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Drive Technology \ Drive Automation \ System Integration \ Services
MOVI-PLC®
Application Solution “SyncCrane“
ManualEdition 03/200811666617 / EN
SEW-EURODRIVE – Driving the world
1 General Information ............................................................................................ 51.1 Structure of the safety notes ....................................................................... 51.2 Right to claim under limited warranty.......................................................... 51.3 Exclusion of liability..................................................................................... 61.4 Other applicable documentation ................................................................. 6
2 Description .......................................................................................................... 72.1 Fields of application .................................................................................... 72.2 Application examples .................................................................................. 92.3 Functional principle of indirect positioning and synchronization ............... 102.4 Program identification ............................................................................... 15
3 Project Planning................................................................................................ 163.1 Prerequisites ............................................................................................. 163.2 Functional description ............................................................................... 173.3 Scaling the drive ....................................................................................... 193.4 Limit switches, reference cams and machine zero ................................... 203.5 Process data assignment.......................................................................... 213.6 Software limit switches.............................................................................. 253.7 Hardware limit switches ............................................................................ 263.8 Safe stop................................................................................................... 27
4 Installation ......................................................................................................... 284.1 Software MotionStudio.............................................................................. 284.2 Wiring diagram MOVIDRIVE® MDX61B................................................... 294.3 Bus installation PROFIBUS DHP11B ....................................................... 304.4 Connecting system bus (SBus 1).............................................................. 30
5 Startup................................................................................................................ 315.1 Prerequisites ............................................................................................. 315.2 Preliminary work ....................................................................................... 315.3 Starting the SyncCrane program .............................................................. 335.4 Parameters/H variables of the MOVI-PLC® ............................................. 495.5 Drive inverter parameters ......................................................................... 505.6 Group signals............................................................................................ 505.7 Program overview of the PLC program..................................................... 53
6 Operation ........................................................................................................... 556.1 Starting the drive....................................................................................... 556.2 Diagnostics monitor .................................................................................. 566.3 Jog mode – unsynchronized ..................................................................... 566.4 Referencing mode..................................................................................... 596.5 Positioning mode – unsynchronized ......................................................... 606.6 Automatic mode ........................................................................................ 626.7 Emergency mode...................................................................................... 676.8 Additional functions................................................................................... 686.9 Cycle diagrams ......................................................................................... 696.10 Fault information ....................................................................................... 76
Manual – MOVI-PLC® Application Solution "SyncCrane"
34
7 Auxiliary Drive (Auxiliary Axis)........................................................................ 777.1 System description.................................................................................... 777.2 Project planning for auxiliary drives .......................................................... 797.3 Startup of auxiliary drives.......................................................................... 837.4 Operation of auxiliary drives ..................................................................... 89
8 Appendix............................................................................................................ 938.1 Frequently asked questions ...................................................................... 93
9 Address List ...................................................................................................... 94
Index ................................................................................................................. 103
Manual – MOVI-PLC® Application S
olution "SyncCrane"1Structure of the safety notesGeneral Information
MOVI-PLC® Application Solution "SyncCrane"1 General Information1.1 Structure of the safety notes
The safety notes in these operating instructions are structured as follows:
1.2 Right to claim under limited warrantyA requirement of fault-free operation and fulfillment of any rights to claim under limitedwarranty is that you adhere to the information in the MOVIFIT®, MOVIDRIVE® orMOVITRAC® documentation. Consequently, read the operating instructions andmanuals before you start working with the unit!
Make sure that the operating instructions and manuals are available to personsresponsible for the plant and its operation, as well as to persons who work independentlyon the unit. You must also ensure that the documentation is legible.
Symbol SIGNAL WORD!Nature and source of hazard.
Possible consequence(s) if disregarded.• Measure(s) to avoid the hazard.
Symbol Signal word Meaning Consequences if disregarded
Example:
General hazard
Specific hazard,e.g. electric shock
HAZARD! Imminent hazard Severe or fatal injuries
WARNING! Possible hazardous situation Severe or fatal injuries
CAUTION! Possible hazardous situation Minor injuries
STOP! Possible damage to property Damage to the drive system or its environment
NOTE Useful information or tip. Simplifies the handling of the drive system
Manual – MOVI-PLC® Application Solution "SyncCrane"
56
1 clusion of liabilityeneral Information
1.3 Exclusion of liabilityYou must comply with the information contained in the operating instructions to ensuresafe operation of MOVIFIT®, MOVIDRIVE® or MOVITRAC® and to achieve thespecified product characteristics and performance requirements. SEW-EURODRIVEassumes no liability for injury to persons or damage to equipment or property resultingfrom non-observance of these operating instructions. In such cases, any liability fordefects is excluded.
1.4 Other applicable documentation• This manual does not replace the detailed operating instructions and the
corresponding manuals.
• Installation and startup of the inverter only by trained personnel observing therelevant accident prevention regulations and the following documents:
– "MOVIFIT® FC" operating instructions and corresponding manuals
– or "MOVIFIT® MC" operating instructions and corresponding manuals
– or "MOVIDRIVE® MDX60B / 61B" operating instructions and correspondingmanuals
– or "MOVITRAC® B Basic Unit" operating instructions and corresponding manuals
ExG
Manual – MOVI-PLC® Application Solution "SyncCrane"
2Fields of applicationDescription
2 Description2.1 Fields of application
The SyncCrane application module is used to implement applications in which drivesmove at a synchronous angle to one another permanently or occassionally, such as:
• Lifting devices
• Cranes
• Hoists
• Travel carriages
The IEC program controls up to 8 MOVIDRIVE® individual axes. In Automatic mode, itsends a virtual master signal to the individual axes switched in synchronous operation.Control of 4 additional auxiliary drives (e.g. pushers/hydraulic units, etc.) is supported.
2.1.1 Advantages of the SyncCrane applicationThe SyncCrane application offers the following advantages:
• Only one MOVI-PLC® is required for controlling the individual axes.
• Open IEC programming lets users make application-specific adjustments.
• The software wizard ensures guided startup and comprehensive diagnosticfunctions.
• High degree of similarity with "SEW application modules".
• In addition to the motor encoder, external absolute encoders (HIPERFACE®/SSI)can be connected and evaluated.
• Common setpoint for automatic mode is ensured by controlling the single axis viavirtual encoder.
• Indirect positioning or indirect synchronization allows for safe system operation in thefollowing cases:
• Different wear of the drive axes
• Slip, for example between drive gear and steel rail
• Design susceptible to vibration
This application solution provides the user with an easy-to-use and guided startupstandard solution based on the principle of "indirect positioning/synchronization".
This solution approach allows the following applications:
• Applications with high requirements on the dynamic properties.
• Applications that are susceptible to vibration due to mechanical conditions (e.g. dueto high elasticity and/or unfavorable load distribution between the drivelines).
Manual – MOVI-PLC® Application Solution "SyncCrane"
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2 elds of applicationescription
2.1.2 Characteristics of positioning mode and jog mode
Characteristics of positioning mode and jog mode:
• Positioning mode based on motor encoder with optional indirect position adjustmentbased on external synchronous encoder.
• Override function for reaching the target in an optimized manner by straightening thelinear deceleration ramp.
• Group / individual axis control of the connected axes.
• Software limit switch evaluation
2.1.3 Characteristics of referencing modeCharacteristics of referencing mode:
• Referencing the motor encoder system to the specified reference offset.
• Depending on the reference travel type, referencing is performed to a standstillposition or the axis system is referenced to a cam position via search travel.
• Adjusting the external encoder signal to the specified reference offset.
• Group control for all connected axes.
• Single-axis control when using the "standstill" reference travel type.
2.1.4 Characteristics of automatic modeCharacteristics of automatic mode:
• Automatic alignment of the physical axes with each restart.
• Synchronous operation with automatic indirect synchronization of the externalencoder system to the virtual encoder position.
• Virtual master value processing with jerk-limited ramp specification.
• Group control for all connected axes.
• Automatic interruption of the motion sequence if an axis fails and/or the specifiedsynchronicity is violated.
2.1.5 Characteristics of emergency modeCharacteristics of emergency mode:
• Jog mode (with motor encoder or without encoder).
• Group / individual axis control of the connected axes.
• Deactivation of the selected absolute encoder detection and monitoring.
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Manual – MOVI-PLC® Application Solution "SyncCrane"
2Application examplesDescription
2.2 Application examplesThe SyncCrane application module offers a wide range of possible applications. Someexamples are given in this section.
Example 1: Multiple column hoist with positioning and synchronization based onHIPERFACE® motor encoder.
Example 2: Gantry crane with indirect positioning and automatic slip compensation bymeans of absolute encoder evaluation.
511850891
511852427
SlaveMaster
SlaveMaster
Manual – MOVI-PLC® Application Solution "SyncCrane"
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2 nctional principle of indirect positioning and synchronizationescription
2.3 Functional principle of indirect positioning and synchronization2.3.1 The Problem
Existing applications with evaluation of the absolute encoder as IPOS encoder (seeIPOS manual chapter "Position detection and Positioning") limit the control dynamicsdue to the properties of the absolute encoder systems and the mechanical conditions(e.g. mounting of the encoder system).
Due to mechanical feedback, the entire system is susceptible to vibrations, which oftenrequires complex optimization of the control parameters on site.
The IPOS-based application module "DriveSync" was implemented according to thisprinciple. Especially when it comes to lifting devices and assembly-hall cranes, whereevaluation of an absolute encoder is necessary in addition, compromises have to bemade in project planning with respect to dynamics.
The SyncCrane application solution simplifies startup and operation.
2.3.2 Conventional solution: Direct position control with absolute encodersThe necessary SHELL parameters are determined during guided startup (SHELL/DIPstartup). Direct position control is part of the firmware. This means no additionalprogramming is required.
During the positioning operation, the cyclically read-in actual position (absolute encoder/motor encoder position) is read in by the profile generator and corrected by adjustmentof the n-controller in case of deviations.
Deviations caused, for example, by slip between motor encoder and absolute encoderthus directly affect the speed profile of the drive.
The following figure shows direct position control with position correction.
536585611
vmax Maximum velocity nC Speed controlleramax Maximum acceleration nact Actual speedPG Profile generator ABS Absolute encoderPC Position controller IPOS IPOSplus® program
DIP 11B
PG PC nC
M
–
+
nact
Vmax
amax
IPOS
–
+
X62
ABS
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Manual – MOVI-PLC® Application Solution "SyncCrane"
2Functional principle of indirect positioning and synchronizationDescription
The following figure shows the speed profile (motor encoder) for direct position control.
774628875
[1] Optimal speed process[2] Real speed process
V [m/s]
t [s]
[1][2]
Manual – MOVI-PLC® Application Solution "SyncCrane"
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2 nctional principle of indirect positioning and synchronizationescription
2.3.3 SyncCrane solution with indirect position control
Unlike direct position control, the absolute encoder signal is only evaluated for correct-ing the specified target position.
During the travel process, the speed profile of the drive is therefore not changed.
Susceptibility to vibration caused by retroactive effects, for example deviations betweenthe absolute encoder detection and motor encoder detection, are minimized in this way.
The user can optimize time delays in absolute encoder sensing and setpoint processingby setting an "override". The override causes an early and softer run-in to target, whichsuppresses overshoots.
This function is part of the SyncCrane application module.
The following figure shows indirect position control with absolute encoder.
536587275
vmax Maximum velocity POSact Actual position motor encoderamax Maximum acceleration POSset Setpoint position motor encoderPG Profile generator ABS Absolute encoderPC Position controller nact Actual speednC Speed controller
Calc
Delta IncPGMOVI-PLC PC nC
M
Posact
Posset
nactX15 Pos
act
Vmax
amax
DIP 11B
+ +
– –
X62
ABS
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Manual – MOVI-PLC® Application Solution "SyncCrane"
2Functional principle of indirect positioning and synchronizationDescription
The following figure shows the speed profile (motor encoder) with override for indirectposition control.
2.3.4 ConclusionThe table below contains a comparison of both solutions and their effects on internalposition control.
Result The following properties do not have an effect on the speed profile of the drive but onthe target position of the position controller if positioning tasks are solved using indirectposition control:
• Slip
• Properties of the absolute encoder
• Mechanical elasticities between absolute encoder sensing and the drive
This leads to a higher dynamic response and thus to improved operating characteristicsfor dynamic positioning applications.
This solution with indirect positioning has been successfully implemented at SEW-EURODRIVE for some time in the area of SRUs with cornering ability, etc.
536580619
V [m/s]
t [s]
Optimal speed process
Real speed process
Direct position control Indirect position control
Mechanical mounting Direct effect No direct effect
Position resolution Direct effect No direct effect
Properties, such as time delay Direct effect No direct effect
Dynamic response that can be achieved
Low due to summation of nega-tive effects
High
Startup effort High, since optimum setting has to be found iteratively
Low
Effort for implementation in the program
No Only parameter setting effort when function modules are available.
Manual – MOVI-PLC® Application Solution "SyncCrane"
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2 nctional principle of indirect positioning and synchronizationescription
2.3.5 SyncCrane solution indirect synchronization to virtual master encoder
Due to the mentioned positive characteristics in relation to indirect positioning, we arecurrently testing if this can also be applied to synchronous operation.
We are working on the approach to superimpose a higher-level control loop for slipcompensation on the firmware function "internal synchronous operation".
Internal control loop: Angular synchronous operation of the motor encoder
Angular synchronous operation is ensured by using the "internal synchronousoperation" technology function.
The specified value for the virtual master is created via SBus object from the MOVI-PLC®. The optimum master value is ensured for the physical axes because the mastervalue can be specified with limited jerk.
The controller parameters can be set "hard" by direct coupling of the drive trains.
Higher-level control loop: Indirect synchronization
To prevent mechanical strain, e.g. caused by slight differences in the crane wheel diam-eter of gantry cranes, the actual position value read in via an absolute encoder must becompared with the position setpoint of the virtual encoder and corrected if necessary.This is implemented by the higher-level indirect synchronization.
The cyclically calculated difference value triggers a compensation movement if specifiedposition windows are exceeded (distinction is made between dynamic and static case).The dynamics of the compensation movement is set during startup.
The following figure shows indirect synchronization.
