flying saw 04 2004

Gearmotors \ Industrial Gear Units \ Drive Electronics \ Drive Automation \ Services

MOVIDRIVEFlying Saw Application

Manual

A5.J56

Edition 04/200411227710 / EN

SEW-EURODRIVE Driving the world

MOVIDRIVE Flying Saw 3

1 Important Notes...................................................................................................... 4

2 System Description................................................................................................ 52.1 Application fields ............................................................................................ 52.2 Application example....................................................................................... 62.3 Program identification .................................................................................... 7

3 Project Planning..................................................................................................... 83.1 Prerequisites .................................................................................................. 83.2 Functional description .................................................................................... 93.3 Determine material travel and web speed.................................................... 133.4 Process data assignment............................................................................. 14

4 Installation ............................................................................................................ 164.1 Software....................................................................................................... 164.2 MOVIDRIVE MDX61B ............................................................................... 174.3 Bus installation MOVIDRIVE MDX61B ...................................................... 194.4 MOVIDRIVE compact MCH4_A................................................................. 26

5 Startup................................................................................................................... 295.1 General information ..................................................................................... 295.2 Preliminary work........................................................................................... 295.3 Starting the "flying saw" program................................................................. 305.4 Parameters and IPOS variables................................................................... 485.5 Starting the drive.......................................................................................... 525.6 Jog mode ..................................................................................................... 535.7 Reference travel........................................................................................... 545.8 Positioning ................................................................................................... 555.9 Automatic mode ........................................................................................... 56

6 Operation and Service ......................................................................................... 606.1 Timing diagrams........................................................................................... 606.2 Fault information .......................................................................................... 666.3 Error messages............................................................................................ 67

7 Index...................................................................................................................... 69

00

I

4 MOVIDRIVE Flying Saw

1 Important Notes

MOVIDRIVE1 Important Notes

Documentation Read this manual carefully before you commence installation and startup ofMOVIDRIVE drive inverters with this application module.

This manual was written assuming that the user has access to and is familiar with theMOVIDRIVE documentation, in particular the MOVIDRIVE system manual.

In this manual, cross references are marked with ''. For example, ( Sec. X.X)means: Further information can be found in section X.X of this manual.

A requirement of fault-free operation and fulfillment of any rights to claim underguarantee is that you observe the information contained in the documentation.

Safety and warning instructions

Always observe the safety and warning instructions in this publication!

This manual does not replace the detailed operating instructions! Installation and startup only by trained personnel observing applicable

accident prevention regulations and the MOVIDRIVE operating instructions!

Electrical hazardPossible consequences: Severe or fatal injuries.

Hazard Possible consequences: Severe or fatal injuries.

Hazardous situationPossible consequences: Slight or minor injuries.

Harmful situationPossible consequences: Damage to the unit and the environment.

Tips and useful information.


2Application fieldsSystem Description

2 System Description2.1 Application fields

The "flying saw" application module is particularly suited to applications in which amoving endless material has to be cut to length. Other applications include synchronousmaterial transport, filling stations, "flying punches" or "flying knives."

The "flying saw" application module is especially suitable for the following sectors: Wood processing Paper, cardboard Plastic Stone Clay

Two basic application types are possible: A parallel saw in which case one drive is needed for the saw carriage (traveling with

the material) and another drive is required for the saw feed A diagonal saw in which case only one drive is necessary; the saw carriage moves

diagonally in relation to the material direction

The "flying saw" offers the following advantages in these applications: User-friendly operator interface Only the parameters required for the "flying saw" (cut length, engagement travel)

need to be entered User-friendly application programs guide you through the process of setting

parameters, so there is no need for complicated programming Monitor mode for optimum diagnostics You do not need any programming experience It doesn't take long to get to know the system


2 Application exampleSystem Description

2.2 Application exampleFlying saw The "flying saw" application module is often used in the wood processing industry. Long

pressed particle boards have to be cut to length.

1. Drive for the saw carriage feed along the longitudinal axis (material direction)2. Drive for the saw feed

05839BXXFigure 1: "Flying saw" in the wood processing industry

1. 2.


2Program identificationSystem Description

2.3 Program identificationYou can use the MOVITOOLS software package to identify which application programwas last loaded into the MOVIDRIVE unit. Proceed as follows: Connect MOVIDRIVE to the PC via the serial port Start MOVITOOLS

Start "Shell" In Shell, select "Display/IPOS information..."

The "IPOS Status" window appears. The entries in this window tell you whatapplication software is stored in MOVIDRIVE.

06710AENFigure 2: IPOS information in Shell

06711AENFigure 3: Display of the current IPOS program version


3 PrerequisitesProject Planning

3 Project Planning3.1 PrerequisitesPC and software The "flying saw" application module is implemented as an IPOSplus program and forms

part of the SEW MOVITOOLS software package. To use MOVITOOLS, you musthave a PC with one of the following operating systems: Windows 95, Windows 98,Windows NT 4.0, Windows Me or Windows 2000.

Inverters, motors and encoders

InvertersThe "flying saw" can only be implemented on MOVIDRIVE units in applicationversion (...-0T). In MOVIDRIVE MDX61B, the inverter can be controlled either usingterminals or a bus. Terminal control is not possible with MOVIDRIVE compactMCH4_A. You can use the system bus provided as standard, the PROFIBUS-DPinterface (MCH41A), the INTERBUS FO interface (MCH42A) or a fieldbus gateway.It is essential for the "flying saw" to have encoder feedback, and consequently itcannot be implemented with MOVIDRIVE MDX60B.

Motors and encoders For operation on MOVIDRIVE MDX61B with DEH11B or MOVIDRIVE compact

MCH4_A: CT/CV asynchronous servomotors (encoder installed as standard) orDR/DT/DV/ AC motors with encoder (Hiperface, sin/cos or TTL).

For operation on MOVIDRIVE MDX61B with DER11B: CM/DS synchronousservomotors with resolver.

Permitted operating modes (P700): Asynchronous motor (CT/CV/DR/DT/DV): CFC operating modes, the "flying

saw" cannot be operated in VFC-n-CONTROL operating modes Synchronous motor (CM/DS): SERVO operating modes

Control viaPossible with MOVIDRIVE

MDX61B compact MCH41A compact MCH42ATerminals Yes, with DIO11B option No NoSystem bus Yes, without option Yes, without option Yes, without optionPROFIBUS-DP Yes, with DFP21B option Yes, without option NoINTERBUS FO Yes, with DFI21B option No Yes, without optionINTERBUS Yes, with DFI11B option Yes, with UFI11A option Yes, with UFI11A optionCANopen Yes, with DFC11B option No NoDeviceNet Yes, with DFD11B option Yes, with UFD11A option Yes, with UFD11A option

In MOVIDRIVE MDX61B with bus control: The optional "I/O card type DIO11B" is notto be connected for operation with bus control. If the DIO11B option is connected, thevirtual terminals cannot be addressed via the bus.

Important:No slip may occur in the slave drive.


3Functional descriptionProject Planning

3.2 Functional descriptionFunctional characteristics

The "flying saw" application offers the following functional characteristics: Control via terminals, system bus or fieldbus: In MOVIDRIVE MDX61B, the

"flying saw" can be controlled either using binary input terminals, the system bus ora fieldbus. Only the system bus or a fieldbus is possible with MOVIDRIVE compactMCH4_A.

Cut length control with/without material sensor or cutting mark control: Youcan select either cut length control or cut length control with label sensor. For cutlength control, you can additionally use a material sensor that starts length control.In cut length control with/without material sensor, a master encoder measures the cutlength of the material to be cut. This information is processed by the inverter andused for starting the saw carriage. There is no need to have any cutting marks on thematerial.

In cut length control with material sensor, a master encoder also measures the cutlength of the material to be cut, but additionally a material sensor is evaluated.Cutting length control starts when the material to be cut reaches this sensor. Thereis no need to have any cutting marks on the material. However, the material sensormay have to detect a mark on the front edge of the material.

50703AXXFigure 4: Cut length control without material sensor

50701AXXFigure 5: Cut length control with material sensor


3 Functional descriptionProject Planning

In cut length control with label sensor, a sensor detects the cutting marks on the ma-terial. This sensor signal is processed as an interrupt in the inverter and is used forstarting the saw carriage.

Protecting the cut edge and "pulling a gap": The "pulling a gap" function causesthe saw carriage to move ahead of synchronism with the material before the sawblade is pulled out. The result is a gap in between the cut edge and the saw blade,thereby preventing the saw blade from leaving any traces on the cut edge. Thisfunction is suitable for use in protecting the cut edge of sensitive material. This func-tion can also be used for separating material that has already been cut.

Immediate cut function by manual interrupt: The saw carriage is startedimmediately by a "0"-"1" edge on a binary input.

Extensive diagnostics: During operation, the monitor will display all important data,such as current cut length, material speed and speed of the saw drive.

Simple connection to the machine control (PLC).

Operating modes The functions are implemented with three operating modes: Jog mode (DI1 = "0" and DI11 = "0")

A "1" signal on binary input DI13 "Jog +" causes the saw carriage motor to turn"clockwise." A "1" signal on binary input DI14 "Jog -" causes the saw carriagemotor to turn "counterclockwise." Bear in mind whether you are using a 2 or 3-stage gear unit.

A "0" signal on binary input DI15 "Rapid speed" results in jog mode at slow speed.A "1" signal on binary input DI15 "Rapid speed" results in jog mode at rapid speed.

