Lust MASTERCONTROL MC6000 Series Instruction Manual

stop return start enter SMART C A R D CTRL min-1 Instruction Manual MASTERCONTROL MC6000 ANTRIEBSTECHNIK

Instruction Manual for MC6000 Series Servocontrollers Valid from Software-Version: V1.1 Item Number: 0792.20B.0-02 Version: December 1995 We reserve the right to make technical changes Terminal Module EKL 300 Mains filter Line choke Mains connection stop return start enter SMART C A R D CTRL min-1 InterBus-S Interface CAN-Bus Interface Servocontroller MC6000 synchronous servomotors series PSx asynchronous servomotors series ASx various cables PC Interface SMARTCARD for easy matching of servocontrollers to the motors I/O Module1 SMARTCARD storages all parameters RS485 SMART C A R D SMART C A R D

MASTERDRIVE drive system. Installation and commissioning must only be carried out by a trained engineer. Please take the time to read the instructions carefully. Following the instructions meticulaously will you time and avoid uncertainty and questions at the commissioning stage. It is essential to read the Instruction Manual because incorrect use of the servodrive can damage both the servodrive itself and also other parts of the installation. Because of the rotating parts of the drive and the high voltages involved, this type of equipment is potentially hazardous to human life. If after reading the instructions you still have questions, do please contact us. Lust Antriebstechnik GmbH Gewerbestr. 5-9 D-35631 Lahnau Germany Tel: +49 6441 966 -0 Fax: +49 6441 966 -137

after power-off Symbols ⇒ Danger! Danger of death by electrocution or rotating machinery. ⇒ Warning: you must follow this instruction. ⇒ Warning: before opening the equipment, disconnect from the mains and wait approximately two minutes for the DC link capacitors to discharge. ⇒ Prohibited: incorrect operation may cause damage to equipment. ⇒ Useful tip, Note.

Technical Specifications of Servocontrollers Installation Instructions Installation, Commissiong Important Instructions for Operation Electrical Connections EMC, Connection to the mains power supply, motor, terminals, encoder, RS485 and Bus system Software Overview Using KEYPAD and SMARTCARD Configuration Assigning input and output functions Processing of reference values, Emergency Stop etc Structure of controls Torque control, speed control and position control Displays and Error Messages Parameter Description by Subject Area I/O Module 1 and EKL300 Servomotor Project Data Technical specifications, dimensional drawings, axial and radial loads, cooling, holding brake, etc Index Parameter Overview (Table) Signposts Especially important for commissioning:

1.1 Safety instructions ............................................................................................. 1-1 1.2 Intended use ...................................................................................................... 1-1 1.3 Manufacturer's Declaration for Servocontrollers ................................................ 1-2 1.4 Manufacturer's Declaration for Servomotors ...................................................... 1-4 1.5 MC6000 with CE Mark ....................................................................................... 1-6 1.6 Instructions for correct EMC installation ............................................................ 1-8 1.7 What are the main benefits of the MASTERDRIVE System? ................................... 1-9 1.8 Details for ordering the MC6000 Servocontroller ............................................. 1-10 1.9 MC6000 Servocontroller Models ...................................................................... 1-11 1.10 Accessories for the MC6000 Servocontroller ................................................... 1-12 2 Technical Specifications for Servocontrollers .............................................. 2-1 2.1 Design and Layout ............................................................................................. 2-1 2.2 Output - motor.................................................................................................... 2-2 2.3 Input - power side .............................................................................................. 2-2 2.4 Resolution of angle of rotation ........................................................................... 2-2 2.5 Ambient conditions............................................................................................. 2-3 2.6 Dimensions and weights .................................................................................... 2-3 2.7 Mounting instructions ......................................................................................... 2-4 3 Installation and Commissioning..................................................................... 3-1 3.1 Instructions for installation ................................................................................. 3-1 3.2 Installation of drive system................................................................................. 3-2 3.3 Commissioning of the drive system ................................................................... 3-2 3.4 Important tips ..................................................................................................... 3-4 4 Electrical Connections .................................................................................... 4-1 4.1 System connection diagram............................................................................... 4-1 4.2 Electromagnetic compatability ........................................................................... 4-2 4.3 Power Terminals .............................................................................................. 4-3 4.3.1 Mains power supply connection ......................................................................... 4-3 4.3.2 Motor connection ............................................................................................... 4-4 4.3.3 Connection of thermistor .................................................................................... 4-6 4.3.4 Connection of braking resistor ........................................................................... 4-7 4.3.5 DC link terminals.............................................................................................. 4-11 4.3.6 MC6000 protection functions ........................................................................... 4-11 4.4 Control Connections ..................................................................................... 4-12 4.4.1 Control terminal allocation................................................................................ 4-12 4.4.2 Specification of control connections ................................................................. 4-13 4.4.3 Key to input and output codes.......................................................................... 4-14 4.4.4 Wiring control terminals ................................................................................... 4-14 4.4.5 ENPO input (ENable POwer stage) ................................................................. 4-17 4.4.6 Input of current reference signals..................................................................... 4-17 4.5 Encoder connection ...................................................................................... 4-18 4.5.1 Resolver cable KRX-Nxx, KRX-KS-xx ............................................................. 4-18 4.5.2 Encoder cable KG1-KSxx, KG2/3-KS-xx ......................................................... 4-19

4.7 Encoder simulation .......................................................................................... 4-22 4.8 InterBus-S-Interface (C1 and C7) .................................................................... 4-24 4.9 CAN-Bus-Interface (C2) ................................................................................... 4-25 5 MC6000 software and overview ...................................................................... 5-1 6 System software .............................................................................................. 6-1 6.1 Layout of the KeyPad......................................................................................... 6-1 6.2 Using the controls .............................................................................................. 6-2 6.2.1 General .............................................................................................................. 6-2 6.3 Controls ............................................................................................................. 6-2 6.4 LCD Display ....................................................................................................... 6-3 6.5 Control levels ..................................................................................................... 6-4 6.6 Examples for setting parameters ....................................................................... 6-5 6.7 Overview of Menu Structure ........................................................................... 6-7 6.7.1 The VAL Menu ................................................................................................... 6-7 6.7.2 The PARA Menu ................................................................................................ 6-8 6.7.3 The CTRL Menu .............................................................................................. 6-10 6.7.4 The CARD Menu ............................................................................................. 6-12 6.8 Setting the parameters for the MC6000 ........................................................... 6-13 7 Configuration Software ................................................................................... 7-1 7.1 Function selectors ........................................................................................... 7-2 7.1.1 Input Functions .................................................................................................. 7-3 7.1.2 Output Functions ............................................................................................... 7-4 7.1.3 Fixed inputs FIF0 und FIF1 ................................................................................ 7-4 7.2 Reference Value Input ..................................................................................... 7-5 7.2.1 Short description of reference inputs.................................................................. 7-5 7.2.2 Description of reference inputs .......................................................................... 7-5 7.2.3 Setting reference inputs ..................................................................................... 7-9 7.3 Special functions ........................................................................................... 7-10 7.3.1 Emergency Stop .............................................................................................. 7-10 7.3.2 Automatic start ................................................................................................. 7-10 7.3.3 Motor potentiometer function (MOP) ................................................................ 7-11 7.3.4 OS00 output as PWM output ........................................................................... 7-11 7.3.5 Torque limitation (SCALE) ................................................................................ 7-12 7.4 Examples of applications .............................................................................. 7-13 7.4.1 Example: analog reference value input ............................................................ 7-13 7.4.2 Example: reference value input using serial interface ...................................... 7-15 7.4.1 Example: switching from fixed reference values .............................................. 7-16 7.4.1 Example: Analog reference value input with switching ..................................... 7-18 8 Control Software .............................................................................................. 8-1 8.1 General control structure ................................................................................... 8-3 8.2 Torque control mode .......................................................................................... 8-4 8.3 Speed Control Mode ........................................................................................ 8-5 8.3.1 Setting speed control ......................................................................................... 8-7 8.3.2 Speed in field weakening ................................................................................... 8-9 8.4 Position Control ............................................................................................... 8-9 8.4.1 Position control without pre-control .................................................................. 8-10 8.4.2 Position control mode ...................................................................................... 8-10

9.1 Operating display ............................................................................................... 9-1 9.2 Error Messages ................................................................................................ 9-1 9.2.1 Warnings and errors in the Servocontroller ........................................................ 9-2 9.2.2 KeyPad operator errors...................................................................................... 9-4 9.2.3 Errors when using SmartCard............................................................................ 9-4 9.2.4 Trouble shooting ................................................................................................ 9-5 10 Description of Parameters ............................................................................ 10-1 10.1 System for Parameter Names ....................................................................... 10-1 10.1.1 Areas _ENCD, _MOT, _TCON, _SCON, _PCON ............................................ 10-1 10.1.2 Other areas and VAL Menü.............................................................................. 10-3 10.2 VAL Menu Parameters ................................................................................... 10-4 10.3 PARA Menu Parameters ................................................................................ 10-5 10.3.1 Configuation area (_CONF) ............................................................................ 10-7 10.3.2 Encoder area (_ENCD) .................................................................................. 10-19 10.3.3 Option slot 1 (_OPTN1) ................................................................................. 10-21 10.3.4 Option slot 2 (_OPTN2) ................................................................................. 10-21 10.3.5 Motor area (_MOT) ........................................................................................ 10-22 10.3.6 Torque control area (_TCON)......................................................................... 10-25 10.3.7 Speed control area (_SCON) ......................................................................... 10-26 10.3.8 Position control area (_PCON)....................................................................... 10-29 10.3.9 Serial interface area (_SIO) ........................................................................... 10-30 10.3.10 KEYPAD area (_KPAD) .................................................................................... 10-33 10.3.11 Safety and error reaction parameters area (_SCTY)...................................... 10-37 10.3.12 Custom software area (_USER)..................................................................... 10-41 10.3.13 Reference value input area (_REF) ............................................................... 10-42 11 Description of I/O Module 1 (AH1) and EKL300........................................... 11-1 11.1 I/O Module 1 .................................................................................................... 11-1 11.2 Terminal allocation I/O Module1 ....................................................................... 11-2 11.3 EKL300 ............................................................................................................ 11-3 11.4 Software description I/O Module 1 ................................................................... 11-5 12 Servomotor Design Specifications............................................................... 12-1 12.1 Synchronous and Asynchronous Servomotor series ........................................ 12-1 12.2 Ordering details for ASx and PSx Servomotors................................................ 12-2 12.3 Servomotor models.......................................................................................... 12-3 12.4 Basic versions of Servomotors ........................................................................ 12-5 12.5 Typical M-n graph for Servomotors .................................................................. 12-6 12.6 Technical specifications: Asynchronous Servomotors ASx-xx .......................... 12-7 12.7 Technical specifications: synchronous Servomotors PSx-xx ............................ 12-8 12.8 Dimensions of Servomotors ........................................................................... 12-10 12.9 Dimensions for shaft, flange and foot ............................................................. 12-11 12.10 Dimensions for motors with self cooling and external cooling ........................ 12-13 12.11 Permissible axial and radial loads .................................................................. 12-14 12.12 Technical specifications: shape and shaft seal IP65....................................... 12-15 12.13 Technical specifications: self cooling and external cooling ............................. 12-16 12.14 Technical specifications: holding brake .......................................................... 12-18 Index Parameter Overview

1-1 1 General 1.1 Safety Instructions Servodrives have high voltage exposed metal components and may also have moving or rotating parts and hot surfaces, so they do of course represent a danger to human life. To prevent serious injury or major damage, only qualified personnel who are trained in working on electrical drives may work on the equipment. To be qualified in this sense a person must be familiar with the arrangement, installation, commissioning and operation of Servodrives and possess appropriate qualifications to work on them. He must read the instruction manual in detail before installation and commissioning and must follow the safety instructions at all times. (IEC 364 and CENELEC HD 384 or DIN VDE 0100 and IEC-Report 664 or VDE 0110 and national health and safety regulations or VBG 4) Repairs to Servodrive components may only be carried out by the manufacturer or by repair centres authorized by the manufacturer. Unauthorized opening of the equipment and unskilled repairs may result in injuries and damage. 1.2 Intended use Servodrives are equipment designed for incorporating in electrical installations or machines. The commissioning of the Servodrive (ie commencing operation as intended) is prohibited until such time as it has been confirmed that the machine complies with the requirements of EC Directive 89/392/EEC (Machinery Directive). EN60204 must be observed. Commissioning (ie starting normal intended operation) is only permitted under conditions of strict adherence to the EMC Directive (89/336/EEC). For the Low Voltage Directive 73/23/EEC the harmonized standards in the series prEN 50178/ DIN VDE 0160 in conjunction with EN 60439-1/DIN VDE 0660 part 500 and EN 60146/DIN VDE 0558 are used for Servodrives. Technical specifications and connection details should be read off the nameplate and from the documentation and must be strictly observed. Servodrives must be protected from excessive loads. In particular no components must be distorted or insulation/separation arrangements be changed during transport and handling. Servocontrollers and Servomotors contain electrostatic components which are vulnerable and can easily be damaged by inappropriate handling. Electrical components must not be mechanically damaged or destroyed. Any work on Servodrives which are live must be strictly in accordance with with currently valid national health and safety regulations (eg VBG 4). Electrical installation must be carried out in accordance with the applicable regulations (relating to conductor cross section, protection, and protective conductor connection etc). Further details are contained in the documentation. Electronic equipment is not inherently fail-safe, so the user must accept responsibility for ensuring that the drive cannot become dangerous in case of failure. If the Servodrive is to be used for special applications (eg in an explosive environment) then the relevant standards and regulations (eg EN50014 and EN50018) must be followed.

1-6 1.5 MC6000 with CE Mark Copy of the CE Test Certificate as as exaple for MC6404 and MC6408:

1-8 L1 L2 L3 M 3~ G PE RB RB + - L1 L2 L3 W V U PTC PTC 1 2 3 4 5 6 7 8 9 10 11 12 13 14 ... with original encoder cable ... with screened control cable ... with good star grounding ... with mains filter (see section 4.2) ... with screened mains cable ... with screened motor cable asynchronous or synchronous Servomotor resolver or optical encoder MC6000 Servocontroller X5 X1 X3 X2 X10 control terminals ≥ 10 mm2 star grounding point (main ground) in cabinet 1.6 Instructions for Correct EMC Installation CE including EMC: The MASTERDRIVE drive system has been designed such that it complies not only with the low voltage directive, but also the EMC directive (assuming appropriate installation) - and even the strict directive for domestic use. Conformance testing was carried out in the renowned Schenck laboratories under laboratory conditions and there is no guarantee that these findings can be transferred to a Servodrive installed in a specific machine or installation. Instructions for the best possible installation are shown in the next diagram. ������������������������������������������ Note: Complete instructions for wiring the Servodrive are contained in Section 4.

1-9 stop return start enter SMART C A R D CTRL min-1 • One Servocontroller for asynchronisous and synchronisous motors ⇒ reduced training and documentation costs. ⇒ reduced cost of spares in stock • KEYPAD - one controller for Servocontrollers and frequency inverters ⇒ reduced familiarization and documentation costs • Chipcard with motor specifications and complete controller matching ⇒ high level of safety when commissioning ⇒ reduced commissioning costs • Equipment flexibility with retrofit accessories ⇒ high degree of flexibility for future requirements • Servocontroller with integrated positioning and sequence control ⇒ reduced space requirements in cabinet ⇒ reduced wiring costs ⇒ reduced drag errors and reduced load on central control • System solution with asynchronous and synchronous motor range ⇒ this gives you the capacity to create the ideal solution in both technical and economic terms • CE conformity ⇒ this means that acceptance of your machine or installation will be straightforward without the drive being a concern. 1.7 What are the main benefits of the MASTERDRIVE System? stop return start enter SMART C A R D CTRL min-1 SMART C A R D Asynchronous Servomotors → ideal economic solution → wide speed setting range with constant maximum performance output → maintenance-friendly Synchronous Servomotors → ultra compact → optimum dynamics → high precision torque control

1-10 1.8 Details for ordering the MC6000 Servocontroller The Servocontroller model is identified by the order code. Non-standard versions are identified by the addition of model codes to the order code. In the model combination represented, there is standardization on one model at each stage (eg control, encoder interface etc). Each model code has a special meaning; see Servocontroller models. Non-listed controllers also use model codes which are not detailed here. The model code 1 - 5 is separated by a comma and these codes can be added in any order. M C 6 x x x 5 4 3 2 1 locations 1 - 5 Example MC6408 , KP0 , D2 , C2 with CAN bus interface with encoder interface for evaluating sin/cos encoder without KP100 controller M C 6 x x x Continuous current (RMS), see MC6000 Technical Specifications Mains voltage, see MC6000 Technical Specifications MASTERCONTROL MC6000 Series Model code for non-standard models Standard model: • with KP100 control unit • with encoder interface for evaluating resolvers • for MC6404 to MC6416: BR1 for MC6432 and MC6464: BR3 with brake chopper power electronic (10% duty cycle) and braking resistor in heat sink with braking chopper power electronic (100% duty cycle) for direct connection to an external braking resistor Order code/type code (standard version)

1-11 Location Version Short Description Described code in Standard With KP100 multifunction control unit. Section 6 KP0 Without KP100 multifunction control unit – Standard Encoder interface for evaluating resolvers. Section 4.5 D2 Encoder interface for evaluating the latest optical encoders, Section 4.5 incremental sin/cos outputs and simultaneous absolute position information as single turn and multi turn variants. Standard Without application hardware in slot X7 – AH1 PLC compatible I/O expansion with 8 inputs and 4 outputs. Section 11 The I/Os are fully programmable. 1.9 MC6000 Servocontroller Models Control 1 2 Encoder Interface 3 Application Hardware The model codes on the nameplate identify how the device is equipped. 4 Bus Interface 5 Braking chopper version Standard Without bus interface in slot X6 – C1 INTERBUS-S interface for local bus link (IBS-L) Section 4.8 C2 CAN-Bus interface (CAN) Section 4.9 C7 INTERBUS-S interface for remote bus connection (IBS-F) Section 4.8 Standard Braking chopper power electronics (10% duty cycle) and Section 4.3.4 (BR1) braking resistor in heat sink. BR3 Braking chopper power electronics (100% duty cycle) without Section 4.3.4 braking resistor (standard version for MC6432 and MC6464).