536582283
X62Slave
VirtEncoder
Download
SynchronousState
= MDX_GEAR_OFFSET
SynchronousSpeed
= VESpeed * Raising
SynchronousSpeed= Staticspeed
OffsetCycleValue = DeltaInc
DeltaInc > PosWindowDynamic
(DeltaInc > PosWindowStatic) &&
(DeltaInc < PosWindowDynamic)
DeltaInc
DeltaInc–
+
DeltaInc
SynchronousState
SynchronousState =
MDX_GEAR_INGEAR
ABS
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Manual – MOVI-PLC® Application Solution "SyncCrane"
2Program identificationDescription
2.4 Program identificationYou can use the MOVITOOLS MotionStudio® software package to identify the programthat was loaded last into the MOVI-PLC®.
From the menu, choose [Diagnostics]/[MOVI-PLC: Information and Remote Control].The "Information" tab page shows the current application.
832287115
Part number A loaded SyncCrane application module can be identified by the part number 18219543.xx
Version The current main version of the application module is displayed in this field.
Release The current release of the application module is displayed in this field.
Manual – MOVI-PLC® Application Solution "SyncCrane"
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3 erequisitesoject Planning
3 Project Planning3.1 Prerequisites3.1.1 PC and software
The SyncCrane application module is implemented in the MOVI-PLC® as IEC code andis part of the MOVITOOLS MotionStudio® software version 5.5 and later.
You require a PC with one of the following operating systems to use the MOVITOOLS®
MotionStudio:
• Windows® 95
• Windows® 98
• Windows® NT 4.0
• Windows® 2000
• Windows® XP
You also require:
• MOVITOOLS® MotionStudio version 5.5 or higher.
• Libraries 2020 or higher.
3.1.2 InverterMOVIDRIVE® • MOVIDRIVE® B with encoder feedback.
• Optional absolute encoder evaluation or HIPERFACE® encoder evaluation.
• Firmware 824 854 0.18 or higher.
• Prior motor startup of the individual axes using the SHELL software
• If required, prior startup of the external HIPERFACE® encoder or absolute encoderusing the SHELL software. The IPOS encoder source SHELL parameter 941, IPOSencoder source must remain set to motor encoder.
• Subsequent configuration of the individual axis for operation with MOVI-PLC® viaDriveStartup. Make sure that different SBus individual addresses are specified.Assign the numbers in increasing order beginning with 1. It is important that thecommunication is set to 1 Mbaud.
• Only PROFIBUS is supported for connection to the bus master with the DHP11Boption.
Connection of motor shaft and load
Positive connectionExternal encoder is not required
Non-positive connectionExternal encoder required
External encoder type Absolute encoder Incremental encoder Absolute encoder
Bus type (required option)
PROFIBUS
Additional MOVIDRIVE® option required
DEH11B or DER11BDIP11B / DEH11B / DER11B
PrPr
Manual – MOVI-PLC® Application Solution "SyncCrane"
3Functional descriptionProject Planning
3.1.3 Motors / gear units
• Asynchronous or synchronous servomotors with motor encoder
• Gear unit / additional gear
• Optimum control behavior is only achieved with mechanically identical design ofslave axes (same gear ration, wheel diameter, etc.).
3.1.4 MOVI-PLC®
• T2 version
3.2 Functional descriptionThe SyncCrane application has the following functional characteristics:
Jog mode
• The drive is moved clockwise or counterclockwise using two bits for directionselection.
• Velocity and ramp can be specified via fieldbus as required.
Referencing mode
• Position adjustment is initiated with the start signal of the external encoder.
• Reference travel establishes the reference point (machine zero) for absolutepositioning operations.
• Three different reference travel types are supported.
Positioning mode
• The target position is specified by the process output data words PO4 and PO5. Thespeed and the ramp can be varied using the fieldbus. The current actual position isreported back via the process input data words PI4 and PI5. The program cyclicallyqueries the target position so that position changes are possible during ongoingpositioning.
• When external HIPERFACE®/SSI absolute encoders are processed, the motortarget position is adjusted during the travel process so that possible slip can becompensated.
Manual – MOVI-PLC® Application Solution "SyncCrane"
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3 nctional descriptionoject Planning
Automatic mode
• Automatic mode is used as motion control based on the technology function "InternalSynchronous Operation" (ISYNC) and is controlled in the inverter. Once automaticmode is selected, the axis system is adjusted to a common "adjust position" inpositioning mode and the axis system is synchronized accordingly. The axis systemcan then be moved using the virtual master encoder.
• Master value specification via virtual encoder is made either in jog or positioningmode.
• The startup wizard lets you specifiy a jerk time for the virtual encoder.
• Position deviations between virtual encoder position and external synchronousencoder are compensated cyclically during ongoing movement. This is to adjust, forexample, varying wear on the drive wheels without limiting positioning accuracy.
Emergency mode
• The drive is moved clockwise or counterclockwise using two bits for directionselection.
• Velocity and ramp can be specified via fieldbus as required.
FuPr
Manual – MOVI-PLC® Application Solution "SyncCrane"
3Scaling the driveProject Planning
3.3 Scaling the driveThe drives are always scaled in increments.
3.3.1 Determining the scaling factors for motor encoder/absolute encoderThe objective is to map all actual position values via the determined scaling factors tothe absolute encoder.
These values are:
• Specified positions for positioning operation of the physical axes
• Position setpoints in synchronous operation via the virtual encoder and cyclicalcompensation between virtual and absolute encoder
• Feedback of actual positions of the physical axes and the virtual master encoder
For draw-wire encoder:
Encoding scaling factor (SHELL parameter 955), for example, for laser distanceencoder:
ScaleFactorMotEncoderEncoder Resolution Gear Box Numerator= ×
×π DDiameter Gear Box Denominator
Inc
mm
ScaleFactorMotEncoder
×[ ][ ]
== ScaleMotEncNum
ScaleMotEncDenom
ScaleFactorAbsEncoderEncoder Resolution Encoder Scaling Fact= × oor Gear Box Numerator
Diameter Gear Box Denominator
Inc
mm
×× ×
[ ][ ]π
SScaleFactorAbsEncoderScaleAbsEncNum
ScaleAbsEncDenom=
ScaleFactorAbsEncoderEncoder Resolution Encoder Scaling Fact= × oor Inc
mm
ScaleFactorAbsEncoderScaleAbsEncNum
ScaleAbsE
1
[ ][ ]
=nncDenom
Manual – MOVI-PLC® Application Solution "SyncCrane"
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3 mit switches, reference cams and machine zerooject Planning
Conversions The following applies:
This means the motor encoder position is calculated as follows with a specified absoluteencoder position:
As well as the absolute encoder position
3.3.2 Determining the scaling factors for virtual encoder
• Setpoint specification refers to the actual position of the absolute encoder.
• The actual position is displayed in the resolution of the absolute encoder.
• The position setpoint is converted internally into the motor encoder.
• Enter the values determined for the external encoder system as conversion factors.
3.4 Limit switches, reference cams and machine zeroNote the following points during project planning:
• The software limit switches must be located within the travel range of the hardwarelimit switches.
• When defining the reference position (position of the reference cam) and thesoftware limit switches, make sure they do not overlap.
• You can enter a reference offset during startup if the machine zero is not located onthe reference cam.
The following formula applies: Machine zero = reference position + reference offset
This way, you can alter the machine zero without having to move the reference cam.
ScaleFactorMotEncoder
MotEncoderPos
ScaleFactorAbsEncoder
Ab=
ssEncoderPos
MotEncoderPosScaleFactorMotEncoder AbsEncoderPos
ScaleFact= ×
oorAbsEncoder
AbsEncoderPosScaleFactorAbsEncoder MotEncoderPos
ScaleFact= ×
oorMotEncoder
NOTEThe user interface limits the scaling factors to 216.
LiPr
Manual – MOVI-PLC® Application Solution "SyncCrane"
3Process data assignmentProject Planning
3.5 Process data assignmentThe higher-level controller (PLC) sends 10 process output data words (PO1 ... PO10)via PROFIBUS. The MOVI-PLC® sends 10 process input data words (PI1 ... PI10) to thehigher-level controller . An extension to 32 process data words is possible as an option.
The following figure shows data exchange with 10 process data words:
The position values are specified/returned in [inc.] or in the user-defined units [mm] or[1/10 mm].
511853963
PO= Process output data
PO1 Control word 1
PO2 Control word 2
PO3 Axis selection:• 1 ... 8 for single-axis operation• 99 for group drive
PO4 Target position with single axis selection in positioning mode "high"
PO5 Target position with single axis selection in positioning mode "low"
PO6 Target position virtual encoder in automatic mode high
PO7 Target position virtual encoder in automatic mode low
PO8 Setpoint speed in [rpm] / [mm/s] / [m/min]
PO9 Acceleration ramp [in ms based on Δn of 3000 rpm]
PO10 Deceleration ramp [in ms based on Δn of 3000 rpm]
PI= Process input data
PI1 Status word 1
PI2 Status word 2
PI3 Axis selection:• 1 ... 8 for single-axis operation• 99 for group drive
PI4 Actual position with single axis selection in positioning mode "high"
PI5 Actual position with single axis selection in positioning mode "low"
PI6 Actual position virtual encoder in automatic mode high
PI7 Actual position virtual encoder in automatic mode low
PI8 Diagnostic bits high byte, low byte
PI9 Diagnostic bits high byte, low byte
PI10 Diagnostic bits high byte, low byte
PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10
PI1 PI2 PI3 PI4 PI5 PI6 PI7 PI8 PI9 PI102
2
2
2
0
1
2
3
2
2
2
4
5
6
2
4
6
1
3
5
X32
2
4
6
1
3
5
X33
X30
2
4
6
1
3
5
8
10
12
7
9
11
X31
X34
MOVI-PLC
Manual – MOVI-PLC® Application Solution "SyncCrane"
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3 ocess data assignmentoject Planning
Expanding the process data words to a number of 32 means the following single-axispositions are transferred:
3.5.1 Process output data wordsThe process output data words are assigned as follows:
PI= Process input data
PI11 Actual position axis 1 positioning mode high
PI12 Actual position axis 1 positioning mode low
PI13 Actual position axis 2 positioning mode high
PI14 Actual position axis 2 positioning mode low
PI15 Actual position axis 3 positioning mode high
PI16 Actual position axis 3 positioning mode low
PI17 ... PI32
See chapter "Auxiliary Drives (Auxiliary Axis)" (see page 77).
Data word Bit no. Description
Process output data word 1 Bit 0 /Controller inhibit
Bit 1 Enable/rapid stop
Bit 2 Enable/stop
Bit 3 Reserved
Bit 4 Reserved
Bit 5 Reserved
Bit 6 Fault reset
Bit 7 Reserved
Bit 8 Start
Bit 9 Jog +
Bit 10 Jog–
Bit 11 Mode selection bit 20
Bit 12 Mode selection bit 21
Bit 13 Mode selection bit 22
Mode:0: Reserved1: Jog mode single/group2: Reference mode single/group3: Positioning mode single/group4: Automatic mode group5: Emergency mode single/group
Bit 14 Reserved
Bit 15 Disable SWLS
Bit 15
Bit 14Bit 13Bit 12Bit 11Bit 10Bit 9Bit 8
Bit 0
Bit 1
Bit 2Bit 3Bit 4Bit 5Bit 6
Bit 7
PrPr
Manual – MOVI-PLC® Application Solution "SyncCrane"
3Process data assignmentProject Planning
Process output data word 2 (Control word virtual encoder)
Bit 0 Reserved
Bit 1 Reserved
Bit 2 Reserved
Bit 3 Reserved
Bit 4 Reserved
Bit 5 Reserved
Bit 6 Reserved
Bit 7 Reserved
Bit 8 Start
Bit 9 Jog +
Bit 10 Jog–
Bit 11 Mode selection bit 20
Bit 12 Mode selection bit 21
Bit 13 Mode selection bit 22
Mode:0: Reserved1: Jog mode single/group2: Reference mode single/group3: Positioning mode single/group4: Automatic mode group5: Emergency mode single/group
Bit 14 Reserved
Bit 15 Disable SWLS
Process output data word 3Axis number
– Single axis selection: 1 ... 8Group selection: 99
Process output data word 4Target position high byte
– Position specification for physical axis in positioning mode (not synchronized)
Process output data word 5Target position low byte
– Position specification for physical axis in positioning mode (not synchronized)
Process output data word 6Target position high byte
– Position specification for virtual axis in positioning mode (synchronized)
Process output data word 7Target position low byte
– Position specification for virtual axis in positioning mode (synchronized)
Process output data word 8Setpoint velocity
– Setpoint speed [rpm] / in user-defined units in jog/position-ing mode
Process output data word 9Acceleration
– Acceleration ramp [ms] in automatic mode with limitation in jog/positioning mode
Process output data word 10Deceleration
– Deceleration ramp [ms] in automatic mode with limitation in jog/positioning mode
Data word Bit no. Description
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3 ocess data assignmentoject Planning
3.5.2 Process input data words
The process input data words have the following meaning:
Data word Bit no. Description
Process input data word 1 Bit 0 Motor turning
Bit 1 Frequency inverter ready for operation
Bit 2 Axis referenced
Bit 3 In position
Bit 4 Selected mode active
Bit 5 Frequency inverter fault/warning
Bit 6 Frequency inverter fault/warning
Bit 7 External encoder fault
Bit 8 ... 15
(with single selection)Inverter/error status
Process input data word 2 Bit 0 Virtual incremental encoder turning
Bit 1 Reserved
Bit 2 Reserved
Bit 3 Virtual incremental encoder in position
Bit 4 Axes synchronous/Ready for virtual encoder
Bit 5 Lag error
Bit 6 Virtual incremental encoder fault/warning
Bit 7 MLC LifeCycleBit
Bit 8 ... 15
Reserved
Process input data word 3Selected axis number
– Single axis selection: 1 ... 8Axis system: 99
Process input data word 4Actual position high byte
– Actual position in user-defined units with single-axis selection (not synchronized)
Process input data word 5Actual position low byte
– Actual position in user-defined units with single-axis selection (not synchronized)
Process input data word 6Actual position high byte
– Actual position virtual master encoder in user-defined units (synchronized)
Process input data word 7Actual position low byte
– Actual position virtual master encoder in user-defined units (synchronized)
Process input data word 8Diagnostics variables, e.g. pow-ered
– Assignment is configurable
Process input data word 9 Diagnostics variables, e.g. error
– Assignment is configurable
Process input data word 10 Diagnostics variables, e.g. InGear
– Assignment is configurable
Bit 15
Bit 14Bit 13Bit 12Bit 11Bit 10Bit 9Bit 8
Bit 0
Bit 1
Bit 2Bit 3Bit 4Bit 5Bit 6
Bit 7
PrPr
Manual – MOVI-PLC® Application Solution "SyncCrane"
3Software limit switchesProject Planning
3.6 Software limit switchesThe software limit switch monitoring function is used to check that the target position isset to appropriate values. During this process, it is not important where the drive ispositioned.
