Nm, 8+8Nm SIMODRIVE base line A SIMODRIVE base line A is mainly used together with SINUMERIK application 802C and SINUMERIK 802C base line at present With the application of SIMODRIVE base line A, this solution shows an outstanding performance price ratio SIMODRIVE base line A Start-Up 1-1 Technical description 3.2 Infeed module General SIMODRIVE base line A is connected to the power supply via the infeed modules The infeed module generates the DC voltage 600V from the line supply And the PWM DC link voltage is provided for the stator windings in the motor The resolver built-in the motor switches over the current to appropriate phase The infeed module is designed with a permissible dynamic overloading 200% for a short time The design of heatsink overtemperature and I2t monitoring protect the power part from over heating Control process Drive enable Pulse enable 64 Monitoring 9 63 Electronics power supply DC link monitoring Monitoring Pulse resistor controller P600 M600 P600 M600 Pre-charge contactor U1 X131 PE L1 V1 W1 L2 L3 3AC 400/415V Fig.3-2 Control process in infeed module 3-2 SIMODRIVE base line A Start-Up Technical description Enable signal The time diagram of the enable signals in infeed module is shown in the Fig.3-3 Enable terminal 63 Enable inhibit terminal 64 Speed setpoint inhibit Internal enable inhibit Output pulse inhibit 240ms Note: 1.Terminal 63 is inhibited.The enable and inhibit act,after approx.1ms, simultaneously on all of the modules When the signal is withdrawn,the drives coast down unbraked 2.Terminal 64 is inhibited.Speed setpoint is set to for all drives and the drives are braked.After the set timers have expired (as supplied:240ms),all of the controllers and pulses are inhibited.The drives brake along the current limit Fig.3-3 Enable signal in infeed module SIMODRIVE base line A Start-Up 3-3 Technical description 3.3 Control module General The control module is intended for feed drives with closed-loop control function It can provide the smoothing function for machine tools The speed controller has the PI characteristics The proportional gain KP, integral action time TN, drift compensation and tachometer calibration can be set using potentiometer The dynamic response in low velocity is improved through speed-controller- adaption The speed controller is to be optimized through varying integral time and proportional gain Control process 3-4 Refer to Fig 3-4 for the control process SIMODRIVE base line A Start-Up Controller enable SIMODRIVE base line A Start-Up 65.1 65.2 56 14 P24EXT/FR+ Setting value Infeed module Speed actual value normalization Speed controller adaption Speed controller Controller inhibit Temperature alarm Device internal enable Central unit ready/fault signal Imax limit Monitoring Fault Shield Motor temperature monitoring Current actual value normalization Current controller Pulse inhibit Pulse distribution X311/ X312 R I2Tmax U2 M 3~ V2 W2 PE M600 P600 Technical description Fig 3-4 Block diagram of control module 3-5 Technical description Enable signal The time diagram of enable signals in control module is shown in Fig.3-5 Axis inhibit terminal 65.1 Axis inhibit terminal 65.2 Speed setpoint inhibit Internal enable inhibit Output pulse inhibit 240ms Note: 1.Terminal 65.1 is inhibited Feed modules are inhibited.Speed setpoint is set to After the set timers have expired (as supplied:240ms), all of the controllers are inhibited Terminal 65.2 is inhibited.Feed modules are inhibited immediately The drives coast down unbraked Fig.3-5 Enable signal in control module Monitoring function Heatsink overtemperature / I2t monitoring ● ● Heatsink overtemperature monitoring: when the heatsink