1-12 1.10 Accessories for the MC6000 Servocontroller Order Description Code KP100 KP100 multifunction control unit for operating the Servocontroller and frequency inverter 0000.ZSC SMARTCARD without data 0792.ZSC, SMARTCARD for adapting the MC6000 Servocontrollers to the xxx-xx-xxxx Servomotor series ASx and PSx Accessories for fitting to the Servocontroller Order Description Code EKL300 Terminal module for external wiring of control terminals of application hardware AH1 and AH2. With connecting cable (KSS252). KSS252 Connecting cable to link MC6000 Servocontroller and EKL300 terminal module . Connecting cable length 1.8m. LBSKK200 Interface converter cable: RS485 to RS232. Cable length approximately 2m. Accessories for fitting externally

2-1 2 Technical Specifications for Servocontrollers 2.1 Design and Layout � � � � � � � � y y y y y y y y PTC PTC U W V L1 L2 L3 6 7 5 4 3 10 11 13 27 12 8 9 2 1 14 26 stop return start enter SMART C A R D 25 �� �� �� �� �� �� �� �� yy yy yy yy yy yy yy yy 15 14 24 22 23 21 20 CTRL min-1 MC6404 ... MC6416 MC6432, MC6464 + - L1 L2 L3 U V W PE PE + - L1 L2 L3 U V W PE PE RB RB 12 16 17 18 19 RB RB + - RB RB PTC PTC PTC PTC No.. Function No. Function 1, 7 LED "Error", red (H2) 15 mains terminals (X1) 2, 6 LED "Ready", green (H1) 16 terminals for braking resistor & PTC 3 slot X6, e.g. for InterBus-S MC6432 or CAN-Bus Interface 17 terminals for PTC MC6464 4 slot X7, e.g. for I/O Module 1, 18 supply terminals MC6432 or PosMod1 19 supply terminals MC6464 5 LED status display, gelb (H3) 20 RS485 serial interface (X8) 8 control terminals (X5) 21 encoder simulation port (X9) 9 jumper for analog ref. value input 22 encoder port (X10) 10 socket for KeyPad (X4) 23 interface port (X11) for 11 terminals for motor & thermistor (X3) InterBus-S or CAN-Bus interface 12 grounding screw as star point for all 24 Interface port (X12) grounding lead connections 25 KeyPad control unit KP100 13 terminals for braking resistor 26 SmartCard for matching the DC link circuit (X2) servocontroller to motors and storage 14 cable clips to reduce stress loading and media for all parameters for correct EMC cable screening 27 KeyPad connector plug

2-2 encoder simulation internal angle resolution pulses / rev Null pulses / rev pulses / rev. degrees G1 sin/cos Incremental 1 G2 sin/cos single turn 2048 0 2 0.00069° G3 sin/cos multi turn 0 R1 Resolver 1 pole pair 1024 1 2 0.088° R2 Resolver 2 pole pair 2048 2 2 0.044° R8 Resolver 3 pole pair 3072 3 3 x 2 0.0293° 2.2 Output - motor Code Unit MC6404 MC6408 MC6412 MC6416 MC6432 MC6464 Rated power (400V mains) 1 S kVA 2,7 5,5 8,3 11 22 44 Voltage (RMS) U V 3 x 0 ... 400 / 460 Cont. current (400V / 460V) 1 I A 4 / 4 8 / 7 12 / 12 16 / 15 32 / 32 64 / 60 Cont. current (400V / 460V) 2 I A 3 / 2 4,5 / 3,5 7,5 / 6 9,5 / 7,5 20 / 17 40 / 32 Pulse current for 10 sec I A 2 · I 1,5 · I Switching frequency f kHz 4, 8, 16 (factory setting 8 kHz) Motor system synchronous or asynchronous Protection against short yes, but not at RB terminals circuit and ground fault Code Unit MC6404 MC6408 MC6412 MC6416 MC6432 MC6464 Mains voltage U V 3 x 400 ... 460 ±10 % Asymmetry of % 3 mains voltage Frequency f Hz 48 ... 62 Power factor of cos > 0,97 fundamental wave Efficiency η % > 95 Power loss P W 115 180 250 310 600 1000 Note: It is not possible to give general details with regard to resolution and precision of torque, speed and position as these values depend not only on Servocontroller but on all the drive elements. 3) at rated voltage and rated current 2.4 Resolution of angle of rotation 2.3 Input - power side 1) assuming switching frequencies of 8 kHz (factory set) or 4 kHz 2) assuming switching frequency of 16 kHz 19 12 13 12

2-3 Code Unit MC6404 MC6408 MC6412 MC6416 MC6432 MC6464 Protection IP20, VBG4 Mounting orientation vertical, wall mounted Weight m kg 6 7,5 10 15 Dimensions A mm 5,8 7 B mm 360 440 C mm 345 425 D mm 95 142,5 190 285 E mm 7,5 F mm 60 100 150 240 G mm 260 290 2.6 Dimensions and weights B C D G stop return start enter SMART C A R D A F E CTRL min-1 Code Unit MC6404 MC6408 MC6412 MC6416 MC6432 MC6464 Cooling air temperature T °C 0 - 40 (up to 1000 m a.s.l.) Type of cooling forced cooling Relative humidity rF % 15 - 85, non condensing (VDE0160) Power reduction relative P % 5 %/°C above 40°C cooling air temperature to cooling air temperature max. 50°C Power reduction relative P % 5 % per 1000 m above 1000 m a.s.l., to installation height max. 2000 m a.s.l. Storage temperature T °C -25 - +55 (VDE0160) Transport temparature T °C -25 - +70 (VDE0160) Vibration (IEC 68-2-6) 2g (IEC68-2-6) 5) When equipped with I/O Module 1 (version AH1) maximum cooling air temperature 40 degrees C 2.5 Ambient conditions

2-4 B A B A B stop return start enter stop return start enter CTRL min-1 CTRL min-1 The Servocontroller is cooled adequately by its heat sink and a metal mounting plate is not required. Minimum mounting distances: A = 150 mm B = 0 mm Exceptions: B = 20 mm with version AH1 (I/O Module 1) B = 20 mm with Servocontrollers of different power i.e. 1 x MC6408, 1 x MC6412 B = 20 mm with other equipment. Do observe minimum mounting distance of the other equipment if greater! 2.7 Mounting instructions Note: These instructions are applicable to the Servocontroller with heat sink and complete enclosure (Standard version). General: The location for installation must be free from conducting or corrosive materials and free from humidity. Servocontrollers are typically housed in cabinets with external air throughflow. They are attached to a mounting board with four M5 screws. It is essential that the minimum separaration distances above and below the unit are observed to avoid overheating. The ventilation slots on the top surface must not be covered or closed off under any circumstances. Warning: Take care to ensure that no foreign bodies, such as metal swarf or screws, drop into the equipment, as it may be damaged beyond repair. Equipment installation spacing: The enclosure dimensions have been designed to allow for power losses in the form of heat dissipation (see power table). To avoid overheating in the enclosure it is important to adhere strictly to the specified minimum installation separation distances. This will ensure long term reliability. There is no restriction however on mounting any number of units directly adjacent to each other with no separation. (Except when using I/O Module 1 AH1).

3-1 TYP: ASH22-20 G1 3-00 Encoder interface Ebncoder type Encoder cable normal festoonable suitable for: analysis for R1 p=1 3) resolvers (standard) R2 p=2 1) KRX-Nxx KRX-KSxx R8 p=3 2) analysis for G1 sin/cos, incremental 1) KG1-KSxx optical encoders G2 sin/cos, single turn 3) _ KG2/3-KSxx (Code D2) G3 sin/cos, multi turn 3) KG2/3-KSxx encoder G1 is installed Therefore cable KG1-KSxx must be used and the Servocontroller must be fitted with optical encoder evaluation (version code D2) 4. Before and during the installation of the Servocontroller the following procedure must be observed: • electrical connections must never be made or disconnected when live. • cables carrying heavy current must be of sufficient cross-section to comply with VDE0110 • take all necessary measures for correct ENC installation (see Section 4.2) • provide Emergency Off facilities • ensure specified environmental conditions (e.g. cooling air) are provided It is essential to check that the encoder type and the encoder cable are compatible as detailed in the table below. Otherwise correct operation cannot be guaranteed. Example for motor name plate: In each case the last two digits ("xx") indicate the length of the cable in metres. The following lengths are available as standard: 05, 10, 15, 20, 25 und 30 m. Suitable for 1) ASx (asynchronous motors), 2) PSx (synchronous motors), 3) ASx und PSx. p - pole pair number of resolver. 3 Installation and commissioning The actual installation procedure must always be matched to the specific application. The instructions in this section are given for general guidance only . 3.1 Instructions for installation 1. Read these instructions thoroughly. 2. Installation and commissioning must be carried out only by a qualified electrical engineer. 3. Check the components supplied: • name plates in accordance with purchase order • do the encoder cable and Servocontroller match the name plates of the installed encoder type?

3-2 2. Cabinet installation of the Servocontroller: follow installation instructions (heat, minimum mounting distances for installation) in Section 2.7. 3. Electrical installation of the Servocontroller: the electrical installation of the Servocontroller depends on its application. Wiring instructions are contained in Section 4 “Electrical Connections”. • open the MC6000 Servocontroller by undoing the screw on the front (bottom right). • wire up motor (including thermistor), do not mix up motor phases • connect encoder cable to motor and Servocontroller • wire up control terminals (observe power stage enable: ENPO) • wire up serial interface, encoder simulation, Bus system or application hardware, eg I/O module 1 (AH1) as appropriate • connect to the mains, but do not switch on yet 4. Check the electrical installation. Check all connections, then close the MC6000 cabinet again. 3.3 Commissioning of the Drive System 1. Function test (correct selftest sequence): • switch on mains power supply • during MC6000 selftest the display is backlit red and displays the message "TEST" • after successful completion of the self test the colour of the display changes to green and the current actual value is displayed in the VAL menu (torque speed or position depending on mode; parameter REFV in the VAL menu) • if the device detects an error during self testing, the red backlit display will indicate the cause of the fault (see Section 9) wait 2 minutes after power-off 3.2 Installation of the drive system 1. When installing the Servomotor in the system or machine observe the instructions in Sections 4.3.2 and 12. If possible delay installing shaft end items (e.g. gears, pulleys, couplings etc.) until after commissioning, so that tests can be carried out without exposed system parts turning. Note: Suitable devices must be used for fitting and removing shaft end items and there must be support at the A end of the shaft. Warning! Safety instructions for Servomotors • after installing the motor check that brake (if present) operates correctly • before commissioning motors with a feather key in the shaft end, the feather key must be securred to prevent it being thrown out if this is not prevented by the presence of drive shaft items such as pulleys, couplings or similar • these motors are designed for operation using a Servocontroller. Direct connection of such motors to the mains may result in their destruction • surface temperatures above 100 degrees C may occur on the motors. Consequently no temperature-sensitive items may be placed or fixed on them. If necessary, measures to prevent people touching them must be provided • the optional emergency hold brake is only designed for a limited number of emergency stops. It is not approved for use as a normal working brake • the PTC in the windings must be connected to the Servocontroller to prevent overheating of the motor

3-3 2. Function Test (correct recognition of direction of rotation): • download the SMARTCARD supplied with the motor (DRIVE). This any previous will match the Servocontroller perfectly to the motor in use. Remember however that customer settings may be overwritten • in the KEYPAD the symbols for the direction of rotation are displayed in the upper section when you turn the motor spindle ( for clockwise and for counterclockwise) • check that when you turn the motor shaft clockwise by hand, when viewed from the flange end of the shaft the symbol appears • if not, please check: - is the encoder cable connected to the motor and Servocontroller? - is the correct cable for the encoder being used? 3. Test correct operation of the protection device (Emergency Off). 4. Carry out the examples for setting parameters on the Servocontroller on page 6-5, to familiarize yourself with the use of the KEYPAD: • Example 1 - setting the user level to MODE=3 • Example 2 - setting the mode to position control 5. Set the parameters for the Servodrive for your application using the KEYPAD. • for commissioning set user level MODE=3. • choose the required control mode CFCON in configuration (_CONF) • now it is a simple matter to control the drive using the CTRL menu and to carry out tests in the required control mode. If the motor is already connected to the system, the user must ensure that the system will not be damaged by operating it. • Set the parameters for the Servodrive in accordance with the Five Point Plan. Section 7 gives further details. Configuring the Servocontroller (Five Point Plan): Parameter Area 1. Read in the SmartCard with the motor specifications (DRIVE area) 2. Select control mode CFCON _CONF (torque, speed or position) 3. Select control location CLSEL _CONF (Control via terminals, serial interface,, InterBus-S, CAN-Bus, etc.) 1) 4. Program function selectors FIS0x, FISAx, _CONF (Allocate functions to inputs and outputs, FOS0x, etc see Section 7.1) 5. Program reference values _REF (see Section 7.2) This sequence of points must be observed during configuration. 1) Control location identifies the source of the control commands START and INV (invert reference value).

3-4 6. Test the drive with the application-specific settings. 7. If you have commissioned the equipment without the shaft items these should now be assembled on the shaft and the drive tested in conjunction with the whole installation.The moment of inertia of the installation in which the motor is being driven should be set in parameter SCJ (_SCON ). If the moment of inertia of the installation in which the motor is being driven is known, or can be estimated, this value should now be set in parameter SCJ (_SCON). 8. The Servocontroller factory settings provide excellent drive behaviour for most applications without any further adjustment. This concludes the commissioning stage. 9. If the drive characteristics are unsatisfactory, (because the moment of inertia of the installation is not known for example) then adjust the control parameters (see Section 8). Your specialist supplier will be pleased to assist, or you can contact the manufacturer direct: Lust Antriebstechnik GmbH Dep. Application Tel . +49 64 41 / 9 66 - 1 57 +49 64 41 / 9 66 - 1 87 Fax +49 64 41 / 9 66 - 1 77 Warning! Download from SMARTCARD first If the motor is operated without the appropriate SMARTCARD (DRIVE) being downloaded first, the control characteristics are not usually as good. It can lead to the motor overspeeding or even being destroyed. 3.4 Important Tips Warning! Do not remove encoder cable Under no circumstances must the encoder cable ever be disconnected during operation because the Servocontroller would loose control of the motor. Uncontrolled rotatation of the drive may result in damage to the motor and to the installation and also danger to human life. Warning! Danger of death Disconnect from mains before working on the equipment. There are dangerously high voltages at the terminals. Wait approximately 2 minutes after disconnection from the mains supply until the DC link circuit capacitors have discharged. wait 2 minutes after power-off Warning! Dange of death Do not touch motor terminals even when the motor is coasting. Dangerously high induction voltages are present at motor terminals U, V and W. 10.It is worth storing the changed parameter settings as a backup on a SMARTCARD. This SMARTCARD will make commissioning additional drives very easy.

4-1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 K1 L1 L2 L3 M 3~ G 0V +24V PE X5 X1 X3 X4 X6 X2 RB RB + - L1 L2 L3 W V U PTC PTC stop return start enter SMART C A R D X8 X9 X10 X11 X12 MC6000 X7 J1 J2 B D A 1 10 13 11 12 2 3 4 5 6 7 8 9 C PARA CTRL CARD VAL min-1 14 ≥ 10 mm2 No. Function No. Function A KeyPad KP100 control unit 6 Encoder B MC6000 PSU 7 EMC screen plate (star point) C MC6000 controller 8 Serial interface (RS485) D Detail of top 9 Encoder simulation port 1 Control terminals 10 Encoder port 2 Jumper for selecting current 11 X11= output, X12= input for reference values (0-20 mA) InterBus S or CAN Bus interface 3 Line reactor (accessory, not essential 12 X6 slot (e.g. for Interbus S for operating controller) or CAN Bus interface) 4 Braking resistor (internal or external) 13 X7 slot (e.g. for PosMod1 or I/O Module 1) 5 Electromagnetic brake (option) 14 Mains filter (accessory, not essential for operating controller Note: Diagrammatic representation only 4 Electrical Connections 4.1 System Connection Diagram

4-2 Warning! Safety Instructions It is absolutely essential to disconnect the equipment from the mains before working on it. Do not work on the equipment within about 2 minutes of switching off, so that the DC circuit capacitors can discharge to a residual voltage of less than 65V. Potential separation between the power section and the control section meets the VDE requirements for safety extra-low voltage. The use of F1 ground fault circuit interrupts is not permissible because of the high leakage current (>3.5 mA). A good star type grounding of the equipment in accordance with VDE0160 must be achieved by connecting the equipment star point (EMC screening plate, see System connection diagram in Section 4.1) with the central star point of the cabinet using a grounding lead cross section of at least 10 mm² 4.2 Electromagnetic compatibility (EMC) Series MC6000 Servocontrollers meet the EMC interference requirements of Standards EN50082-2, IEC801-4 (VDE0843). For the Servocontroller to comply with these interference standards the measures marked with a 'X' in Table A below are essential. If these procedures are followed interference level 4 requirements will be met in accordance with IEC801-4 (Burst), but if a non-screened control cable is used, interference will be level 2. To comply with the radio interference regulations EN50081-2, EN55011 (emission of interference) the measures marked with a 'X' in Table B must be carried out. wait 2 minutes after power-off Measures Effect/Reason A B 1. Screw Servocontroller to metal mounting plate using serrated locking washers Good conductivity, high surface area contact X X 2. Ground lead contact across at least 10 mm² on the PE rail in the cabinet Good star type grounding because leakage currents > 3,5 mA X X 3. All cable screening to be grounded at both ends using cable clamp Screening effect is lost if the screening is opened up into a pig tail X X 4. Power cable and control cable must be physically separated This avoids mutual induced interference X X 5. Route mains and motor cables separately This avoids mutual induced interference X X 6. Use screened control cable Avoid induced interference on control signals X X 7. Use original encoder cable Avoid induced interference on encoder signals X X 8. Use screened motor cable Avoid the emission of interference via motor connection X 9. Screw mount mains filter directly adjacent to Servocontroller on metal mounting plate using serrated locking washers (If the distance is < 20 cm screened cable is not usually required Avoid the emission of interference via the mains connection; good conductivity, large surface area contact X

4-3 CTRL min-1 Instructions for Correct EMC Installation 4.3 Power Terminals 4.3.1 Mains power supply connection Mains power supply to the MASTERCONTROL is via terminals L1, L2, L3 and PE (at the grounding screw). The Servocontroller must be protected by fuses specified in the table below in order to meet VDE636, Part 1. The cross section of the cable conductor must be appropriate to the current loading. Conductor cross sections for mains and motor connections: 1) if the overload capacity if not to be used (high pulse current for 10 seconds) L1 L2 L3 M 3~ G PE RB RB + - L1 L2 L3 W V U PTC PTC 1 2 3 4 5 6 7 8 9 10 11 12 13 14 ... with original encoder cable ... with screened control cable ... with good star grounding ... with mains filter (see section 4.2) ... with screened mains cable ... with screened motor cable asynchronous or synchronous Servomotor resolver oder optical encoder MC6000 Servocontroller X5 X1 X3 X2 X10 control terminals ≥ 10 mm2 star grounding point (main ground) in cabinet 2. 7. 8. 6. 3. 3. 3. 9. All cable screening must be grounded to the enclosure using cable clamps �� �� �� �� �� �� �� �� � �� � � � 3. Installation using serrated washers 1. K1 L1 L2 L3 PE X1 L1 L2 L3 ≥ 10 mm2 Unit MC6404 MC6408 MC6412 MC6416 MC6432 MC6464 Recommended conductor mm² 1,5 2,5 4 4 6 1) 16 1) cross section Maximum possible mm² 4 10 35 conductor cross section Recommended mains fuse A 10 20 25 35 50 100 (25)1) (35)1) (63)1)