In contrast to the monitoring of the hardware limit switches, the monitoring function forthe software limit switches makes it possible to detect whether there is an error in thetarget specifications before the axis starts to move.
3.6.1 Moving clear of the software limit switchMoving outside the software limit switches is also possible. For this purpose, theDisableLS bit is assigned in automatic mode in process output data word 1 (PO1) and/or process output data word 2 (PO).
• For unsynchronized motion PO1:15 / SW LS = TRUE
• For synchronized motion (automatic mode) PO1:15 / SW LS = TRUE and PO2:15 /SW LS = TRUE
Process input data word 11Axis 1 actual position high byte
– Actual position axis 1 in user-defined units
Process input data word 12Axis 1 actual position low byte
– Actual position axis 1 in user-defined units
Process input data word 13Axis 2 actual position high byte
– Actual position axis 2 in user-defined units
Process input data word 14Axis 2 actual position low byte
– Actual position axis 2 in user-defined units
Process input data word 15Axis 3 actual position high byte
– Actual position axis 3 in user-defined units
Process input data word 16Axis 3 actual position low byte
– Actual position axis 3 in user-defined units
Data word Bit no. Description
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3 ardware limit switchesoject Planning
3.7 Hardware limit switches3.7.1 Preliminary work
Hardware limit switch processing is not supported by default. If you still want to use hard-ware limit switches, you will have to perform the following steps:
• Example of 2 inverters each of them with own hardware limit switches:
– Connect the CW hardware limit switch of inverter 1 in series with inverter 2.
– Set a hardware input for each inverter to "/Hardware limit switch CW".
– Connect the CW hardware limit switches to the two inputs.
– Wire the CCW hardware limit switch in an analogous manner.
3.7.2 Fault responseIn the event of a fault, the drive inverter goes to status F29 "Limit switch approached".Ongoing movements are interrupted with the "Emergency stop ramp".
3.7.3 Moving clear of the hardware limit switchCorrect the operating mode selection in such a way that travel movement away from thehardware limit switch position can be triggered.
You can use one of the following ways to do so:
• Move group unsynchronized away from the limit switch:
– Select "jog" mode.
– Specify the jog direction away from the limit switch position.
– Acknowledge the fault.
– The travel movement is started.
– The drives have moved clear of the limit switch once they change from unit status"9" (limit switch approached) to "A".
– You can interrupt the motion sequence by deselecting the operating mode.
• Move group synchronized away from the limit switch:
– Select "automatic" mode.
– Select the jog mode of the virtual encoder.
– Specify the jog direction away from the limit switch position.
– Acknowledge the fault.
– The travel movement is started.
– The drives have moved clear of the limit switch once they change from unit status"9" (limit switch approached) to "A".
– You can interrupt the motion sequence by deselecting the operating mode.
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Manual – MOVI-PLC® Application Solution "SyncCrane"
3Safe stopProject Planning
3.8 Safe stopA Safe stop can only be achieved by safe disconnection of the jumpers at terminal X17(with safety switch or safety PLC).
The 7-segment display shows a "U" to indicate Safe stop active state.
For more information on the Safe stop function, refer to the following publications:
• Safe disconnection for MOVIDRIVE® MDX60B/61B - Conditions
• Safe disconnection for MOVIDRIVE® MDX60B/61B - Applications
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4 ftware MotionStudiostallation
4 Installation4.1 Software MotionStudio
The MOVITOOLS® "SyncCrane" application module is part of the MOVITOOLS®
MotionStudio software (version 5.50 and higher). For older MOVITOOLS® MotionStudioversions or for updates of the application module, you can execute the installation fileSyncCrane.exe.
Technology versionThe "SyncCrane" application module can only be used with MOVI-PLC® unit version(T2). The application modules cannot be used with units in the standard version.
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Manual – MOVI-PLC® Application Solution "SyncCrane"
4Wiring diagram MOVIDRIVE® MDX61BInstallation
4.2 Wiring diagram MOVIDRIVE® MDX61B
672388747
* Factory setting
X13:
X14:
X15:
123456789
1011
Option DEH11B
1
8
9
15
X10:TF1
DGNDDBØØ
DOØ1-CDOØ1-NODOØ1-NC
DOØ2VO24VI24
DGND
123456789
TF/TH inputRef. potential binary signals/Brakee Relay contact/Ready* NOC NCC/Fault*+24V output+24V inputRef. potential binary signals
DIØØDIØ1DIØ2DIØ3DIØ4DIØ5DCOMVO24DGNDST11ST12
/Controller inhibitNo functionNo functionNo functionNo functionNo functionReference X13:DIØØ...DIØ5+24V outputRef.potential binary signalsRS-485+RS-485–
MOVIDRIVE® slaves 1 ... 8
InputExternal encoder
Option DEH11BMotor encoder(Connection: operating instr. MOVIDRIVE®)
(Connection: operating instr. MOVIDRIVE®)
15
1
8
9
Option DEH11B (motor encoder):high-resolution sin/cos encoder,
HIPERFACE® encoder or incremental encoder(CT/CV or DT/DV/D motors)
Option DEH11B:Incremental encoder TTL/RS-422
with DC 24 V supply
Imax = 180 mA
X16:123456
DiØ6DoØ3DoØ4
DiØ7
DoØ5DGND
No functionNo functionNo functionRef. potential binary signal
No functionNo function
X62:
Option DIP11BSSI absolute encoder
1
5
6
9
Option DIP11B (SSI encoder):
X12:123
DGNDSC11SC12
System bus+System bus–
20
21
22
23
24
25
26
S-Bus coupling
DIO 00 ReferenceCamDIO 01 SetEmergencyModeDIO 02 ReservedDIO 03 ReservedDIO 04 FailureDetectedDIO 05 ReservedDIO 06 ReservedDIO 07 Reserved
DHP11B
X3
1X
32
X3
3X
30
X3
4
10
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4 s installation PROFIBUS DHP11Bstallation
4.3 Bus installation PROFIBUS DHP11B
4.4 Connecting system bus (SBus 1)
NOTEFor information on the bus installation, refer to the "MOVI-PLC® DHP11B ControlCard" manual.
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DHP11B
X31
LED 1
LED 2LED 3LED 4LED 5
LED 6
LED 7X
32
X33
X30
X34
20
21
22
23
24
25
26
13
123
123
1
1
2
123
123
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X12:DGNDSC11SC12
123
S 11
S 13S 14
ON OFF
X12:DGNDSC11SC12
123
S 12S 11
S 13S 14
ON OFF
X12:DGNDSC11SC12
123
S 11
S 13S 14
S 12
ON OFF
Control unit Control unit Control unit
System busReference
System busReference
System busReference
System busHigh System busHigh System busHighSystem busLow System busLow System busLow
System busTerminating resistor
System busTerminating resistor
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Manual – MOVI-PLC® Application Solution "SyncCrane"
5PrerequisitesStartup
5 Startup5.1 Prerequisites
Correct project planning and installation are the prerequisites for successful startup. Fordetailed project planning information, refer to the "MOVIDRIVE® MDX60/61B" systemmanual.
Check the installation, the encoder connection and the installation of the DHP11Bcontrol card by following the installation instructions in the "MOVIDRIVE® MDX60B/61B"operating instructions, in the fieldbus manuals, and in the document at hand("Installation" chapter).
For additional information, refer to the following documents:
• For information on the theory of operation of the MPLCMotion_MDX library as wellas on the startup of MOVIDRIVE® inverters with MOVI-PLC®, refer to the"MPLCMotion_MDX Library for MOVI-PLC®" manual.
• For notes on the theory of operation of the MPLCTecGearMotion_MDX library, referto the "MPLCTec..._MDX MPLCTecVirtualEncoder Libraries for MOVI-PLC®"manual.
• For supplementary notes on the theory of operation of the "internal synchronousoperation" technology function, refer to the "MOVIDRIVE® MDX61B InternerSynchronous Operation (ISYNC)" manual.
5.2 Preliminary workPerform the following steps before startup of the SyncCrane application:
5.2.1 Startup of the individual MOVIDRIVE® axesStart up the individual MOVIDRIVE® axes as follows:
1. Perform a startup of the individual axes using the SHELL software. Select thefollowing operating mode:
2. Configure the individual axes using the "DriveStartup for MOVI-PLC®" tool foroperation with the MOVI-PLC®. Make sure that different SBus single addresses areassigned and that the baud rate is set to 1 MBaud.
MOVIDRIVE® MDX61B with asynchronous motor
Operating mode CFC&IPOS / VFC N-control & IPOS
MOVIDRIVE® MDX61B with synchronous motor
SERV&IPOS operating mode
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5 eliminary workartup
5.2.2 Starting up the individual MOVIDRIVE® axes using the "DriveStartup for MOVI-PLC® tool"
Start up the individual MOVIDRIVE® axes as follows:
1. Open [MotionStudio] / [Technology Editors] / [DriveStartup for MOVI-PLC].
2. Perform DriveStartup to prepare the MOVIDRIVE® axes for operation with the MOVI-PLC®.
3. Assign different SBus addresses (1 ... 8) in increasing order, beginning with 1.
4. Select [Parameter tree] / [Unit function] / [Serial communication SBUS2] and setparameter P894, SBUS2 baud rate to 125 kBaud.
5. Select [Parameter tree] / [Unit function] / [Serial communication SBUS1] and setparameter P884, SBUS1 baud rate to 1 MBaud.
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5Starting the SyncCrane programStartup
5.3 Starting the SyncCrane programMake a right mouse click on 0:MOVI-PLC® and select [Application modules]/[Sync-Crane for MOVI-PLC®].
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5.3.1 Initial screen
The initial screen of the "SyncCrane" application is opened.
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Initial screen
[Cancel] User interface is closed without saving
[Help] Button for opening the online help file
[Monitor] Online diagnostics and control modeThe button is disabled if• you are not online• the application module has not been detected
[Startup] Open the startup screenClick this button to take the application into operation.
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5Starting the SyncCrane programStartup
If you want to load saved application data, choose [File] / [Open settings] from the menu.
If you have modified the settings, you can save them by selecting [File] / [Save settings]from the menu, or you can check them by selecting [File] / [View settings] from the menu.
HAZARD!Risk of crushing if the motor starts up unintentionally.
Severe or fatal injuries. • Stop the system before you begin startup and bring the system into a safe
condition. • Make sure that the system cannot be activated during startup.
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5.3.2 Selecting the individual startup steps
For initial startup, you have to perform each step one after the other. If you perform a re-startup, you can directly go to the required startup step. The "Download" step is requiredas last step both for partial and complete startup.
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Selection of startup steps
Step 1 Project settings
Step 2 Individual axis/scaling factors group
Step 3 Scaling factors virtual axis
Step 4 Axis parameter group
Step 5 Synchronous operation parameters
Step 6 Monitoring functions
Step 7 Download
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5Starting the SyncCrane programStartup
5.3.3 Step 1: Project settings
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Field Description
SyncCrane configuration This input field is used to specifiy the number of individual axes in the axis system. The value range is limited to 1...8.
Configuration process input data word 8...10
Use the selection fields to choose the information you want to have transmitted via process input data words 8, 9, and 10.
Configuration of auxiliary drives If you want to use more auxiliary drives, you have to set the selection field to "Yes" before starting the wizard.
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5.3.4 Step 2: Individual axis/scaling factors group (position scaling)Position scaling This window is used to define the basic settings for position scaling.
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Field Description
Source actual position This selection field lets you choose between motor encoder and external synchronous encoder and/or SSI encoder.
Place of encoder detection From this field you can select whether the encoder is mounted on the motor shaft or on the track, for example when the system is prone to slip.
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5Starting the SyncCrane programStartup
Scaling the motor encoder
On this startup screen you determine the position resolution for the motor encoder.
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Field Description
Diameter Use these input fields to specify the mechanical data.You can enter values with two decimal places.Gear ratio
External ratio
Counting direction This field lets you invert the direction of rotation of the motor.
Calculate The determined position resolution for the motor encoder system is entered in the input fields "Increments" and "Distance".The determined scaling factors are limited to 216.
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Scaling the syn-chronous encoder
On this startup screen you determine the position resolution for the synchronousencoder. If the synchronous encoder is mounted to the motor shaft, some input fieldsare disabled and show default values of the motor encoder.
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Field Description
Diameter Use these input fields to specify the mechanical data.You can enter values with two decimal places.Gear ratio
External ratio
Startup of the synchronous encoder:
Encoder type Choose the encoder type from this field.
Encoder scaling This field is used to enter a value for approximating the physical resolution of the absolute encoder with the resolution of the motor encoder system.This selection field directly influences the control behavior of the application module.
Counting direction In this field you can invert the counting direction of the synchronous encoder depending on the direction of rotation of the motor.
Encoder resolution This field is used to enter the resolution of the absolute encoder.
Calculate The determined position resolution for the motor encoder system is entered in the input fields "Increments" and "Distance".The determined scaling factors are limited to 216.
NOTEIf you use a laster distance measuring instrument in the above example, you candirectly enter the resolution specified by the manufacturer, for instance 8 increments/mm, in the input fields [Increments] and [Distance]. Do NOT press the [Calculate]button in this case.
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5Starting the SyncCrane programStartup
Result of encoder scaling
This window is used to determine the resolution between motor encoder and synchro-nous encoder, and to define the user units for the position setpoint.