Reference travel (DI1 = "1" and DI11 = "0")The reference position is defined by reference travel to one of the two limit switches.Reference travel is started with a "1" signal on binary input DI12 "Start." The "1"signal must be present at DI12 for the entire duration of the reference travel. You canenter a reference offset during startup. The reference offset can be used for alteringthe machine zero point without having to adjust the limit switches. The followingformula applies:Machine zero = reference position + reference offset

50700AXXFigure 6: Cut length control with label sensor


3Functional descriptionProject Planning

Positioning (DI1 = "0" and DI11 = "1")The "positioning" mode is used for position-controlled movement of the saw drivebetween the home position and the parking position. A "0" signal on binary input DI13selects the home position. A "1" signal on binary input DI13 selects the parkingposition. Positioning is started with a "1" signal on binary input DI12 "Start." The "1"signal must be present on DI12 for the entire duration of positioning.The drive immediately moves to its new position if DI12 remains "1" and a newposition is specified using DI13.

Automatic mode (DI1 = "1" and DI11 = "1")During startup, you specify whether cut length control with/without material sensor isactive or if cut length control with label sensor is active. Cut length control without material sensor: A "0"-"1" edge on binary input DI12

"Start" (process output data PO1:10) starts automatic mode. The "1" signal mustbe present at DI12 (PO1:10) for the entire duration of automatic mode. Thematerial length is counted starting from the "0"-"1" edge on DI12 "Start." Terminal control: From the cut length table ( Startup), select the required cut

length in binary coded form via binary inputs DI15 ... DI17. The operatingmode (cut length control with/without material sensor, or cut length control withlabel sensor) is set at startup and cannot be changed during running opera-tion. To set another operating mode, you have to perform startup again.

Bus control with one process data word (1 PD): From the cut length table (Startup), select the required cut length in binary coded form via process outputdata PO1:13 ... PO1:15. The operating mode (cut length control with/withoutmaterial sensor, or cut length control with label sensor) is set at startup andcannot be changed during running operation. To set another operating mode,you have to perform startup again.

Bus control with three process data words (3 PD): You can set any cut lengthvia fieldbus. Via fieldbus, you can also switch to another operating mode (cutlength control with/without material sensor, cut length control with labelsensor) during running operation.

Cut length control with material sensor: A "0"-"1" edge on binary input DI12 "Start"(process output data PO1:10) starts automatic mode. The "1" signal must bepresent at DI12 (PO1:10) for the entire duration of automatic mode. The materiallength is counted starting from the "0"-"1" edge on DI2 "Sensor" (= materialsensor). Terminal control: From the cut length table ( Startup), select the required cut

length in binary coded form via binary inputs DI15 ... DI17. The operatingmode (cut length control with/without material sensor, or cut length control withlabel sensor) is set at startup and cannot be changed during running opera-tion. To set another operating mode, you have to perform startup again.


3 Functional descriptionProject Planning

Bus control with one process data word (1 PD): From the cut length table (Startup), select the required cut length in binary coded form via process outputdata PO1:13 ... PO1:15. The operating mode (cut length control with/withoutmaterial sensor, or cut length control with label sensor) is set at startup andcannot be changed during running operation. To set another operating mode,you have to perform startup again.

Bus control with three process data words (3 PD): You can set any cut lengthvia fieldbus. Via fieldbus, you can also switch to another operating mode (cutlength control with/without material sensor, cut length control with labelsensor) during running operation.

Cut length control with label sensor: A "1" signal on binary input DI12 "Start"(process output data PO1:10) starts automatic mode. The "1" signal must bepresent at DI12 (PO1:10) for the entire duration of automatic mode.

Following the sawing process, the "pulling a gap" function can be used to move thesaw blade away from the cut edge. A "1" signal on binary input DI13 (process outputdata PO1:11) starts the "pulling a gap" function. You set the size of the gap duringstartup.Repositioning can be initiated once the drive reaches the reversing position. A "1"signal on binary input DI14 "Repositioning" (process output data PO1:12) moves thedrive back to the home position. This "1" signal can remain permanently set. The sawcarriage is started again once the cut length is reached or with the next signal edgeon binary input DI2 "Sensor."

Inputs Jog mode Reference travel Positioning Automatic modePA1:8 / DI10 "0" "1" "0" "1"PA1:9 / DI11 "0" "0" "1" "1"PA1:10 / DI12 - Start reference

travelStart positioning Start automatic mode

PA1:11 / DI13 Jog + - Start park positioning Pulling a gapPA1:12 / DI14 Jog - - - RepositioningPA1:13 / DI15 Rapid speed - - Cut length 20

PA1:14 / DI16 - - - Cut length 21

PA1:15 / DI17 - - - Cut length 22


3Determine material travel and web speedProject Planning

3.3 Determine material travel and web speedThe web speed must be known to set the cut length for the sawing process. The webspeed can be determined in two ways: A slip-free encoder is mounted on the material web as closely as possible to the

"flying saw." This encoder is connected as external encoder (= master encoder ) toX14: of the saw carriage drive. The incremental distance information from theexternal encoder is used for measuring the speed and the material travel.

The incremental travel information of the motor encoder on the material feed drive isused for determining the web speed and the material travel. For this purpose, anX14-X14 connection is required from the MOVIDRIVE drive inverter on the webdrive to the MOVIDRIVE drive inverter on the saw carriage drive.

The ratio between the travel resolution of the motor encoder and the externalencoder must be less than 20:1 to determine the web speed and the material travelwith sufficient accuracy.


3 Process data assignmentProject Planning

3.4 Process data assignmentYou can also control the "flying saw" application module via a bus. All MOVIDRIVEfieldbus options as well as the system bus (Sbus) provided as standard are supported.The virtual terminals in control word 2 are used for bus control ( MOVIDRIVE Field-bus Unit Profile).

Process output data

Assignment of the process output data words: PO1: Control word 2

Please note: The MOVIDRIVE option "I/O card type DIO11B" must not to be installedfor bus control!Special characteristics of operation with three process data words: The values of PO2 "Setpoint cut length" and PO3 "Minimum reversing position" are

transferred to the inverter with the scaling "0.1 user travel unit."

04427AXXFigure 7: Data exchange via process dataPO = Process output data PI = Process input dataPO1 = Control word 2 PI1 = Status word 2PO2 = Setpoint cut length (IPOS PO DATA) PI2 = Actual cut length (IPOS PI DATA)PO3 = Min. reversing position (IPOS PO DATA) PI3 = Actual saw drive position (IPOS PI DATA)

E Q

PE

PA

PA1

PE1

PA2

PE2

PA3

PE3

Minimum reversing position: Earliest possible position of the saw carriage at which thedrive can be decoupled and it is possible to move back to the home position.

Virtual input terminals Fixed assignment15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

Virtual terminal 8DI17 P617

Controller inhibit/Enable


Enable/Rapid stop

Virtual terminal 6DI15 P615 Enable/Stop

Virtual terminal 5DI14 P614 /Hold control


Rampswitchover


Parameter set switchover

Virtual terminal 2DI11 P611 Fault reset

Virtual terminal 1DI1 P610 Reserved


3Process data assignmentProject Planning

PO2: Setpoint cut length

PO3: Minimum reversing position

Process input data

Assignment of the process input data words: PI1: Status word 2

PI2: Actual cut length

PI3: Actual saw drive position

PO2 Setpoint cut length15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

[0.1 user unit]

PO3 Minimum reversing position15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

[0.1 user unit]

Virtual output terminals Fixed definition15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

Virtual terminal 8DO17 P637

Output stageenabled


InverterReady


PO dataenabled


Currentramp generator set


CurrentParameter set

Virtual terminal 3DO12 P632 Fault/warning


Right limit switchactive


Left limit switchactive

PI2 Actual cut length15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

[0.1 user unit]

PI3 Actual saw drive position15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 1 0

[0.1 User unit]


4 SoftwareInstallation

4 Installation4.1 SoftwareMOVITOOLS The "flying saw" application module is part of the MOVITOOLS software package

(version 3.0 and higher). Proceed as follows to install MOVITOOLS on your computer: Insert the MOVITOOLS CD into the CD ROM drive of your PC Select "Start\Run..." Type "{drive letter of your CD drive}:setup" and press the Enter key The MOVITOOLS setup menu appears. Follow the instructions of the installation

wizard

You can now use the Program Manager to start MOVITOOLS. If a MOVIDRIVE unitis connected to your PC, select the correct port (PC COM) and set peer-to-peer connec-tion. Select to display the inverter in the "Connected Inverters" window.

Application version

The "flying saw" application module can be used on MOVIDRIVE units in applicationversion (...-0T). The application modules cannot be used with units in the standardversion (-00).

06510BENFigure 8: MOVITOOLS window


4MOVIDRIVE MDX61BInstallation

4.2 MOVIDRIVE MDX61B

06501AENFigure 9: Wiring diagram MOVIDRIVE MDX61B with option DIO11B and DEH11B or DE11B.

