maacpmicro1-eng.pdf

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ACOPOSmicroUser's Manual

Version: 1.00 (March 2013)Model no.: MAACPMICRO1-ENG

All information contained in this manual is current as of its creation/publication. We reserve the right to changethe contents of this manual without warning. The information contained herein is believed to be accurate asof the date of publication; however, Bernecker + Rainer Industrie-Elektronik Ges.m.b.H. makes no warranty,expressed or implied, with regard to the products or documentation contained within this manual. In addition,Bernecker + Rainer Industrie-Elektronik Ges.m.b.H. shall not be liable for any incidental or consequential damagesin connection with or arising from the furnishing, performance or use of this documentation. Software names, hard-ware names and trademarks are registered by their respective companies.

2 ACOPOSmicro User's Manual 1.00

2013/04/08:1.00:1.00.23

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Chapter 1: General information

Chapter 2: System features

Chapter 3: Technical data

Chapter 4: Installation

Chapter 5: Dimensioning

Chapter 6: Wiring

Chapter 7: Operation - Stepper motor modules

Chapter 8: Operation - Inverter modules

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Chapter 9: Operation - Power supply

Chapter 10: Safety technology

Chapter 11: Standards and certifications

Appendix A: Abbreviations

Appendix B: Variable mapping in Automation Studio

Appendix C: CE declaration of conformity

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ACOPOSmicro User's Manual 1.00 7

Chapter 1 General information................................................................................. 151 Manual history..................................................................................................................................................152 Safety notices...................................................................................................................................................15

2.1 Organization of safety notices....................................................................................................................152.2 General information.................................................................................................................................... 152.3 Intended use...............................................................................................................................................162.4 Protection against electrostatic discharge..................................................................................................162.5 Transport and storage................................................................................................................................162.6 Handling and installation............................................................................................................................ 172.7 Operation.................................................................................................................................................... 17

2.7.1 Protection against touching electrical parts..........................................................................................172.7.2 Protection against hazardous movements............................................................................................182.7.3 Protection against burns....................................................................................................................... 18

2.8 Specifications for functional safety.............................................................................................................183 Terminology......................................................................................................................................................19

Chapter 2 System features........................................................................................211 The ACOPOSmicro drive system.................................................................................................................... 21

1.1 One solution for all applications.................................................................................................................211.2 Flexibility..................................................................................................................................................... 211.3 Integrated I/O..............................................................................................................................................211.4 Compact dimensions.................................................................................................................................. 221.5 Keying and identification............................................................................................................................ 221.6 Variable nominal voltage ranges................................................................................................................221.7 ACOPOSmicro stepper motor modules..................................................................................................... 221.8 ACOPOSmicro inverter modules................................................................................................................221.9 Modular cooling design.............................................................................................................................. 231.10 Control and connection elements.............................................................................................................231.11 Dimensions................................................................................................................................................241.12 Software....................................................................................................................................................24

1.12.1 PLCopen motion control function blocks............................................................................................ 241.12.2 Higher productivity with Smart Process Technology.......................................................................... 251.12.3 ACOPOSmicro Perfect for CNC applications as well......................................................................251.12.4 Quick and easy commissioning.......................................................................................................... 251.12.5 Tools for straightforward and efficient diagnostics..............................................................................25

2 Topologies........................................................................................................................................................ 262.1 Compact solution for small and mid-sized machines.................................................................................262.2 Customized system combinations..............................................................................................................272.3 APC620 embedded for centralized control, visualization and operation....................................................28

Chapter 3 Technical data.......................................................................................... 292 Stepper motor modules................................................................................................................................... 31

2.1 Overview..................................................................................................................................................... 312.2 80SD100XD.C044-01................................................................................................................................. 32

2.2.1 Order data.............................................................................................................................................322.2.2 Technical data.......................................................................................................................................32

2.3 80SD100XD.C04X-13.................................................................................................................................352.3.1 Order data.............................................................................................................................................352.3.2 Technical data.......................................................................................................................................35