4-4 Mains filter max. current recommended for FN351-8-29 8 A MC6404 FN351-16-29 16 A MC6408 FN351-25-33 25 A MC6412 FN351-36-33 36 A MC6416 The Servocontroller may only be connected to the mains power supply at 120 second intervals. During commissioning and after an Emergency Off the voltage supply may be switched on again directly. Mains filter for correct EMC connection of Servocontroller M 3~ G 0V +24V X3 W V U PTC PTC The motor connection must be laid in screened to reduce interference effects. The screening is to be connected to the enclosure (PE) over a wide surface area and without reduction in cross section, at both ends. The best large surface area connection of the screening to the device is obtained using a cable clip. The motor cable should not be separated (eg at terminals within the cabinet) because the screening effect is lost. Warning: Danger of Death Motor phases U, V and W must not be switched over at the motor end or device end. If the motor phases are switched over the Servocontroller loses control of the motor and the motor may buck or accelerate in an uncontrolled manner. This can result in damage to the whole installation. There may also be danger to human life. Explanation: In a controlled drive (frequency inverter) switching over of motor phases results in reversal of the rotating field and hence direction of rotation of the motor. In a controlled drive of this type switch-over would cause a fault in the control loop of the control circuit. Warning: Danger of Death Do not touch motor terminals. Dangerously high induction voltages are present at motor terminals U, V and W, even during coasting.. Note: Long Motor Leads Especially in the case of screened motor cables there are leakage currents which are not insignificant. The actual leakage current depends on the length of the cable, the structure of the cable, cable routing and motor type. The output currents quoted in Technical Specifications (Section 2) apply up to a cable length of 10m. Above 10m cable length for screened motor cables it must be assumed that there will be a reduction in effective output current from the Servocontroller of • approximately 50 mA per metre length (at 8kHz) and • approximately 70 mA per metre lengfth (at 16 kHz). Maximum length is 50m (longer lengths to order). 4.3.2 Motor Connection The motor connection is via terminals U, V, W and PE (grounding screw) on the Servocontroller (X3). The cross section of the cable conductor must be appropriate for the current loading.

4-5 Motors with terminal boxes For correct EMC wiring of motors, screw glands with large surface area screening contact should be used, such as TOP-T-S by Lütze. Various cable outlet arrangements can be obtained by turning the terminal box (square terminal boxes can be turned by 90° rectangular ones by 180°). It is important to ensure correct sealing of cable outlets or IP65 protection cannot be ensured. Warning: Dange of Fire Surface temperatures of above 100°C occur on the motors. No temperature-sensitive items may be placed or fixed on them. Motor maintenance The only motor maintenance that is required is the cleaning of the surface of motor. The radial deep groove ball bearings of the motors are sealed bearings designed for 20,000 operating hours. Series ASx and PSx must not be dismantled. If the motor has an external fan, this must be connected appropriately and the correct direction of rotatation of the fan checked (c.f. direction of rotation arrow on the fan casing). An adequate supply of cooling air is required for effective cooling. Motor cooling Permissible environmental temperature of motors is -5 to 40°C. The motors must be mounted such that adequate heat dissipation is provided by convection and radiation. In the case of self cooling motors, overheating problems may result from cramped installation (eg in confined spaces or shafts). 1 2 3 1 = U 2 = V 3 = W = PE 1 = L1 2 = N = PE 1 2 IP65 protection is only provided in the case of approved wiring of connectors, both of them fully engaged. Suitable matching connector: eg Interconnectron, Type LPNA 08B NN + – 1 2 U V W BR BR2 U V W 4 3 2 1 No. Function 1 PTC Thermistor 2 Holding brake (option) 3 Not allocated 4 Motor Motors with connector 1 U 2 PE 3 W 4 V A Brake + B Brake – C PTC D PTC Contact Allocation No. 1 2 3 A B C D 4

4-6 U R Schützkontakt Bremse Holding brake (if present) The zero play permanent magnet single disk holding brake is fail-safe, ie the brake is on when there is no voltage. The holding brake is switched on and off when the equipment is stationary. If the holding brake is used as an Emergency Stop brake, the permissible service life of the brake must be observed. At the rated response temperature the PTC resistor has a value >3 kΩ (see DIN44081 and 44082). On reaching this resistance value the Servocontroller responds with the error message Motor Over Temperature (E-OTM). If the termistor is not connected both PTC terminals should be jumpered at the Servocontroller. This jumper is factory fitted and should be removed when the thermistor is connected. If motors of different manufacture are used it is important to ensure that the PTC is electrically insulated in accordance with DIN VDE0530 Part 1. Warning! The motor PTC does not provide adequate thermal monitoring in the case of dynamic processes with overload in PSx motors, sizes M, N & O. In such cases you must please contact Lust to check design values to avoid destruction of the motor. 4.3.3 Connection of thermistor The thermistor (PTC), which is integral in the motor casing, is connected to the Servocontroller for thermal monitoring of the motor. Contacts 1 and 2 are connected in the motor terminal box to the 2 PTC terminals (X3) in the MC6000. The PTC connection is screened and must be connected to ground at both ends. PTC connection: • via separate screened cable or • together with motor cable or • together with connection cable for electromagnetic holding brake (option). As a consequence of the inductivity of the holding brakes there is a voltage peak which occurs when the exciter current is switched off: this peak can be over 1000 V. To avoid this voltage peak a suppressor circuit with a varistor should be used (recommended type Q69-X3022). In the case of motors with integral holding brake a reduction in maximum speed may be required (see Section 12 "Servomotor Design Specifications"). Suggestion for suppressor circuit for brake Motors with integral IP65 shaft seal (option) For motors with integral IP65 shaft seal (option) the permissible maximum speed must be observed (see Section 12 "Servomotor Design Specifications"). Operational reliability can only be achieved with adequate lubrication. Excessive speed of rotation will result in destruction of the seal lips. Section 12 "Servomotor Design Specifications" contains further important guidance on motors. Contactor contact Brake

4-7 4.3.4 Connection of braking resistor In regenerative operation, eg during braking of the drive, the motor feeds the energy back to the Servocontroller which increases the voltages in the DC link circuit. If the voltage exceeds approximately 745 V DC the internal braking transistor is switched on and the regenerative energy is converted into heat by the braking resistor. If the DC link circuit exceeds the maximum permissible value of 780 V DC, the Servocontroller produces the error message Over Voltage E-OV and blocks the power stage. Over voltage can occur if large masses are braked and/or short braking times are set. At terminals RB the Servocontroller is not short circuit proof or ground fault resistant. The MC6000 is available in the following versions: The MC6000 Servocontroller is available in the following versions: Notes: EDi is the on time of the internal braking transistor (duty cycle). The MC6432 and MC6464 Servocontrollers are not available with internal braking resistor. An external braking resistor can be connected directly. Braking the drive has implications for the safety of the machine and the installation For this reason the design values of braking resistor and braking transistor must be checked with regard to the application before commissioning. During commissioning safe operation must be checked. If the design values are incorrect (resulting in overload) the braking resistor and the braking circuit may be destroyed and the machine and the installation may be damaged. Model code Braking transistor Braking resistor Peak braking power Continuous duty factor cdf (EDi) Standard (BR1) internal internal for 8 s 10% BR2 internal external for 8 s 10% BR3 internal external continuous 100% Overload (failure of the braking system) can also injur or kill people, eg in the case of lifting application. Braking chopper version selction and design values are shown on the next page. Braking power code unit MC6404 MC6408 MC6412 MC6416 MC6432 MC6464 Peak braking power internal Pmax kW 6 – cyclic braking operation 1) P eff W 60 20 90 30 – continuous braking operation 1) P effg W 115 180 250 310 – minimum resistance in Ohms R min Ω 75 33 21 15 of external braking resistors 2) 1) Applies to internal braking resistor. When using an external braking resistor (BR2, BR3) the continuous braking performance is determined by the continuous performance of the resistor. 2) Applies to version codes BR2 and BR3. The peak braking performance is determined by the value of the resistor.

4-8 Selection of braking chopper versions and design values: 1. Draw the operating profile of your drive (n/t, M/t, see Fig. 1a). 2. Calculate the required peak braking torque and peak braking performance (see Fig. 1b) : Where PBr max. ≥ 6 kW then use external braking resistor: 3. Calculate effective braking performance (see Fig. 1b): Where PBr eff. ≤ Peff. (see Table, z. B. 60 W for MC6404) ⇒ Version code standard ≤ 10 % · Pmax ⇒ external resistor (BR2) ≤ Pmax 1) ⇒ external resistor (BR3) > Pmax 1) ⇒ external braking chopper JM - moment of inertia of the motor JL - moment of inertia of the load, reduced to the motor shaft ML - load moment, prefix sign shows direction of effect n' - speed before braking [min-1] n - speed after braking [min-1] tBr - braking duration R U P Br ZK Br ≤ 2 max with UZK= 745 V, Ensure that: RBr ≥ Rmin (see Table Page 4-5) Fig. 1: Example for operating profile: a lifting application. t n, M t PBr P3 P5 t1 t2 t3 t4 t5 t6 tSp Abb. a Abb. b M/t n/t P6 = PBr max MBr max M3 M5 )* Formula applies to ML= const., JL=const. M J J n n t M P M n Br M L Br L Br Br s max max max min ( )( ') , )* , = + − ⋅ = ⋅ ⋅ 9 55 9 55 � P P t P t P t t Br eff Sp = ⋅ + ⋅ + ⋅ 3 3 5 5 6 6 2 2 1) Pmax= 6 kW for RB= 90 Ω; 7,4 kW (75 Ω); 16,7 kW (33 Ω); 26,4 kW (21 Ω); 37 kW (15 Ω).

4-9 Warning - Danger of Death! It is your responsibility to ensure that the braking process remains within the approved limits in the graph in diagram 2 and below the limit values in the table below. For longer periods of braking at higher braking power, the power stage will be blocked to protect it from overvoltage. When this occurs the Servocontroller will not control the motor in any way. The motor or the installation may be damaged. Danger of death! Fig. 2: Permissible Braking Power related to braking duration EDBr. 6 4 3 2 1 10 20 30 40 50 60 70 80 90 100 110 120 P kW tBr s 0 50 100 EDBr % 5 Peff Pmax A BR2 (90 Ω) BR3 (90 Ω) B 10 20 30 40 60 70 80 90 1 2 Standard version: A - single braking process (waiting time ≥ 10 min., heat sink temperature ≤ 60° C). B - Cyclic braking with braking duration EDBr. BR2 and BR3: For details of other braking resistors see table below. The continuous performance of the external resistor must be appropriate! 1 - permissible operation for single braking (Example 1). 2 - operation for cyclic braking, use BR2 not permissible (Example 2). 1) Any point on the curves can be calculated from the permissible braking energy Emax. 2) Only for MC6412 to MC6464; 3) only for MC6432, MC6464; 4) only for MC6464. Note: It is important to differentiate between • Internal ON duration EDi : switch-on limit of internal braking transistor (duty cycle) EDi= 10 % means max. 8 seconds braking with peak braking power per cycle EDi= 100 % means no limit continuous peak braking performance possible.. • Braking duration EDBr: Br Sp Br Br eff eff max Permissible Braking Power related to braking duration ED BR3 Braking time t . (only (applies to t = 120 s) s 0 ... 8 10 20 30 40 60 120 0 ... 120 Braking duration ED % 0 ... 6,6 8,3 16,6 25 33,3 50 100 0 ... 100 E 1) Braking power Curve A kW 6 4,8 2,4 1,6 1,1 0,6 P – 4.800 Ws Curve B kW device dependent P = E / t – P · 120 s BR2 with 90 kW 6 4,8 2,4 1,6 1,2 0,8 0,4 6 48.000 Ws BR2 with 75 kW 7,3 5,9 2,9 1,9 1,4 0,98 0,49 7,3 59.000 Ws BR2 with 33 2) kW 16,7 13,4 6,7 4,4 3,3 2,2 1,1 16,7 134.000 Ws BR2 with 21 3) kW 26,3 21,1 10,5 7 5,2 3,5 1,7 26,3 211.000 Ws BR2 with 15 4) kW 37 29,6 14,8 9,8 7,4 4,9 2,4 37 296.000 Ws max Br Ω Ω Ω Ω Ω Braking duration ED Sum of braking time Cycle duration Br = ⋅100 % Br

4-10 Using the internal braking resistor (Standard model): For a single braking process within a ten minute period the peak braking power of 6kW may be applied for 8 seconds (see Diagram 2, curve A). This assumes that the temperature of the side- mounted heat sink is ≤ 60° C before the start of braking. For cyclic braking the braking poweer and duration can be read off curve B in Diagram 2. Continuous braking power is shown in the table on page 4-5. In the case of regenerative applications, i.e. continuous braking (an exception) permissible continuous braking power corresponds to power loss. Example : Checking an operating point for single braking processes (curve A) A drive with an MC6404 is being used at occasional irregular intervals (always >10 min.) for raising and lowering a tool. The braking power required has been calculated at 2.2 kW for 20 seconds. Is the internal braking resistor adequate for this purpose? 1. Permissible braking energy: 2. Condition for each operating point: in the example: ⇒ The internal resistor is adequate if the temperature of the heat sink is ≤ 60° C before the braking operation. Check correct operation during commissioning. Examplel : 2 Checking an operating point for cyclic braking (curve B) Is the internal braking resistor still adequate if the lifting operation is to be every 90 seconds (including 6 seconds total braking time) on a regular basis? 1. Braking duration: Braking time: 2. Permissible braking energy: for the MC6404: 3. Condition for each working point: in the example: ® from the table on pages 4-7, at the foot: ⇒ An external braking resistor is in fact required. Using an external braking resistor (BR2 and BR3): BR2 only: Peak braking power is limited by the braking circuit to 8 seconds. The waiting time after a braking operation (or cyclic braking application) is shown in Fig. 2. BR2 and BR3: The resistance value must be at least that shown in the table or damage to the braking transistor may result. Continuous braking power depends on the continuous and peak braking power of the resistance value of the resistor. If there is an internal resistor, it must be disconnected and its connections insulated. As the braking resistor generates heat it is essential to ensure it is mounted with adequate separation from the servocontroller. E P s E kW s Ws P t E kW s Ws E A A Br eff Br A A max max max max max . . , . = ⋅ = ⋅ = ⋅ ≤ ⋅ = ≤ 8 6 8 48 000 2 2 20 44 000 ED s s t s s E P s E W s Ws P t E kW s Ws E E Ws Br EDBr B eff B Br eff EDBr B B = = = ⋅ = = ⋅ = ⋅ = ⋅ ≤ ⋅ = > = 6 90 6 7 120 6 7 8 120 60 120 7 200 2 2 8 17 600 48 000 , %. , % . . , . . max max max max max (assuming 120 s cycle) for BR2 with RB = 90 Ω. Internal braking resistor is not adequate

4-11 4.3.5 DC Link Circuit Terminals An external braking chopper can be connected to these terminals in order to increase braking power especially in dynamic applications. Following consultation with the manufacturers, LUST, you can: 1. feed in the DC link voltage or 2. connect the DC link circuits of several Servocontrollers. All auxiliary supplies are generated from the DC link voltage. Warning - Danger of Death! Voltage at terminals > 500 V DC! 4.3.6 MC6000 Protection Functions Electrical equipment is so designed that in an emergency rapid switch-off is possible to protect human life or to prevent damage to the installation. In the case of a Servodrive there is danger particularly from the rotating parts of the drive (both for people and also for installation componenents). The MC6000 Servocontroller offers two possibilities for switch-off if there is danger from the rotating drive: 1. Blocking the power stage: The power stage can be blocked directly (without software control) via input ENPO (X5). This separates the motor from control and it then coasts on uncontrolled or it can be braked using a mechanical brake (see Section 4.4.4). Warning: Cancel Start before switching on ENPO input again. Otherwise the system will try to correct the difference between the reference value and the actual value which has arisen in the meantime - i.e. the drive will start of its own accord. 2. Emergency Stop: This is triggered via a programmable input to which the function Emergency Stop has been allocated. The motor will then be braked to a stop at the set maximum torque value regeneratively and held in this position. It is also possible to use Emergency Stop via a programmable braking ramp (see Section 7.3.1). These protection functions do not constitute safety arrangements in the sense of VDE0100 The usual Emergency Off arrangement in the mains supply is also possible if the Servocontroller has to be isolated from power in an emergency. Switching off the power supply disconnects the motor from the mains and it coasts on uncontrolled. However, it will only stop after some considerable delay because the stored energy has to be dissipated through friction alone. It is possible to provide the MC6000 control section with an external 24V supply so that control functions and communication are maintained (supply at +24V and DGND terminals). The Emergency Off safety arrangements of the Servodrive must meet the relevant standards and regulations specific to the application (e.g. VDE0100)!