X22:

X23:

X14:

DEH11B DER11B

X15:

TF1DGNDDB

DO1-CDO1-NODO1-NC

DO2VO24VI24

DGND

123456789

10

123456789

10

123456789

MOVIDRIVE MDX61B

/EndschalterRechts/EndschalterLinks

X13:

X10:

DIDI1DI2DI3DI4DI5

DCOMVO24DGNDST11ST12

123456789

1011 RS-485 -

RS-485 +

= +-24 V

DI1DI11DI12DI13DI14DI15DI16DI17

DCOMDGND

DO1DO11DO12DO13DO14DO15DO16DO17DGND

=+ -24 V

DIO11B

DEH11B

X14X15

11

1515

88

99

11

88

99

1515

DER11B

X14X15

11

66

55 99

1515

11

88

99

X12:

DGNDSC11SC12

123

SBus

Motor encoder:Incremental encoder (DEH11B) or resolver (DER11B)(Connection MOVIDRIVEMDX61B operating instructions)

Input external encoder,Incremental encoder 5 V TTL(Connection MOVIDRIVEMDX61B operating instructions)

Systembus ref. potentialSystembus highSystembus low

IPOS input: mode 2^0IPOS : mode 2^1IPOS : selection Dmin 2^0IPOS : selection Dmin 2^1IPOS : set DminIPOS : set DmaxIPOS : reservedIPOS : reset length counterReference X22: DI1...DI17Reference potential for binary signals

inputinputinputinputinputinputinput

IPOS output: mode 2^0IPOS : mode 2^1IPOS : selection Dmin 2^0IPOS : selection Dmin 2^1IPOS : Dmax reachedIPOS : wrenchedIPOS : friction factor table readIPOS : length reached

outputoutputoutputoutputoutputoutputoutput

Reference potential for binary signals

Ref. potential forbinary signals

Enable/Rapid stop

/Controller inhibitCW/stopCCW/stop

Reference X13:DI...DI5

Ref. potential forbinary signals

Ref. potential forbinary signals+24V input

TF/TH input

Common relay contactReady foroperation

Contactnormally closedContactnormally open

/Brake

/fault

+24V output

+24Voutput


4 MOVIDRIVE MDX61BInstallation

Inputs Jog mode Reference travel Positioning Automatic modeDI1 "0" "1" "0" "1"DI11 "0" "0" "1" "1"DI12 - Start reference travel Start positioning Start automatic modeDI13 Jog + - Start park positioning Pulling a gapDI14 Jog - - - RepositioningDI15 Rapid speed - - Cut length 20

DI16 - - - Cut length 21

DI17 - - - Cut length 22

Outputs Jog mode Reference travel Positioning Automatic modeDO1 "0" "1" "0" "1"DO11 "0" "0" "1" "1"

DO12 Master and slave in synchronous operation

Master and slave in synchronous operation



DO13 Pulling a gap finished Pulling a gap finished Pulling a gap finished Pulling a gap finishedDO14 Cut length 2^0 Cut length 2^0 Cut length 2^0 Cut length 2^0DO15 Cut length 2^1 Cut length 2^1 Cut length 2^1 Cut length 2^1DO16 Cut length 2^2 Cut length 2^2 Cut length 2^2 Cut length 2^2DO17 Position reached Position reached Position reached Position reached


4Bus installation MOVIDRIVE MDX61BInstallation

4.3 Bus installation MOVIDRIVE MDX61BOverview For the bus installation, please note the information in the relevant fieldbus manuals

supplied with the fieldbus interfaces. Please refer to the operating instructions forinformation about installing the system bus (SBus).

06504AXXFigure 10: Bus types

BUS-

S1

BIO

PIO

DFD11B

Mod/

DEVICE-NET

S2DR(0)DR(1)NA(0)NA(1)

NA(2)NA(3)NA(4)

10NA(5)

X30

OFF

Net

12345

P R O F I

B U S

PROCESS FIELD BUS Device NetSBus

DFO11B

PD(2)PD(1)PD(0)NA(6)NA(5)NA(4)NA(3)NA(2)NA(1)NA(0)DR(1)DR(0)

BUSOFF

STATE

GUARD

COMM

S1

11

012

34

CANopen

12

34

12

34

nc

R

S2

X30 CANopen

3

0123

4

DFI21BINTERBUS

DFP21BPROFIBUS

DP

ADRESS

X30PROFIBUS

DP

DFI11BINTERBUS

Please note: The MOVIDRIVE option "I/O card type DIO11B" must not be installed forbus control!


4 Bus installation MOVIDRIVE MDX61BInstallation

PROFIBUS (DFP21B)

The PROFIBUS documentation package contains detailed information. This packagecan be ordered from SEW-EURODRIVE. The documentation package contains theGSD files and type files for MOVIDRIVE to help with project planning and to facilitatestartup.

Technical Data

Pin assignment

Option PROFIBUS fieldbus interface type DFP21BPart number 824 240 2Resources for startup/diagnostics MOVITOOLS software and DBG60B keypadProtocol option PROFIBUS-DP to EN 50170 V2 / DIN E 19245 T3

Supported baud rates Automatic baud rate detection from9.6 kbaud ... 12 Mbaud

Connection 9-pin sub D socketAssignment according to EN 50170 V2 / DIN 19245 T3

Bus termination Not integrated, must be implemented in the PROFIBUS connector.

Station address 0 ... 125, can be set using DIP switchGSD file SEW_6003.GSDDP identity number 6003 hex = 24579 decWeight 0.2 kg (0.44 lb)

1. Green LED: RUN2. Red LED: BUS FAULT3. DIP switch for setting the station address4. 9-pin sub D socket: bus connection

PROFIBUSDP

RUN

BUSFAULT

2222

0123

222

456

DFP

X30

ON

ADDRESSnc

PROFIBUSDP

06506AXXFigure 11: Assignment of 9-pin sub D plug to EN 50170 V2

(1) 9-pin sub D connector(2) Twist the signal wires together!(3) Conductive connection is necessary between the plug housing and the shield!

384569

RxD/TxD-P (B/ )BRxD/TxD-N (A/ )ACNTR-PDGND (M5V)VP (P5V)DGND (M5V)

(1)

(2)

(3)



INTERBUS with fiber optic cable (DFI21B)

The INTERBUS FO documentation package contains detailed information. Thispackage can be ordered from SEW-EURODRIVE.

Technical data

Connection assignment

Option INTERBUS fieldbus interface type DFI21B (FO)Part number 824 311 5Resources for startup/diagnostics MOVITOOLS software, DBG60B keypad and CMD toolSupported baud rates 500 kbaud and 2 Mbaud, can be selected via DIP switch

ConnectionRemote bus input: 2 F-SMA connectorsRemote bus output: 2 F-SMA connectorsOptically controlled FO interface

Weight 0.2 kg (0.44 lb)

1. DIP switch for process data length, PCP length and baud rate2. Diagnostic LEDs3. FO: Remote IN4. FO: Incoming remote bus5. FO: Remote OUT6. FO: Outgoing remote bus

DFIINTERBUS

1.

2.

3.

4.

5.

6.

Position Signal Direction Wire color of FO cable3 FO remote IN Receive data Orange (OG)4 Incoming remote bus Send data Black (BK)5 FO remote OUT Receive data Black (BK)6 Outgoing remote bus Send data Orange (OG)



INTERBUS (DFI11B)

The INTERBUS documentation package contains detailed information. This packagecan be ordered from SEW-EURODRIVE.

Technical data

Pin assignment Conductor color abbreviations to IEC 757.

Option INTERBUS fieldbus interface type DFI11BPart number 824 309 3Resources for startup/diagnostics MOVITOOLS software and DBG60B keypad

ConnectionRemote bus input: 9-pin sub D connectorRemote bus output: 9-pin sub D socketRS-485 transmission technology, 6-core shielded and twisted-pair cable

Module ID E3hex = 227decWeight 0.2 kg (0.44 lb)

1. DIP switch for setting the number of process data2. 4 green LED: Diagnostic LEDs3. 1 red LED: Diagnostic LED4. 9-pin sub D plug: Remote bus input5. 9-pin sub D socket: Remote bus output

DFI11BINTERBUS

1.

2.

3.

4.

5.

04435AXXFigure 12: Assignment of the 9-pin sub D socket of the incoming remote bus cable and the

9-pin sub D plug of the outgoing remote bus cable

(1) 9-pin sub D socket of the incoming remote bus cable(2) Twist the signal wires together!(3) Conductive connection is necessary between the plug housing and the shield!(4) 9-pin sub D plug of the outgoing remote bus cable(5) Jumper pin 5 with pin 9!

61723

/DODO/DIDI

COM

E Q

(1)

(2)

(3)

6172359

/DODO/DIDI

COM

(4)(2)

(3)(5)

GNYEPKGYBN

GNYEPKGYBN



CANopen (DFC11B)

The CANopen documentation package contains detailed information. This package canbe ordered from SEW-EURODRIVE.

Technical data

Pin assignment

Option CANopen fieldbus interface type DFC11BPart number 824 317 4Resources for startup/diagnostics MOVITOOLS software and DBG60B keypad

Supported baud rates

Can be selected via DIP switch: 125 kbaud 250 kbaud 500 kbaud 1000 kbaud

Connection9-pin sub D connectorAssignment to CiA standard2-core twisted cable to ISO 11898

Bus termination Can be switched on using DIP switch (120 )Address range 1 ... 127, can be selected using DIP switchWeight 0.2 kg (0.44 lb)

1. DIP switch for process data length, module ID and baud rate2. Display and diagnostic LEDs3. DIP switch for switching the bus terminating resistor on and off4. 9-pin sub D plug: bus connection

DFO

PD(2)PD(1)PD(0)NA(6)NA(5)NA(4)NA(3)NA(2)NA(1)NA(0)DR(1)DR(0)

BUSOFF

STATE

GUARD

COMM

S1

11

012

34

CANopen

12

34

12

34

nc

R

S2

X30 CANopen

3

0123

4

1.