2.4 80SD100XD.C0XX-01................................................................................................................................ 392.4.1 Order data.............................................................................................................................................392.4.2 Technical data.......................................................................................................................................39

2.5 80SD100XD.C0XX-21................................................................................................................................ 422.5.1 Order data.............................................................................................................................................422.5.2 Technical data.......................................................................................................................................42

2.6 80SD100XS.C04X-01................................................................................................................................. 452.6.1 Order data.............................................................................................................................................45

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2.6.2 Technical data.......................................................................................................................................452.7 80SD100XS.C0XX-01.................................................................................................................................48


2.8 Status LEDs................................................................................................................................................512.9 Monitoring the 24 VDC power supply........................................................................................................ 512.10 Monitoring the power supply.................................................................................................................... 512.11 Overtemperature cutoff............................................................................................................................. 512.12 Switching inductive loads......................................................................................................................... 522.13 Power consumption.................................................................................................................................. 52

2.13.1 CPU power supply.............................................................................................................................. 522.13.2 Motor power supply............................................................................................................................ 52

3 Inverter modules.............................................................................................................................................. 543.1 Overview..................................................................................................................................................... 543.2 System requirements..................................................................................................................................543.3 80VD100PD.C000-01................................................................................................................................. 55


3.4 80VD100PD.C022-01................................................................................................................................. 583.4.1 Order data.............................................................................................................................................583.4.2 Technical data.......................................................................................................................................58

3.5 80VD100PS.C00X-01................................................................................................................................. 613.5.1 Order data.............................................................................................................................................613.5.2 Technical data.......................................................................................................................................61

3.6 80VD100PS.C02X-01................................................................................................................................. 643.6.1 Order data.............................................................................................................................................643.6.2 Technical data.......................................................................................................................................64

3.7 Status LEDs................................................................................................................................................673.7.1 Status changes when booting the operating system loader.................................................................673.7.2 LED status R/R, ERR........................................................................................................................... 673.7.3 LED status indicators - POWERLINK...................................................................................................68

3.8 POWERLINK node number switches.........................................................................................................683.9 Power consumption.................................................................................................................................... 68

3.9.1 CPU power supply................................................................................................................................ 683.9.2 Motor power supply.............................................................................................................................. 68

3.10 Backup battery for ACOPOSmicro with EnDat encoder inputs............................................................... 693.10.1 Service life...........................................................................................................................................693.10.2 Battery-backed (EBI) encoder.............................................................................................................693.10.3 Changing the battery.......................................................................................................................... 69

4 Power supply module...................................................................................................................................... 714.1 Order data.................................................................................................................................................. 714.2 Technical data............................................................................................................................................ 714.3 Status LEDs................................................................................................................................................734.4 Block diagram.............................................................................................................................................734.5 Parallel operation........................................................................................................................................734.6 Error monitoring..........................................................................................................................................74

Cutoff characteristic - Power output.............................................................................................................. 75Output current during overload...................................................................................................................... 75

5 Accessories...................................................................................................................................................... 775.2 Terminal blocks.......................................................................................................................................... 78

5.2.1 Terminal block for connecting additional inputs/outputs.......................................................................795.2.2 Terminal blocks for connecting the I/O and CPU power supplies........................................................ 805.2.3 Terminal blocks for connecting motors.................................................................................................815.2.4 Terminal blocks for the connection of power supply units................................................................... 835.2.5 Terminal block sets...............................................................................................................................84

5.3 POWERLINK cables...................................................................................................................................855.3.1 Order data.............................................................................................................................................85

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5.3.2 Technical data.......................................................................................................................................855.3.3 Dimensions and pinout......................................................................................................................... 86

5.4 X2X Link cables......................................................................................................................................... 875.4.1 X2X Link device attachment cable....................................................................................................... 875.4.2 X2X Link device connection cable........................................................................................................88

5.5 Braking resistors.........................................................................................................................................895.5.1 80XBR0025.010-11............................................................................................................................... 895.5.2 80XBR0055.010-11............................................................................................................................... 90