shutdown temperature is reached, the fault signal is output And the axes are stopped I2t monitoring: when the limiting becomes active, the fault signal is output And the axes are stopped Motor overtemperature ● 3-6 SIMODRIVE base line A feed modules with closed-loop control for servomotors are equipped with an evaluation circuit for the PTC thermistors integrated in the motor windings The monitoring combination is intended to protect the motors against inadmissible high winding temperatures (trip temperature 150°C) SIMODRIVE base line A Start-Up Servomotor General SIEMENS 1FK7 servomotors are provided to connect with SIMODRIVE base line A 1FK7 AC servomotors are extremely compacted permanent-magnetic synchronous motors Together with the SIMODRIVE base line A, the 1FK7 motors are powerful system with high functionality The built-in resolver system is used to control the speed and position The motors are designed for operation without external cooling, and the heat is dissipated through the motor surface The 1FK7 motors have a high overload capability Technical data Refer to Table 4-1 for the technical parameters of 1FK7 motor Table 4－1 Technical data of 1FK7 servomotor Designation Parameter Remarks Rated speed 3000 rpm Pole pairs Encoder Resolver, 4-pole pairs Motor type AC servomotor (permanent-magnetic synchronous motor) Material of magnetic field Rare-earth magnetic material Protection degree IP64 (option: IP65, in addition, IP67 for the drive end flange) EN60034-5; IEC60034-5 Insulation of stator windings (as per EN60034-1; IEC60034-1) Temperature class F Winding temperature rise ∆T=100K at ambient temperature of +40ºC Cooling type Natural air cooling Temperature monitoring KTY84 Temperature sensor in stator winding Paint finish Unpainted Machine Tools Works responsible Motor shaft Plain shaft /with fitted key and keyway DIN748-3; IEC60072-1 Rotational accuracy, concentricity and axial run-out Tolerance N (standard) DIN42955; IEC60072-1 Vibration severity Grade N (standard) EN60034-14; IEC60034-14 Noise level 1FK704: 55dB； 1FK706: 65dB； 1FK708: 70dB； EN21680 SIMODRIVE base line A Start-Up 4-1 Servomotor Please refer to Table 4-2 for the ordering data of 1FK7 servomotors The speed–torque characteristics can be referred in the Fig.4-1 to Fig.4-5 Order data Notice: The data in the table and figures below are only adapted to the application with SIMODRIVE base line A Table 4-2 Order data Order No Static torque (Nm) 5AF71-1S□0 1FK70605AF71-1S□0 1FK70635AF71-1S□0 1FK70805AF71-1S□0 1FK70835AF71-1S□0 Weight 1) (Kg) Motor phase current (A) I0 I0 Rated speed 2) 1/min 4.9 1.8 2.2 3000 4.7 3.7 4.5 3000 11 7.3 11.5 6.6 8.0 3000 6.6 6.8 10 4.0 4.8 3000 13.3 16 10.5 14 8.6 10.4 3) 3000 M0 M0 2.5 2.6 5.0 9.1 (60) 1FK7042- Rated torque (Nm) Mrated(100) (100) (60) (100) Pole Note: 1) without brake 2) 3) 4-2 It’s recommended that the speed of the servomotor configured for SIMODRIVE base line A is set as 2250rpm This servomotor shall be derated when complete temperature rise of windings ∆T=100K SIMODRIVE base line A Start-Up Servomotor 1FK7042 - 5AF71 11 10 Torque [Nm] S3 - 25% S3 - 40% S3 - 60% S1 (100K) S1 (60K) 0 500 1000 1500 2000 2500 3000 3500 Speed [min-1] Fig 4-1 Motor speed – torque diagram 1FK7042-5AF71-1S□0 Remarks in the above graphics (valid for the sequent figures): S1 (60K): torque output during continous operation at temperature rise of 60K; S1 (100K): torque output during continous operation at temperature rise of 100K; S3 –60%: load cycle in case of intermittent periodic duty, 60% means the ratio of working time with constant load to the whole cycle; S3 –40%: load cycle in case of intermittent periodic duty, 40% means