2.

3.

4.

06507AXXFigure 13: Assignment of 9-pin sub D socket of the bus cable

(1) 9-pin sub D socket(2) Twist the signal wires together!(3) Conductive connection is necessary between the plug housing and the shield!

6723

DGNDCAN HighCAN LowDGND

(1)

(2)

(3)



DeviceNet (DFD11B)

The DeviceNet documentation package contains detailed information. This package canbe ordered from SEW-EURODRIVE.

Technical data

Terminal assignment

The assignment of connecting terminals is described in the DeviceNet specificationVolume I, Appendix A.

Option DeviceNet fieldbus interface type DFD11BPart number 824 312 3Resources for startup/diagnostics MOVITOOLS software and DBG60B keypad

Supported baud ratesCan be selected using DIP switch: 125 kbaud 250 kbaud 500 kbaud

Connection5-pin Phoenix terminalAssignment according to DeviceNet specification(Volume I, Appendix A)

Permitted line cross section According to DeviceNet specification

Bus termination Use of bus connectors with integrated bus terminating resistor (120 ) at the start and finish of a bus segment.

Address range that can be set (MAC-ID) 0 ... 63, can be selected using DIP switchWeight 0.2 kg (0.44 lb)

1. LED display2. DIP switch for setting node address (MAC-ID) and baud rate3. 5-pin Phoenix terminal: bus connection

BUS-

S1

BIO

PIO

DFD

Mod/

DEVICE-NET

S2DR(0)DR(1)NA(0)NA(1)

NA(2)NA(3)NA(4)

10NA(5)

X30

OFF

Net

12345

1.

2.

3.

Terminal Meaning ColorX30:1 V- (0V24) Black (BK)X30:2 CAN_L Blue (BU)X30:3 DRAIN BrightX30:4 CAN_H White (WH)X30:5 V+ (+24 V) Red (RD)



Connection of system bus (SBus 1)

Max. 64 CAN bus stations can be interconnected using the system bus (SBus). TheSBus supports transmission systems compliant with ISO 11898.The "Serial Communication" manual contains detailed information about the systembus. This manual can be obtained from SEW-EURODRIVE.

SBus wiring diagram

Cable specification Use a 2-core twisted and shielded copper cable (data transmission cable withbraided copper shield). The cable must meet the following specifications: Conductor cross section 0.75 mm2 (AWG 18) Line resistance 120 at 1 MHz Capacitance per unit length 40 pF/m (12 pF/ft) at 1 kHzSuitable cables include CAN bus or DeviceNet cables.

Shielding Connect the shield at either end to the electronics shield clamp of the inverter or themaster control and ensure the shield is connected over a large area. Also connectthe ends of the shield to DGND.

Line length The permitted total line length depends on the baud rate setting of the SBus (P816): 125 kBaud 320 m (1056 ft) 250 kBaud 160 m (528 ft) 500 kbaud 80 m (264 ft) 1000 kBaud 40 m (132 ft)

Terminating resistor

Switch on the system bus terminating resistor (S12 = ON) at the start and end of thesystem bus connection. Disconnect the terminating resistor at the other devices (S12= OFF).

Only if P816 "SBus baud rate" = 1000 kbaud:MOVIDRIVE compact MCH4_A units must not be combined with other MOVIDRIVEunits in the same system bus combination.The units may be combined at baud rates 1000 kbaud.

06182AENFigure 14: System bus connection

There must not be any difference of potential between the units connected with theSBus. Take suitable measures to avoid a difference of potential, such as connectingthe unit ground connectors using a separate line.


4 MOVIDRIVE compact MCH4_AInstallation

4.4 MOVIDRIVE compact MCH4_A

05863AENFigure 15: MOVIDRIVE compact MCH4_A wiring diagram


4MOVIDRIVE compact MCH4_AInstallation

PROFIBUS-DP (MCH41A) pin assignment

Refer to the instructions in the MOVIDRIVE compact (MCV/MCS or MCH) operatinginstructions.

INTERBUS FO (MCH42A) pin assignment

Refer to the instructions in the MOVIDRIVE compact MCH operating instructions.

04915AXXFigure 16: Assignment of 9-pin sub D plug to EN 50170 V2(1) X30: 9-pin sub D connector(2) Twist the signal wires together!(3) Conductive connection is necessary between the plug housing and the shield!

384569

RxD/TxD-P (B/ )BRxD/TxD-N (A/ )ACNTR-PDGND (M5V)VP (P5V)DGND (M5V)

(1) (2)

(3)

05208AXXFigure 17: FO connection assignment

Connection Signal Direction Wire color of FO cable

X30 FO remote IN(incoming remote bus)

Receive data Orange (OG)X31 Send data Black (BK)X32 FO remote OUT

(outgoing remote bus)Receive data Black (BK)

X33 Send data Orange (OG)

X14

X15

X10

X11

X12

X30

X31

X32

X33

1234567891011

123456789

1234567

U CC BA RD TR FO1

FO2

L

X14

X15

X30

X31

X32

X33U CC BA RD TR FO

1FO

2

L

OG

OG

OG

BK

BK

BK


4 MOVIDRIVE compact MCH4_AInstallation

System bus (SBus) MCH

The "System bus (SBus)" manual contains detailed information. This manual can beordered from SEW-EURODRIVE.Max. 64 CAN bus stations can be interconnected using the system bus (SBus). TheSBus supports transmission systems compliant with ISO 11898.

Cable specification Use a 2-core twisted and shielded copper cable (data transmission cable withbraided copper shield). The cable must meet the following specifications: Conductor cross section 0.75 mm2 (AWG 18) Line resistance 120 at 1 MHz Capacitance per unit length 40 pF/m (12 pF/ft) at 1 kHzSuitable cables include CAN bus or DeviceNet cables.

Shielding Connect the shield at either end to the electronics shield clamp of the inverter or themaster control and ensure the shield is connected over a large area. Also connectthe ends of the shield to DGND.

Line length The permitted total cable length depends on the baud rate setting of the SBus(P816): 125 kBaud 320 m (1056 ft) 250 kBaud 160 m (528 ft) 500 kbaud 80 m (264 ft) 1000 kBaud 40 m (132 ft)


Switch on the system bus terminating resistor (S12 = ON) at the start and end of thesystem bus connection. Disconnect the terminating resistor at the other devices (S12= OFF).

Only if P816 "SBus baud rate" = 1000 kbaud:MOVIDRIVE compact MCH4_A units must not be combined with other MOVIDRIVEunits in the same system bus combination.The units may be combined at baud rates 1000 kbaud.

05210AENFigure 18: MOVIDRIVE compact MCH4_A system bus connection

X10: X10: X10:

S 12 S 12 S 12S 11 S 11 S 11

ON OFF ON OFF ON OFF

123456789

1011

123456789

1011

123456789

1011

SC11SC12DGNDSC21SC22



Reference potential Reference potential

System bus high System bus high System bus high

System bus high System bus high System bus high

System bus low System bus low System bus low

System bus low System bus low System bus lowSystem bus

Terminating resistorSystem bus

Terminating resistorSystem bus


Controlunit Controlunit Controlunit

Reference potential

There must not be any difference of potential between the units connected with theSBus. Take suitable measures to avoid a difference of potential, such as connectingthe unit ground connectors using a separate line.


5General informationStartup

5 Startup5.1 General information

Correct project planning and installation are the prerequisites for successful startup.Refer to the MOVIDRIVE MDX60/61B and MOVIDRIVE compact system manuals fordetailed project planning instructions.Check the installation, including the encoder connection, by following the installationinstructions in the MOVIDRIVE operating instructions and in this manual ( Sec.Installation).

5.2 Preliminary workPerform the following steps before startup: Connect the inverter to the PC using the serial port.

With MDX61B: Xterminal via UWS21A option with PC-COM With MCH4_A: TERMINAL via USS21A option with PC-COM

Install the SEW MOVITOOLS software (version 3.0 or higher). Start up the inverter with "MOVITOOLS/Shell."

MDX61B or MCH4_A with asynchronous motor: CFC operating modes MDX61B or MCH4_A with synchronous motor: SERVO operating modes

Select the "ISYNC" technology function from the "MOVITOOLS/Shell/Startup/SelectTechnology Function..." menu.

"0" signal at terminal DI "/CONTROLLER INHIBIT/."

05864AENFigure 19: Starting up the inverter

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5 Starting the "flying saw" programStartup

5.3 Starting the "flying saw" programGeneral information

Start "MOVITOOLS/Shell" Select "Startup/Flying saw"

Initial startup The startup windows will appear immediately if the "flying saw" is started for the firsttime.

05866AENFigure 20: Starting the "Flying saw" program

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5Starting the "flying saw" programStartup

Control signal source, fieldbus parameters and process data description

Control signal source: "FIELDBUS" or "SBUS" is set automatically with bus control."TERMINALS" is set automatically with terminal control.

Fieldbus parameters: Set the fieldbus parameters. Fixed parameters are blockedand cannot be changed.