4-12 4.4 Control Connections The MC6000 Servocontroller can be linked via the terminal strip to a superordinate controller (e.g: PLC). The terminals carry: • two analog inputs for reference value input • three digital inputs, two of them fully programmable • two digital outputs, fully programmable • auxiliary voltages for reference value input (± 10 V) • auxiliary voltages for digital inputs and outputs (+ 24 V) The fully programmable inputs and outputs (IS00, IS01, ISA0, ISA1, OS00, OS01) can perform various functions. Each input and each output has a function selector which allocates the required function (see Section 7). The analog reference value inputs can also be used as digital inputs. Output OS00 can also be used as a pulse width modulated output. The output signal (0 to +24V) is intended for slow response pointer instruments but not for processing in controls. The control lines must be screened. The cable screen must be grounded at both ends, at the Servocontroller using the cable clamp provided for the purpose. The control inputs and outputs have a common potential, which is isolated from the mains potential. The control inputs and outputs are not potential-isolated via optocouplers, as most programmable controls (PLC) are themselves potential-isolated. 4.4.1 Control Terminal Allocation (X5) 1) Connections are also used for the control section when there is an external +24V supply Terminal Terminal Description of Terminals No. identification 1 +10V Voltage supply for reference value input 2 - 10V 3 ISA0- Analog reference value input 0 (differential) 4 ISA0+ +10 to -10 V / +20 to -20 mA 5 ISA1 Analog reference value input 1: 0 to +10 V / 0 to +20 mA 6 AGND Ground for analog reference value input 7 +24V +24 V-supply for digital 8 +24V inputs and outputs 1) 9 IS00 Digital standard inputs 10 IS01 freely assignable using software 11 ENPO Input power stage (Enable Power Output) 12 OS00 Standard outputs 13 OS01 OS00 can also be used as a PWM output 14 DGND Ground for digital standard inputs and outputs 1)

4-13 Auxiliary supplies: • ±10 V DC, ±5%, short circuit proof, max. load 2 mA • +24 V DC, internal: ±10%, short circuit proof, max. load 200 mA • +24 V DC, with external supply (all other voltages are generated from +24 V): ±20%, current requirements: typically 0,5 A (all inputs and outputs loaded, no cards in slots 1 and 2); max. 3 A (slots 1 & 2 occupied) Analog reference value • for entering reference values with voltage or inputs ISA0-, ISA0+, ISA1: current (configurable using jumpers J1 and J2) • with protection against external voltage spikes • cascading of several drives possible using voltage reference value and current reference value • can also be used as fully programmable +24V digital inputs • sampling time 1 ms • offset matching factory-set (hardware) Control inputs IS00, IS01: • fully programmable • sampling time 1 ms • delay time input filter 10 ms • PLC compatible, +24 V logic to DGND • Switching level HIGH = 19,2 to 26,8 V DC LOW = 0 to 4,8 V DC (other voltages not permissible) • contact current 6,4 mA (24 V), 8 mA (30 V) • input impedance 3,9 kΩ Power stage enable ENPO: • hardware enabling of power stage • delay time input filter 10 ms • PLC compatible, +24 V- logic to DGND • high level = power stage enabled Outputs OS00, OS01: • digital +24V outputs, high active • short circuit proof • fully programmable • sampling time: 1 ms • max. load per output: 65 mA • internal freewheeling diode • OS00 can also be used as PWM output: * pulse width modulated output signal * PWM frequency: 200 Hz * minimum load: 1 kΩ * can be used as quasi analog signal (0 to+24V) for pointer instruments kΩ kΩ ≥ Ω Ω ISA 0 ISA 1 Range U -10 ... +10 V 0 ... +10 V I -20 ... +20 mA 0 ... 20mA Input U 100 94 Impedance I 500 500 Resolution 11 Bit 10 Bit Accuracy 3 % ± 1 LSB 1 % ± 1 LSB Switching level LOW= < 4,8 V digital HIGH= > 8 V 4.4.2 Specification of Control Connections

4-14 The diagrams show the switching arrangements of the control terminals. Differential analog input ISA0 1. Input of voltage reference value ISA0 = - 10 to + 10 V; Resolution 11 Bit (10 Bit per direction of rotation); 2. Input of current reference value ISA0 = - 20 to +20 mA; Resolution 11 Bit (10 Bit per direction of roation); Jumper J1 must be set 3. Use as digital input 4.4.4 Wiring of Control Terminals +10 V ISA0- -10 V ISA0+ ISA1 +24V +24V IS00 IS01 ENPO OS00 OS01 X5 1 2 3 4 5 6 7 8 9 10 11 12 13 14 +10 V ISA0- -10 V ISA0+ ISA1 +24V +24V IS00 IS01 ENPO OS00 OS01 X5 1 2 3 4 5 6 7 8 9 10 11 12 13 14 - 20 ... +20 mA +10 V ISA0- -10 V ISA0+ ISA1 +24V +24V IS00 IS01 ENPO OS00 OS01 X5 1 2 3 4 5 6 7 8 9 10 11 12 13 14 -10 ... +10 V ≥ 20 K J2 J1 � � � y y y J2 J1 � � � y y y J2 J1 � � � y y y AGND AGND AGND +24V O0 SPS / PLC 14 DGND 4.4.3 Identification of Input and Output Codes The codes for inputs and outputs are made up as follows: I S0 0 Number of I/O Location (module) Input / Output 1) only in connection with PosMod1, 12 I/8 0 per module. 1) Code Device(module) Description Input/Output IS00, IS01 Servocontroller S Standard inputs OS00, OS01 S Standard outputs ISA0, ISA1 SA Analog inputs IP1x PosMod1 P1 x= 0 to 7 OP1x x= 0 to 3 ICyx CAN-Module C x= 0 to 7, y= 0 to 7 OCyx x= 0 to 7, y= 0 to 7 IExx I/O Module 1 E xx= 00 to 07 OExx xx= 00 to 03

4-15 Analog input ISA1 1. Input of voltage reference value ISA1 = 0 to + 10 V; Resolution 10 Bit 2. Input of current reference value ISA1 = 0 to +20 mA; Resolution 10 Bit; Jumper J2 must be set 3. Use as digital input Digital Standard Inputs IS00, IS01 +10 V ISA0- -10 V ISA0+ ISA1 +24V +24V IS00 IS01 ENPO OS00 OS01 X5 1 2 3 4 5 6 7 89 10 11 12 13 14 0 ... 10 V ≥ 10 K +10 V ISA0- -10 V ISA0+ ISA1 +24V +24V IS00 IS01 ENPO OS00 OS01 X5 1 2 3 4 5 6 7 89 10 11 12 13 14 0 ... 20 mA +10 V ISA0- -10 V ISA0+ ISA1 +24V +24V IS00 IS01 ENPO OS00 OS01 X5 1 2 3 4 5 6 7 8 9 10 11 12 13 14 J2 J1 � � � y y y J2 J1 � � � y y y J2 J1 � � � y y y AGND AGND AGND +24V O0 SPS / PLC 14 DGND +10 V ISA0- -10 V ISA0+ ISA1 +24V +24V IS00 IS01 ENPO OS00 OS01 123 4 5 6 7 8 9 10 11 12 13 14 X5

4-16 Outputs OS00, OS01 1. Use as digital output 2. Use as PWM output Output voltage range: 0 - 24V minimum load: R2 ≥ 1 kΩ Wired in parallel with a PLC (e.g. use of 5 digital inputs and 2 digital outputs) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 X5 +10 V ISA0- -10 V ISA0+ ISA1 +24V +24V IS00 IS01 ENPO OS00 OS01 1 2 3 4 5 6 7 8 9 10 11 12 13 14 X5 max. 65mA +24V DGND R2 +10 V ISA0- -10 V ISA0+ ISA1 +24V +24V IS00 IS01 ENPO OS00 OS01 X5 1 2 3 4 5 6 7 8 9 10 11 12 13 14 +24V O1 O3 O2 O0 O4 I0 I1 SPS / PLC AGND DGND

4-17 4.4.5 ENPO Input (Enable power stage) ENPO input (Enable Power Output) enables or disables the power stage transistors of the Servocontroller. The input is directly hard wired in the hardware. Apply +24 V to the input to enable the power stage. ENPO Digital Input Enable Power Stage 1. Facility for blocking power stage is used 2. If not used +24V should be applied to the input The ENPO input can be used for an emergency function (see Section 4.3.6). If the input is set to LOW the power stage is locked and the power to the motor is cut off. This input can also be used to reset faults. To reset an error message the HIGH level is cancelled at input ENPO and then reapplied. Errors can also be reset using the KEYPAD multifunction control unit. 4.4.6 Input of Current Reference Values Both Jumpers J1 and J2 can be used to select input reference at analog input ISA0 and ISA1 as voltage or current reference signal. The jumpers are immediately under the control terminals. Internal resistance: 500 Ω (with current reference values) +10 V ISA0- -10 V ISA0+ ISA1 +24V +24V IS00 IS01 ENPO OS00 OS01 1 2 34 5 6 7 8 9 10 11 12 13 14 +10 V ISA0- -10 V ISA0+ ISA1 +24V +24V IS00 IS01 ENPO OS00 OS01 1 23 4 5 6 7 8 9 10 11 12 13 14 X5 X5 +10 V ISA0- -10 V ISA0+ ISA1 +24V +24V IS00 IS01 ENPO OS00 OS01 1 2 34 5 6 7 8 9 10 11 12 13 14 X5 J2 J1 � � � y y y Use as ISA0 ISA1 J1 J2 Input for voltage reference value Input for current reference values Digital input

4-18 X10 The encoder cable is supplied ready for use. This cable connects the round connector on the motor casing to the 15 way Sub-D socket in the device lid as shown in the system connection plan. The encoder cable must not be separated, for example to feed signals via terminals in the cabinet. Ensure that the knurled screws on the Sub-D connector case are screwed home tight! The MASTERCONTROL Servocontroller recognises which encoder is connected by reading in the SMARTCARD so no manual adjustment is necessary. Warning! It is absolutely essential to ensure that the encoder interface, encoder type and encoder cable are compatible (see Section 3.1 "Instructions for Installation") otherwise correct functioning cannot be guaranteed. Warning - Danger of Death! Under no circumstances must the encoder cable ever be withdrawn during operation because the Servocontroller would lose all control of the motor. This could lead to damage to the motor and the equipment and also be a source of danger to people because of the uncontrolled rotation of the drive. 4.5.1 Resolver Cable KRX-Nxx, KRX-KSxx KRX-Nxx Cable not festoonable Lapp Unitronic CY Pi CY 3x2x0,25 KRX-KSxx Cable festoonable Lapp Ölflex Servo-FD 760 P Connector X1 Sub-D 15-pin metal housing Connector X2 Signal connector 12-pin socket Interconnectron SPNA12B NNNN 169 (for KRX-Nxx) PLD121 NV 171187 (for KRX-KSxx) X10 Motor end A B xx = length of cable in metres Standard lengths: xx = 05, 10, 15, 20, 25, 30 m; max. 50 m (longer lengths to order) 4.5 Encoder Connection A B Function Color 1 inner screen 2 inner screen 3 n. c. 4 5 REF+ yellow 5 7 REF- green 6 n. c. 7 2 COS+ pink 8 n. c. 9 inner screen 10 n. c. 11 n. c. 12 10 SIN+ white 13 1 SIN- brown 14 11 COS- gray 15 n. c. outer screen to casing

4-19 KG1-KSxx KG2/3-KSxx 4.5.2 Encoder Cables: KG1-KSxx and KG2/3-KSxx xx = length of cable in metres Standard Lengths: xx = 05, 10, 15, 20, 25, 30 m; max. 50 m (longer lengths to order) X10 Motor end A B Encoder Cable Technical Specifications A B Function Color 1 bridge pin 2 1 K pin 4 3 5 V blue 4 C 5 V, 1 K pin 2 brown/green 5 A 0 V white/green 6 bridge pin 7 J B+ gray 8 H R- black 9 n. c. 10 n. c. 11 0 V white 12 E A+ brown 13 F A- green 14 K B- pink 15 G R+ red outer screen to casing A B Function Color 1 T DATA+ gray 2 U DATA- pink 3 D 5 V blue 4 C 5 V brown/green 5 A 0 V white/green 6 V inner screen 7 J B+ blue/black 8 n. c. 9 S CLK- yellow 10 R CLK+ purple 11 B 0 V white 12 E A+ green/black 13 F A- yellow/black 14 K B- red/black 15 n. c. outer screen to casing KG1-KSxx Cable not festoonable, Heidenhain 244 957 01 KG2/3-KSxx Cable festoonable, Heidenhain 266 306 01 Connector X1 Sub-D 15-pin metal housing Connector X2 Connector19-pin socket Schaltbau Munchen T1 Unit KRX-Nxx KRX-KSxx KG1-KSxx KG2/3-KSxx for encoder types R1, R2, R8 G1 G2, G3 festoonable no yes yes minimum radius fixed routed cable mm 60 k. A. 40 loose routed cable mm – 120 100 temperature range: fixed routed cable °C - 30 ... + 70 k. A. - 35 ... + 80 loose routed cable °C – - 30 ... + 70 - 10 ... + 80 cable diameter, approx. mm 9,9 9,4 8,0 outer sheath material PVC PUR PUR chemical resistance flame retardant flame retardant, resists moisture and microbes Resistant to oil, moisture & microbes (VDE0472)

4-20 4.6 Serial Interface RS485 The MASTERCONTROL RS485 Serial Interface is available at the 9-pin Sub-D connector X8. The Serial Interface is potential-isolated via optocoupler to improve resistance to interference and an external voltage supply is required for that purpose X8 There are three ways of connecting & using the RS485 interface: 1. potential-free, + 24 V supply. 2. potential-free, + 5 V supply. 3. not potential-free, use of internal + 5 V supply. The block diagram below shows the serial interface and connection options: +5V_B RS485 Driver GND_B GND_B +5V_B DGND +5V_B DIRECTION TxD RxD GND_B +5V GND_B DGND +5V 9 X8 3 2 8 RS485+ RS485- 5 4 6 7 +5V +24V OUT 24V_IN +5V_B* B C A D 9 X8 3 2 8 5 4 6 7 9 X8 3 2 8 5 4 6 7 +5V GND +24V GND 3 1 2 No. Function A isolated by optocoupler B conversion to RS485 level C RS485 connection via X8 D connection versions for supply voltage 1, 2, 3 wiring for versions 1, 2, 3

4-21 The following table shows the allocation of the RS485 interface and the version-specific connections required. The connections listed are made within the cable connector. Pin no. Assignment Version 1 Version 2 Version 3 X8 (RS485) (external + 24 V) (external + 5 V) (internal + 5 V) 1 n.c. n.c. n.c. n.c. 2 GND_B GND GND GND, bridge pin 8 3 +5V_B bridge pin 7 bridge pin 9 4 RS485- RS485- RS485- RS485- 5 RS485+ RS485+ RS485+ RS485+ 6 24V_IN + 24 V supply n.c. n.c. 7 +5V_B* bridge pin 3 n.c. n.c. 8 GND n.c. n.c. GND, bridge pin 2 9 +5V n.c. n.c. bridge pin 3 Screening: The serial interface must be connected using screened cable and the screening must be grounded via the connector housing to grounding conductors. If Bus operation must be ensured in case of mains power supply failure, then the +24 V voltage for the control section must be an external supply (see Section 4.4.1)! Sub-D 25pol. PC-RS232 2 TxD 3 RxD 7 GND PCs with RS232 interface (25-pin Sub-D socket) can be connected using the interface connector cable which is available as an accessory (LBSKK200). This cable which converts the RS485 signals to RS232 uses the internal + 5V supply of the Servocontroller. This cable is not intended for networking but is simply used to connect a single Servocontroller to a PC. The serial interface parameters (e.g. baud rate) are in area _SIO. The interface supports the LustBus data transfer protocol and up to 30 frequency inverters and Servocontrollers can be networked.

4-22 4.7 Encoder Simulation Encoder simulation provides position information, e.g. when operating with superordinate position control in twin device technology (see diagram Twin Device Technology below) or in the mode position servocontrol mode (special software in preparation). Encoder simulation provides +5V level signals. In resolvers, the number of pulses per revolution is obtained by multiplying the pole pair number P of the resolver with the standard pulse count 1024. Because of the pole pair number, R2 resolvers produce 2 null pulses per revolution and R8 resolvers produce 3. If this is not desirable, the single pole pair resolver R1 can be used. +A +B +R +A +B +R + + + + G I / O MC6000 M 3 ~ B C A 1 2 3 4 5 6 8 3 ~ stop return start enter SMART C A R D CTRL min-1 +/- 10V + + I / O 7 Twin Device Technology: Servorcontroller receives speed reference values (±10V) from positioning control and returns encoder simulation as position information. Encoder simulation is provided at connector X9 (25 pin Sub-D socket). This simulates an incremental encoder with square wave output signals using the signals from the encoder connected at X10. Encoder simulation is generated using hardware switching. The signals are time continuous and quasi delay free (only few gate times). Using encoder simulation does not produce a restriction on maximum speed. X9 Encoder at X10 G1 G2 G3 G4 R1 (p=1) R2 (p=2) R8 (p=3) Pulses per rev. at X9 2048 1024 1024 2048 3072 Null pulses per rev. 1 0 0 0 1 2 3 No. Function No. Function A Control level 3 I/O module B Drive level 4 Encoder simulation C Process level 5 I/O signals from/to process 1 PLC with control unit 6 Reference cams, safety limit switches 2 Serial interface SIO 7 Drives (RS485, InterBus-S, CAN-Bus) 8 Single process

4-23 + - MC3486 +1x -1x 120E 4K7 4K7 +5V Connection Cable: Twisted pair with complete screening, screening grounded at both ends. Max. cable length 20m. Note: The superordinate control must be able to process the encoder simulation high output frequencies. Example: f = 3000 min-1 · 2048 pulses = 102 kHz. If necessary, an industry standard external frequency divider can be used. x = A, B or R Additional Input for incremental encoders Servocontrollers which are equipped to evaluate signals from optical encoders (Version code D2) also have an additional function which can be used in future by specific software modules. In this equipment the X9 connector can also be used as an input for an additional incremental encoder with square-wave output signals. Encoder simulation and incremental encoder input both use non-inverted and inverted signals (e.g. +1A=LOW → -1A=HIGH). Evaluation of encoder simulation signals Line receiver MC3486 is suitable for evaluating differential signals. The line should be terminated with a 120 Ω resistor. If required, the output signals from the MC3486 can be potential-isolated via an optocoupler. Pin no. X9 Assignment Function 1 +5V output in the case of incremental encoder: input to supply encoder (load 40 mA) 2 n.c. 3 +2R incremental encoder input 4 n.c. 5 +2B incremental encoder input 6 n.c. 7 +2A incremental encoder input 8 n.c. 9 n.c. 10 n.c. 11 n.c. 12 GND 13 +1R encoder simulation output 14 +5V 15 +1B encoder simulation output 16 -2R incremental encoder input 17 -1B encoder simulation output 18 -2B incremental encoder input 19 -2A incremental encoder input 20 +1A encoder simulation output 21 n.c. 22 -1A encoder simulation output 23 n.c. 24 -1R encoder simulation output 25 GND n.c. not connected 1 encoder simulation output 2 incremental encoder input (only in the case of encoder interface for optical encoders (Model D2) not for encoder interface for resolver (n.c.) R reference signal from an incremental encoder (zero pulse) A track A of incremental encoder B track B of incremental encoder