the ratio of working time with constant load to the whole cycle; S3 –25%: load cycle in case of intermittent periodic duty, 25% means the ratio of working time with constant load to the whole cycle; Max.torque curve: it is the characteristics curve of max torque, which can not be exceeded [a] MASTERDRIVES MC：VDC link=540V(DC)、Vmotor=340Vrms 1FK7060 - 5AF71 20 Torque [Nm] 15 10 S3 - 25% S3 - 40% S3 - 60% S1 (100K) S1 (60K) 0 500 1000 1500 2000 2500 3000 3500 Speed [min-1] Fig 4-2 Motor speed – torque diagram 1FK7060-5AF71-1 S□0 SIMODRIVE base line A Start-Up 4-3 Servomotor 1FK7063 - 5AF71 35 30 Torque [Nm] 25 20 S3 - 25% 15 S3 - 40% 10 S3 - 60% S1 (100K) S1 (60K) 0 500 1000 1500 2000 2500 3000 3500 Speed [min-1] Fig 4-3 Motor speed – torque diagram 1FK7063-5AF71-1S□0 1FK7080 - 5AF71 25 20 Torque [Nm] 15 S3 - 25% S3 - 40% 10 S3 - 60% S1 (100K) S1 (60K) 0 500 1000 1500 2000 2500 3000 3500 Speed [min-1] Fig 4-4 Motor speed – torque diagram 1FK7080-5AF71-1S□0 4-4 SIMODRIVE base line A Start-Up Servomotor 1FK7083 - 5AF71 30 S3 - 25% Torque [Nm] S3 - 40% 20 S3 - 60% S1 (100K) 10 S1 (60K) 0 500 1000 1500 2000 2500 3000 3500 Speed [min-1] Fig 4-5 Motor speed – torque diagram 1FK7083-5AF71-1S□0 Dimension servomotor Please refer to Fig.4-1 and Table 4-3 for the mounting dimensions of the Fig.4-6 Motor size Table 4-3 Motor dimensions Order No 1FK70425AF71-1S□0 1FK70605AF71-1S□0 1FK70635AF71-1S□0 1FK70805AF71-1S□0 1FK70835AF71-1S□0 a1 b1 c1 e1 f f1 g2 h i2 s2 120 80 10 100 96 90 48 40 155 110 10 130 126 3.5 105 63 50 155 110 10 130 126 3.5 105 63 50 186 130 13 165 155 3.5 119.5 77.5 58 11 186 130 13 165 155 3.5 119.5 77.5 58 11 SIMODRIVE base line A Start-Up 4-5 Servomotor Table 4-3 Motor dimensions (con’d) Order No 1FK70425AF71-1S□0 1FK70605AF71-1S□0 1FK70635AF71-1S□0 1FK70805AF71-1S□0 1FK70835AF71-1S□0 4-6 Without brake o1 o2 k k With brake o1 o2 d d6 I t u 162 101 134 191 101 163 19 M6 40 21.5 157 93 125 200 93 168 24 M8 50 27 202 138 170 245 138 213 24 M8 50 27 156 91 124 184 91 152 32 M12 58 35 10 194 129 162 245 152 213 32 M12 58 35 10 SIMODRIVE base line A Start-Up SIEMENS NUMERICAL CONTROL LTD.,NANJING,CHINA Suggestions Corrections For publication/Manual: R&D Division No.18,Siemens Road, Jiangning Development Zone 211100 NANJING People’s Republic of China SIMODRIVE base line A Start-Up Manufacturer Documentation Zip code: 211100 Telephone: 025－52101888 Fax: 025－52101666 From Technical manual Name Order No: 6SN1197-0AB21-0BP1 Edition: Company/dept street 09.2004 Should you come across any printing errors when reading this publication, please notify us on this sheet Suggestions for improvement are also welcome Telephone Telefax Suggestions and / or correction: SIMODRIVE base line A Document structure General Documentation: Catalog SINUMERIK 802S Leaflet Technical Manual: Start-Up SINUMERIK 802S Start-up Siemens AG Automatisierungs- und Antriebstechnik Motion Control Systems Postfach 3180, D – 91050 Erlangen Bundesrepublik Deutschland www.siemens.com © Siemens AG 2004 Subject to change without prior notice Order No.: 6SN1197-0AB21-0BP1 Printed in the Federal Republic of Germany .. .Start-Up 09/2004 Edition simodrive SIMODRIVE base line A Introduction Installation SIMODRIVE base line A Start-Up Technical description Technical Manual... Drive SIMODRIVE base line A 09 2004 Edition SIMODRIVE base line A ® Documentation Key to editions The editions listed below have been published prior to the current edition The column headed "Note"... reference to the previous edition Marking of edition in the "Note" column: A New documentation B Unrevised reprint with new order number C Revised edition of new issue Edition 2003.09 2004.09 Order