Process data description: Set the functions of process output data word PO2. Youcan set one of the following functions: No function: Setting for cut length control and for operation with one process data

word (1 PD). The cut lengths are available as table values. Setpoint cut length: Setting for operation with three process data words (3 PD)

and cut length control. The cut length is specified as variable via the bus.If "No function" is set, then process output data word PO3 also has no function. If"Setpoint cut length" is set, PO3 has the "Minimum reversing position" function. Theminimum reversing position is the earliest possible position of the saw drive at whichthe drive can be decoupled and it is possible to move back to the home position.

05867AENFigure 21: Setting the control signal source, fieldbus parameters and process data

description

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Calculating the master scaling

Diameter of driving wheel or spindle pitch: Select whether you have to enter"Diameter of driving wheel" or "Spindle pitch." Enter the value in [mm]. The valuemust not exceed three decimal positions.

Gearing ratio (i gear unit): Enter the gear ratio of the gear unit. The value must notexceed three decimal positions.

External ratio (i additional gear): Enter the gear ratio of the additional gear if youare using one. Enter the value 1 if you are not using an additional gear. The valuemust not exceed three decimal positions.

Encoder resolution [Inc]: Enter the resolution of the motor encoder in incrementsaccording to the nameplate.

Calculating the master scaling: Click the button. The program thencalculates the pulses per distance in [increments/mm].

Stiffness synchronous drive control: You can set the stiffness of the control loopused for synchronous drive control. The default setting is 1. Set a value less than 1if the slave drive is tending to oscillate. Set a value greater than 1 if the slave cannotfollow the master (lag eror). Make changes in small steps, for example 0.01. Theusual range of values is 0.7 ... 1.3.

05872AENFigure 22: Setting parameters for calculating the master scaling

User travel unit [Inc/...]: The user unit "mm" is set by default. You must enter alarger user travel unit, for example "cm", for travel distances in excess of 6.50 m. Youwill then have to change the conversion factor manually, e.g. "60" instead of "6" forthe user travel unit "cm" instead of "mm."

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Calculating the slave scaling

Diameter of driving wheel or spindle pitch: Select whether you have to enter"Diameter of driving wheel" or "Spindle pitch." Enter the value in [mm]. The valuemust not exceed three decimal positions.

Gearing ratio (i gear unit): Enter the gear ratio of the gear unit. The value must notexceed three decimal positions.

External ratio (i additional gear): Enter the gear ratio of the additional gear if youare using one. Enter the value 1 if you are not using an additional gear. The valuemust not exceed three decimal positions.

Calculating the slave scaling: Click the button. The program thencalculates the pulses per distance in [increments/mm].

Changing direction of rotation: Use this setting if the slave is running in oppositedirection to the master. Do not use parameter P350 "Change direction of rotation."

Diagonal cut: If you are using a diagonal saw, enter the required angle between thesaw feed direction and the material feed direction. The correction value enables youto align the cut angle exactly. Enter a maximum of 10 % as correction angle, theresolution is 0.01 %. If you are not using a diagonal saw, enter the value 0 for boththe angle and the correction.

05870AENFigure 23: Setting parameters for calculating the slave scaling

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Jog mode, reference travel and positioning

Jog mode: Set the "Rapid speed", "Slow speed" and "Ramp" parameters. Reference travel: Define the positions of the software limit switches, the reference

offset and the reference travel type. The reference offset can be used for altering themachine zero point without having to adjust the reference point. You can set thefollowing reference travel types: Type 0: Referencing to the next encoder zero pulse Type 3: Referencing to the CW limit switch (falling edge of the limit switch) Type 4: Referencing to the CCW limit switch (falling edge of the limit switch) Type 5: No reference travel, current position is machine zero point

Positioning parameters: Set the "Positioning speed", "Positioning ramp", "Homeposition" and "Parking position" parameters. The home position is the rest positionfor the "flying saw." The sawing procedure starts from the home position. You canuse the parking position to move the "flying saw" out of the working area formaintenance work.

05873AENFigure 24: Setting parameters for jog mode, reference travel and positioning

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Parameters for the saw

In this startup window, you define how the "flying saw" will be controlled. You can makethe following settings:

Cut length control without material sensor: You specify the cut length. Theposition of the material is measured either using an external encoder on the web orthe motor encoder of the web drive. With control via terminals (MDX61B with DIO11Boption) or via bus (fieldbus or system bus) with one process data word (1 PD), youcan specify a maximum of eight cut lengths at startup. You must select the cut lengthfor the particular sawing procedure in binary code using binary inputs DI15, DI16 andDI17 (terminal control) or the process output data PO1:13, PO1:14 and PO1:15 (buscontrol with 1 PD). In control via fieldbus with three process data words (3 PD), youcan specify the variable cut length with the process output data word PO2 using thefieldbus.

Cut length control with material sensor: Specify the cut length in the same wayas for cut length control. Control is effected by a sensor behind the saw drive. Thesensor signal is sent to binary input DI2. The saw carriage is started depending onthe set cut length when the material reaches this sensor. Note the following rulewhen specifying the cut length:Cut length sensor distance + engaging distance(Sensor distance = distance between home position of the saw and material sensor)

50703AXXFigure 25: Cut length control without material sensor

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[1] = Sensor distance[2] = Engaging distance

Cut length control with label sensor: Labels must be attached to the materialwhich is to be sawn. A sensor must detect the labels. The sensor signal is sent tobinary input DI2 and triggers the sawing procedure.

[1] = Sensor distance label[2] = Engaging distance

53658AXXFigure 26: Cut length control with material sensor

53660AXXFigure 27: Cut length control with label sensor

[2][1]

[2][1]

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I



Cut length control without material sensor:

Engaging distance: Enter the distance in [mm] for the startup cycle process. Theslave drive (= saw carriage) is brought into synchronous operation with the masterdrive (= material feed) during the startup cycle process.

Cut length [mm]: With control via terminals and bus (system bus or fieldbus) withone process data word (1PD), you have to enter the required cut lengths in this field.You can specify up to 8 different cut lengths. You select the required cut length usingbinary inputs DI15 ... DI17 (terminal control) or via the process output data PO1:13... PA1:15 (bus control with 1 PD).

This cut length table is not required for control via fieldbus with three process datawords (3 PD). Specify the cut length with process output data word PO2 via thefieldbus.

05874AENFigure 28: Parameters for the saw in cut length control without material sensor (terminal

control or bus control with one process data word (1 PD))

Binary input or process output data PO1

Cut length no.1 2 3 4 5 6 7 8

DI15 or PO1:13 "0" "1" "0" "1" "0" "1" "0" "1"DI16 or PO1:14 "0" "0" "1" "1" "0" "0" "1" "1"DI17 or PO1:15 "0" "0" "0" "0" "1" "1" "1" "1"

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Cut length control with material sensor:

You must enter the following values in addition to cut length control: Sensor distance: Enter the distance between home position of the saw and material

sensor in [mm]. Sensor delay time: Enter the delay of the material sensor in [ms]. This value effects

the startup cycle mode control of the saw drive.

05875AENFigure 29: Parameters for the saw in cut length control with material sensor (terminal control

or bus control with one process data word (1 PD)).

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Cut length control with label sensor:

Sensor distance: Enter the distance between home position of the saw and labelsensor in [mm].

Sensor delay time: Enter the delay of the label sensor in [ms] ( data sheet of thesensor). This value effects the startup cycle mode control of the saw drive.

05880AENFigure 30: Parameters for the saw in cut length control with label sensor

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Repositioning and pulling a gap

Parameters for repositioning: The saw drive must be moved back to the homeposition after the sawing procedure is complete. This process is called repositioning.You have to set various parameters for this step. Smooth repositioning: "YES" or "No". "YES"means that repositioning takes place

with the lowest possible acceleration and as smoothly as possible. This settingreduces stress on the mechanism and cuts down the waiting time in the homeposition.

Max. repositioning speed: Enter the value in [1/min] for the maximum motorspeed at which repositioning should take place. Make sure that the maximumpermitted speed ( P302) is not exceeded.

Min. repositioning ramp: Enter the value in [s] of the minimum ramp time foraccelerating the repositioning drive.

Minimum reversing position: Enter the value in [mm] of the position from whichthe saw drive responds to the repositioning signal.

Pulling a gap: The "pulling a gap" function pulls the saw blade away from thematerial after the sawing procedure is complete. In this way, you can implement whatis referred to as "cut edge protection." Pulling back the saw blade prevents additionalmarks on the cut edge. In addition, you can use this function for separating the cutmaterial so that it can be processed more easily subsequently. Pulling a gap: "time-controlled" or "position-dependent". "Time-controlled" means

that the gap is established using the values for "Synchronization speed" and"Synchronization ramp". "Position-dependent" means that the gap is established

05881AENFigure 31: Setting parameters for repositioning and "pulling a gap" (time-controlled)

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using the "Master distance" value. Gap: Enter the size of the gap in [mm]. Synchronization speed ("time-controlled" only): Motor speed for time-controlled

"pulling a gap." Note that the "Synchronization speed" must be faster than theweb speed.

Synchronization ramp ("time controlled" only): Acceleration ramp for time-controlled "pulling a gap."

Master distance ("position-dependent" only): The "pulling a gap" function iscompleted by the time the material has covered this distance.

Saving changes The program prompts you to save your entries. The saved startup data are nowavailable in your file system for further processing.

05881AENFigure 32: Setting parameters for repositioning and "pulling a gap" (position-dependent)

04444AENFigure 33: Saving changes

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Download Press "Download". All necessary settings are automatically made in the inverter and the"Flying saw" IPOS program is started.