5.6 Hose clamps...............................................................................................................................................915.7 Backup battery............................................................................................................................................915.8 Accessories included in delivery................................................................................................................ 92

5.8.1 ACOPOSmicro multilingual warning stickers........................................................................................92

Chapter 4 Installation.................................................................................................931 General information..........................................................................................................................................932 ACOPOSmicro with cold plate.........................................................................................................................93

2.1 Dimension diagram for ACOPOSmicro with cold plate..............................................................................932.2 Cold plate mounting................................................................................................................................... 942.3 Unmounting from the cold plate.................................................................................................................94

3 Power supply module...................................................................................................................................... 953.1 Dimension diagram for the power supply module..................................................................................... 95

Chapter 5 Dimensioning............................................................................................971 Fuse protection................................................................................................................................................ 972 Power consumption - Stepper motor modules................................................................................................ 98

Chapter 6 Wiring...................................................................................................... 1011 EMC-compatible installation...........................................................................................................................101

1.1 General information.................................................................................................................................. 1011.2 Installation notes.......................................................................................................................................101

2 Stepper motor modules................................................................................................................................. 1022.1 Pinout overview........................................................................................................................................ 102

2.1.1 80SD100XD.C044-01..........................................................................................................................1022.1.2 80SD100XD.C04X-13......................................................................................................................... 1032.1.3 80SD100XD.C0XX-01.........................................................................................................................1042.1.4 80SD100XD.C0XX-21.........................................................................................................................1052.1.5 80SD100XS.C04X-01..........................................................................................................................1062.1.6 80SD100XS.C0XX-01......................................................................................................................... 107

2.2 X1 - Power unit supply.............................................................................................................................1082.2.1 X1 diagram - Power supply................................................................................................................ 108

2.3 X2 - Power supply for the CPU and digital inputs/outputs.......................................................................1082.3.1 X2 connection - Input/Output circuit diagram..................................................................................... 109

2.4 X3A/X3B - X2X Link connections............................................................................................................ 1102.5 X4/X5 - Stepper motor connection...........................................................................................................111

2.5.1 X4/X5 - Output diagram - Stepper motor connection.........................................................................1112.6 X6 - Encoder inputs................................................................................................................................. 112

2.6.1 Incremental encoders..........................................................................................................................1122.7 X7 - Additional inputs/outputs.................................................................................................................. 113

2.7.1 Input circuit diagram for additional digital inputs................................................................................ 1132.7.2 Output circuit diagram for additional digital outputs........................................................................... 1132.7.3 Input circuit diagram for additional analog inputs...............................................................................114

2.8 Protective ground connection PE.............................................................................................................1143 Inverter modules............................................................................................................................................ 115

3.1 Pinout overview........................................................................................................................................ 1153.1.1 80VD100PD.C000-01, 80VD100PD.C022-01.....................................................................................1153.1.2 80VD100PS.C00X-01, 80VD100PS.C02X-01.................................................................................... 116

3.2 X1 - Power unit supply.............................................................................................................................117

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3.2.1 X1 diagram - Power supply................................................................................................................ 1173.3 X2 - Power supply for the CPU and digital inputs/outputs.......................................................................117

3.3.1 X2 connection - Input/Output circuit diagram..................................................................................... 1183.4 X3 - POWERLINK connections................................................................................................................1193.5 X4/X5 - Servo motor connection..............................................................................................................119

3.5.1 X4/X5 - Input/Output circuit diagram - Temperature sensor / Stepper motor connection................... 1203.6 X6 - Encoder inputs................................................................................................................................. 120

3.6.1 EnDat 2.2 interface............................................................................................................................. 1203.6.2 Resolver.............................................................................................................................................. 121

3.7 Protective ground connection PE.............................................................................................................1224 Power supply module.................................................................................................................................... 124

4.1 X1 - Mains input.......................................................................................................................................1244.2 X2 - Power output 24 to 80 VDC.............................................................................................................1244.3 X3 connection - Chopper output.............................................................................................................. 1254.4 X4 connection - Voltage output 24 VDC / 2 A.........................................................................................1254.5 X5 - X2X Link interface............................................................................................................................126