4-24 4.8 InterBus-S Interface (C1 and C7) Version Code C1: Local Bus Connection (IBS-L) C7: Remote Bus Connection (IBS-F) The Bus connection is via X11 and X12: X11 - InterBus-S output (Sub-D connector socket) X12 - InterBus-S input (Sub-D connector plug) X11 X12 �� �� �� �� �� �� �� yy yy yy yy yy yy yy PTC PTC U W V L1 L2 L3 RB RB + - 4 5 1 2 3 Screening: The Bus must be wired using a screened cable and the screening must be grounded to a grounding conductor via the connector housing. X11 Assignment X12 1 Uv0 1 2 Uv0 2 3 + 5 V 4 RBST 5 SLI 5 6 CKI 6 7 CRI 7 8 DI 8 9 COM 9 10 COM 10 11 RC 11 12 SLO 12 13 CKO 13 14 CRO 14 15 D0 15 n.c. 3, 4 Local Bus connection (C1): Sub-D 15-pin Remote Bus connection (C7): Sub-D 9-pin X11 Connection X12 1 D0 1 2 DI 2 3 COM 3 5 + 5 V 6 /D0 6 7 /DI 7 9 RBST 4, 8 n.c. 4, 5, 8, 9 No. Function 1 Connection for slot 1 (X6) 2 Connection X11 and X12 3 LED "Bus supply voltage OK " 4 LED "parameter channel initialised " 5 LED "TRANSMIT / RECEIVE"

4-25 Note: For further information on the installation, please consult the InterBus-S Installation Handbook by Messrs. Phoenix Contact (IBS SYSINST UM). 4.9 CAN-Bus Interface (C2) The Bus connection is via X11 and X12: X11 - Sub-D 9-pin connector socket X12 - Sub-D 9-pin connector plug X11 X12 Note: To ensure uninterruptible operation of the InterBus-S independently of the MC6000 mains power supply, the Servocontroller should be operated using an external +24V supply (see Section 4.4.1). Screening: The Bus must be wired using a screened cable and the screening must be grounded to a grounding conductor via the connector housing. 1) External +24V supply required (24 V DC, ± 10 %, 100 mA)! X11, X12 Allocation 1 5 V 2 CAN_L 3 GND-CAN 1) 4 ADR0 5 ADR1 6 GND-CAN 1) 7 CAN_H 8 ADR2 9 24V-CAN 1) Technical Specifications Supply voltage: 24 V DC ± 20 % for MC6000 controller Current: max. 3 A (slots 1 and 2 occupied), typically 0.5 A Interface version: C1 - Local Bus C7 - Remote Bus (2 conductor) Module identification: Factory setting 211,i.d. may be changed Data: Processing data - control word - reference value, channel width can be set PCP-Data - channel width can be set

4-26 Facilities for allocating device addresses: a) using a parameter (Addresses 0 - 29) b) using DIP switches on the PCB (Addresses 0 - 29) c) using a coded plug (Addresses 0 - 7) Connect address pins with pin 1 (+5V) X - Setting of no significance No. Function 1 linking for slot 1 (X6) 2 DIP switch for device addresses 3 X11 and X12 connector � � � � � � � y y y y y y y PTC PTC U W V L1 L2 L3 RB RB + - ON 1 2 3 4 5 6 7 8 3 1 2 ON 1 2 3 4 5 6 7 8 Technical Specifications Supply voltage: 24 V DC ± 20 % for MC6000 controller 24 V DC ± 10 % for CAN-Bus, pin 9 (X11, X12) Current: max. 3 A (slots 1 and 2 occupied), typically 0,5 A Baud rate: can be set from 50 kBit/s (1 km line length) to 1 MBit/s (40 m line length) Transmission: CAN-Bus to ISO11898 DIP switch/Pin No. ADRx 8 7 6 5 4 3 2 1 Address X X X 0 0 0 0 0 0 X X X 0 0 0 0 1 1 X X X 0 0 0 1 0 2 X X X : : : : : : X X X 1 1 1 0 1 29 Note: To ensure uninterruptible operation of the CAN-Bus independently of the MC6000 mains power supply, the Servocontroller should be operated using an external +24V supply (see Section 4.4.1).

5-1 5 MC6000 Software and Overview This section provides an overview of the Servocontroller software structure. The following sections provide further detail. The MC6000 Servocontroller software consists of 3 types: The software is immediately much easier to use if these categories are understood since only a fraction of the MC6000 software is actually of direct significance to the user. The operation software provides the user interface. It set parameters for the Servodrive, eg via the KEYPAD control unit or a PC. Operation using KEYPAD, Configuration of Control circuit for PC or bus systems Servocontroller, torque, speed and motor and en- position any special important Using the coder (matching matching by control for: Servocontroller to the application) technicians see Section 6 and separate Section 7 Section 8 descriptions Software des MC6000 Bedienung Konfiguration Regelung Operation Configuration Control MC6000 Software Parameter setting. The configuration software is used for setting parameters for individual components. Some parameters depend on the drive system hardware, eg the motor and encoder specifications and data specific to that the controller, (eg device rated current, options fitted etc). The motor and encoder data are stored on the SMARTCARD and can be downloaded to the equipment for automatic compatibility matching using the KEYPAD. The hardware configuration of the Servocontroller is recognised automatically and can be displayed using the KEYPAD. Because these data do not have to be set it is actually not very important for the user to be familiar with them. Matching the MC6000 Servocontroller to the specific application is part of the drive system configuration process. A function must be assigned to the freely assignable control input, for example, and the type of reference value input must be defined. This part of the configuration process is therefore important for the initial matching of the system to the application. Configuration is covered comprehensibly in Section 7 "Configuration Software".

5-2 The Control Software contains the internal control structures of the Servocontroller. The parameters in these control circuits include controller application and the lag time of the torque controller. As these parameters have been factory-set for best results, they will only need modifying in exceptional cases by qualified users. The control software is described in Section 8 "Control Software". In normal use there is no need to become involved in the complicated control structures.

6-1 6 System Software It is very simple to use the Servocontroller and set the parameters using the KP100 KEYPAD which is supplied as standard. 6.1 Layout of the KEYPAD Dimensions and weights stop return start enter VAL Hz SMART C A R D 2 4 3 5 6 7 1 No. Description Function 1 LCD display 140 segments, backlit, red/green 2 key Scroll backw3ards in menu structure, change value 3 key Scroll forwards in menu structure, change value 4 stop/return key Stop (CTRL menu), exit or exit from selected menu 5 start/enter key start (CTRL menu), confirm or select menu option 6 SmartCard chip card data store storage of device settings 7 cable max length 0.30 m Dimensions WxHxD mm 62x158x21 Weight g 100 Protection VBG4, IP20 Ambient temperature °C 0 - 40

6-2 PARA CTRL CARD VAL 6.2 Using the keys 6.2.1 General The equipment carries out a self test (display backlit in red) when the mains power supply is switched on. The instantaneous value of the control value is displayed (display backlit in green) when the test is complete. The VAL menu option is active. Press the stop/return key twice to return to the menu and see the menu options available. The current menu is always displayed on one line of the display. 6.3 Controls The arrow keys M and L are used for selecting menu options and specific parameters and for changing them. Press once to jump to the next menu branch or parameteror to increment or decrement a parameter value by the smallest step size. If a key is held down displayed values will change until released (scroll function). The stop/return key is used for exiting from a menu branch or cancelling parameter changes (old value is retained). The start/enter key is used for selecting menu branches and parameters and storing changes. stop return start enter stop return start enter stop return start enter stop return start enter KeyPad display: VAL PARA CTRL CARD Description Value Parameter Control Card Function: display values edit parameters control drive read/write SmartCard

6-3 6.4 LCD Display PARA CTRL CARD VAL %VA hmin-1 Hz/s 12 13 14 20 21 8 9 10 11 15 16 17 18 19 22 No. Description Function 8 Counterclockwise symbol for output rotating field counterclockwise enabled 9 Clockwise symbol for output rotating field clockwise enabled 10 Acceleration ramp symbol displayed when acceleration enabled 11 Braking ramp symbol displayed when braking enabled 12 3 digit display 7 segment display for editing status, parameter number or exponential 13 VAL menu display actual values, eg: speed 14 PARA menu change parameter setting 15 CTRL menu control drive from KeyPad 16 CARD menu load/save device settings using SmartCard 17 Physical unit to 20 displays %, V, A, VA with automatic assignment 18 Physical unit to 20 displays h, min-1 with automatic assignment 19 Physical unit to 20 displays s with automatic assignment 20 5 digit display 15 segment display for parameter name and value 21 Barchart caption displays formula characters/physical units for 22 22 10 column barchart displays selected parameter values

6-4 6.5 Control Levels The control level or mode is set using the parameter MODE (see PARA Menü). The number of parameters which can be edited and displayed depends on the mode selected. Modes 2 - 4 are protected from unauthorized access by passwords. The passwords allow access to all lower levels/modes. It is always a good idea to select the lowest possible level because then only those parameters which are really necessary are displayed. If the levels/modes are used systematically the parameters which are important for safe and reliable operation of the Servodrive are protected from unauthorised access. When the user wants to change the operating level (mode) he is automatically asked for his password — PWx (x stands for the mode requested). The password to be entered is the one entered in _KPAD as a password under PSWx for the level in question. The KEYPADs displays top left whether a parameter is just displayed independently of the current operating level or whether it can also be edited (parameter status): “-E-”: parameter status flashing If a user tries to edit a parameter which in the current operating mode/level can only be displayed this fact is indicated by error ATT1 (reset using start/end key). Note: If no key is pressed for 10 minutes the operating level is reset to Level 1. This avoids the risk of unauthorized access to a higher operator level after a parameter changing session. MODE Used for Comment Password PSWx 1 User without access authorization, no parameter editable, the most for status monitoring important parameters displayable 2 Users with basic knowledge, for the most important parameters 222 minimum operation editable, many displayable 3 Commissioning all parameters necessary for Users with advanced knowledge & standard applications can be 333 for control using the serial interface edited, many parameters can Interbus S, CAN be displayed 4 Users with technical control all control parameters can be expertise and for control using the edited and displayed 444 serial interface Display Meaning -S- Parameter can only be shown -E- Parameter can be edited "-E-“ Parameter is edited

6-5 Example1 - Setting user level to MODE=3: First the user level should be changed from 1 to 3. The MODE parameter in KEYPAD (_KPAD) must be edited and then the password (— PW3 —) must be entered. The password for this level is factory set to the value 333. We are assuming that you are starting at menu level in the PARA menu. 6.6 Examples for Setting Parameters The procedure for editing parameters can best be understood through examples. We recommend that you make these changes during actual commissioning of the Servocontroller. Note: You can cancel or exit from any action by pressing stop/return key. Reset to factory settings: • single parameter: press L and M simultaneously • all parameters: press L and M while switching mains on, KEYPAD will display RESET. Then download (read in) SMARTCARD (DRIVE) for matching to the motor. Symbols used: - x - - any parameter status (-S- or -E-) NNNNN - any parameter "-E-" - parameter status flashing (signifies Edit mode) Display Action Description MENU start/enter Open PARA Menu _CONF L or M Search _KPAD _KPAD start/enter Select _KPAD - E - MODE start/enter Access to editing in MODE parameter “- E -” 1 L To edit MODE "- E -“ 3 start/enter Select user level 3 start/enter --PW3-- start/enter Password request - E - 0 L Input password 333 Exit MODE parameter 333 stop/return Confirm password MODE stop/return Exit subject area Menu level _KPAD MENU

6-6 Display Action Description MENU start/enter Open PARA menu _KPAD or Search _CONF area _CONF start/enter Select _CONF area - x - NNNNN or Search for parameter CFCON - E - CFCON start/enter Enter edit mode of parameter CFCON "- E -“ NNNNN or Search PCON mode "- E -“ PCON start/enter Select PCON mode - E - CFCON or Possible search for further parameters to be edited in area _CONF - x - NNNNN stop/return Exit from area _CONF _CONF or Possible search for further parameters to be edited in the PARA menu NNNNN stop/return Exit from PARA menu MENU Example 2 - Setting Position Control mode By way of an example control mode is here set to Position Control. The corresponding parameter is CFCON (CONFIGURATION CONTROL) in _CONF, which contains the system configuration. The parameter CFCON must be set to PCON mode (POSITION CONTROL). It is only possible to change the mode at user level MODE=3 (or higher). At user levels 1 and 2 it is only possible to display the current mode. All Servocontroller parameters can be edited and displayed in a similar way.

6-7 6.7 Overview of Menu Structure VAL start enter start enter stop return stop return PARA PARA start enter start enter start enter stop return CTRL start enter start enter start enter stop return CARD CARD CARD start enter start enter start enter stop return stop return MOP A B C D VAL CTRL CARD VAL %VA hmin-1 Hz/s VAL PARA PARA VAL PARA CTRL CTRL CARD CTRL stop return stop return stop return start enter stop return A VAL Menu selected (display actual values) PARA Menu selected (set parameters) CTRL Menu selected (control drive from KeyPad) CARD Menu selected (load/save using SmartCard) B Display parameter value. Using arrow key, change to... Select area Password prompt, factory setting = 465 READ= load WRITE= save LOCK= enable write protect UNLCK= disable write C ... next parameter Select parameter Enter password Select parameter area Start with start/enter key D Display parameter value Display parameter value, or change Enable MOP function Function terminated error- free MOP = Motor operated potentiometer function in the CTRL Menu (Section 6.6.3 ). 6.7.1 The VAL Menu The VAL menu is used exclusively for displaying actual and fixed values. Parameters cannot be edited here. The number of parameters available depends on the user level (parameter MODE). To display the value of a parameter select the required parameter name by pressing L or M (scrolling) and then press the start/enter key to confirm. When the Servocontroller starts the KEYPAD displays this menu with the value of the parameter selected shown as the continuous actual value in the PARA menu. The default is factory-set. This is the control reference value, the parameter REFV (Reference Value).

6-8 Included in the actual values which can be displayed in the VAL Menu are, for example, the effective output current or speed. In addition parameters are available which provide information on the (instantaneous) condition of the device: software version, status word, service hours, most recent error etc. There is a complete listing of the VAL Menu parameters in Section 10.2. 6.7.2 The PARA Menu In the PARA menu the user can change parameters, those parameters to which the current user level affords him access. Setting parameters is described in Section 5.7. The PARA menu has sub menus. The parameters are grouped by subjects which makes dealing with large numbers of parameters much easier. The parameters are grouped by function-related subjects (not by parameter number). Grouping them by function in this way makes them fairly simple to use. The following subject areas are defined: Note: Not all the subjects displayed listed here can be displayed on the KEYPAD. The reason is that subjects which are dependent on device configuration and current operating mode do not contain parameters and are not displayed in the PARA menu. This makes it easier to make a selection from the relevant subjects. In the standard version of the device, subjects _OPT1, _OPT2 and _USER are not displayed as there are no corresponding parameters available. Code Term Description _CONF Configuration System configuration (controller HW/SW) _ENCD Encoder Opt. encoders & resolvers _OPT1 Option1 Slot 1 (X6) _OPT2 Option2 Slot 2 (X7) _MOT Motor Motor parameters _TCON Torque Control Torque control _SCON Speed Control Speed control _PCON Position Control Position control _SIO Serial Input/Output Configuration of serial interface _KPAD KeyPad KeyPad settings _SCTY Security Error responses and safety input _USER User Special parameters for custom software _REF Reference Parameter s for generating reference values

6-9 Only parameters from 3 subject areas, namely _CONF, _KPAD and _REF have a special meaning. _CONF contains the general configuration of the Servocontroller and the whole drive system. This can be used for selecting the control mode: control of torque, speed or position. There are some settings in _KPAD which relate to the KEYPAD, eg the user level and the continuous display of the continuous actual value. Parameters in areas _MOT and _ENCD depend on the type used and are stored on the motor- specific SMARTCARD supplied. The corresponding parameters in these areas can be viewed, but no changes can be made there. For this reason these two areas are more or less irrelevant for users. Control circuit parameters are in _TCON, _SCON and _PCON and are factory-set for optimum results. Small adjustments may be necessary in specific cases, (eg moment of inertia of the installation). This is described in detail in Section 8 "Control Software". _OPT1 and _OPT2 are reserved for parameters in versions with option slot X6 and X7, (eg InterBus-S Interface). The _USER area is reserved for customer-specific custom software. In the standard version of the equipment these areas are not required and are therefore not displayed. The groups _SIO and _SCTY are of subordinate importance. They may be used for one-off matching, eg baud rate of serial interface (_SIO) or error reactions (_SCTY). Note: Numbers are always displayed with 2 digits before and 2 digits after the decimal point. If, for example, you enter the display automatically converts to exponential representation PARA PARA This applies to the PARA and CTRL Menus.

6-10 6.7.3 The CTRL Menu This menu is used for operating the drive with any preferred reference value using the KEYPAD. Depending on the operating mode a reference value can be entered for torque, speed or position. In speed control, acceleration and braking ramps (parameters ACCR and DECR in the subject area _REF) can be used. The factory settings disable the ramps and accelerate and brake the drive at maximum torque. The KEYPAD is a higher priority control location than any of the others (terminals, SIO, etc.). Consequently whenever a reference value is entered using KEYPAD, control is switched to the KEYPAD automatically. Any other reference values from other control locations are disabled. Note: 1. The CTRL Menu is password protected. Password prompt: PASSW (factory setting = 465). The password can be changed using parameter PSWCT (_KPAD). 2. The CTRL Menu can only be accessed when the drive is stationary. 3. Whilst the CTRL Menu is selected (even if STOP is displayed), control is not possible from any other control location. Drive control using the KEYPAD (CTRL Menu): At menu level the CTRL Menu is accessed by pressing the start/enter key. If “STOP” is displayed it means that no reference value has been entered via the KEYPAD. Press start/enter again to edit the reference value. The reference value is expressed as an exponential to allow a wide range of settings. Holding down the M key changes the editing position and pressing the L key increments each digit, cycling back to 0 after 9. If the reference value is entered in full, it is swtiched to the drive simply by pressing start/enter. Note: The reference value is always displayed with the highest value unit in the 10 column. As it is displayed as an exponential, the number will often look different from what has been entered. The reference value can be changed on-line by pressing the stop/return key once. Pressing the stop/return key twice allows off-line editing. Press the stop/return key once more to exit from the editing mode. At the same time the reference value display on KEYPAD is replaced by the message STOP. Press the stop/return key to leave CTRL Menu and return to the main menu. Control has returned to the original control location.