Starting the monitor

After the download, the program asks you if you want to start the monitor.

Select "Yes" to switch to the monitor where you can start in the required operating mode.Select "No" to switch to MOVITOOLS/Shell.

05882AENFigure 34: Download window

05884AENFigure 35: Monitor Yes/No

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Monitor The monitor with the status display appears immediately if the "flying saw" is restartedafter initial startup has already been performed. Operation without bus: You can select between "Status" and "State." Operation with fieldbus/system bus: In addition to "Status" and "State," you can also

display "Fieldbus process data 1" and "Fieldbus process data 2."

Status

Repeated startup Press "Startup" if you want to repeat the startup. The startup windows will appear (Initial startup).

05913AENFigure 36: "Flying saw" monitor, status display

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State The "State" tab shows a condition chart with the possible conditions of the "flying saw."The chart shows the current condition and in what direction a change of condition ispossible.

05914AENFigure 37: "Flying saw" monitor, condition display

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Operation with fieldbus/system bus

If operating with the fieldbus/system bus, you can also have the fieldbus process datadisplayed.

Fieldbus process data 1

Only for operation with fieldbus/system bus:

05915AENFigure 38: "Flying saw" monitor, fieldbus process data 1

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Fieldbus process data 2

Only for operation with fieldbus/system bus:

05917AENFigure 39: "Flying saw" monitor, fieldbus process data 2

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Control in the monitor

In addition to monitor operation, you can also simulate a control in the "Fieldbus processdata 2" display. "0" signal at terminal DI "/CONTROLLER INHIBIT/." For this purpose, activate the "control" radio button above "PO1". You can now activate and deactivate the individual bits of the control word (PO1) and

specify values for the process output data words PO2 and PO3. Press "Send PO" to send these control words to the inverter.

The inverter now performs the travel command in accordance with these specifications.

05917AENFigure 40: Control simulation

DI "/CONTROLLER INHIBIT" = "0" must be set to switch from "Control" to"Monitor."

"Monitor" must be active to exit the "flying saw" program.

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5 Parameters and IPOS variablesStartup

5.4 Parameters and IPOS variablesStartup automatically sets the following parameters and IPOS variables, which areloaded into the inverter during the download:Parameter number P... Index Description100 8461 Setpoint source101 8462 Control signal source

228 8438 Feedforward filter (DRS)240 8513 Synchronous speed241 8514 Synchronous ramp

600 8335 Binary input DI01601 8336 Binary input DI02602 8337 Binary input DI03603 8338 Binary input DI04604 8339 Binary input DI05605 8919 Binary input DI06 (MDX61B only)606 8920 Binary input DI07 (MDX61B only)610 8340 Binary input DI10611 8341 Binary input DI11612 8342 Binary input DI12613 8343 Binary input DI13614 8344 Binary input DI14615 8345 Binary input DI15616 8346 Binary input DI16617 8347 Binary input DI17

620 8350 Binary output D001621 8351 Binary output D002622 8916 Binary output D003 (MDX61B only)623 8917 Binary output D004 (MDX61B only)624 8918 Binary output D005 (MDX61B only)630 8352 Binary output D010631 8353 Binary output D011632 8354 Binary output D012633 8355 Binary output D013634 8356 Binary output D014635 8357 Binary output D015636 8358 Binary output D016637 8359 Binary output D017

700 8574 Operating mode

803 8595 Parameter lock

813 8600 SBus address815 8602 SBus timeout delay816 8603 SBus baud rate

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5Parameters and IPOS variablesStartup

819 8606 Fieldbus timeout delay831 8610 Response fieldbus timeout836 8615 Response SBus timeout

870 8304 Setpoint description PO1871 8305 Setpoint description PO2872 8306 Setpoint description PO3873 8307 Actual value description PI1874 8308 Actual value description PI2875 8309 Actual value description PI3876 8622 PO data enable

900 8623 Reference offset903 8626 Reference travel type920 8633 SW limit switch CW921 8634 SW limit switch CCW960 8835 Modulo function

IPOS variable DescriptionH0 Control signal source for IPOS programH1 PO2 descriptionH2 Slave typeH3 Slave valueH4 i gear unit slaveH5 i additional gear slaveH6 Slave pulsesH7 Slave distanceH8 Diagonal angleH9 Master typeH10 Master valueH11 i gear unit masterH12 i additional gear masterH13 Master pulsesH14 Master travelH15 StiffnessH16 MFilterTimeH17 GFMasterH18 GFSlaveH19 Unit slave 1H20 Unit slave 2H21 Unit master 1H22 Unit master 2

H26 Rapid speedH27 Creep speedH28 Jog rampH29 Software limit switch CW user

Parameter number P... Index Description

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5 Parameters and IPOS variablesStartup

H30 Software limit switch CCW userH31 Use hardware limit switchH32 Reference offset userH33 Reference travel type - userH34 Travel speedH35 RampH36 Home position - userH37 Home positionH38 Parking position userH39 Parking position

H41 Automatic mode for IPOS programH42 Engaging distance userH43 Engaging distanceH44 Label sensor distance userH45 Label sensor distanceH46 Sensor delay time userH47 Sensor delay timeH48 Number of cut lengths for IPOS programH49 Cut length 1 - userH50 Cut length 1H51 Cut length 2 userH52 Cut length 2H53 Cut length 3 userH54 Cut length 3H55 Cut length 4 userH56 Cut length 4H57 Cut length 5 - userH58 Cut length 5H59 Cut length 6 userH60 Cut length 6H61 Cut length 7 userH62 Cut length 7H63 Cut length 8 userH64 Cut length 8H65 Number of actual cut lengthsH66 Automatic mode user

H70 Smooth repositioningH71 Travel speedH72 RampH73 Minimum reversing position userH74 Minimum reversing positionH75 Maximum reversing position userH76 Maximum reversing positionH77 Minimum cut length userH78 Minimum cut length

IPOS variable Description

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5Parameters and IPOS variablesStartup

H79 Maximum master speed - userH80 Maximum master speedH81 Speed unitH82 Pulling a gapH83 Gap userH84 GapH85 Gap master distance userH86 Gap master distance

H90 Bus type for GetSys commandH91 Master encoder resolutionH92 Diagonal cut correctionH93 Material sensor distance userH94 Material sensor distance

IPOS variable Description

Do not alter these parameters and IPOS variables after startup!

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5 Starting the driveStartup

5.5 Starting the driveFollowing the download, switch to the "flying saw" monitor by selecting "Yes." You canset the operating mode using terminals DI1 and DI11 in terminal control or bits 8 and9 of "PO1: control word" in bus control.

Operating modes

Jog mode (DI1 = "0", DI11 = "0"): Direction of rotation as seen onto the drive sideof the motor. DI13 = "1": Motor is turning clockwise. DI14 = "1": Motor is turning counterclockwise. DI15 = "0"/"1": Jog mode at slow speed/rapid speed With regard to the direction of rotation, bear in mind whether you are using a 2 or

3-stage gear unit.

Reference travel (DI1 = "1", DI11 = "0"): Reference travel is started by DI12 = "1." The reference position is defined by reference travel to one of the two limit

switches. The reference offset is set during startup and you can use it to alter themachine zero without having to move the limit switch.

The following formula applies: Machine zero = reference position + referenceoffset

Positioning (DI1 = "0", DI11 = "1"): Positioning is started by DI12 = "1." DI13 = "0"/"1": Movement to home position/parking position. Positioning is used for moving between the home and parking position under

position control.

Automatic mode (DI1 = "1", DI11 = "1") Automatic mode is started by DI12 = "1." The drive is moved to the home position by DI14 = "1." Terminal control or fieldbus with one process data word (1 PD): During startup of

the "flying saw", you define whether cut length control or cut length control withlabel sensor is active in automatic mode.

Note the following points to start the drive. This procedure applies to all operatingmodes: Binary inputs DI "//CONTROLLER INHIBIT//" and DI3 "ENABLE/RAPID STOP/

must get a "1" signal. Only for operation with fieldbus/system bus: Set the control bit PO1:0

"CONTROLLER INHIBIT/ENABLE" = "0" and the control bits PO1:1"ENABLE/RAPID STOP" and PO1:2 "ENABLE/STOP" = "1."

Operating modeTerminal (in bus mode, virtual terminal in control word PO1)

DI1 (PO1:8) DI11 (PO1:9)Jog mode "0" "0"Reference travel "1" "0"Positioning "0" "1"Automatic mode "1" "1"

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5Jog modeStartup

5.6 Jog mode DI1 (PO1:8) = "0" and DI11 (PO1:9) = "0"Specify the direction of rotation as seen onto the drive side of the motor. With regard tothe direction of rotation, bear in mind whether you are using a 2 or 3-stage gear unit.DI13 = "1" = Motor is turning clockwise (CW)DI14 = "1" = Motor is turning counterclockwise (CCW)DI15 = "0" = Jog mode in slow speedDI15 = "1" = Jog mode in rapid speedThe speeds for slow speed and rapid speed and the ramp are set during startup of the"flying saw."

06256AENFigure 41: Jog mode

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5 Reference travelStartup

5.7 Reference travel DI1 (PO1:8) = "1" and DI11 (PO1:9) = "0"DI12 = "1" starts reference travelThe reference position is defined by reference travel to one of the two limit switches. Thereference offset is set during startup and you can use it to alter the machine zero withouthaving to move the limit switch.The following formula applies: Machine zero = reference position + reference offset

06258AENFigure 42: Reference travel

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5PositioningStartup

5.8 Positioning DI1 (PO1:8) = "0" and DI11 (PO1:9) = "1"DI12 = "1" = Starts positioningDI13 = "0" = Positioning to home positionDI13 = "1" = Positioning to parking positionPositioning is used for moving between the home and parking position under positioncontrol.