Chapter 7 Operation - Stepper motor modules.....................................................1271 Function models.............................................................................................................................................127

1.1 Minimum cycle time..................................................................................................................................1271.2 Minimum I/O update time.........................................................................................................................1271.3 Operation with bus controller................................................................................................................... 127

2 Standard function model................................................................................................................................1282.2 Registers for stepper motor control......................................................................................................... 128

2.2.1 Position................................................................................................................................................1282.2.2 Error/Status......................................................................................................................................... 1292.2.3 Motor ID.............................................................................................................................................. 1302.2.4 Motor configuration............................................................................................................................. 1302.2.5 Holding current, nominal current, maximum current...........................................................................1312.2.6 Module configuration...........................................................................................................................1312.2.7 Error acknowledgment / Digital output of motor brake....................................................................... 1312.2.8 Position latch.......................................................................................................................................1322.2.9 usSinceTrigger.................................................................................................................................... 1322.2.10 Latch trigger status........................................................................................................................... 1322.2.11 Life cycle counter.............................................................................................................................. 1322.2.12 Latch configuration............................................................................................................................1322.2.13 Trigger configuration......................................................................................................................... 1322.2.14 Temperature......................................................................................................................................1332.2.15 Motor ID trigger.................................................................................................................................1332.2.16 Full step threshold............................................................................................................................ 1332.2.17 Heat sink temperature...................................................................................................................... 1332.2.18 DC link voltage..................................................................................................................................134

2.3 Registers for ACOPOSmicro with an encoder.........................................................................................1342.3.1 ABR counter........................................................................................................................................1342.3.2 ABR counter latch...............................................................................................................................1342.3.3 ABR control register............................................................................................................................1342.3.4 ABR configuration............................................................................................................................... 1342.3.5 ABR advanced configuration.............................................................................................................. 135

2.4 Registers for ACOPOSmicro variants with additional digital inputs/outputs............................................ 1352.4.1 Status of digital inputs and outputs.................................................................................................... 1352.4.2 Counter configuration..........................................................................................................................1352.4.3 Set digital outputs / Counter control register......................................................................................1362.4.4 Counter................................................................................................................................................1362.4.5 Counter latch.......................................................................................................................................1362.4.6 Counter configuration..........................................................................................................................136

2.5 Registers for ACOPOSmicro variants with additional analog inputs........................................................1372.5.1 Status of the analog inputs.................................................................................................................137

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2.5.2 Analog input 1 / Analog input 2..........................................................................................................1372.6 Trace functionality for ACOPOSmicro variants with analog inputs.......................................................... 137

2.6.1 Trace registers.................................................................................................................................... 1372.6.2 Trace runtime configuration................................................................................................................ 1382.6.3 Trace library........................................................................................................................................ 139

3 Ramp function model.....................................................................................................................................1403.2 Register description..................................................................................................................................141

3.2.1 Set position/speed...............................................................................................................................1413.2.2 Current position (cyclic)...................................................................................................................... 1413.2.3 Current position (acyclic).................................................................................................................... 1413.2.4 Input status..........................................................................................................................................1413.2.5 Control word........................................................................................................................................1413.2.6 Status.................................................................................................................................................. 1423.2.7 Mode....................................................................................................................................................1423.2.8 Motor brake.........................................................................................................................................1433.2.9 UDCL DC link voltage.........................................................................................................................1433.2.10 Temperature of output stage............................................................................................................ 1433.2.11 Temperature...................................................................................................................................... 1433.2.12 Maximum speed................................................................................................................................1433.2.13 Maximum acceleration...................................................................................................................... 1433.2.14 Maximum deceleration...................................................................................................................... 1443.2.15 Position setpoint 1............................................................................................................................ 1443.2.16 Position setpoint 2............................................................................................................................ 1443.2.17 Referencing speed............................................................................................................................ 1443.2.18 Referencing configuration................................................................................................................. 1443.2.19 Full step threshold............................................................................................................................ 1443.2.20 Jolt time limitation............................................................................................................................. 1443.2.21 Read back control word....................................................................................................................1443.2.22 Read back mode...............................................................................................................................1443.2.23 Referenced zero position for cyclic counter..................................................................................... 1453.2.24 Referenced zero position for acyclic counter................................................................................... 1453.2.25 Reversing loop.................................................................................................................................. 1453.2.26 Error code......................................................................................................................................... 1453.2.27 Holding current, nominal current, maximum current.........................................................................1453.2.28 Motor ID............................................................................................................................................ 146