6-11 CTRL Menu Structure CTRL Menu selected. Press the start/enter key to change to password prompt. Press the start/enter key to initiate password changes. Enter the password with the arrow keys (factory setting = 465). This has to be entered every time after a mains supply reset. Press the start/enter key to confirm the password (control terminals are blocked automatically). Press the start/enter key to start reference value input. The last digit flashes. It can be changed with the L key. Pressing the M key moves to the next position. The fifth position on the extreme left is reserved for the direction of rotation (—) = counterclockwise and ( ) = clockwise. The exponential can be entered as the last digit. Pressing the start/enter key starts the controller and the motor is run up to the reference value. Motor operated potentiometer (MOP) function using KEYPAD: press L key to increase reference value online press M key to reduce reference value online The ramp symbol flickers to indicate that the value is being changed. Pressing the stop/return key once causes the motor to continue running with a constant reference value. A new reference value can be entered. Pressing the start/enter key again causes the Servocontroller to use the new reference value. Pressing the stop/return key twice stops the motor. Note: Online means that the motor output will follow the reference value change immediately. The reference value changes initially in small increments which gradually increase if one of the arrow keys is held down. Small increments (with smallest increments, speed = 1/655 RPM, programmable with CTLFA (_KPAD)) are sometimes not visible on the display, but the ramp symbol flickers to represent the changing value. start enter stop return start enter start enter 0...9 start enter stop return 0...9 CTRL CTRL CTRL CTRL CTRL CTRL stop return stop return start enter CTRL start enter

6-12 6.7.4 The CARD Menu This menu is used for reading from and writing to the SMARTCARD for storing device settings and for automatic matching to specific motors. The CARD Menu contains 4 functions: READ and WRITE Functions The parameters on the SMARTCARD have been grouped by activity. These groupings do not correspond to the subject areas in the PARA Menu. When you write to the SMARTCARD all parameters are saved. After selecting READ, select the required area. It is possible to read just one section of a SMARTCARD which contains the complete parameter set. Setting Identification Read ... ALL All All parameters OPTN1 Option 1 Parameters for model in slot 1 (X6) OPTN2 Option 2 Parameters for model in slot 2 (X7) APPLI Application Application-specific parameters SYSTM System General system configuration REFRC Reference Parameters for setting reference values and Function selectors DRIVE Drive Drive parameters stop return start enter CTRL min-1 SMART C A R D Function Description READ Read some or all parameters from the SmartCard WRITE Save all parameters on the SmartCard LOCK Enable SmartCard write-protected UNLOCK Disable SmartCard write-protection Note: 1. The CARD Menu can only be selected when control is disabled. 2. Control cannot be started whilst you are still in the CARD menu. 3. For this reason there is an automatic switch to the VAL Menu after 10 minutes. 4. Parameters which are dependent on existing hardware or which are determined by software settings are not stored on the SMARTCARD. These parameters are identified in Section 10 as "not stored", eg hardware and software status word (CFHSW and CFSSW in subject area _CONF). 5. Bus system operation: whilst the SMARTCARD is being read from or written to, the bus is disabled. If the bus watchdog is switched on it may therefore be triggered. SMARTCARD for ASx and PSx Servomotors The SMARTCARD is used for minor matching to Ser- vomotors in the series ASx and PSx. All motor parameters and complete controller specifications are stored on the SMARTCARD under DRIVE. The motor type is printed on the SMARTCARD. It is also possible to save all parameters on this SMARTCARD (setting ALL).

6-13 6.8 Setting the parameters for the MC6000 Parameters for the Servocontroller are set in the PARA Menu. When the PARA Menu is selected the first subject area is displayed. Now select the required area containing the parameters to be edited. Press the L or M arrow keys to scroll through the subject areas. Confirm selection by pressing the start/enter key.. Now the first parameter of the selected area is displayed. As you have now selected the required subject area you can access all the parameters in this area by scrolling up and down (using L or M arrow keys). Parameter status is displayed top left. An -S- (Show) indicates that this parameter is for display only and cannot be edited. The letter -E- (Edit) indicates that the parameters can be edited. Parameter status depends mainly on the operating level (MODE parameter). Press the start/enter key to go into edit mode. Edit mode is indicated by the flashing parameter status “-E-”. The parameter value can now be changed using L and M arrow keys. The new setting can be confirmed by pressing start/enter or cancelled by pressing stop/return. PARA Menu structure The PARA Menu has been selected. Tap the start/enter key to change the subject level.. The L or M arrow keys are used for selecting a subject area, eg. _CONF = configuration of controller. Tap the start/enter key to change the parameter level. Use the L or M arrow keys to select parameters, eg CFCON = control mode. Tap the start/enter key to edit the parameter. Use the L or M arrow key to select, eg SCON = speed control. Tap the start/enter key to confirm the selection. Another area, _REF = reference value input is described on the next page. Press the stop/return key to exit from any level immediately. The last stored value is retained. PARA PARA PARA PARA PARA start enter stop return start enter stop return start enter

6-14 PARA menu structure (parameters expressed as an exponential) _REF = reference value input selected. Tap the start/enter key to change to the parameter level. Select the parameter level with the arrow keys L or M eg. RFIX1 = fixed reference value 1 Tap the start/enter key for parameter change (edit). The last digit will flash. This can now be changed using the L arrow key. The M arrow key moves to the next position. The fifth digit on the extreme left is reserved for direction of rotation: (—) = counterclockwise and ( ) = clockwise. The last position can be used to show the exponential. Pressing the start/enter key confirms the change. Value confirmation is possible at any time during the change process. PARA PARA PARA PARA start enter stop return start enter stop return start enter 0...9 start enter stop return 0...9 Changing parameters Changes in parameter values usually take effect immediately, ie they become effective whilst the drive is controlled. In the case of some parameters however a reset is necessary because any change in these parameters could have far reaching consequences. A reset can be triggered by: especially suitable for setting 1. Leaving the PARA Menu parameters using KEYPAD after setting parameters 2. Reset and execute universal (control via terminals, serial interface or start command Bus system) 3. Setting the parameter PLRDY universal, but not convenient when setting (_KPAD) parameters using the KEYPAD On reset the parameter list is checked for validity and dependent parameters are calculated. There is a short pause for updating the parameter list. In order to avoid this delay when starting the drive, the reset can be triggered manually in advance (option 1 or 3 above).

7-1 7 Configuration Software It is important to differentiate between the two types of parameters in the configuration software: a) Parameters which relate to the actual hardware. These are recognised automatically by the Servocontroller and stored on the SMARTCARD supplied; the user can display them on the KEYPAD : Control parameters in areas _TCON, _SCON and _PCON depend on the motor and are also stored on the SMARTCARD. b) Parameters which relate to the specific application. These can be entered by the user as appropriate. xxx = wildcard, any alphanumeric character This sequence must always be observed during configuration. Configuring the Servocontroller (Five-Point Plan): Parameter Area 1. Read in the SmartCard with the motor specifications (DRIVE area) 2. Select control mode CFCON _CONF (torque, speed or position) 3. Select control location CLSEL _CONF (Control via terminals, serial interface,, InterBus-S, CAN-Bus, etc.) 1) 4. Program function selectors FIS0x, FISAx, _CONF (Allocate functions to inputs and outputs, FOS0x, etc see Section 7.1) 5. Program reference values _REF (see Section 7.2) 1) The control location identifies the source of control commands START and INV (invert reference value). Parameter Area Description MOxxx _MOT Motor data (rated speed, moment of inertia, SmartCard resistance, inductivity, etc.) ECxxx _ENCD Encoder data SmartCard (line count, pole pair count etc.) CFMOT _CONF Motor type (asynchronous/synchronous) SmartCard CFPNM _CONF Device performance class (rated current) automatic CFCMX _CONF max. output current automatic OPTN1 _CONF Detection of module in option slot 1 (X6) automatic OPTN2 _CONF Detection of module in option slot 2 (X7) automatic CFHSW _CONF Hardware status word automatic TYPE VAL menu Device type automatic

7-2 7.1 Function Selector Each input and each output (I/O) of the device has a parameter which allocates a function to the input or output. These parameters are called function selectors and are found in Configuration (_CONF). Standard unit has two digital inputs (IS00, IS01), two analog inputs (ISA0-/+, ISA1) and two outputs (OS00,OS01). The associated function selectors are FIS00, FIS01, FISA0, FISA1, FOS00 and FOS01. Output OS00 can also be used as a PWM output. Section 7.6 contains examples of the use of function selectors. I/O Module 1: If the number of inputs and outputs on the standard equipment is inadequate for an application, an additional 8 inputs and 4 outputs can be made available by using the I/O Module 1. The additional inputs and outputs have the same functionality as the inputs and outputs of the standard equipment. The associated function selectors are in _OPTN2 of the PARA-Menu. I/O Module 1 is described in Section 11. Advantages of the SMARTCARD: All parameter settings can be stored on SMARTCARDs and transferred to other servo spindles. In this way several drives can have their parameters set to identical values quickly and reliably. By reading in the SMARTCARD (READ - ALL) all settings can be copied to other drives. This eliminates the need for steps 2 to 5 in the Five-Point Plan. If you only wish to copy the configuration (for example if there are various motors), then read in areas SYSTM and REFRC from a SMARTCARD consecutively. The control parameters have been optimised for the motor in the factory settings and stored on the SMARTCARD. By reading in the motor data, the Servocontroller is automatically set for best results with the motor in use. In most applications it is not necessary to make any further changes. If it should arise, however, that after configuration the drive characteristics are not satisfactory, then the control parameters should be matched (e.g. set the moment of inertia of the installation or the set-up mode for speed control, see Section 8). Warning! Not reading the SMARTCARD with motor data will usually result in inferior control characteristics. There is also the danger that the motor may accelerate uncontrollably and may even be destroyed.

7-3 Warning! When a function is changed it is enabled immediately (this applies to all input function selectors). The drive will start instantly the moment the function START is assigned to an input. 7.1.1 Input Functions Each of the inputs IS00, IS01, ISA0 and ISA1 (when using the I/O Module also IE00 to IE07) can undertake one of the following functions if the appropriate function selector has its parameter set accordingly (_CONF and _OPTN2). The described function is carried out if there is high level at the input (Exception: emergency stop and hardware position slot are low active). Note: Inputs which have been assigned the same function operate as an OR-Link. 1) Functions /STOP, MP-UP, MP-DN and SCALE are described in Section 7.3 "Special Functions". Settings: Function: OFF Switch off input (if not required) START Start control with set reference value INV Invert reference value ,of reference value channels 3 & 4 (see diagram, Structure of Reference Value Input /STOP Emergency Stop function triggered by applying a low level signal 1) ADy-x Switching between reference value sources (see Section 7.2) /ENDL, Detecting hardware limit switches (ccw/cw) with low level /ENDR If a limit switch has been triggered, the device can be turned in the other direction. E-EXT Signal input for error messages from an external device (e.g. from the PLC). The response of the Servocontroller is determined by parameter R-EXT (_SCTY). MP-UP, Motor potentiometer function (changing reference value by push button). MP-DN Input MP-UP increments and input MP-DN decrements the reference value by the value of parameter PINC (_REF) (see also Section 7.2 Reference Value Input) 1) OPTN1, The input is made available to the module in option slot 1 or 2 OPTN2 (for function see the relevant description) No function if module not present USER0, USER1 The input can be used by the custom software USER2, USER3 No function in the case of standard software ANALG The input is used as an analog reference value input Only possible for analog inputs ISA0 and ISA1 SCALE Scaling torque limitation TCMMX from 0 - 100 %. Only for input ISA1. 1) SPEED Direct input for rapid speed setting (avoids reference value input) Used in conjunction with a superoridinate position controller. Scaling using RNA0. Only for input ISA0.

7-4 7.1.2 Functions of Outputs Each of the outputs OS00 and OS01 (when using an I/O module, also OE00 to OE03) can undertake one of the following functions if the parameters are set for the appropriate function selector (_CONF or _OPTN2). The output produces high level when the condition is fulfilled. 1) The function ANALG is described in Section 7.3.4 "OS00 as PWM output". 7.1.3 Fixed Inputs FIF0 and FIF1 The Servocontroller also provides two simulated "inputs" using selectors FIF0 and FIF1 (Function Selector Fixed Input; Area _CONF). These always have the fixed value 1 (High level) so they can be used instead of a continuously on switch. Fixed inputs are useful if the Start signal or inverting in the reference value input is switched on continuously. Setting: Function (the output is set if...): OFF Switch off output (if not required) ERR ...there is a fault (error). WARN ...there is a warning (error without error response). /ERR ...there is no error. /WARN ...there is no warning. ACTIV ...control is active (green LED flashing). ROT_R, ...clockwise, counterclockwise, stationary; depends on ROT_L, parameter SPD_0 (CONF). ROT_0 LIMIT ...the actual value of the control has reached a limit value; depends on parameters RLIM1, RLIM2 (_REF). REF ...the actual value has reached the reference value (window); depends on parameters REF_R (_CONF). ASM ...an asynchronous motor has been parametered. SIO The output is controlled by control word (SCTL1 (_SIO) OPTN1, The output is assigned to the module in slot 1 or 2 OPTN2 (for function, see specific description). No function is module not present. ERRW ...there is a warning or error. /ERRW ...there is no warning and no error. USER0, USER1 The output can be used by custom software USER2, USER3 No function in the case of standard software ANALG only for output OS00! The output provides a PWM signal. The value of the analog output is is determined by parameter FOA0 (_CONF).

7-5 7.2 Reference Value Input 7.2.1 Short Description of Reference Inputs The purpose of reference value input is to prepare an externally entered reference value and to transfer it to the control. Parameters for reference value input are set specific to the application when commissioning the Servo drive. Four reference value selectors are used for selecting any number of reference value sources (e.g. analog input, serial interface etc.). Each reference value selector has a permanent link with an internal reference value channel. The channels are linked and can also be processed mathematically. This produces the overall reference value which is then fed to the control. Irrespective of the control mode, the reference values are entered in the same way. The reference value entered always refers to the selected mode. Therefore the unit of this parameter always relates to the current mode (Nm, min-1 or r (=rotations)). 7.2.2 Description of Reference Inputs The diagram "Structure of Reference Value Input" shows the detailed structure of reference inputs. The parameters for reference value input can be edited in _REF (Reference) of the PARA-Menu and also display. The parameters which have been calculated, and therefore cannot be edited, are identified in the diagram with an asterisk (*) after the parameter number. There are 16 reference value inputs (A): • 2 analog inputs • RS485 serial interface • digital reference value input (not with standard software) • motorised potentiometer (MOP) via digital inputs • POSMOD1position controller • Bus-Interfaces (e.g. Interbus-S-Local Bus Link) • Application Hardware (e.g. I/O-Module 1) • 8 fixed reference values which can be set via software Reference Value Selectors (B): Depending on the setting, the four reference value selectors RSSL1 to RSSL4 (Reference Source Selector) the reference channels are fed from the reference sources. Each reference source can be used as an input for several channels i.e. several selectors can point to one source. An offset SADD1 to SADD4 (Selector Addition) can be added to the selectors. This offset consists of a 4-bit data word (= 0 -15). The offset can be changed using digital inputs if the function selectors are suitably configured (c.f. Section on Function Selectors). In this way, the settings of the reference selectors can be changed using digital inputs and switching is possible between various reference sources, e.g. between two fixed values. The use of selectors and switching via input is explained using examples in Section 7.4.

7-6 Structure of Reference Value Input RCON (=0) REF1 433* RSSL1 417 SADD1 421* + SADD2 422* + RSSL4 420 SADD4 424* + ROPT2 432* ROPT1 431* RDIG 430* RPOT 429* RSIO 428* RA1 426* RA0 425* REF5 437* REF4 436* REF2 434* REF3 435* REF6 438* REFV 447* RLIM2 81x RLIM2 RLIM2 RLIM1 80x RFIX6 79x RFIX5 78x RFIX4 77x RFIX3 76x RFIX2 75x RFIX1 74x RSSL2 418 RSSL3 419 + SADD3 423* RF3FA 448 + - +/- + - + ACCR 842 DECR 852 + % FIxxx= INV Off RLIM2 81x RLIM1 80x FISA1= ANALG RNA1 83x FISA0= ANALG RNA0 82x B C A 1 10 14 11 12 2 3 4 5 6 7 8 9 15 17 18 19 20 START ACTV 400* - D RCON RCON RLIM2 RCON 0 ...10 V 0 ...20 mA ± 10 V ± 20 mA START STOPR 496 16 13 15 FISA0= SPEED RNA0 82x

7-7 Key to "Structure of Reference Value Input" : In parameters whose numbers end in an "x", the last position represents the type of control selected: * - Parameters read only cannot be edited. Symbols used: Reference value source (input) Reference value selector (switch) Mathematical effect Intermediate reference values, for display only Reference value limit x Control mode 1 Torque control 2 Speed control 3 Position control 1) Not available with standard software. 2) Acceleration ramp and braking ramp only available in speed control mode. 3) The drive coasts out of control if START is disabled. If this is undesirable, set drive to new reference value (e.g. speed 0 min-1) or use stop ramp. Explanation on Reference Value Sources (A): • It is unusual for all four reference value channels to be required. The channels not required are switched off by setting the appropriate selector to the value RCON (Reference Constant). This is a software constant which has the value =0. The reference value channels 1, 2 and 4 are shown as switched off in the diagram (factory setting). • Both analog inputs can be adjusted using parameters RNA0 or RNA1 (Reference Normal Analog Input). The value of these parameters indicates which reference value is to be entered if a maximum value of + 10 V or + 20 mA is applied to the input. e.g.: Mode speed control, RNA1 = 3000 means that a speed of 3000 rpm corresponds to a reference value of + 10 V When using analog inputs, the function selectors e.g. FISA0 (_CONF) should have their parameters set accordingly. • If reference values are to be entered via the serial interface, then the appropriate sector of the required reference value channel must be switched to RSIO. • There are six software reference value sources RFIX -RFIX6 (Reference Fixed Input) with fixed reference values; these are freely available. These fixed values can be edited here directly. No. Function No. Function A Reference value sources The diagram shows the reference value B Ref. value selectors of 4 ref. val. channels selectors with factory settings C Ref. val. channels & intermediate ref. vals. D Calculation of overall reference value 11 Sign reversal possible 1 Rapid reference value channel for ±10V 12 Ramp generator 2) 2 Constants for switching off channel 13 Effective only after START 3 analog ref value inputs ISA0, ISA1 14 Reference value limit 4 Ref. value input serial interface 15 Start command closes the switch & 5 MOP function (via digital inputs) initiates acceleration ramp 3) 6 Input of digital reference values 1) 17 Automatic switchover with FISA0-SPEED 7 Ref. values from module in slot 1 or 2 16 Stop ramp (Emergency Stop) 8 Fixed ref/. vals (parameters can be set) 18 Overall reference value 9 Ref value selector with offset facility 19 Actual value of control 10 Percentage reference value matching 20 To the control structure