511979403
Field Description
Calculate Press this button to determine the values for the "Motor encoder" and "Synchronous encoder" input fields resulting from the position resolution units of motor encoder and synchronous encoder.
User units for position reso-lution
After having selected the unit for the position setpoint in this selection field, you have to activate it by clicking the "Calculate" button.
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5.3.5 Step 3: Scaling the virtual encoderScaling the virtual encoder
A description of the input fields on this window is already included in the description forthe previous windows.
Enter the values from the already determined values from the "Scaling the synchronousencoder" field in the "Scaling the virtual encoder" field.
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NOTEThe input fields described in steps 3 are not relevant for you if you choose the "Group"option in the dropdown menu "Individual axis/scaling factor group" described inchapter 3 "Selecting the individual startup steps".
In this case, the values from "Scaling the synchronous encoder" are used.
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5Starting the SyncCrane programStartup
Result of encoder scaling
A description of the input fields on this window is already included in the description forthe previous windows.
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5.3.6 Step 4: Parameters and limitsParameters and limits
This window is used to set the limits for travel range and velocity.
672848139
Group Field Description
Limit switch Software LS CW
The software limit switches limit the permissible travel range for the "Jog", "Positioning", and "Automatic" operating modes.The specified value refers to the increments of the synchronous encoder.The wizard does not support the activation of hardware limit switches.
Software LS CCW
Reference travel
Reference offset
Enter the reference offset in increments in relation to the synchronous encoder.
Reference type The reference travel type defines the movement sequence for detect-ing the mechanical zero point. You can choose between 3 different reference travel types.
Type 1 Standstill (individual axis or group drive)
Type 2 Synchronized search travel of the group for right end reference cam (MOVI-PLC DI00 X31:3)
Type 3 Synchronized search travel of the group for left end reference cam (MOVI-PLC DI00 X31:3)
Reference speed 1 and 2
When selecting reference travel type 2 or 3, the cam is searched with reference travel velocity 1.Next moving clear of the cam takes place (and then ended) with reference travel velocity 2.
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Manual – MOVI-PLC® Application Solution "SyncCrane"
5Starting the SyncCrane programStartup
5.3.7 Step 5: Synchronous operation parametersThis window is used to make the settings for indirect synchronization.
Limits Maximum speed position-ing
You can limit the specified positioning speed by entering the value.
Maximum speed jog mode
You can limit the specified jog speed by entering the value.
P302 Nmax speed controller
Enter a value at least 10 % higher than the maximum positioning and/or jog speed.
Group Field Description
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Group Field Description
Positioning controller
Synchronization mode Two procedures are supported for compensating the position difference between virtual master value and absolute encoder position:• Offset state machine: Acyclic ramp-guided position
correction. Recommended is an entry of 120% in the [PosSpeed Raising Factor Dynamic] input field.
• Register loop: Cyclic position correction. Recommended is an entry of 100 % in the [PosSpeed Raising Factor Dynamic] input field.
PosWindow dynamic The IEC program determines cyclically the difference between the virtual master value and the actual position of the synchronous encoder. The difference is corrected when the difference position exceeds the specified "dynamic position window".
PosSpeed Raising Factor Dynamic
The difference position is corrected using the synchronous speed. This is the multiplication of the virtual setpoint speed with the PosSpeed Raising Factor Dynamic.
PosSpeed Static The sycnhronous speed is set to this value when the virtual master encoder is at standstill. Compensation movements at standstill are performed at reduced velocity.
Parameters for optimiza-tion
Virtual encoder jerk time The positioning behavior of systems prone to vibration can be improved significantly by specifying a jerk limit of the virtual encoder.
P228 Filter precontrol DRS Setpoint filter for the master speed. The setting range is 0 ... 100 ms.
P971 Synchronization phase
Setpoint for optimizing the synchronization behvior of the MOVIDRIVE® individual axes and the MOVI-PLC®.
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5Starting the SyncCrane programStartup
5.3.8 Step 6: Monitoring functions
This window is used to set the monitoring functions.
672860427
Field Description
Position monitoring The specified value in relation to the synchronous encoder influences the "IPOSinPosition" message. The value must be set in such a way that the "IPOSinPosition" message does not change after having reached the target.
Lag error window The motion is stopped when the position difference between the synchronous encoders of the axis system is exceeded in the monitoring window.
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5.3.9 Step 7: Downloading data
The data are loaded to the MOVI-PLC® as soon as you have entered all parameters.
The following functions are performed during download:
• MPLC program is downloaded
• Startup parameters are downloaded
• MPLC program is started
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NOTEBefore you click the [Download] button, make sure that all applications of theMOVITOOLS® MotionStudio are closed (PLC Editor, parameter tree, etc.).
Do not start any applications and do not change to other applications after havingpressed the [Download] button.
Wait until download is complete. Download is complete when the initial screen of theapplication module appears.
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5Parameters/H variables of the MOVI-PLC®Startup
5.4 Parameters/H variables of the MOVI-PLC®
The wizard for startup, operation, and diagnostics of the application module is imple-mented in the SEW-EURODRIVE ApplicationBuilder. The ApplicationBuilder uses theremanent "H variables" of the MOVI-PLC® for:
• saving the startup data
• intermediate saving of diagnostics variables
• mapping process data communication between bus master and MOVI-PLC®.
The following table shows the data buffer MOVI-PLC® H variables 0 ... 1450.
Segment H variables Saved data
1st segment
H000 SwitchMonitor H H0001 PO1. . . H0099 PO99H0101 PI1. . . H0199 PI99
Process input data words and process output data words
The setpoint source can be switched from fieldbus to RS-485 via the variable H0000. This allows for controlling the application module by means of the control mode of the Appli-cationBuilder or a DOP operator terminal.
2nd segment
H0200 Axis status bits (e.g. InGear). . . H0218
Status bits of the indi-vidual axes
–
3rd segment
H0220 Axis 1. . . DiagnosticsH0249 e.g. InverterState
Diagnostics variables of individual axes
• Actual positions• Currents• Operating states, etc.
H0220 Axis 2. . . DiagnosticsH0279 e.g. InverterState
. . .
. . .
. . .
H0520 Axis 12. . . DiagnosticsH0549 e.g. InverterState
4th segment
H0600 VirtualAxis. . . DiagnosticsH0629 e.g. ActualSpeed
Diagnostics variables of the virtual axis
• Actual positions• Actual speed, etc.
H0630 Reserved. . .H0739
5th segment
H0740 AppBuilder. . . Startup Rand Single AxisScalingH1450
Startup data of the ApplicationBuilder
• Scaling factors• Limits, etc.
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5 rive inverter parametersartup
5.5 Drive inverter parametersThe following parameters are written to the drive inverter each time the startup wizardis opened or the program is started:
5.6 Group signals5.6.1 Bit-coded representation
Group signals are displayed in bit code.
The group signal makes the following possible:
• Evaluating the status of the individual axes by interpreting the logical axis address
• Querying the status of the entire axis system by interpreting the group signal (bit "0")
For example, the "InGear" signal would be displayed as follows:
Parameter number Index Description Setting
350 8537 Motor direction of rota-tion
Normal/inverted
945 8891 Encoder type Ext. Encoder
950 8777 Encoder type DIP Ext. DIP encoder
946 8894 Counting direction Ext. Encoder
951 8776 Counting direction Ext. DIP encoder
944 8787 Scaling factor Ext. Encoder
955 8784 Scaling factor Ext. DIP encoder
302 8517 Max. motor speed Motor parameters
971 9226 Synchronization phase –
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Bit 0 True= Axis1 InGear AND Axis2 InGear AND....
Bit 1 Axis LogAdr 1 "InGear"
Bit 2 Axis LogAdr 2 "InGear"
Bit 3 Axis LogAdr 3 "InGear"
Bit 4 Axis LogAdr 4 "InGear"
Bit 5
Bit 6
Bit 7
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5Group signalsStartup
5.6.2 Documentation of implemented group signals
The creation of "Bit 0" is treated differently for the implemented group signals.
Group signals, for the interpretation of which "all axes" must have the same status, areANDed.
The following figure shows the group signal "all" connected axes in engaged state.
Group signals, for the evaluation of which it is relevant if any of the connected axes hasa fault, are ORed.
The following figure shows the group signal "one" of the connected axes in fault state.
536595595
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ANDAxis 1 in gear
Axis 2 in gear
Axis 3 in gear
...
Axis n in gear
All axes in gear
ORAxis 1 inverter error
Axis 2 inverter error
Axis 3 inverter error
Axis n inverter error
...
Inverter error
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The implemented group signals are documented in the following table:
Meaning H[...] Logic Creation of the axis-related single bit
AllConnected 212 AND (gAxisInterfaceOut[j].Connected),j)
AllInPosition 200 AND (ABS(gsPIData.TargetPos32 -gAxisSyncCrane[j].ActPosExt ))< H[E_POSWINDOW]),j)
Active 201 OR (ABS(gAxisInterfaceOut[j].InverterData.ActualSpeed)) > 50),j)
AllPowered 202 AND (gAxisInterfaceOut[j].Powered) ,j
AllReady 203 AND (gAxisIntefaceOut[j].InverterData.InverterStatus)> 0) ,j)
InverterError 204 OR (gAxisInterfaceOut[j].InverterError),j)
FBError 205 OR (gAxisInterfaceOut[j].FBError),j
AllReferenced 206 AND (gAxisInterfaceOut[j].InverterData.Referenced),j)
AllRequestedModeActive 208 AND gAxisInterfaceIn[j].AxisMode = gAxisInterfaceOut[j].ActualAxisMode),j)
LagWarning 207 OR (ABS(gVEInterfaceOut.VirtualAxisData.ActualPositionJerkLim - gAxisSync-Crane[j].ActPosExt))< H[E_LAGWINDOWWARNING]),j)
LagFailure 208 OR (ABS(gVEInterfaceOut.VirtualAxisData.ActualPositionJerkLim - gAxisSync-Crane[j].ActPosExt))< H[E_LAGWINDOWFAILURE]),j)
AllInGear 209 AND (gAxisInterfaceOut[j].InGear) ,j)
AllInAdjustPosition 211 AND (ABS(gStatusbits.AdjustPosition - gAxisSyncCrane[j].ActPosExt ))< H[E_POSWINDOW]),j)
MonitoringExtEnc 213 OR (ABS(gAxisSyncCrane[j].ActPosMot - gAxisSyncCrane[j].ActPosExt))< H[E_EXTENCWINDOW]),j)
AdjustPosition 210 Cyclically calculated adjustment positionnCalcDummy := nCalcDummy + gAxisSyncCrane[j].ActPosExt; gStatusbits.AdjustPosition := nCalcDummy/ snActNumberOfAxis;
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5Program overview of the PLC programStartup
5.7 Program overview of the PLC programThe following figure shows the program structure TASK1_MAIN_PRG:
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Axis Factors
(AppBuilder)
AxisConfiguration
fbConfig
gsA
xis
Inte
rfaceIn
.Axis
1..
.12
Virtual Axis Factors
(AppBuilder)
PI
Source: H-Variables
or Profibus
fbInSignals
PO Data
Program for
sequence control
fbInterface
Axis control: axis 1
fbAxixControlGearA1
Axis control: axis 2
fbAxixControlGearA2
PO
fbOutSignals
Axis control: axis 8
fbAxixControlGearA2
gsPODat
PO1-PO10
Axis
1A
xis
2A
xis
8
Axis
1A
xis
2A
xis
8
gsPIData
PI1- PI10
Status bit
TASK1_MAIN_PRGH-Variables
Databuffer
Diagnostics axis 1
Diagnostics axis 2
Diagnostics axis 8
gsA
xis
Inte
rfaceO
ut.A
xis
1... 8
gsA
xis
SyncC
rane.A
xis
1... 8
gsS
tatu
sB
its
PI Data
cylic free wheeling TASK
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Overview of program run times of the different TASKsThe following table shows the program overview for the PLC program with 2 connectedaxes.
TASK1_MAIN_PRGMain program
TASK2_VEVirtual encoder
Function • AxisConfiguration• InSignals• Interface• AxisControl• OutSignals
• VEAxisControl
Run time [ms] 17 5
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Manual – MOVI-PLC® Application Solution "SyncCrane"
6Starting the driveOperation
6 Operation6.1 Starting the drive
After the download, switch to the monitor of the SyncCrane application module.
6.1.1 Operating modes for fieldbus control
NOTESelection of the modes and plausible feedback of the status bits are only ensured if anaxis number (99 for broadcast, or 1 ... 12 for single axis mode) is transferred viaprocess data word 3.
Operating mode PO1:13
PO1:12
PO1:11
Description
Default 0 0 0 No axis is moved.
Jog mode 0 0 1 • An individual axis or the group can be moved via the Jog+ and Jog– inputs.
• The travel parameters velocity, acceleration ramp and deceleration ramp can be specified via process output data words PD8, PD9, and PD10.If no velocity is specified, the axis will move at 0.2 rpm.
• Unsynchronized motion sequence is supported for controlling single axes or a group of axes.
Referencing mode 0 1 0 • Motor encoder and absolute encoder position are referenced when start is set.
• Reference travel establishes the reference point (machine zero) for positioning operations.
• Single axis control is only supported for referencing to the standstill position.
• Group control is supported.
Positioning mode 0 1 1 • After a target position has been specified (PO4, PO5) and start has been set, the referenced single axis or group can be moved.
• The travel parameters velocity, acceleration ramp and deceleration ramp can be specified via process output data words PD8, PD9, and PD10. If no velocity is specified, the axis will move at 0.2 rpm.
• Unsynchronized motion sequence is supported for controlling single axes or a group of axes.
Automatic mode(virtual encoder and synchronous operation)
1 0 0 • When start is set, the group is aligned and the technology function "internal synchronous operation" is activated.
• Controlling the virtual encoder lets you move the axis system (jog mode or positioning mode).
• For group control, only synchronized motion sequences are supported.
Emergency mode 1 0 1 • Emergency mode can be activated by selecting [ApplicationBuilder] / [ProjectSettings] / [Emergency Mode] YES and restarting the controller.
• An individual axis or the group can be moved via the Jog+ and Jog– inputs.