3.3 Registers for ACOPOSmicro variants with additional digital inputs/outputs............................................ 1473.4 Registers for ACOPOSmicro variants with additional analog inputs........................................................1493.5 Trace functionality for ACOPOSmicro variants with analog inputs.......................................................... 150

3.5.1 Trace registers.................................................................................................................................... 1503.5.2 Trace runtime configuration................................................................................................................ 1513.5.3 Trace library........................................................................................................................................ 151

3.6 Ramp function model operation............................................................................................................... 1533.6.1 Control word........................................................................................................................................1533.6.2 Status register..................................................................................................................................... 1543.6.3 State machine..................................................................................................................................... 155

Chapter 8 Operation - Inverter modules................................................................ 1571 ACP10 software............................................................................................................................................. 157

1.1 Adding parameter groups manually......................................................................................................... 1572 EnDat 2.2 interface........................................................................................................................................ 158

2.1 Parameter IDs.......................................................................................................................................... 1582.2 Functions.................................................................................................................................................. 158

2.2.1 Serial data transfer............................................................................................................................. 1582.2.2 Monitoring and error handling.............................................................................................................1582.2.3 Encoder errors and warnings............................................................................................................. 1592.2.4 Initialization active............................................................................................................................... 1602.2.5 Position value not synchronous with absolute value..........................................................................160

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2.2.6 Error in the multi-turn position............................................................................................................ 1602.3 Encoder card functions.............................................................................................................................160

2.3.1 Parameter IDs..................................................................................................................................... 1602.3.2 Position measurement........................................................................................................................ 1602.3.3 Diagnostic values................................................................................................................................ 1612.3.4 Encoder temperature.......................................................................................................................... 1612.3.5 Example: Reading additional information........................................................................................... 1612.3.6 Encoder status ENCOD_STATUS...................................................................................................... 161

Chapter 9 Operation - Power supply..................................................................... 1631 Function models.............................................................................................................................................163

1.1 Minimum cycle time..................................................................................................................................1632 Standard function model................................................................................................................................163

2.2 StatusPacked01........................................................................................................................................1642.3 ControlPacked01...................................................................................................................................... 1642.4 Voltage01..................................................................................................................................................1642.5 Current01.................................................................................................................................................. 1642.6 Temperature01-03.................................................................................................................................... 1652.7 ConfigPacked01........................................................................................................................................1652.8 ChopperOffset01.......................................................................................................................................1652.9 VoltageSet01............................................................................................................................................ 1652.10 CurrentSet01...........................................................................................................................................1652.11 TempLimitBleeder01............................................................................................................................... 1652.12 TempAmbBleeder01............................................................................................................................... 1662.13 TempInitBleeder01..................................................................................................................................1662.14 RBleeder01............................................................................................................................................. 1662.15 RthBleeder01.......................................................................................................................................... 1662.16 CthBleeder01.......................................................................................................................................... 1662.17 TempBleeder01...................................................................................................................................... 166

3 Function model: CANIOBusController........................................................................................................... 167

Chapter 10 Safety technology................................................................................ 1691 Standard safety technology ("Wired safety technology")...............................................................................169

1.1 General information.................................................................................................................................. 1691.2 Principle - Implementing the safety function............................................................................................ 169

1.2.1 Additional function...............................................................................................................................1721.3 Enable input connected in accordance with Safety Category 3 / SIL 2 / PL d.........................................173

1.3.1 STO, Category 3 / SIL 2 / PL d (Variant A)....................................................................................... 1731.3.2 STO, Category 3 / SIL 2 / PL d (Variant B)....................................................................................... 174