06259AENFigure 43: Positioning

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5 Automatic modeStartup

5.9 Automatic mode DI1 (PO1:8) = "1" and DI11 (PO1:9) = "1"DI12 = "1" = Starts automatic modeDI14 = "1" = Starts repositioningTerminal control or fieldbus with one process data word (1 PD): During startup of theflying saw, you define whether cut length control or cut length control with label sensoris active in automatic mode.

Cut length control

The setpoint cut length is specified in two ways when cut length control is active:1. In terminal control, using binary code via binary inputs DI15 ... DI17. A maximum of

eight different cut lengths are possible.2. In control via fieldbus or system bus, the cut length is specified using process output

data PO1:13, PO1:14 and PO1:15.

06260AENFigure 44: Automatic mode with cut length control

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5Automatic modeStartup

Sequence of cut length control

Note the following sequence for cut length control: Apply "1" signals to binary inputs DI "/Controller inhibit" and DI1 "Enable/rapid

stop." Only for operation with fieldbus/system bus: Set the following control bits:

PO1:0 "Controller inhibit/enable" = "0" PO1:1 "Enable/rapid stop" = "1" PO1:2 "Enable/Stop" = "1"

Terminal control or fieldbus with one process data word (1 PD): Select the requiredcut length via DI15 ... DI17 or PO1:13 ... PO1:15.

Fieldbus with three process data words (3 PD): Specify the cut length with processoutput data word PO2.

Start automatic mode with DI12 (PO1:10) "Start" = "1." The "1" signal must be activefor the entire duration of positioning.

Apply a "1" signal to binary input DI14 (PO1:12) "Repositioning." The signal must bepresent at least until the home position is reached.

The drive now moves to the home position and waits there until the set materiallength is reached. With cut length control without material sensor, the material lengthis counted starting from the "0"-"1" edge at DI12 "Start." With cut length control withmaterial sensor, the material length is counted starting from the "0"-"1" edge at DI2"Sensor."

When the material length has been reached, the drive automatically engages andsynchronizes itself with the master position. Binary output DO12 (PI1:10) "Drivesynchronous" is set to "1" during synchronous operation.

Once the drive reaches the set reversing position, movement back can be triggeredby a "1" signal at binary input DI14 (PO1:12) "Repositioning." The drive disengagesand moves back to the home position under position control.

When the drive reaches the home position, binary output DO17 (PI1:15) "Homeposition reached" is set to "1." The drive stops with position control.

Note the following points: The "1" signal can be permanently present at binary input DI14 (PO1:12)

"Repositioning." The drive disengages when reaching the minimum reversingposition and moves back to the home position.

The drive remains in synchronous operation if DI14 (PO1:12) "Repositioning"remains set to = "0."

Use the "pulling a gap" function if you want to separate the material following the cut.Proceed as follows: Apply a "1" signal to binary input DI14 (PO1:11) "Gap." Once the minimum

reversing position is reached, an offset corresponding to the value entered duringstartup is established. The "1" signal can be permanently present.

Once the drive has reached the offset value, binary output DO13 (PI1:11) "Gapfinished" is set to "1." The drive remains in synchronous operation.

Fault F42 "Lag fault" is signaled if the cut length is set so small that the material feedhas already exceeded the cut length by the time the home position is reached.Remedy: Less feed.

00

I


5 Automatic modeStartup

Cut length control with label sensor

The setpoint cut length is determined by labels when cut length control with label sensoris active. The labels must be located on the material to be cut and are detected by asensor.

06262AENFigure 45: Automatic mode with cut length control with label sensor

00

I


5Automatic modeStartup

Sequence of cut length control with label sensor

Note the following sequence for cut length control with label sensor: Apply "1" signals to binary inputs DI "/Controller inhibit" and DI1 "Enable/Rapid

stop." Only for operation with fieldbus/system bus: Set the following control bits:

PO1:0 "Controller inhibit/enable" = "0" PO1:1 "Enable/rapid stop" = "1" PO1:2 "Enable/Stop" = "1"

Start automatic mode with DI12 (PO1:10) "Start" = "1." The "1" signal must be activefor the entire duration of positioning.

Apply a "1" signal to binary input DI14 (PO1:12) "Repositioning." The signal must bepresent at least until the home position is reached.

The drive now moves to the home position until a "0"-"1" signal edge on binary inputDI2 "Sensor" starts the sawing procedure.

The drive automatically engages and synchronizes itself with the material to be cut.Binary output DO12 (PI1:10) "Drive synchronous" is set to "1" during synchronousoperation.

Once the drive reaches the set reversing position, movement back can be triggeredby a "1" signal at binary input DI14 (PO1:12) "Repositioning." The drive disengagesand moves back to the home position under position control.

When the drive reaches the home position, binary output DO17 (PI1:15) "Homeposition reached" is set to "1." The drive stops with position control.

Note the following points: The "1" signal can be permanently present at binary input DI14 (PO1:12) "Reposi-

tioning." The drive disengages when reaching the minimum reversing position andmoves back to the home position.

The drive remains in synchronous operation if DI14 (PO1:12) "Repositioning"remains set to "0."

Use the "pulling a gap" function if you want to separate the material following the cut.Proceed as follows: Apply a "1" signal to binary input DI14 (PO1:11) "Gap." Once the minimum

reversing position is reached, an offset corresponding to the value entered duringstartup is established. The "1" signal can be permanently present.

Once the drive has reached the offset value, binary output DO13 (PI1:11) "Gapfinished" is set to "1." The drive remains in synchronous operation.

00

I


6 Timing diagramsOperation and Service

6 Operation and Service6.1 Timing diagrams

The following prerequisites apply to the timing diagrams: Startup performed correctly DI "/CONTROLLER INHIBIT" = "1" (no inhibit) DI1 "ENABLE/RAPID STOP" = "1"

Jog mode

With control via fieldbus/system bus, you must set the following bits in control word PO1: PO1:0 = "0" (CONTROLLER INHIBIT/ENABLE) PO1:1 = "1" (ENABLE/RAPID STOP) PO1:2 = "1" (ENABLE/STOP)

06255AXXFigure 46: Timing diagram of jog modeDI1 = Mode selection (1) = Start jog mode, clockwiseDI11 = Mode selection (2) = Switch mode slow speed rapid speedDI13 = Clockwise (3) = Switch mode rapid speed slow speedDI14 = Counterclockwise (4) = Start jog mode, counterclockwiseDI15 = Slow speed/rapid speed n1 = Slow speed for jog modeDB = /Brake Set during commissioning

n2 = Rapid speed for jog modeSet during commissioning

n [1/min]

n1n2

0-n1-n2

DI1

DI11

DI13

DI14

DI15

(1) (4)(2) (3)


6Timing diagramsOperation and Service

Reference travel

06439AXXFigure 47: Reference travel timing diagramDI4 = /Right limit switch (1) = Start reference travelDI5 = /Left limit switch (2) = CCW limit switch reachedDI1 = Mode selection (3) = Reference position reachedDI11 = Mode selectionDI12 = Start reference travelDO2 = Axis referenced

n [1/min]

n1

0

DI4

DI

DI1

DI11

DI12

5

DO2

(1) (2) (3)



Positioning

06440AXXFigure 48: Positioning timing diagramDI1 = Mode selection (1) = Start positioningDI11 = Mode selection (2) = Target = Home position reachedDI12 = Start positioning (3) = Parking position is selected as targetDI13 = Select target for positioning (4) = Target = Parking position reached"0" = Home position, "1" = Parking positionDO17 = Target position reached

n [1/min]

n1

-n1

0

DI1

DI11

DI12

DI13

DO17

(1) (2) (4)(3)



Automatic modeCut length control without material sensor

06441AXXFigure 49: Timing diagram for automatic cut length control mode without material sensorDI1 = Mode selection (1) = Start material detection, length isDI11 = Mode selection adopted, length measured from this pointDI12 = Start automatic mode (2) = Start repositioningDI13 = Pulling a gap (3) = Home position reachedDI14 = Repositioning (4) = Cut length reached, start sawing procedureDI15 = Cut length binary coded 2^0 (5) = Synchronous speed reached, cut length forDI16 = Cut length binary coded 2^1 the next sawing procedure is adoptedDI17 = Cut length binary coded 2^2 (6) = Minimum reversing position reached, start DO12 = Drive in synchronous operation pulling a gapDO13 = Pulling a gap finished (7) = Pulling a gap finishedDO17 = Home position reached (8) = Sawing procedure finished because DI14 = "1"

immediately start repositioning(9) = Home position reached

n [1/min]

n1

-n1

n2

0

DI1

DI11

DI12

DI13

DI14

DI15

DI16

DI17

DO12

DO13

DO17

(2) (3) (4) (6)(5) (7) (8) (9)(1)