7-8 • The other software reference values RLIM1 and RLIM2 have a fixed function assigned to them. RLIM1 (Reference Limit 1) is the lower limit of the reference value, RLIM2 (Reference Limit 2) the upper limit. Both limit values, like the freely available fixed values, can be edited directly. RLIM1 and RLIM2 can also be used as reference value inputs. At the same time, both these parameters also represent the maximum and minimum values for a reference value which is entered via a different reference value source. If the reference value entered reaches the limit value RLIM1 or RLIM 2, then this is indicated by the flashing red LED and the direction of rotation symbol in the KEYPAD display flashing. Reference Value Channels and Intermediate Reference Values (C): The calculated intermediate reference values can be displayed using parameters REF1 to REF6. Channels REF1 and REF2 and also channels REF3 and REF4 always work together. Channel 2 is subtracted from channel 1, channel 4 is subtracted from channel 3. The reference value of channel 3 can be matched in percentage terms using Factor RF3FA . The prefix can be changed using an input to which function INV has been assigned. Parameter ACCR (Acceleration Ramp) determines the accleration ramp and parameter DECR (Deceleration Ramp) determines the deceleration ramp. Acceleration and deceleration ramps are only available in the speed control mode. The unit used in these parameters is min-1s-1. The ramp generator can be swtiched off by setting ACCR or DECR =0. Then the drive accelerates or decelerates with maximum torque (parameter TCMMX in area _TCON) to the reference speed. The ramp generator is triggered by the START signal. The drive coasts on uncontrolled if the START signal is withdrawn (c.f. Stop ramp Section 7.3.1). Calculation of the Overall Reference Value (D): The total reference value is produced by the switching of all reference value channels together. The total reference value can be limited to one area by using the parameters RLIM1 and RLIM2. CTRL-Menu If the CTRL menu of the KEYPAD is used to control the drive, channel 3 is used automatically. Ramps ACCR and DECR can be used to control speed. Reference value channels 1, 2 and 4 and also inverting are switched off. Direct Input for Superordinate Position Control The setting FISA0= SPEED (_CONF) should be selected for ±10V speed reference values if the Servocontroller is to be driven from an external positioning control using speed reference values. This provides time-efficient monitoring and processing of speed reference values (250 µs). For scaling use the parameter RNA0 (_REF) as described for the analog input. The reference value selectors should be switched off RSSLx= RCON (_REF) otherwise the error message E-PAR (error in parameter list) will be displayed. If the SPEED function is selected, control is not possible via the CTRL-Menu. POSMOD1 A separate rapid reference value channel has been arranged for the integrated positioning and sequence control POSMOD1 and arranged in the MC6000. It is used for transferring position reference values and processing profiles to the control. If POSMOD1 is inserted in slot X7 there is automatic switching to this module (when POSMOD1 is removed, all selectors will be reset automatically to the factory setting). The reference value input must not be programmed when positioning control is used. Any previous settings in the area _REF are disabled when POSMOD1 is inserted in the slot.

7-9 7.2.3 Setting Reference Value Input a) If reference values are to be provided continuously from one reference value source: • Set a reference value selector, e.g. RSSL3 to the required reference value source. • Only in the case of speed control: set parameters for the acceleration and deceleration ramp ACCR and DECR (_REF). • If necessary set parameter for an inversion of reference value on channel 3 using the function selector of an input. • If necessary, parameter a percentage matching of the reference value using RF3FA (_REF). 0 = Low Level 1 = High Level After the reference value selectors have been set and hence the required reference value source(s) has/have been selected, other reference value input parameters can be set. Which parameters are to be set depends on the reference value selector and reference value source(s) selected. For examples, see Section 7.4 "Examples". ISA0 ISA1 RSSL3 = (Offset +1) (Offset +4) 0 0 RFIX1 (Default) 1 0 RFIX2 0 1 RFIX5 1 1 RFIX6 ISA0 ISA1 RSSL3 = (Offset +1) (Offset +8) 0 0 RFIX1 (Default) 1 0 RFIX2 0 1 RCON (off) 1 1 RA0 Setting Offset binary Offset decimal ADx-0 0001 b 1 ADx-1 0010 b 2 ADx-2 0100 b 4 ADx-3 1000 b 8 b) Switching between a number of reference value sources using external signals: • Set RSSL3 (for example) to the reference value to be selected if there are no external signals at the inputs. • Using the diagram "Structure of reference value input" check how many reference value sources are to be handled by applying external signals. e.g.: If there is to be switching between RFIX1 and RFIX2 the extent of switching =1. • Now the appropriate function has to be assigned to the input e.g. ISA0 at which you wish to feed in the external signals for switching. In the case of the example that would be FISA0 = AD3-0. The setting AD3-0 produces an offset to the basic setting of the reference value selector RSSL3. The value of the offset is derived from a binary 4-bit word. • If additionally the function FISA1 = AD3-2 is allocated to input ISA1, then the following switching facilities for RSSL3 = RFIX1 result: • With FISA1 = AD3-3 the following transfer occurs: Note: A number of reference value selectors can be used in order to superimpose reference values from a variety of sources.

7-10 7.3 Special Functions 7.3.1 Emergency Stop (/STOP) The Emergency Stop function can be used as an additional protective function. Emergency Stop can be triggered from a variety of difference control locations: The ramp can be entered in units min-1s-1 at which the motor is to be braked down to Speed=0, using the Stop Ramp parameter STOPR (_CONF). With the setting STOPR= 0 (factory setting) the motor is braked at the set torque limit (TCMMX in area _TCON) as quickly as possible (Emergency Stop without ramp). Control of the drive remains switched on and the motor is held speed controlled in this position. The Emergency Stop can be activated from any control mode. Note If torque limiting (SCALE Function) is activated, it also takes effect in the case of an Emergency Stop. Resetting the Emergency Stop: Emergency Stop condition remains until the /STOP-Signal and the Start signal have both been reset. Warning! The ENPO signal must not be discontinued during the Emergency Stop condition or the motor would be isolated from its control. In that case, the Servocontroller would lose control of the motor and the motor would coast on uncontrolled. 7.3.2 Auto Start In many applications it may be necessary to enable control automatically after switching on mains power. In such cases the parameter AUTO should be set to the value "ON" in the area (_CONF). After mains power is switched on (even after a short power failure) control is automatically switched on if the Start signal is present Note: 1. The Start Signal may be applied continuously if a fixed input FIF0 or FIF1 (_CONF) =START. The input IS00 can then have another function assigned to it. 2. There is no Start signal after a mains power supply failure when controlling from the CTRL- Menu. Control Application Emergency stop triggered by Control terminals Input configured as „/STOP“ Serial interface Bit in control word SCNTL (_SIO) Interbus-S See InterBus-S data transfer protocol CAN-Bus See CAN-Bus data transfer protocol E/A-Module Input configured as„/STOP“

7-11 7.3.4 Output OS00 as PWM Output Output OS00 can be used as a PWM output. Note however that the output signal is only suitable for display instruments with slow response but not for processing in controls. An external filter can be used however to smooth the signal if necessary and produce an analog signal. Setting Output TORQE instantaneous torque SPEED instantaneous speed POS instantaneous position CURNT instantaneous effective output current IA0 input differential at input ISAO IA1 input value at input ISA1 The following parameters in the _CONF area are used to configure the PWM output: Factory setting: SPEED FOA0 Function selector which determines what value shall be outputted at output OS00 Four modes can be set using the parameter MPCNF (_CONF) : Parameter RSSLx= RPOT (_REF): Set MOP as reference value source Parameter MPCNF (_CONF): Select operating mode (MOP configuration) Parameter RINC (_REF): Determines step for increment/decrement Input with MP-UP function Increases reference value Input with MP-DN function Reduces reference value 7.3.3 Motor-operated Potentiometer Motor-operated Potentiometer (MOP) function means that the reference value is increased or reduced by a specific amount via two digital inputs or via the L and M arrow keys of the KEYPAD. MPCNF Mode MP-UP input MP-DN input Function 0 condition controlled 0 0 - without reset 1 0 Increase ref. value 0 1 Reduce ref value 1 1 - 1 condition controlled 0 0 - with reset 1 0 Increase ref value 0 1 Reduce ref value 1 1 Reference value = 0 2 flank controlled 0 0 - without reset 0 > 1 0 Increase ref value 0 0 > 1 Reduce ref value 1 1 - 3 flank controlled 0 0 - with reset 0 > 1 0 Increase ref value 0 0 > 1 Reduce ref value 1 1 Reference value =0 PWM Frequency 200 Hz Transition Frequency (internal low pass filter) 1 kHz Output voltage range 0 to +24 V

7-12 Other parameters for output OS00 as PWM output: OA0MN minimum output value; value of output at 0V; factory setting= 0 OA0MX maximum output value; value of output at +24V; factory setting= 0 Example: The instantaneous speed is outputted via OS00 with factory setting of these parameters and selection of the PWM function by setting FOS00=ANALG (_CONF). The parameters OA0MN and OA0MX determine the speed window: speed: 0 ... 3000 U/min entsprechen output voltage: 0 ... 24 V Note: The SCALE Function limits the reference value for torque, i.e. the torque generated by the Servocontroller (see diagram). Additional dynamic forces from the moment of inertia of the load may also act on the motor shaft. 7.3.5 Torque Limitation (SCALE) In many applications there is a requirement for the torque limitation to be adjusted continuously. The SCALE function can be used to adjust the torque limitation via the analog input ISA1. When the SCALE function is enabled it also affects Emergency Stop. FISA1= SCALE 0 ... +10 V 0 ... 20 mA 0 .. 100 % TCMMX M G MC6000 0 V +10 V FISA1= SCALE 1 2 3 4 +TCMMX -TCMMX - - ISA1 0 ... 100 % TCMMX _SCON _TCON 5 Example: Winding Drive To avoid the wound material breaking, a certain torque must not be exceeded. The tension value is captured by the compensating jockey and the torque is corrected accordingly. Code: 1 Compensating jockey 2 Upper jockey stop (M=0, n=0) 3 Lower jockey stop (M=max., n=max.) 4 Speed reference value 5 Bobbin with wound material corresponds to

7-13 +10 V ISA0- -10 V ISA0+ ISA1 +24V +24V IS00 IS01 ENPO OS00 OS01 X5 1 2 3 4 5 6 7 8 9 10 11 12 13 14 10k DGND AGND 7.4 Examples of Applications This section explains the control terminal arrangements, programming the function selectors and the reference value input by way of examples. 7.4.1 Example: Analog Reference Value Input A synchronous machine is to be driven with speed control using an analog reference value (0 - 10V) in the range -3000 to +3000min-1. In an emergency the motor is to coast on independently of the control. In case of error a 24 volt relay is to be operated. a) How should the control terminals be connected? b) What parameter settings should be made? c) What parameters should be set if an asymetrical speed range of -1000 to +3000 min-1 is required? Solution: a) Control terminal connections: b) Setting configuration parameters using the Five-Point plan: Parameter Setting Area 1.Read in the SmartCard with the motor specifications 2.Select control mode CFCON SCON _CONF 3.Select control location CLSEL TERM _CONF 4.Set function selectors: _CONF IS00 =Start control FIS00 START IS01 =Reverse (change direction) FIS01 INV ISA0 =No function FISA0 OFF ISA1 = Reference values (0 to 10 V) FISA1 ANALG OS00 =Error message display FOS00 ERR OS01 =No function FOS01 OFF 5.Program reference values: _REF Use reference value channel 3, RSSL1 RCON switch off other channels RSSL2 RCON RSSL3 RA1 RSSL4 RCON Scaling: 10 V = 3000rpm RNA1 3000 1) 1) Displayed as 30.00 *E2

7-14 Ref. Value IS01 Speed 0 to + 10 V 0 0 to + 3000 rpm 0 to + 10 V 1 0 to - 3000 rpm Result: Ref. Value IS01 Speed 0 to + 10 V 0 +1000 to +3000 rpm 0 to + 10 V 1 +1000 to +3000 rpm Ref value Speed 0 to 10 V -1000 to 3000 rpm 2.5 V 0 rpm Note: The Servocontroller parameter settings are factory-set so that the acceleration and deceleration ramps (ACCR and DECR) are switched off and the matching factor RF3FA = 100 %. The parameters of the drive are already set to meet the requirements of the operation. The control circuits have been set to suit the motor by reading in the SMARTCARD and do not require any further matching in standard applications. c) Setting parameters for asymmetrical speed range Solution 1: with prefix switching A fixed reference value channel 1 is switched on which continuously adds 1000 min-1 to the reference value of the analog input. The following changes should be made: RSSL1 = RFIX1 RFIX1 = 1000 RNA1 = 2000 Result: Solution 2: without prefix switching Using a fixed reference value 1000 min-1 are continuously subtracted from the reference value of the analog input. The following changes should be made: RSSL1 = RFIX1 RFIX1 = -1000 RNA1 = 4000 FIS01 = OFF Result:

7-15 7.4.2 Example: Reference Value Input using Serial Interface Torque values are to be transferred to a drive via the Serial Interface. How should the parameters be set? Solution: Use the Five-Point Plan for the configuration. The parameters in area _SIO should be checked and matched up if necessary. This may be necessary particularly for the baud rate (SBAUD) and the device address (SADDR). The drive will then be controlled using control word SCTL1. Do not forget to bridge signal ENPO to + 24 V! Parameter Setting Area 1. Read in SmartCard with motor data 2. Select control mode CFCON TCON _CONF 3. Select control location CLSEL SIO _CONF 4. Do not set function selectors as no _CONF inputs or outputs are required 5. Program reference value input: _REF Use reference value channel 1, RSSL1 RSIO switch off other channels RSSL2 RCON RSSL3 RCON RSSL4 RCON

7-16 7.4.3 Example: Switching Fixed Reference Values The Servo drive is to operate to the speed profile as in the diagram below. A PLC provides the reference values in the required time frame. An Emergency Stop will provide protection. How should the parameters be set? n1 = 6000 min-1 t1 = 3 s n2 = 1000 min-1 t2 = 1 s n3 = 0 min-1 t3, t4 and t5 are non-critical and are derived from t1 und t2 n4 = - 500 min-1 Solution: The reference value channel 3 is used (RSSL3) so that the ramp generator can be used. Speeds n1 to n4 are programmed as fixed reference values RFIX1 to RFIX4. The reference value selector RSSL3 is set to the first reference value RFIX1. Switching between the reference values is on a bit-coded basis via inputs IS01 and ISA0. Both inputs change the value of the offset for reference value channel 3 (parameter SADD3) by means of using its binary value. So that Bit 0 of ISO1 and Bit 1 of ISA0 are affected, the function selector should be set as follows: FIS01 = AD3-0 Bit 0 of offset for RSSL3 FISA0 = AD3-1 Bit 1 of offset for RSSL3. The following arrangement shows the value of the offset parameter and the selected reference value in relation to the two inputs. The superordinate PLC sets the inputs IS01 and ISA0 to suit the speed profile. -n +n n1 n2 n4 min-1 n t1 t2 t3 t4 t5 t1 t s n3 Bit 1 Bit 0 Value of Resultant 0 0 0 RFIX1 0 1 1 RFIX2 1 0 2 RFIX3 1 1 3 RFIX4 (ISA0) (IS01) SADD3 reference value

7-17 Acceleration and braking ramp are determined from: ACCR: DECR: 6000 1000 1 5000 1 1 1 − = − − − min min s s Times t3 bis t5 can be calculated: t s s t s s t s s 3 1 1 1 4 1 1 1 5 1 1 1 1000 5000 0 2 500 2000 0 25 500 5000 01 = = = = = = − − − − − − − − − min min , min min , min min , Please note that under certain circumstances and especially in field weakening the available torque may not be sufficient to accelerate as required at specific moments of inertia. Setting parameters: When these settings have been entered, the drive parameters are fully customized to meet your requirements. 6000 3 2000 1 1 1 min min − − − = s s Parameter Setting Area 1. Read in SmartCard with motor data 2. Choose control mode CFCON SCON _CONF 3. Choose control location CLSEL TERM _CONF 4. Set function selectors: _CONF IS00 = Start control FIS00 START IS01 = Switch bit FIS01 AD3-0 ISA0 = Switch bit 1 FISA0 AD3-1 ISA1 = Emergency Stop FISA1 /STOP 5. Program reference value input: _REF Use reference value channel 3, RSSL1 RCON switch off other channels RSSL2 RCON RSSL3 RFIX1 RSSL4 RCON enter fixed reference values RFIX1 6000 RFIX2 1000 RFIX3 0 RFIX4 -500 Enter limit values RLIM1 -500 RLIM2 6000 Enter ramps ACCR 2000 DECR 5000

7-18 7.4.4 Example: Analog reference value input with switching A drive is to be driven with an analog reference value a) 0 to + 10 V b) - 10 V to + 10 V Using a switch the drive will be ramp controlled to 0 rpm or to a different speed. What parameters should be set? a) 0 to + 10 V: Result: b) - 10 V ... + 10 V: Result: Ref value ISA1 speed 10 V to+10 V 0 3000 to +3000 U/min 10 V to +10 V 1 0 rpm Ref value ISA0 speed 0...+10 V 0 0 to +3000 rpm 0...+10 V 1 0 rpm Parameter Setting Area 4. Set function selectors _CONF IS00 = Start control FIS00 START IS01 = ohne Funktion FIS01 OFF ISA0 = Switching bit 3 FISA0 ANALG ISA1 = Ref value ( 0...10 V ) FISA1 AD3-3 5. Program reference value input RSSL1 RCON _REF RSSL2 RCON Use channel 3, RSSL3 RA0 switch off others RSSL4 RCON Fixed ref value, e.g. 0 rpm RFIX2 0 Scaling: 10 V = 3000 rpm RNA0 3000 Parameter Setting Area 4. Set function selectors _CONF IS00 = Start control FIS00 START IS01 = not allocated FIS01 OFF ISA0 = Switching to bit 3 FISA0 AD3-3 ISA1 = Reference value ( 0...10 V ) FISA1 ANALG 5. Program reference value input RSSL1 RCON _REF RSSL2 RCON Use reference value channel 3 RSSL3 RA1 switch off others RSSL4 RCON Fixed reference value, e.g. 0 rpm RFIX1 0 Scaling: 10 V = 3000 rpm RNA1 3000

8-1 8 Control Software The MASTERCONTROL MC6000 servocontroller works on the principle of flux vector control. Flux vector control means that current is introduced into the part of the motor where the field is strongest. In this way the current is converted most efficiently into torque. The result is maximum utilization of the motor with the best possible dynamic performance and with minimum losses. This produces a very high level of efficiency. Traditionally DC servo-motors have been used for dynamic drive applications because they can be regulated very simply as analog units. Nowadays because of the tremendous increase in the capacity of electronics these drives are being replaced by dynamic digitally-controlled AC induction servomotors. These have considerable advantages over DC servos: • Reproducibility: Digital control produces excellent reproducibility because there is no drift caused by temperature or over time. This is especially important in positioning applications. • Precision: Resolution and precision are inherently higher when using a digital version than with analog control. • The price: Because they are simpler, three phase motors are also cheaper. • Space requirements: The AC motor is considerably more compact than the DC motor. • Service Life: AC servo motors are virtually non-wearing, whereas DC motors are expensive to maintain and repair (e.g. brushes). • Speed: The speed range is wider and ranges from 1 rpm up to maximum of 12,000 rpm, (asynchronous machines with field weakening). A digital drive controlled by MASTERCONTROL is suitable for all applications in which one or more of the following characteristics are important: • Constant speed (concentricity) • Positioning accuracy • Dynamics • Constant torque • Disturbance suppression (varying load) MASTERCONTROL can be used for controlling both synchronous and asynchronous motors. Asynchronous motors are extremely robust and permit high maximum rpm in field weakening and are required for example for the main spindle drive in machine tools. The advantages of synchronous motors with permanent magnet excitation may be seen in their minimum size and dynamic response.