• The travel parameters velocity, acceleration ramp and deceleration ramp can be specified using process output date words PD8, PD9, PD10. If no velocity is specified, the axis will move at 0.2 rpm.
• Moving the axes without encoder evaluation is supported.
• Unsynchronized motion sequence is supported for controlling single axes or a group of axes.
Manual – MOVI-PLC® Application Solution "SyncCrane"
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6 iagnostics monitorperation
6.2 Diagnostics monitor6.2.1 Diagnostics monitor: Monitor mode
During ongoing operation, you can open the monitor using the following menu path:
[MotionStudio]/[Application modules]/[SyncCrane for MOVI-PLC]
In monitor mode, the process input and process output data transferred via fieldbus aredisplayed in decoded format.
6.2.2 Diagnostics monitor: Control modeTo control the application module without higher-level controller, click the [Controller]button.
6.3 Jog mode – unsynchronized
512022411
Interface description
Mode selection PO1:Bit11 = TRUEPO1:Bit12 = FALSEPO1:Bit13 = FALSE
Jog + PO1:9
Jog– PO1:10
Disable SWLS PO1:15
DO
Manual – MOVI-PLC® Application Solution "SyncCrane"
6Jog mode – unsynchronizedOperation
Axis number PO3 Broadcast 99 or single axis mode 1 ... 12
Velocity specification PO8 in [rpm] or [user units]
Velocity limit Startup parameter
Overlapping Startup parameter
Position limiting Software limit switch startup parameter
Ramp specification PO9 Acceleration ramp in [ms]PO10 Deceleration ramp in [ms]
Brief description After selecting a direction of rotation, the single axis (PO3 1 ... 4) or the entire axis system (PO3 = 99) can be operated in jog mode. If software limit switches were assigned, the travel range is restricted to these limits.
Prerequisite • Operating mode is selected• Drive is enabled
Functional description
The direction is selected using Jog+ or Jog-. If the software limit switch right is set > software limit switch left, the travel range is limited to 3 position windows (startup) before the respective software limit switch.If the Disable SWLS bit is set, the limitation of the travel range is deactivated.For the travel movement, positioning indirectly takes place to the external encoder.Without evaluation the limit switches, the axis can be moved endlessly.The drive stops with position control if the direction selection is not enabled or both directions are selected at the same time.The specified ramp time is used for accelerating/decelerating the drive.The specified velocity of the jog mode is compared to the velocity limit and limited if necessary.
Interface description
Manual – MOVI-PLC® Application Solution "SyncCrane"
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6 g mode – unsynchronizedperation
6.3.1 Supplement jog mode of the virtual axis - synchronized
For documentation of the operating mode, see above. For differences in the interface,see below.
Mode selection PO2:Bit11 = TRUEPO2:Bit12 = FALSEPO2:Bit13 = FALSE
Prerequisite All axes are engaged. This is indicated by PI2:4 "Axes synchronous".Prerequisite: • "Automatic" mode is selected and "Start" is set via
process data word 1.• The axes are enabled (display "A: technology
function" of the 7-segment display)
Jog + PO2:9
Jog– PO2:10
Disable SWLS PO2:15
Velocity specification PO8 in [rpm] or [user units]
Velocity limit Startup parameter
Jerk limitation Startup parameter
Position limiting Software limit switch startup parameter
Ramp specification PO9 Acceleration ramp in [ms]PO10 Deceleration ramp in [ms]
JoO
Manual – MOVI-PLC® Application Solution "SyncCrane"
6Referencing modeOperation
6.4 Referencing mode
Interface description
Mode selection PO1:Bit11 = FALSEPO1:Bit12 = TRUEPO1:Bit13 = FALSE
Start referencing PO1:8
Axis number PO3 Broadcast 99 or single axis mode 1 ... 12
Speed selection –
Velocity limit Startup parameter
Ramp specification –
Reference travel type Startup parameter
Reference offset • Startup parameter• Specification of actual position of the encoder after reference travel
has been completed.
Reference speed 1 Setpoint speed for search travel to the reference cam
Reference speed 2 Setpoint speed for moving clear of the reference cam
Brief description Depending on the selected reference type, the encoders (motor encoder and external or absolute encoders) are set to the specified reference offset at a standstill or by traveling to a cam.
Prerequisite • Axes have been mechanically aligned, e.g. in jog mode.
• Operating mode is selected and start is set• Drive is enabled
Functional description
Encoder adjustment is initiated using bit PO1:8 “Start”.The individual axes have to be aligned mechanically prior to reference travel, e.g. by selecting single axis in jog mode.The following movement is carried out depending on the reference type:• Standstill reference type
The actual position of the drives is the reference point. Enable is withdrawn and reference travel type 8 is started in the inverter.Individual axes can be referenced using this reference type only.
• Reference type Cam CW to X31:3 of the MOVI-PLC®
Reference point is the reference cam mounted to CW. The motion sequence is controlled via the synchronous operation of the axis system. The synchronous operation system is moved with refer-ence speed 1 until an edge occurs at input X31:3 and is then stopped. By reversing the travel direc-tion, the cam is then moved clear of with reference speed 2, and subsequently all axes are referenced to the specified reference position.
• Reference type Cam DI00 CCW to X31:3 of the MOVI-PLC®
For a description, see reference type cam CW but in reversed search direction
Manual – MOVI-PLC® Application Solution "SyncCrane"
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6 sitioning mode – unsynchronizedperation
6.5 Positioning mode – unsynchronized
Interface description
Mode selection PO1:Bit11 = TRUEPO1:Bit12 = TRUEPO1:Bit13 = FALSE
Start referencing PO1:8
Disable SWLS PO1:15
Axis number PO3 Broadcast 99 or single axis mode 1 ... 12
Position setpoint PO4 and PO5 in [inc]
Velocity specification PO8
Velocity limit Startup parameter
Overlapping Startup parameter
Position limiting Software limit switch startup parameter
Ramp specification • PO9 acceleration ramp• PO10 deceleration ramp
Jerk limitation –
Brief description Movement takes place to the specified target position when the setpoint position is selected and start is set. It is possible to move an individual axis (PO3 1 ... 12) or the entire axis system (PO3 = 99).
Prerequisite • Operating mode is selected• Drive is enabled
Functional description
The positioning sequence is started using bit PO1:8 Start.The user specifies the absolute target position via fieldbus.Speed and ramp times are adopted from the specified process data words and compared to the limitations from the startup.The position specification can be changed during ongoing operation. When the drive reaches the target position, it stops with position control and sends back the “In position” signal by setting bit PO1:3.If software limit switches are defined, the target position will be checked cyclically for plausibility. If a position is specified, which lies outside the software limit switch range, a fault message will be issued and the ongoing movement will be stopped. This monitoring function can be deactivated with the input bit Disable SWLS.
PoO
Manual – MOVI-PLC® Application Solution "SyncCrane"
6Positioning mode – unsynchronizedOperation
6.5.1 Supplement positioning mode of the virtual axis - synchronized
The following table shows the differences in the interface. Prerequisite is that "Auto-matic" mode is selected with "Start" set via process data word 1.
Interface description
Mode selection PO2:Bit11 = TRUEPO2:Bit12 = TRUEPO2:Bit13 = FALSE
Prerequisite All axes are engaged. This is indicated by PI2:4 "Axes synchronous".Prerequisite: • "Automatic" mode is selected and "Start" is set via process data word
1.• The axes are enabled (display "A: technology function" of the 7-
segment display)
Start PO2:8
Disable SWLS PO2:15
Position setpoint PO6 and PO7 in [inc]
Velocity specification PO8
Velocity limit Startup parameter
Jerk limitation Startup parameter
Position limiting Software limit switch startup parameter
Ramp specification • PO9 acceleration ramp• PO10 deceleration ramp
Manual – MOVI-PLC® Application Solution "SyncCrane"
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6 tomatic modeperation
6.6 Automatic modeSelecting "Automatic" mode means a sequencer is run through and the followingfunctions are processed:
Initialization is repeated in the following cases:
• Selecting an operating mode
• Positive edge of Start
• Reset of the axes following an encoder error
• Drives change to "A" state (technology function)
Automatic mode is initialized • The axis system is adjusted to the calculated common "adjust position".
• The virtual encoder position is referenced to the adjust position.
• "Synchronous operation" mode is activated
Cyclical program section: Processing the virtual encoder
• Cyclical processing of the virtual setpoints• Cyclical correction/slip compensation between the virtual
master encoder position and the read-in external encoder position in synchronous operation.
• Monitoring of lag error, encoder error, and inverter error
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Manual – MOVI-PLC® Application Solution "SyncCrane"
6Automatic modeOperation
The following figure shows the automatic mode:
536573963
Initializing
Adjust the MOVIDRIVE
axis
Adjust the virtual
encoder
All axis in position
Encoupling the axis
Virtual encoder in position
Control the virtual
encoder ( jog mode or
positioning)
All axis InGear
Ready for virtual encoder
Cyclic slip
compensation
Manual – MOVI-PLC® Application Solution "SyncCrane"
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6 tomatic modeperation
6.6.1 Interface description
Interface description
Mode selection PO1:Bit11 = FALSEPO1:Bit12 = FALSEPO1:Bit13 = TRUE
Mode selection virtual encoder
See description jog mode/positioning mode (supplement virtual encoder)
Start PO1:8
Axis number PO3 Broadcast 99
Position setpoint PO6 and PO7 virtual master encoder position
Position limiting Startup parameter limitation of virtual master encoder
Ramp specification • PO9 acceleration ramp [ms]• PO10 deceleration ramp [ms]
Brief description The entire system is moved synchronously in automatic mode.
Prerequisite • Operating mode is selected and start is set• Drive is enabled• No axis fault present• No lag error• No external encoder error• No error on PI1:Bit 6
Functional description
Automatic mode enables the user to operate the axis system synchronously. After selecting automatic mode or upon changing to the inverter status "A", the slave axes are adjusted to a calculated "adjust position". The slave axes signal a completed adjustment process via feedback bit PO2:Bit4 "Axes synchronous".From this time on, the axis system can be moved by controlling the virtual encoder. This is done by activating PO2 and jog mode or positioning mode.The axis system follows the actual value of the virtual encoder according to the principle of indirect synchronization. This means the setpoint is converted for the motor encoder to a position setpoint of the internal synchronous operation. At the same time, slip is compensated by monitoring the external encoder position. The slave axes signal during the movement whether a lag warning error was issued by means of feedback bits.Refer to the following chapters for detailed informa-tion on the adjustment mode and synchronization functions.
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Manual – MOVI-PLC® Application Solution "SyncCrane"
6Automatic modeOperation
6.6.2 Submode adjustment mode
The following figure shows the calculation of the adjustment position, for example for 3slave axes.
Interface description
536577291
Position [inc]
ActPos Slave3
32 inc
ActPos Slave2
12 inc
ActPos Slave1
-15 inc
10 20 30 40-30 -20 -10 0
AdjustPos = (-15 inc + 12 inc + 32 inc )/ 3
= 9,67 inc
Interface description
Mode selection Not required (adjust position is determined cyclically)
Brief description The absolute position offset of all connected axes is read in and then the mean position deviation is calculated. At the start of the adjustment process, all axes are adjusted to this position.
Functional description The calculated position offset is compensated by a positioning movement of the slave axes with the specified speed and ramp limits. "InPosition" is signaled back after completed compensation movement.
Manual – MOVI-PLC® Application Solution "SyncCrane"
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6 tomatic modeperation
6.6.3 Submode synchronous mode
The following figure shows synchronous mode with absolute encoder sensing.
Interface description
536572299
MDx Slave 1
MOVI-PLC
DHP
11B
DHE/
DHR
11B
MDxB DIP
21B
X33X12
X15
X14
X62
Motor with
Motor-Encoder
Absolute
SSI-Encoder
e.g.Laser
MDxB DIP
21B
X12
X15
X14
X62
Motor with
Motor-Encoder
Absolute
SSI-Encoder
e.g.Laser
MDx Slave 2
DHE/
DHR
11B
Interface description
Velocity limit Startup parameters synchronization speed
Ramp limit Startup parameters synchronization ramp
Master source Virtual master encoder
Slave source ISYNC Motor encoder
Slave source slip detection External HIPERFACE® encoder or absolute encoder
Slip compensation Startup parameter
Brief description The technology function ISYNC ensures angular synchronism between master and motor encoder.At a higher level, the position difference between the virtual master encoder and the absolute encoder system (or external HIPERFACE® encoder) is detected and corrected via a control element.
Prerequisite • Operating mode is selected• Drive is enabled
Functional description
For information/descriptions of the ISYNC technol-ogy function, refer to the "MOVIDRIVE® MDX61B Internal Synchronous Operation (ISYNC)" manual.For information on slip compensation, refer to the section "Functional principle of indirect positioning and synchronization" (see page 10).
AuO
Manual – MOVI-PLC® Application Solution "SyncCrane"
6Emergency modeOperation
6.7 Emergency mode
Interface description
Mode selection PO1:Bit11 = TRUEPO1:Bit12 = FALSEPO1:Bit13 = TRUE
Jog + PO1:9
Jog– PO1:10
Axis number PO3 Broadcast 99 or single axis mode 1 ... 12
Velocity specification PO8 in [rpm] or [user units]
Velocity limit Startup parameter
Ramp specification PO9 Acceleration ramp in [ms]PO10 Deceleration ramp in [ms]
Digital input You can influence the emergency mode by activating the digital input "SetEmergencyMode-DI01 X31:4":• DI01 SetemergencyMode = False: The position-controlled procedure
switches the inverter to "speed specification" mode.• DI01 SetemergencyMode = True: The position-controlled procedure
switches the inverter to "speed specification" mode and disables the external encoder or absolute encoder, if installed. In this way, the drive can even be moved with a defective absolute encoder.
Brief description If emergency mode was activated using the user interface, the drive can also be moved in the event of an encoder error.
Prerequisite • Operating mode is selected• Drive is enabled• MOVI-PLC® was restarted
Functional description
The direction is selected using Jog+ or Jog-. The travel movement is triggered by a specified speed. Once emergency mode is selected using the ApplicationBuilder startup, other operating modes cannot be selected any longer.The drive stops with position control if the direction selection is not enabled or both directions are selected at the same time.The specified ramp time is used for accelerating/decelerating the drive.The specified velocity of the jog mode is compared to the velocity limit and limited if necessary.Automatic mode cannot be selected anymore when the digital input (set emergency mode DI01 X31:4) is activated.