Cut length control with material sensor

06457AXXFigure 50: Timing diagram for automatic cut length control mode with material sensorDI2 = Material sensor signal (1) = Start material detection, cut length isDI1 = Mode selection adopted, length measured from this pointDI11 = Mode selection (2) = Start repositioningDI12 = Start automatic mode (3) = Home position reachedDI13 = Pulling a gap (4) = Cut length reached, start sawing procedureDI14 = Repositioning (5) = Synchronous speed reached, cut length forDI15 = Cut length binary coded 2^0 the next sawing procedure is adoptedDI16 = Cut length binary coded 2^1 (6) = Minimum reversing position reached, start DI17 = Cut length binary coded 2^2 pulling a gapDO12 = Drive in synchronous operation (7) = Pulling a gap finishedDO13 = Pulling a gap finished (8) = Sawing procedure finished because DI14 = "1"

immediately DO17 = Home position reached start repositioning

(9) = Home position reached

n [1/min]

n1

-n1

n2

0

DI11

DI12

DI13

DI14

DI15

DI16

DI17

DI2

DI1

DO12

DO13

DO17

(2) (3) (4) (6)(5) (7) (8) (9)(1)



Cut length control with label sensor

06442AXXFigure 51: Timing diagram for automatic cutting mark controlDI2 = Sensor signal cutting mark (1) = Start repositioningDI1 = Mode selection (2) = Home position reachedDI11 = Mode selection (3) = Start sawing procedureDI12 = Start automatic mode (4) = Minimum reversing position reached, start DI13 = Pulling a gap pulling a gapDI14 = Repositioning (5) = Pulling a gap finishedDO12 = Drive in synchronous operation (6) = Sawing procedure finished because DI14 = "1"

immediately DO13 = Pulling a gap finished start repositioningDO17 = Home position reached (7) = Home position reached

n [1/min]

n1

-n1

n2

0

DI2

DI1

DI11

DI12

DI13

DI14

DO12

DO13

DO17

(1) (2) (3) (4) (5) (6) (7)


6 Fault informationOperation and Service

6.2 Fault informationThe fault memory (P080) stores the last five fault messages (faults t-0 to t-4). The faultmessage of longest standing is deleted whenever more than five fault messages haveoccurred. The following information is stored when a malfunction occurs:Fault that occurred Status of binary inputs/outputs Operating status of the inverter Inverter status Heat sink temperature Speed Output current Active current Unitutilization DC link voltage ON hours Enable hours Parameter set Motorutilization.There are three switch-off responses depending on the fault; the inverter remainsblocked in fault status: Immediate switch-off:

The unit can no longer brake the drive; the output stage goes to high resistance inthe event of a fault and the brake is applied immediately (DB "/Brake" = "0").

Rapid stop:The drive is braked with the stop ramp t13/t23. The brake is applied once the stopspeed is reached (DB "/Brake" = "0"). The output stage goes to high resistanceafter the brake reaction time has elapsed (P732 / P735).

Emergency stop:The drive is braked with the emergency ramp t14/t24. The brake is applied once thestop speed is reached (DB "/Brake" = "0"). The output stage goes to highresistance after the brake reaction time has elapsed (P732 / P735).

Reset A fault can be acknowledged by: Switching the power supply off and on again.

Recommendation: Observe a minimum switch-off time of 10 s for the input contactorK11.

Reset by binary input DI3. Startup of the "Flying saw" causes this binary input to beassigned with the "Reset" function.

Only for operation with fieldbus/system bus: "0""1""0" signal at bit PO1:6 incontrol word PO1.

Press the reset button in the MOVITOOLS Manager.

Manual reset in MOVITOOLS/Shell (P840 = "YES" or [Parameter] / [Manual reset]). Manual reset with DBG60B (MDX61B) or DBG11A (MCH4_A).

Timeout active If the inverter is controlled via a communication interface (fieldbus, RS-485 or SBus) andthe power was switched off and back on again or a fault reset was performed, then theenable remains ineffective until the inverter once again receives valid data via the inter-face, which is monitored with a timeout.

02771AENFigure 52: Reset with MOVITOOLS


6Fault messagesOperation and Service

6.3 Fault messagesDisplay The fault or warning code is displayed in BCD format. The following display sequence

is adhered to:

Following a reset or if the fault or warning code resumes the value 0, the displayswitches to the operating display again.

Fault list The following table shows a selection from the complete list of faults ( MOVIDRIVEoperating instructions). Only those faults are listed that can occur specifically with thisapplication.A dot in the "P" column indicates that the response is programmable (P83_ Faultresponse). The factory set fault response appears in the "Response" column.

01038AXX

Flashes, ca. 1 s

Display off, ca. 0.2 s

Tens, ca. 1 s


Ones, ca. 1 s


Fault code Designation Response P Possible cause Remedy

00 No fault -

07 VZ overvolt-age

Immediate switch-off DC link voltage too high

Extend deceleration ramps Check connection leads to the braking resistor Check technical data of braking resistor

08 n-monitoring Immediate switch-off

Speed controller or current controller (in VFC operating mode without encoder) operating at setting limit due to mechanical overload or phase failure in the power supply or motor.

Encoder not connected correctly or incorrect direction of rotation.

nmax is exceeded during torque control.

Reduce load Increase deceleration time setting (P501 or

P503). Check encoder connection, swap A/A and B/B

pairs if necessary Check encoder voltage supply Check current limitation Extend ramps if necessary Check motor cable and motor Check mains phases


6 Fault messagesOperation and Service

10 IPOS-ILLOP Emergency stop

Incorrect command detected during running of IPOSplus program.

Incorrect conditions during command execution.

Check program memory content and correct if necessary.

Load correct program into program memory. Check program sequence ( IPOSplus manual)

14 Encoder Immediate switch-off

Encoder cable or shield not connected correctly

Short circuit/broken encoder wire Encoder defective

Check encoder cable and shield for correct connec-tion, short circuit and broken wire.

25 EEPROM Rapid stop Access to the EEPROM of the memory card has failed

Call up default setting, perform reset and set parameters again.

Contact SEW service if the error occurs again. Replace memory card.

28 FieldbusTimeout Rapid stop No communication between master and slave within the projected response moni-toring.

Check communications routine of the master Extend fieldbus timeout time (P819)/deactivate

monitoring

29 Limit switch reached

Emergency stop

A limit switch was reached in IPOSplus operating mode.

Check travel range. Correct user program.

31 TF sensor NoneResponse

Motor too hot, TF sensor has tripped TF sensor of motor not connected or

not connected properly Connection of MOVIDRIVE and TF on

motor interrupted No jumper between X10:1 and X10:2.

Let motor cool off and reset fault Check connections/link between MOVIDRIVE

and TF. If no TF is connected: Jumper X10:1 with X10:2. Set P835 to "NO RESPONSE"

36 No option Immediate switch-off

Type of option card not allowed. Setpoint source, control signal source

or operating mode not permitted for this option card.

Incorrect encoder type set for DIP11A.

Use correct option card. Set correct setpoint source (P100). Set correct control signal source (P101). Set correct operating mode (P700 or P701). Set the correct encoder type.

42 Lag error Immediate switch-off

Incremental encoder connected incor-rectly

Accelerating ramps too short P component of positioning controller

too small Speed controller parameters set

incorrectly Value of lag error tolerance too small

Check rotary encoder connection Extend ramps Set P component to higher value Set speed controller parameters again Increase lag error tolerance Check encoder, motor and mains phase wiring Check mechanical components can move freely,

possibly blocked up

94 EEPROM checksum

Immediate switch-off

Inverter electronics faulty. Possibly due to EM interference or defect. Send the unit in for repair.

Fault code Designation Response P Possible cause Remedy


7

7 IndexAApplication examples 3Application fields 2Automatic mode 53

Cut length control 53Cut length control with label sensor 55

Automatic mode, with label sensor 62Automatic mode, with material sensor 61Automatic mode, without material sensor 60

BBus control 16

CConnection

System bus (SBus) 22DDescription of flying saw 2

EError messages

Error list 64

FFault information 63Functional characteristics 6Functional description 6

IIdentification 4Installation 13

Application version 13CANopen 20DeviceNet 21INTERBUS 19INTERBUS with FO 18MCH4_A 23MDX61B with bus control 16MDX61B with terminal control 14MOVITOOLS 13PROFIBUS 17Software 13System bus 22

JJog mode 50, 57

MMonitor 40

Operation with fieldbus/system bus 42

PPositioning 52, 59Process data assignment 11Process input data 12

Process output data 11Program identification 4Project planning

Automatic mode 8Inverter, motor and gear unit 5Jog mode 7Material travel and web speed 10MDX61B with bus control 5Operating modes 5, 7PC and software 5Positioning 8Process data assignment 11Process input data 12Process output data 11Reference travel 7

RReference travel 51, 58Reset 63

SSafety instructions 1Starting the drive 49Startup 26

Control signal source 28Cut length control with label sensor 33, 36Cut length control with material sensor 32, 35Cut length control without material sensor 32, 34Download of startup data 39General information 26Initial startup 27Jog mode, reference travel, positioning 31Master scaling 29Parameters and IPOS variables 45Parameters for the saw 32Preliminary work 26Repositioning, pulling a gap 37Slave scaling 30Starting the program 27

System bus (SBus)Connection 22

System description 2

TTerminal control 14Timeout 63Timing diagram

Automatic mode, with label sensor 62Automatic mode, with material sensor 61Automatic mode, without material sensor 60Jog mode 57Positioning 59Reference travel 58

Timing diagrams 57

WWarning instructions 1

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Documents

flying saw program

movidrive compact mch4

material travel

reference travel

program identification

system description

application fields

application example