8-2 The MC6000 servocontroller can be operated in three modes: • Torque Control (TCON) • Speed Control (SCON) • Position Control (PCON) The servocontroller has three control circuits which are superimposed on each other (see diagram). Depending on the mode, the subordinate control circuits are enabled e.g. in speed control only the speed controller and torque controller are enabled. The speed reference value (7) is then supplied directly by the reference value, the position controller (E) is disconnected and does nothing. The parameters of the control loops are classified in the PARA menu in three areas _TCON, _SCON and _PCON. Torque and speed controls are in the form of PI controllers, the position controller is in the form of a P controller. The gain (P proportion) and the adjustment time (I proportion) of the individual controllers may be set as parameters in the specific area. The control circuits are matched automatically to the motor data by downloading the SMARTCARD which produces excellent results with the specific motor. Tedious fine tuning of controller settings is a thing of the past. Depending on the application it may be necessary, however, to match one or two specific parameters, if, for example, the system has a high moment of inertia (see Section 8.3, item 3 and Section 8.3.1). Control circuit cycling times: Torque controller: 125 µs Speed controller: 250 µs (with optical encoders G1, G2, G3, G4) 500 µs (with resolvers R1, R2, R8) Position controller and pre-controller: 500 µs M 3 ~ G - - - B D C A 1 2 3 4 5 6 8 9 E 7 No. Function No. Function A Modulator and power stage D Speed control B Processing of actual values E Position control C Torque control 1 Voltage capture 6 Speed actual value 2 Current capture 7 Speed reference value 3 Speed and position signal 8 Position actual value 4 Torque actual value 9 Position reference value 5 Torque reference value

8-3 8.1 General Control Structure The basic structure shown here applies to all types of control. Additional structure diagrams build on this. Note: The formation of the differential from the reference value minus actual value occurs in the controller block and is not shown separately for the sake of simplicity. This applies also to the other block diagrams. Motor data such as rated speed (MOSNM), rated current (MOCNM), rated torque (MOMNM), moment of inertia (MOJNM) etc. are stored in _MOT. The ASM has a number of other parameters: rotor resistance (MOR_R), magnetizing inductance (MOL_M). In addition there are also maximum speed (MOSMX) and motor constants (MOMC0...MOMC4) in the field weakening area. The switching frequency of the modulator can be controlled using parameter PMFS (_CONF). The torque controller parameters which can be set in _TCON are: gain (TCG), reset time (TCTLG) and torque limitation (TCMMX). The scanning time of the TCTS controller is fixed at 125 µs. The torque controller has two inputs m1* and m2* which can be summated internally. The second input is necessary for inputting initial control values in position control and also for torque control. This is explained in the following sections. Each of the torque controller inputs has limits. The aim of limits is to ensure that the permitted limit values are not exceeded. The limits of input m1* are dynamic and depend on input value m2*. M 3 ~ C A B _TCON _CONF _MOT TCG TCTLG TCMMX TCTS TCTLG m1* m2* PMFS MOxxx : : TCG +TCMMX -TCMMX TCMMX-m2* -TCMMX-m2* No. Function A Asynchronous or synchronous motors B Modulator and power stage C Torque controller m1* and m2* are torque controller inputs

8-4 8.2 Torque Control Mode As shown in the diagram, the speed controller is also enabled in torque control mode. This special feature offers the following advantages: • The speed controller limits the speed to the maximum value set in parameter SCSMX. The controller works as a P controller. Reset time SCTLG is inactive. • If an Emergency Stop is triggered, the speed controller brakes the drive at the maximum torque configured using TCMMX down to rpm n=0. This is an error condition which can be reset by canceling and enabling the power stage ENPO by resetting. The I proportion SCTLG of the speed controller is switched for the execution of Emergency Stop Relevant parameters: 1. Torque maximum value TCMMX (_TCON) Generally the torque limit should be determined by the servocontroller, as the maximum torque of the motor can be approximately five times the nominal torque, but the device can only take double the rated current for ten seconds. If the application requires limitation of torque then TCMMX should have its parameters set accordingly. Note: TCMMX limits the reference value of the torque. Only when the shaft is stationary does this correspond to torque limitation on the motor shaft. In the case of extreme external moments of inertia it may also apply in the dynamic context. Torque limitation can also be set from 0 - 100% on-line using the function SCALE via analog input ISA1 (see Section 7.3.5). 2. Speed Maximum Value SCSMX (_SCON) This parameter limits the maximum rpm of the motor, also when it is in torque control mode. The maximum value of the parameter is determined by the rated speed MOSNM of the motor in use. The maximum speed should be limited to suit the application as appropriate. _TCON TCTLG m1* m2* TCG +TCMMX -TCMMX TCMMX-m2* -TCMMX-m2* SCSMX -SCSMX B A 1 2 3 _SCON (SCTLG) SCG SCG SCGFA SCTLG SCSMX SCJ SCTS TCG TCTLG TCMMX TCTS No. Function A Torque controller B Speed controller 1 To modulator and power stage 2 Torque reference value 3 Speed reference value

8-5 3. Lag time of torque controller TCTLG (_TCON) the lag time is optimized for the motor and no adjustment is necessary. 4. P gain of torque controller TCG (_TCON) The gain is optimized for the motor and no adjustment is necessary. 8.3 Speed Control Mode The speed controller obtains its reference value from the inputs n1* and n2*. Input n2 is only required for precontrol in position control and is otherwise disabled. The speed controller generates a torque reference value which is transmitted to the torque controller. Relevant Parameters: 1. Torque limit TCMMX is the only parameter from the _TCON area which is set to suit the requirements of specific applications (see “Torque Control Mode”). 2. Maximum Values of Speed SCSMX (_SCON) Limit of speed controller MOSNM (_MOT) Rated speed of motor (SM and ASM) MOSMX (_MOT) Maximum speed of motor (only in the case of ASM, only for speed limitation) The parameter SCSMX limits the maximum speed of the motor. The maximum value for this parameter is obtained from the data of the motor in use. In the case of synchronous motors this is the rated speed MOSNM and in the case of asynchronous motors the maximum speed MOSMX (in the field weakening area). The parameters for SCSMX speed limitation are always set to be application-specific. m1* m2*=0 SCSMX -SCSMX _SCON SCTLG SCG SCG SCGFA SCTLG SCSMX SCJ SCTS FCxxx VCxxx 1 2 n2*=0 n1* No. Function 1 To torque controller 2 Speed actual value n1*= Speed reference value m1*= Torque reference value Note when using positioning and sequencing control POSMOD1 (AH2): 1. Asynchronous motors can only be operated up to the rated motor speed MOSNM (_MOT) and field weakening cannot be used. 2. Motor parameter K14 must be used to limit operating speed (not SCSMX).

8-6 3. P gain of speed controller The total P gain results from the following parameters. SCG (_SCON) Parameter for P gain of speed controller SCGFA (_SCON) For scaling and fine adjustment of SCG (0 - 999%, factory setting 100%) SCJ (_SCON) Moment of inertia of installation MOJNM (_MOT) Moment of inertia of motor. This is set to suit the motor by loading the motor specification from the SMARTCARD SCG is factory set on the assumption that the moment of inertia of the installation = 0. The moment of inertia of the installation should be set using the parameter SCJ. This results in proportional matching of the resulting controller gain. Using parameter SCGFA it is possible to fine tune the gain on-line. The gain of the controller is calculated as follows: SCG SCJ MOJNM MOJNM SCGFA ∗ + ∗ ∗ ( ) % 2 100 . If the moment of inertia of the installation is not known, the function of the Servocontroller should be used for setting speed control, as described in Section 8.3.1. Permissible maximum values for SCG, SCGFA and SCJ are each calculated such that the total controller gain is in the permitted area of 0 - 108. 4. Reset time of speed controller SCTLG (_SCON) The lag time should be calculated in advance for the basic setting of the Servocontroller and does not normally need to be changed again.

8-7 n(t) t 1. 2. 3. 4. 1 2 3 4 8.3.1 Setting speed control The MC6000 speed controller has a function for setting the speed control step. When a speed step is applied the step response from the drive is captured. From this response the quality of the control circuit can be judged and the P proportion of the speed controller can be set. This function should be used especially in cases where the moment of inertia of the installation is not known exactly. The step response provides the following Servocontroller values automatically: a) Rise time TA b) First overshoot c) Number of overshoots which are grater than 10% of the first overshoot a) Rise time TA b) First overshoot c) Number of overshoots which are greater than 10% of the first overshoot Definition: overshoot = maximum value (1) - reference value (4) TA n(t) t 95 % No. Function 1 First overshoot distance 2 10 % of first overshoot distance 3 Overshoots counted (excluding 1st overshoot) 4 Reference value

8-8 Using setup mode (Setup mode) Setup mode is used for setting up the speed control circuit, taking into account the moment of inertia of the installation. The motor must therefore be connected to the installation. Setup mode cannot be used in conjunction with the SCOPE function of MCWORK. Safety waring: Remember that the connected motor will rotate in setup mode. You as user are responsible for ensuring safety. 1. Select MODE = 4 (_KPAD) 2. Enable speed control CFCON = SCON (_CONF) (otherwise the error message E-PAR will be displayed with the error location number 118) 3. Switch off ramps: set parameters ACCR and DECR =0 (_REF) 4. Activate setup mode with SETUP = ON (_CONF) 5. Re-initialize (which returns to the main MENU) 6. Operate the speed control with reference value 0 rpm (e.g. using the CTRL menu) then apply a positive or negative step of approximately 50 to 100 rpm. When the motor reaches the reference speed the control can be switched off again. 7. The values of the speed step response of the system (Servocontroller and link) can be read in _SCON of the PARA-Menu: • STIME Setup Time Rise time • 1OVER First Overshoot First overshoot • 10PC Ten Percent Number of overshoots until the amplitude has reduced to less than 10% of the first overshoot The values of the rise time and the first overshoot are only valid if the torque limitation of the motor was not reached (otherwise control behaves in non-linear fashion). If the limit case occurs because too high a reference value step has been set STIME and 1OVER will be preceded by a negative prefix. In this case the step response must be obtained again with a step to a lower speed. 8. Optimizing the step response by matching SCGFA (_SCON). In most applications a step response is required which has the minimum first overshoot. After the first or, at the very latest, the second overshoot, the overshoot distances should be less than 10 % of the first overshoot (Parameter 10PC < 1). In general it is true to say that the rise time is shorter when SCGFA is increased (and vice versa) but this can also render the control loop unstable. Main Sequences: 1 slow increase to final speed without overshoot (aperiodic sequence) 2 very short rise time but strong overshoot 3 short rise time with minimum overshoot (usually preferable) n(t) t 1 2 3

8-9 9. If a new reference value step is entered, the parameters of the SETUP mode are updated automatically. 10.The SETUP mode is switched off when SETUP = OFF (_CONF). The speed controller is factory set to the symmetrical optimum with control filter: The first overshoot is 15%. The speed controller uses speed steps larger than approximately 50 to 100 rpm (depending on the drive) for speed limitation. The torque controller executes the speed change. The 15% overshoot only applies to the range within which the speed controller is active (small signal). Example: Speed step 0 → 3000 min-1 Speed controller limitation from 50 to 100 min-1 15% of above overshoot = 7.5 - 15 min-1 8.3.2 Speed in field weakening Asynchronous motors can be run at high speed with reduced torque in the field weakening range. The graph shows the main features of torque relative to speed in the field weakening range. Speed/torque graph for an asynchronous motor Relevant Parameters The MC6000 Servocontroller has additional parameters for operating in the field weakening area (speed control _SCON, FCxxx, VCxxx). The parameters have already been optimized for the specific machine using the SMARTCARD at the factory and no further adjustment is necessary. MN M0 nmax nN M Nm n min-1 8.4 Position Control The position control circuit is integral in the Servocontroller and is used in conjunction with the positioning and sequence control POSMOD1 (option). POSMOD1 provides the position reference value for the internal position controller, prepares the functions necessary for positioning and also includes an operating and programming interface.

8-10 8.4.1 Position control without pre-control This is actually only a theoretical control as the MASTERCONTROL Servocontroller uses an integral pre-control which is described in the next section. Operation without pre-control is described here for the sake of simplicity. 8.4.2 Position control mode In position control an additional pre-control and reference value smoothing is executed. Pre- control means that speed reference values and torque reference values are generated from the position reference value and fed to the specific controller. This results in very short control reaction times and the position controller hardly has to intervene. The motor is simulated in the MASTERCONTROL Servocontroller. From a technical point of view the motor and installation count as onesystem. The system cannot be overloaded because the Servocontroller does not demand more than the system can deliver. The position reference value is also smoothed so that it is possible to home in on set target positions virtually without overshoot. Relevant Parameters: 1. Torque limit TCMMX (in the _TCON area) is the only parameter which has to be set to suit the specific the application (see “Torque Control Mode”). 2. The _SCON parameters are also important in position control (see „Speed Control Mode“). 3. P-Amplification of Position Controller The total P gain results from the parameters: PCG (_PCON) parameter for P-amplification of position controller PCGFA (_PCON) for scaling and fine setting of PCG (0 - 999%) The total P-gain is calculated as follows: PCG PCGFA ∗ 100% . The maximum value of the product is 16383, and the limits of PCG and PCGFA are matched dynamically to it. For pre-control to work reliably it is necessary for the value of parameter SCJ to correspond approximately to the actual moment of inertia of the installation. Otherwise position control may produce unsatisfactory results. The response may be too dynamic (with a tendency to overshoot) or too unresponsive. In such cases it may be necessary to match the gain of the position controller. Fine adjustment of the gain on a percentage basis can be carried out on- line using parameter PCGFA. 4. Acceleration of the position controller can be limited by parameter PCAMX (_PCON). The unit of acceleration of the acceleration limit value is rpm/s. 5. Maximum values for position control are provided by software and hardware limit switches. No. Function 1 To position controller 2 Position actual value p1*= Position ref value n1* n2*=0 _PCON PCG PCGFA PCG PCGFA PCAMX PCTS 1 2 p1*

9-1 9 Displays and Error Messages 9.1 Operating Display The MC6000 Servocontroller has three LEDs which provide current status information. The location of the LEDs is visible above the control terminals when the front panel of the cabinet is open. The two main LEDs (red and green) are also visible from the front through the cover. LED green (H1) LED red (H2) LED yellow (H3) Status off on flash off on flash off on flash X X X device is switched off X X X Servocontroller ready X X X Servocontroller ready & warning X X X control enabled X X X control enabled & warning X X X flux build-up phase X X X flux build-up phase and warning X X X control must be initialized or is being initialized X X X control must be initialized or is being initialized and warning X X X reference value limit enabled (RLIM1, RLIM2) 1) X X X error X X X error response X X X charging relay not driven 9.2 Error Messages x, xx, xxx - wild card characters: represent any alpha numeric character Resetting of warnings and Servocontroller errors (after correcting the cause): • rising flank on ENPO input of control terminals warning: This disconnects the Servocontroller from the motor. The motor coasts on/rotates freely • Press the KEYPAD stop/return key for approximately 3 seconds • Set the ‘Reset Error’ bit in the SIO controller (only when controlling using RS485 serial interface; CLSEL = SIO) • Set the ‘Reset Error’ bit in InterBus-S/CAN-Bus (only when controlling using InterBus-S/CAN-Bus; CLSEL = OPTN1) 1) In addition KEYPAD flashes the symbol the indicate direction of rotation ( or ) KeyPad display: red red LED (H2): LED on KeyPad displays: Section E-xxx Warning or fault on Servocontroller 9.2.1 ATTx KeyPad operating error 9.2.2 ERRxx SmartCard error 9.2.3 Errors are indicated by:

9-2 9.2.1 Warning and errors in the Servocontroller Warnings: safe operation not affected, no further reaction (display only) Errors: safe operation is affected, programmable reaction Six defined error reactions can be programmed. These range from a warning to an error reaction in which the drive is stopped by Emergency Stop and locked. The standard setting and programming of error reactions is described in detail in the Description of Parameters in Section 10.2.11. In case of error, an error message and a location number (top left on the screen display) are displayed. Accurate diagnosis is assisted by the error location number. If an error occurs which you cannot correct without the assistant of LUST, please give our service engineer the error location number. Error Error Cause Solution locat. no. OFF 1 undervoltage, d.c. link voltage connect increased <425 V (also displayed on normal voltage supply or restore power off) power E-CPU --- processor defective 1) E-OC 1 overvoltage caused by incorrectly check control circuit parameters, f or insulation fault or internal check installation; 1) defect in device E-OV 1 over-voltage from brake 1) chopper overload set DECR ramp to slower (braking too long or too hard (_REF), set external braking resistor or or chopper; mains power supply over-voltage adjust mains voltage E-OLI 1 Servocontroller I*t switch off reduce load, reduce (exceeding permitted I*t) maximum torque TCMMX (_TCON) E-OTI 1 Servocontroller overtemperature: ambient temperature too high or; improve ventilation; load too high (power stage or brake 1) install higher capacity chopper) Servocontroller or external braking resistor or braking chopper E-OTM 1 motor overtemperature (PTC in the let motor cool off motor triggered): PTC not connected; connect PTC or bridge terminals; or motor overload 1) install more powerful motor E-OLM I²-t motor monitoring reduce load (currently no function) E-FLW drag error accelerate or reduce load E-WDG 11 Watchdog for RS485 triggered check busmaster or increase SWDGT (_SIO) set parameters or short circuit, ground