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6 ditional functionsperation
6.8 Additional functions6.8.1 External encoder monitoring function
6.8.2 Lag error window monitoring function
6.8.3 Fieldbus master monitoring function
Interface description
Lag error window Startup parameter
Time monitoring Startup parameter
Brief description To detect wire breakage of draw-wire encoders, the positions between motor encoder and synchronous encoder are sensed cyclically during ongoing movement.If this condition is violated, feedback is provided by the described status bits and an error message in the IEC.
Prerequisite Ongoing movement (actual speed > 50 prm)
Interface description
Lag error prewarning window Startup parameter
Time monitoring Startup parameter
Brief description In Automatic mode, a position comparison is made cyclically between the calculated averaged position of all axes involved, and the position offset of eeach axis to the reference position.If this condition is violated, feedback is provided by the described status bits and an error message in the IEC.
Prerequisite • Ongoing movement• Automatic active
Interface description
Operating principle Diagnostics function, which monitors the bus communication to the master controller cyclically. If this condition is violated, feedback is provided by the described status bits and an error message in the IEC.
Prerequisite Control via the PROFIBUS interface
AdO
Manual – MOVI-PLC® Application Solution "SyncCrane"
6Cycle diagramsOperation
6.9 Cycle diagramsThe following conditions apply to the cycle diagrams:
• Startup has been performed correctly
• DI00 "/Controller inhibit" = "1" (no inhibit)
• PO1:1 = "1" (Enable/halt)
• PO1:2 = "1" (Enable/stop)
• PO3 = "99" for group control or "1 ... 12" for single axis selection
The values for the dynamic parameters are transferred using the following processoutput data words:
• PO8 = Setpoint velocity
• PO9 = Acceleration ramp
• PO10 = Deceleration ramp
• PO45 = Target position for positioning mode (unsynchronized)
• PO67 = Target position for automatic mode (synchronized)
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6 ycle diagramsperation
6.9.1 Jog mode
536573963
[1] Axis starts when the jog+ bit is set[2] Axis starts when the jog– bit is set
Position Description
PO1:8 Start
PO1:9 Jog +
PO1:10 Jog–
PO1:11 "0" Mode 20
PO1:12 "0" Mode 21
PO1:13 "0" Mode 22
PI45 Actual position 32 bit
PA1:12
[1]
PA1:9
PA1:10
PA1:11
PE45
PA1:8
PA1:13
[2]
CO
Manual – MOVI-PLC® Application Solution "SyncCrane"
6Cycle diagramsOperation
6.9.2 Referencing mode
536593931
[1] Referencing starts when the start bit is set[2] The drive is referenced once the PI1:2 message (IPOS reference) is set.
Position Description
PO1:8 Start
PO1:11 "0" Mode 20
PO1:12 "1" Mode 21
PO1:13 "0" Mode 22
PI1:2 IPOS reference
PI45 Actual position 32 bit
PE1:2
PA1:8
PE45
eg. 54896
> 6 s
PA1:12
PA1:11
PA1:13
[1] [2]
0
Manual – MOVI-PLC® Application Solution "SyncCrane"
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6 ycle diagramsperation
6.9.3 Positioning mode
The following figure shows unsynchronized positioning operation of the individual axis/group.
536590603
[1] Start positioning[2] Positioning is interrupted by revoking start[3] Positioning[4] Positioning finished. PI1:3 message (IPOS in position) set.
Position Description
PO1:8 Start
PO1:11 "0" Mode 20
PO1:12 "1" Mode 21
PO1:13 "1" Mode 22
PO45 Setpoint position
PI1:3 IPOS in position
PI45 Actual position 32 bit
PE1:3
PE45
PA1:8
PA1:12
PA1:11
PA1:13
[1] [2] [3] [4]
CO
Manual – MOVI-PLC® Application Solution "SyncCrane"
6Cycle diagramsOperation
6.9.4 Automatic mode
The following figure show synchronized positioning mode of the group with positioningof the virtual encoder.
536575627
[1] Automatic mode selected[2] Activation of operating mode with the start input[3] Feedback "Axis system synchronized – ready for virtual encoder"[4] Positioning of the virtual encoder mode selected[5] Start of movement PO2:8 input "start"[6] Positioning finished. PI2:3 message (virtual encoder in position) set.[7] Decoupling of axis system by deselecting the operating mode
PE2:3
PE67
PA1:8
PA1:12
PA1:11
PA1:13
PA2:11
PA2:8
PA2:12
PA2:13
PE2:4
[2] [3] [5][1] [4] [6] [7]
Manual – MOVI-PLC® Application Solution "SyncCrane"
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6 ycle diagramsperation
Position Description
PO1:8 Start (automatic mode)
PO1:11 "0" Mode 20 (automatic mode)
PO1:12 "0" Mode 21
PO1:13 "1" Mode 22
PO2:8 Start (start of virtual encoder)
PO2:11 "1" Mode 20 (positioning mode of the virtual encoder)
PO2:12 "1" Mode 21
PO2:13 "0" Mode 21
PO67 Setpoint position virtual encoder
PI2:3 IPOS in position
PI2:4 Axis system synchronized – ready for virtual encoder
PI67 Actual position of axis system 32 bit
CO
Manual – MOVI-PLC® Application Solution "SyncCrane"
6Cycle diagramsOperation
6.9.5 Emergency mode
The following figure shows unsynchronized emergency mode of the individual axis/group.
The following additional prerequisites apply to emergency mode:
• X31:4 (DI01 set emergency mode) was set.
• MOVI-PLC® was restarted with set DI01.
536588939
[1] Axis starts when the jog+ bit is set[2] Axis starts when the jog– bit is set
Position Description
PO1:8 Start
PO1:9 Jog +
PO1:10 Jog–
PO1:11 "1" Mode 20
PO1:12 "1" Mode 21
PO1:13 "1" Mode 22
PI1:0 Motor turning
PE1:0
500 [1/min]
– 500 [1/min]
PA1:12
[1]
PA1:9
PA1:10
PA1:11
PA1:8
PA1:13
[2]
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6 ult informationperation
6.10 Fault information
Error code
Description Description
FF0201h E_MPLC_INVALIDNUMBEROFAXIS Invalid number of axes. A maximum of 12 axes can be selected.
FF0202h E_MPLC_INVALIDACTAXISNUMBER Invalid axis selection. Permitted:• PO3 = 99 (group control)• PO3 = 1 ... 12 (single axis control)
FF0203h E_MPLC_SYNCCRANE_LIMITSWITCHCW The specified position or actual position is outside the defined software limit switch.
FF0204h E_MPLC_SYNCCRANE_LIMITSWITCHCCW The specified position or actual position is outside the defined software limit switch.
FF0205h E_MPLC_SYNCCRANE_FIELDBUSTIMEOUT Fieldbus communication was interrupted. All setpoints are cleared internally.
FF0206h E_MPLC_SYNCCRANE_EXTENCODER External encoder provides implausible val-ues. Axis system is stopped in automatic mode.
FF0207h E_MPLC_SYNCCRANE_HMIFAILURE Communication while accessing the wizard was interrupted. All setpoints are cleared internally.
FF0208h E_MPLC_SYNCCRANE_LAGERROR The set lag error was exceeded in automatic mode (distance from external encoder position to virtual master encoder). The axis system is stopped.
FaO
Manual – MOVI-PLC® Application Solution "SyncCrane"
7System descriptionAuxiliary Drive (Auxiliary Axis)
7 Auxiliary Drive (Auxiliary Axis)7.1 System description7.1.1 Fields of application
Many applications with the SyncCrane application module are characterized bycontrolling several sequences of motion via a common interface between MOVI-PLC®
and the higher-level fieldbus master.
In many crane applications, for example, more auxiliary drives are required in additionto the feed axes synchronized using the SyncCrane application module in order tocontrol the lifting and Z movement of the load suspension.
Example: Hall crane with 3 motion axes:
Up to 4 auxiliary axes can be integrated without additional programming work. TheApplicationBuilder wizard is available for startup and diagnostics.
Users can choose between 3 different profiles to cover an as large as possibleapplication area:
• Position 16 bit
• Position 32 bit
• Velocity
One of the 3 profiles can be set for each of the 4 auxiliary axes. The profile is accessedusing 4 process data words.
682447883
Axis Description
X Motion sequence of the synchronized feed axes controlled via SyncCrane interface.
Z Position-controlled axis for moving the load suspension.
Y Position-controlled axis for lifting movement of the load suspension.
Manual – MOVI-PLC® Application Solution "SyncCrane"
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7 stem descriptionuxiliary Drive (Auxiliary Axis)
7.1.2 Application examples
• Hall crane with 2 additional auxiliary axes for handling the load suspension using the"positioning 32 bit" profile.
• Moving platform with position-controlled lancet drive for automating the load transfervia auxiliary axis using the "positioing 16 bit" profile.
• Travel carriage with control of an additional hydraulic unit using the "velocity" profile.The hydraulic unit is operated without encoder by specifying a setpoint speed.
675365643
SyncCrane
PO1
PO10
PI1
PI10
AuxAxis 1..4
PO17
PO32
PI17
PI32
AuxAxis1 AuxAxis2 AuxAxis4
SBus 2
SBus 1
SyncCrane A1 SyncCrane A2 SyncCrane A8SyncCrane A3
2
2
2
2
0
1
2
3
2
2
2
4
5
6
2
4
6
1
3
5
X32
2
4
6
1
3
5
X33
X30
2
4
6
1
3
5
8
10
12
7
9
11
X3
1X
34
MOVIPLC
MOVI-PLC®
SyA
Manual – MOVI-PLC® Application Solution "SyncCrane"
7Project planning for auxiliary drivesAuxiliary Drive (Auxiliary Axis)
7.2 Project planning for auxiliary drives7.2.1 Functional description
Functional characteristics
The auxiliary drives provide the following functional characteristics:
7.2.2 Process data assignmentThe higher-level controller (PLC) sends a process data range of 4 PD for each auxiliarydrive via PROFIBUS.
The following figure shows data exchange with 4 process data words:
Addressing of process data words:
Mode Profile 1Pos 16 bit
Profile 2Pos 32 bit
Profile 3Velocity
Mode 0 Default mode Default mode Default mode
Mode 1 Jog mode Jog mode Jog mode with velocity specification1)
1) with startup of the "velocity" profile.
Mode 2 Referencing mode Referencing mode Default mode
Mode 3 Positioning mode Positioning mode Default mode
Mode Description
Jog mode • The drive is moved clockwise or counterclockwise with position control using two bits for direction selection.
• Velocity and ramp can be specified via fieldbus as required depending on the profile.
Jog mode with star-tup of the "velocity" profile
• The set operating mode can also be used without encoder.• The drive is moved clockwise or counterclockwise using two bits for direction
selection.• Velocity and ramp can be specified via fieldbus as required.
Referencing mode • Reference travel and position adjustment of the external encoder are initiated with the start signal.
• Reference travel establishes the reference point (machine zero) for absolute positioning operations.
Positioning mode • When the axes are referenced and start is set, the received target position results in a positioning operation.
• Velocity and ramp can be specified via fieldbus as required depending on the profile.
657595787
Number of auxiliary drives 1 2 3 4
Axis 1 PD 29 ... 32 25 ... 28 21 ... 24 17 ... 20
Axis 2 PD – 29 ... 32 25 ... 28 21 ... 24
Axis 3 PD – – 29 ... 32 25 ... 28
Axis 4 PD – – – 29 ... 32
PO1 PO2 PO3 PO4
PI1 PI2 PI3 PI42
2
2
2
0
1
2
3
2
2
2
4
5
6
2
4
6
1
3
5
X3
2
2
4
6
1
3
5
X3
3X
30
2
4
6
1
3
5
8
10
12
7
9
11
X3
1X
34
MOVI-PLC
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7 oject planning for auxiliary drivesuxiliary Drive (Auxiliary Axis)
Process output data words
PO1 = Control word 1
512061835
Bit no. Description
Bit 0 /Controller inhibit
Bit 1 Enable/rapid stop
Bit 2 Enable/stop
Bit 3 Reserved
Bit 4 Reserved
Bit 5 Reserved
Bit 6 Fault reset
Bit 7 Reserved
Bit 8 Start
Bit 9 Jog+
Bit 10 Jog–
Bit 11 Mode 20
Bit 12 Mode 21
Bit 13 Reserved
Bit 14 Ramp switch-over
Bit 15 Disable SWLS
Process output data word
Profile 1Pos 16 bit
Profile 2Pos 32 bit
Profile 3Velocity
PO1 Control word Control word Control word
PO2 Setpoint velocity Setpoint velocity Setpoint velocity
PO3 Setpoint ramp Setpoint position 32 high Setpoint ramp
PO4 Setpoint position 16 Setpoint position 32 low Reserved
Bit 15
Bit 14Bit 13Bit 12Bit 11Bit 10Bit 9Bit 8
Bit 0
Bit 1
Bit 2Bit 3Bit 4Bit 5Bit 6
Bit 7
PrA
Manual – MOVI-PLC® Application Solution "SyncCrane"
7Project planning for auxiliary drivesAuxiliary Drive (Auxiliary Axis)
Process input data words
PI1 = Status word 1
512061835
Bit no. Description
Bit 0 Motor turning
Bit 1 Frequency inverter ready for operation
Bit 2 IPOS axis referenced
Bit 3 IPOS in position
Bit 4 Brake released
Bit 5 Frequency inverter fault/warning
Bit 6 Limit switch CW
Bit 7 Limit switch CCW
Bit 8 ... 15
Inverter/error status
Process input data word Profile 1Pos 16 bit
Profile 2Pos 32 bit
Profile 3Velocity
PO1 Status word Status word Status word
PO2 Actual speed Actual speed Actual speed
PO3 Reserved Actual position 32 high Reserved
PO4 Actual position 16 Actual position 32 low Actual position 16
Bit 15
Bit 14Bit 13Bit 12Bit 11Bit 10Bit 9Bit 8
Bit 0
Bit 1
Bit 2Bit 3Bit 4Bit 5Bit 6
Bit 7
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7 oject planning for auxiliary drivesuxiliary Drive (Auxiliary Axis)
7.2.3 Control configuration
The SyncCrane application module is designed for controlling a maximum of 4additional auxiliary drives. The inverters are connected via CAN2 of the MOVI-PLC®
(X:32) with a baud rate of 500 kBaud.
The inverters have to be set with SBus address 9 ... 12. It is recommended that youmake the setting using the DriveStartup tool.
Number of auxiliary axes 1 2 3 4
SBus baud rate (kBaud) 500 500 500 500
SBus address axis 1 9 9 9 9
SBus address axis 2 – 10 10 10
SBus address axis 3 – – 11 11
SBus address axis 4 – – – 12
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PrA
Manual – MOVI-PLC® Application Solution "SyncCrane"
7Startup of auxiliary drivesAuxiliary Drive (Auxiliary Axis)
7.3 Startup of auxiliary drives7.3.1 Starting the "Auxiliary axis" program
Make a right mouse clock on Serial 0:MOVI-PLC and select [MotionStudio] /[Diagnostics] / [Application Builder] / [AuxiliaryAxis_E.mon]
Initial screen The initial screen of the "Auxiliary Axis" application is opened.
Proceed as follows to perform initial startup:
• Begin initial startup of the individual axes with axis 1. To do so, choose "Axis 1" fromthe "Select individual axis number" selection field.
• Enter the number of required auxiliary axes in the "Maximum number of axes"selection field. You can choose a maximum of 4 axes.
• Define the start address for the operating variables (startup and diagnosticsvariables) in the "H start address" input field. Start address 1200 is recommended forthe SyncCrane application module.
• "H start index" is the converted start index of the variable range.
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7 artup of auxiliary drivesuxiliary Drive (Auxiliary Axis)
The following display elements are available for diagnostic purposes:
• PD start address
• H variable
• Startup
• H start index
Button Description
Startup Click here to trigger startup of the application.The following chapters describe the next steps.
Monitor The button is disabled if• you are not online• the application module has not been detected
Cancel Click this button to exit the startup wizard.
NOTEIf you want to load saved application data, choose [File] / [Open settings] from themenu.
StA
Manual – MOVI-PLC® Application Solution "SyncCrane"
7Startup of auxiliary drivesAuxiliary Drive (Auxiliary Axis)
Fieldbus parameters
This window is used to specify the process data profile of your auxiliary axis.
757879691
Field Description
Active axis number You can read the selected axis number from this field.
SBus address The specified SBus address is shown in this field.
Process data profile You can choose one of three process data profiles. The following functions are supported:• Positioning 16 bit• Positioning 32 bit• Velocity specification
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7 artup of auxiliary drivesuxiliary Drive (Auxiliary Axis)
Calculating the scaling factors
On this startup screen you determine the position resolution for the selected encodersystem.
757885835
Field Description
Diameter Enter the mechanical data in this field. You can enter values with two decimal places.Gear ratio
External ratio
Calculate The determined position resolution for the motor encoder system is entered in the input fields "Increments" and "Distance".The determined scaling factors are limited to 216.
StA
Manual – MOVI-PLC® Application Solution "SyncCrane"
7Startup of auxiliary drivesAuxiliary Drive (Auxiliary Axis)
Parameters and limits
In this window you can set the travel range and velocity limits.
757891723
Group Field Description
Limit switch Software limit switch CW
The software limit switches limit the permitted travel range for the following operating modes:• Jog• Positioning• AutomaticThe specified value refers to the increments of the synchronous encoder.The processing of hardware limit switches is not intended.
Software limit switch CCW
Hardware limit switches Choose whether you want hardware limit switches to be evaluated. They are evaluated on MOVIDRIVE® as follows:• X13:5 DI04 with /Limit switch CW• X13:6 DI05 with /Limit switch CCW
Reference travel
Reference offset Enter the reference offset in increments in relation to the synchronous encoder.
Reference type The reference type defines the movement sequence for detecting the mechanical zero point.
Limits Maximum speed posi-tioning
You can limit the specified positioning speed by entering the value.
Maximum speed jog mode
You can limit the specified jog speed by entering the value.
Maximum motor speed Enter a value at least 10 % higher than the maximum positioning and/or jog speed.
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7 artup of auxiliary drivesuxiliary Drive (Auxiliary Axis)
Downloading data The data are loaded to the MOVI-PLC® as soon as you have entered the startupparameters.
757909899
NOTEActivating the "ResetCold" input element will reset the MOVI-PLC® after havingdownloaded the input values.
As SBus communication with the connected inverters is interrupted briefly, they willsignal "SBUS2 timeout" until fault F46 is acknowledged.
StA
Manual – MOVI-PLC® Application Solution "SyncCrane"
7Operation of auxiliary drivesAuxiliary Drive (Auxiliary Axis)
7.4 Operation of auxiliary drives7.4.1 Starting the drive
After the download, switch to the monitor of the Auxiliary axis application module.
Operating modes (fieldbus control)
Operating mode PO1:13 PO1:12 PO1:11 Description
Default 0 0 0 No axis is moved.
Jog mode 0 0 1 • Individual axes or the group can be moved via the Jog+ and Jog- inputs.
• Specify the following values:• Process output data words• Travel parameters• Velocity• Ramp
If no velocity is specified, the axis will move at 0.2 rpm.
Referencing mode 0 1 0 • The IPOS encoder position is referenced when start is set.
• Reference travel establishes the reference point (machine zero) for positioning operations.
Positioning mode 0 1 1 • The referenced single axis can be moved once a target position is specified and start is set.
• Specify the process output data words, travel parameters, velocity, and ramp. If no velocity is specified, the axis will move at 0.2 rpm.
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7 peration of auxiliary drivesuxiliary Drive (Auxiliary Axis)
Diagnostics moni-tor: Monitor mode
During ongoing operation, the monitor can be opened via [MotionStudio] / [Diagnostics]/ [Application Builder] / [AuxiliaryAxis_E.mon].
In monitor mode, the process input and process output data transferred via fieldbus aredisplayed in decoded format.
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Manual – MOVI-PLC® Application Solution "SyncCrane"
7Operation of auxiliary drivesAuxiliary Drive (Auxiliary Axis)
Parameters Startup automatically sets the following parameters:
Parameter number Parameter Setting
SHELL P302 Maximum speed 1 Specified value from "parameters and limits"
SHELL P920 CW SW limit switch Specified value from "parameters and limits"
SHELL P921 CCW SW limit switch Specified value from "parameters and limits"
SHELL P603 Binary input DI04 /Limit switch CW or no function
SHELL P604 Binary input DI05 /Limit switch CCW or no function
SHELL P903 Reference travel type Specified value from "parameters and limits"
SHELL P900 Reference offset Specified value from "parameters and limits"
H2047 H_STARTADDRESS –
Hxxx + 1 H_OFFSET –
Hxxx + 2 H_OFFSETAXIS –
Hxxx + 3 PD_STARTADDRESS –
Hxxx + 4 PD_OFFSET –
Hxxx + 5 H_IBSTATUS_A1 –
Hxxx + 6 H_IBSTATUS_A2 –
Hxxx + 7 H_IBSTATUS_A3 –
Hxxx + 8 H_IBSTATUS_A4 –
Hxxx + 9 MONITOR_CTRL –
Hxxx + 10 H_STARTADDRESS_A1 –
Hxxx + 11 H_STARTADDRESS_A2 –
Hxxx + 12 H_STARTADDRESS_A3 –
Hxxx + 13 H_STARTADDRESS_4 –
Hxxx + 14 H_MAXAXISNUMBER –
Hxxx + 15 H_ACTAXISNUMBER –
Hxxx + 16 H_AUXIBSTATUS –
[H_STARTADDRESS_A1] + 0 PO1 –
[H_STARTADDRESS_A1] + 1 PO2 –
[H_STARTADDRESS_A1] + 2 PO3 –
[H_STARTADDRESS_A1] + 3 PO4 –
[H_STARTADDRESS_A1] + 10 PI1 –
[H_STARTADDRESS_A1] + 11 PI2 –
[H_STARTADDRESS_A1] + 12 PI3 –
[H_STARTADDRESS_A1] + 13 PI4 –
[H_STARTADDRESS_A1] + 20 BUS_ADDRESS –
[H_STARTADDRESS_A1] + 21 BUS_PDPROIFILE –
[H_STARTADDRESS_A1] + 25 SCALE_SOURCE –
[H_STARTADDRESS_A1] + 26 SCALE_TYPE –
[H_STARTADDRESS_A1] + 27 SCALE_VALUE –
[H_STARTADDRESS_A1] + 28 SCALE_RESOLUTION –
[H_STARTADDRESS_A1] + 29 SCALE_GEARINGRATIO –
[H_STARTADDRESS_A1] + 30 SCALE_EXTRATIO –
[H_STARTADDRESS_A1] + 31 SCALE_SPEEDRES –
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7 peration of auxiliary drivesuxiliary Drive (Auxiliary Axis)
[H_STARTADDRESS_A1] + 32 SCALE_INC –
[H_STARTADDRESS_A1] + 33 SCALE_DISTANCE –
[H_STARTADDRESS_A1] + 34 SCALE_NUMERATOR –
[H_STARTADDRESS_A1] + 35 SCALE_DENOMINATOR –
[H_STARTADDRESS_A1] + 40 LIM_LSCCW –
[H_STARTADDRESS_A1] + 41 LIM_LSCW –
[H_STARTADDRESS_A1] + 42 LIM_HWLS –
[H_STARTADDRESS_A1] + 43 LIM_REFOFFSET –
[H_STARTADDRESS_A1] + 44 LIM_REFTYPE –
[H_STARTADDRESS_A1] + 45 LIM_Ramp1 –
[H_STARTADDRESS_A1] + 46 LIM_Ramp2 –
[H_STARTADDRESS_A1] + 47 LIM_MAXSPEEDAUTO –
[H_STARTADDRESS_A1] + 48 LIM_MAXSPEEDJOG –
[H_STARTADDRESS_A1] + 49 LIM_MAXSPEED –
[H_STARTADDRESS_A2+ 0 PO1 Structure axis 2
[H_STARTADDRESS_A3+ 0 PO1 Structure axis 3
[H_STARTADDRESS_A4+ 0 PO1 Structure axis 4
Parameter number Parameter Setting
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Manual – MOVI-PLC® Application Solution "SyncCrane"
8Frequently asked questionsAppendix
8 Appendix8.1 Frequently asked questions
• Why do the axes not signal "Connected"?
• Was "DriveStartup" performed for each individual axis?
• Are the SBus addresses of the inverters different?
• Is the SBus wiring correct (terminating resistors)?
• Why does the enabled drive vibrate without mode selection?
• Check the calculated scaling factors and position windows.
• Which values have to be entered in the wizard in the "SingleAxisScaling" input fieldsif solely a motor encoder is to be used?
• Fill all fields by clicking on the "Default" button.
• Enter value "1" in the numerator and denominator fields.
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9 ddress List
9 Address List
Germany
HeadquartersProductionSales
Bruchsal SEW-EURODRIVE GmbH & Co KGErnst-Blickle-Straße 42 D-76646 BruchsalP.O. BoxPostfach 3023 • D-76642 Bruchsal
Tel. +49 7251 75-0Fax +49 7251 75-1970http://[email protected]
Service Compe-tence Center
Central SEW-EURODRIVE GmbH & Co KGErnst-Blickle-Straße 1 D-76676 Graben-Neudorf
Tel. +49 7251 75-1710Fax +49 7251 [email protected]
North SEW-EURODRIVE GmbH & Co KGAlte Ricklinger Straße 40-42 D-30823 Garbsen (near Hannover)
Tel. +49 5137 8798-30Fax +49 5137 [email protected]
East SEW-EURODRIVE GmbH & Co KGDänkritzer Weg 1D-08393 Meerane (near Zwickau)
Tel. +49 3764 7606-0Fax +49 3764 [email protected]
South SEW-EURODRIVE GmbH & Co KGDomagkstraße 5D-85551 Kirchheim (near München)
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West SEW-EURODRIVE GmbH & Co KGSiemensstraße 1D-40764 Langenfeld (near Düsseldorf)
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Electronics SEW-EURODRIVE GmbH & Co KGErnst-Blickle-Straße 42 D-76646 Bruchsal
Tel. +49 7251 75-1780Fax +49 7251 [email protected]
Drive Service Hotline / 24 Hour Service +49 180 5 SEWHELP+49 180 5 7394357
Additional addresses for service in Germany provided on request!
France
ProductionSalesService
Haguenau SEW-USOCOME 48-54, route de Soufflenheim B. P. 20185F-67506 Haguenau Cedex
Tel. +33 3 88 73 67 00 Fax +33 3 88 73 66 00http://[email protected]
Production Forbach SEW-EUROCOME Zone Industrielle Technopôle Forbach SudB. P. 30269F-57604 Forbach Cedex
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Tel. +33 1 64 42 40 80Fax +33 1 64 42 40 88
Additional addresses for service in France provided on request!
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Manual – MOVI-PLC® Application Solution "SyncCrane"
9Address List
Algeria
Sales Alger Réducom 16, rue des Frères ZaghnounBellevue El-Harrach16200 Alger
Tel. +213 21 8222-84Fax +213 21 [email protected]
Argentina
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Tel. +61 3 9933-1000Fax +61 3 9933-1003http://[email protected]
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Austria
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Additional addresses for service in Brazil provided on request!
Bulgaria
Sales Sofia BEVER-DRIVE GmbHBogdanovetz Str.1BG-1606 Sofia
Tel. +359 2 9151160Fax +359 2 [email protected]
Cameroon
Sales Douala Electro-ServicesRue Drouot AkwaB.P. 2024Douala
Tel. +237 33 431137Fax +237 33 431137
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Canada
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Toronto SEW-EURODRIVE CO. OF CANADA LTD. 210 Walker Drive Bramalea, Ontario L6T3W1
Tel. +1 905 791-1553Fax +1 905 791-2999http://[email protected]
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China
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Guangzhou SEW-EURODRIVE (Guangzhou) Co., Ltd.No. 9, JunDa RoadEast Section of GETDDGuangzhou 510530
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Croatia
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Czech Republic
Sales Praha SEW-EURODRIVE CZ S.R.O.Business Centrum Praha Lužná 591CZ-16000 Praha 6 - Vokovice
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ProductionAssemblyService
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Hungary
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Tel. +36 1 437 06-58Fax +36 1 437 [email protected]
India
AssemblySalesService
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Tel. +91 265 2831086Fax +91 265 2831087http://[email protected]@seweurodriveindia.com
Ireland
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Dublin Alperton Engineering Ltd. 48 Moyle RoadDublin Industrial EstateGlasnevin, Dublin 11
Tel. +353 1 830-6277Fax +353 1 [email protected]://www.alperton.ie
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Ivory Coast
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Japan
AssemblySalesService
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Korea
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Busan SEW-EURODRIVE KOREA Co., Ltd.No. 1720 - 11, Songjeong - dongGangseo-kuBusan 618-270
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Latvia
Sales Riga SIA Alas-KuulKatlakalna 11CLV-1073 Riga
Tel. +371 7139253Fax +371 7139386http://[email protected]
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Lebanon
Sales Beirut Gabriel Acar & Fils sarlB. P. 80484Bourj Hammoud, Beirut
Tel. +961 1 4947-86 +961 1 4982-72+961 3 2745-39Fax +961 1 4949-71 [email protected]
Lithuania
Sales Alytus UAB IrsevaNaujoji 19LT-62175 Alytus
Tel. +370 315 79204Fax +370 315 [email protected]://www.sew-eurodrive.lt
Luxembourg
AssemblySalesService
Brüssel CARON-VECTOR S.A.Avenue Eiffel 5B-1300 Wavre
Tel. +32 10 231-311Fax +32 10 231-336http://[email protected]
Malaysia
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Johore SEW-EURODRIVE SDN BHD No. 95, Jalan Seroja 39, Taman Johor Jaya81000 Johor Bahru, JohorWest Malaysia
Tel. +60 7 3549409Fax +60 7 [email protected]
Mexico
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Queretaro SEW-EURODRIVE MEXIKO SA DE CVSEM-981118-M93Tequisquiapan No. 102Parque Industrial QueretaroC.P. 76220Queretaro, Mexico
Tel. +52 442 1030-300Fax +52 442 1030-301http://[email protected]
Morocco
Sales Casablanca Afit5, rue Emir AbdelkaderMA 20300 Casablanca
Tel. +212 22618372Fax +212 [email protected]
Netherlands
AssemblySalesService
Rotterdam VECTOR Aandrijftechniek B.V. Industrieweg 175 NL-3044 AS RotterdamPostbus 10085NL-3004 AB Rotterdam
Tel. +31 10 4463-700Fax +31 10 4155-552http://[email protected]
New Zealand
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Auckland SEW-EURODRIVE NEW ZEALAND LTD. P.O. Box 58-428 82 Greenmount driveEast Tamaki Auckland
Tel. +64 9 2745627Fax +64 9 2740165http://[email protected]
Christchurch SEW-EURODRIVE NEW ZEALAND LTD. 10 Settlers Crescent, FerrymeadChristchurch
Tel. +64 3 384-6251Fax +64 3 [email protected]
Norway
AssemblySalesService
Moss SEW-EURODRIVE A/SSolgaard skog 71N-1599 Moss
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Peru
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Lima SEW DEL PERU MOTORES REDUCTORES S.A.C.Los Calderos, 120-124Urbanizacion Industrial Vulcano, ATE, Lima
Tel. +51 1 3495280Fax +51 1 3493002http://[email protected]
Poland
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Lodz SEW-EURODRIVE Polska Sp.z.o.o.ul. Techniczna 5 PL-92-518 Łódź
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24 Hour Service Tel. +48 602 739 739(+48 602 SEW SEW)
Portugal
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Coimbra SEW-EURODRIVE, LDA.Apartado 15 P-3050-901 Mealhada
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Romania
SalesService
Bucureşti Sialco Trading SRL str. Madrid nr.4 011785 Bucuresti
Tel. +40 21 230-1328Fax +40 21 230-7170 [email protected]
Russia
AssemblySalesService
St. Petersburg ZAO SEW-EURODRIVE P.O. Box 36 195220 St. Petersburg Russia
Tel. +7 812 3332522 +7 812 5357142Fax +7 812 3332523http://[email protected]
Senegal
Sales Dakar SENEMECA Mécanique GénéraleKm 8, Route de Rufisque B.P. 3251, Dakar
Tel. +221 338 494 770Fax +221 338 494 [email protected]
Serbia
Sales Beograd DIPAR d.o.o.Ustanicka 128aPC Košum, IV floorSCG-11000 Beograd
Tel. +381 11 347 3244 / +381 11 288 0393Fax +381 11 347 [email protected]
Singapore
AssemblySalesService
Singapore SEW-EURODRIVE PTE. LTD. No 9, Tuas Drive 2 Jurong Industrial Estate Singapore 638644
Tel. +65 68621701Fax +65 68612827http://[email protected]
Slovakia
Sales Bratislava SEW-Eurodrive SK s.r.o.Rybničná 40SK-831 06 Bratislava
Tel. +421 2 33595 202Fax +421 2 33595 [email protected]://www.sew-eurodrive.sk
Žilina SEW-Eurodrive SK s.r.o.Industry Park – PChZulica M.R.Štefánika 71SK-010 01 Žilina
Tel. +421 41 700 2513Fax +421 41 700 [email protected]
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Manual – MOVI-PLC® Application Solution "SyncCrane"
9Address List
Banská Bystrica
SEW-Eurodrive SK s.r.o.Rudlovská cesta 85SK-974 11 Banská Bystrica
Tel. +421 48 414 6564Fax +421 48 414 [email protected]
Košice SEW-Eurodrive SK s.r.o.Slovenská ulica 26SK-040 01 Košice
Tel. +421 55 671 2245Fax +421 55 671 [email protected]
Slovenia
SalesService
Celje Pakman - Pogonska Tehnika d.o.o.UI. XIV. divizije 14SLO - 3000 Celje
Tel. +386 3 490 83-20Fax +386 3 490 [email protected]
South Africa
AssemblySalesService
Johannesburg SEW-EURODRIVE (PROPRIETARY) LIMITEDEurodrive House Cnr. Adcock Ingram and Aerodrome RoadsAeroton Ext. 2Johannesburg 2013P.O.Box 90004Bertsham 2013
Tel. +27 11 248-7000Fax +27 11 494-3104http://[email protected]
Capetown SEW-EURODRIVE (PROPRIETARY) LIMITED Rainbow ParkCnr. Racecourse & Omuramba RoadMontague GardensCape TownP.O.Box 36556Chempet 7442 Cape Town
Tel. +27 21 552-9820Fax +27 21 552-9830Telex 576 [email protected]
Durban SEW-EURODRIVE (PROPRIETARY) LIMITED2 Monaceo PlacePinetownDurbanP.O. Box 10433, Ashwood 3605
Tel. +27 31 700-3451Fax +27 31 [email protected]
Spain
AssemblySalesService
Bilbao SEW-EURODRIVE ESPAÑA, S.L. Parque Tecnológico, Edificio, 302E-48170 Zamudio (Vizcaya)
Tel. +34 94 43184-70Fax +34 94 43184-71http://[email protected]
Sweden
AssemblySalesService
Jönköping SEW-EURODRIVE ABGnejsvägen 6-8S-55303 JönköpingBox 3100 S-55003 Jönköping
Tel. +46 36 3442 00Fax +46 36 3442 80http://[email protected]
Switzerland
AssemblySalesService
Basel Alfred lmhof A.G.Jurastrasse 10 CH-4142 Münchenstein bei Basel
Tel. +41 61 417 1717Fax +41 61 417 1700http://[email protected]
Thailand
AssemblySalesService
Chonburi SEW-EURODRIVE (Thailand) Ltd.700/456, Moo.7, DonhuarohMuang Chonburi 20000
Tel. +66 38 454281Fax +66 38 [email protected]
Slovakia
Manual – MOVI-PLC® Application Solution "SyncCrane"
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9 ddress List
Tunisia
Sales Tunis T. M.S. Technic Marketing Service5, Rue El Houdaibiah 1000 Tunis
Tel. +216 71 4340-64 + 71 4320-29Fax +216 71 [email protected]
Turkey
AssemblySalesService
Istanbul SEW-EURODRIVE Hareket Sistemleri San. ve Tic. Ltd. Sti. Bagdat Cad. Koruma Cikmazi No. 3 TR-34846 Maltepe ISTANBUL
Tel. +90 216 4419164, 3838014, 3738015Fax +90 216 3055867http://[email protected]
Ukraine
SalesService
Dnepropetrovsk SEW-EURODRIVEStr. Rabochaja 23-B, Office 40949008 Dnepropetrovsk
Tel. +380 56 370 3211Fax +380 56 372 2078http://[email protected]
USA
ProductionAssemblySalesService
Greenville SEW-EURODRIVE INC. 1295 Old Spartanburg Highway P.O. Box 518Lyman, S.C. 29365
Tel. +1 864 439-7537Fax Sales +1 864 439-7830Fax Manuf. +1 864 439-9948Fax Ass. +1 864 439-0566Telex 805 550 http://[email protected]
AssemblySalesService
San Francisco SEW-EURODRIVE INC. 30599 San Antonio St.Hayward, California 94544-7101
Tel. +1 510 487-3560Fax +1 510 [email protected]
Philadelphia/PA SEW-EURODRIVE INC. Pureland Ind. Complex 2107 High Hill Road, P.O. Box 481Bridgeport, New Jersey 08014
Tel. +1 856 467-2277Fax +1 856 [email protected]
Dayton SEW-EURODRIVE INC.2001 West Main Street Troy, Ohio 45373
Tel. +1 937 335-0036Fax +1 937 [email protected]
Dallas SEW-EURODRIVE INC.3950 Platinum Way Dallas, Texas 75237
Tel. +1 214 330-4824Fax +1 214 [email protected]
Additional addresses for service in the USA provided on request!
Venezuela
AssemblySalesService
Valencia SEW-EURODRIVE Venezuela S.A.Av. Norte Sur No. 3, Galpon 84-319Zona Industrial Municipal NorteValencia, Estado Carabobo
Tel. +58 241 832-9804Fax +58 241 838-6275http://[email protected]@cantv.net
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Manual – MOVI-PLC® Application Solution "SyncCrane"
Index
Index
AAdditional functions................................................68
External encoder monitoring function ................68Fieldbus master monitoring function ..................68Lag error window monitoring function ................68
Adjustment mode ...................................................65Advantages ..............................................................7Application examples ...............................................9Automatic mode ...........................................8, 18, 62Auxiliary axis ..........................................................77
Fields of application ...........................................77Operation ...........................................................89Project planning .................................................79System description.............................................77
Auxiliary drive.........................................................77Fields of application ...........................................77Project planning .................................................79Startup ...............................................................83System description.............................................77
Auxiliary drivesOperation ...........................................................89
BBus installation PROFIBUS DHP11B.....................30
CConnecting system bus (SBus1)............................30Cycle diagrams ......................................................69
Automatic mode .................................................73Emergency mode...............................................75Jog mode ...........................................................70Positioning mode ...............................................72Referencing mode..............................................71
DDetermining the scaling factors
Motor encoder/absolute encoder .......................19virtual encoder ...................................................20
Diagnostics monitor................................................56Documentation
applicable.............................................................6
EEmergency mode.........................................8, 18, 67Exclusion of liability ..................................................6
FFAQs......................................................................93Fault information ....................................................76Fields of application .................................................7Frequently asked questions...................................93Functional description............................................17
GGroup signals.........................................................50
HH variables of the MOVI-PLC®..............................49
IIndirect position control ..........................................12Indirect positioning, functional principle .................10Indirect sychronization ...........................................10Inerter requirements ..............................................16Installation
MotionStudio Software.......................................28
JJog mode .....................................................8, 17, 56
LLimit switches ........................................................20
MMachine zero .........................................................20MotionStudio, Installation.......................................28MOVIDRIVE® MDX61B
Wiring diagram...................................................29MOVI-PLC®
Parameters/H variables .....................................49
OOperation ...............................................................55Operation of auxiliary drives ..................................89
PParameters
Drive Inverter .....................................................50MOVI-PLC®.......................................................49
PLC program, program overview...........................53Positioning mode .........................................8, 17, 60
Manual – MOVI-PLC® Application Solution "SyncCrane"
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Index
Positioning, indirect ................................................10Prerequisites
Motor / gear unit.................................................17Startup ...............................................................31
Process data assignment.......................................21Process input data words.......................................24Process output data words ....................................22PROFIBUS DHP11B, Bus installation....................30Program identification ............................................15Project planning for auxiliary drives .......................79
RReference cams.....................................................20Referencing mode........................................8, 17, 59Requirements
Inverter...............................................................16MOVI-PLC®.......................................................17Software.............................................................16
Right to claim under limited warranty .......................5
SSafe stop................................................................27Safety notes
Structure ..............................................................5Scaling factors for motor encoder/absolute encoder..
19Scaling factors for virtual encoder..........................20Scaling the drive ....................................................19Software limit switches...........................................25Software requirements ...........................................16Starting the drive....................................................55Startup ...................................................................31
MOVIDRIVE® individual axes............................31Preliminary work ................................................31Prerequisites ......................................................31
Startup of auxiliary drives.......................................83Structure of the safety notes ....................................5SyncCrane
Initital screen......................................................34Starting program ................................................33Startup steps......................................................36
Synchronization, indirect ........................................10Synchronous mode ................................................66System bus (SBus1), connection...........................30System description for auxiliary drives...................77
WWiring diagram MOVIDRIVE® MDX61B................29
Manual – MOVI-PLC® Application S
olution "SyncCrane"SEW-EURODRIVE – Driving the world
How we’re driving the world
With people whothink fast anddevelop thefuture with you.
With a worldwide service network that isalways close at hand.
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SEW-EURODRIVE GmbH & Co KGP.O. Box 3023 · D-76642 Bruchsal / GermanyPhone +49 7251 75-0 · Fax +49 7251 [email protected]