1.4 Enable input circuits in accordance with Safety Category 3 / SIL 2 / PL d and functionality (STO, SS1, SS2,SLS, SOS)...................................................................................................................................................... 174

1.4.1 STO, SLS, SOS - Safety Category 3 / SIL 2 / PL d...........................................................................1751.4.2 SS1, SLS, SS2 - Safety Category 3 / SIL 2 / PL d (Variant A).......................................................... 1771.4.3 SS1, SLS, SS2 - Safety Category 3 / SIL 2 / PL d (Variant B).......................................................... 179

Chapter 11 Standards and certifications............................................................... 1831 Applicable European directives......................................................................................................................1832 Applicable standards......................................................................................................................................1833 Environmental limits....................................................................................................................................... 183

3.1 Mechanical conditions in accordance with IEC 61800-2......................................................................... 1833.1.1 Operation.............................................................................................................................................1833.1.2 Transport............................................................................................................................................. 183

3.2 Climate conditions in accordance with IEC 61800-2............................................................................... 1843.2.1 Operation.............................................................................................................................................1843.2.2 Storage................................................................................................................................................1843.2.3 Transport............................................................................................................................................. 184

4 Requirements for immunity to disturbances (EMC).......................................................................................184

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4.1 Evaluation criteria (performance criteria)................................................................................................. 1844.2 High-frequency disturbances in accordance with IEC 61800-3............................................................... 184

4.2.1 Electrostatic discharge........................................................................................................................ 1844.2.2 Electromagnetic fields......................................................................................................................... 1844.2.3 Burst.................................................................................................................................................... 1854.2.4 Surge...................................................................................................................................................1854.2.5 High-frequency conducted disturbances.............................................................................................185

5 Requirements for emissions (EMC)...............................................................................................................1855.1 High-frequency emissions in accordance with IEC 61800-3....................................................................185

5.1.1 Limit values for disturbance voltage on the power mains connections in the frequency band from 150kHz to 30 MHz............................................................................................................................................. 1855.1.2 Electromagnetic emissions................................................................................................................. 185

6 Other environmental limit values in accordance with IEC 61800-2...............................................................1867 International certifications.............................................................................................................................. 186

Appendix A Abbreviations...................................................................................... 1871 General information........................................................................................................................................1872 Overview.........................................................................................................................................................187

Appendix B Variable mapping in Automation Studio...........................................1891 Overview.........................................................................................................................................................1892 80SD100XD.C044-01 - Standard function model..........................................................................................190

2.1 Overview of registers................................................................................................................................1902.2 Error: Error/Status.....................................................................................................................................1902.3 StatusOutput14: Error acknowledgment / Digital output of motor brake..................................................1912.4 StepperLatchStatus: Latch trigger status................................................................................................. 1912.5 StepperLatchConfig: Latch configuration................................................................................................. 1912.6 TriggerConfig: Trigger configuration.........................................................................................................1912.7 StatusOutput15: ABR control register...................................................................................................... 192

3 80SD100XD.C044-01 - Ramp function model...............................................................................................1933.1 Overview of registers................................................................................................................................1933.2 Motor brake.............................................................................................................................................. 193

4 80SD100XD.C04X-13 - Standard function model......................................................................................... 1944.1 Overview of registers................................................................................................................................1944.2 Error: Error/Status.....................................................................................................................................1944.3 StatusOutput14: Error acknowledgment / Digital output of motor brake..................................................1954.4 StepperLatchStatus: Latch trigger status................................................................................................. 1954.5 StepperLatchConfig: Latch configuration................................................................................................. 1954.6 TriggerConfig: Trigger configuration.........................................................................................................1954.7 StatusOutput15: ABR control register...................................................................................................... 1964.8 Digital_in_do_rb: Status of digital inputs and outputs..............................................................................1964.9 StatusOutput16: Set digital outputs / Counter control register.................................................................196

5 80SD100XD.C04X-13 - Ramp function model.............................................................................................. 1975.1 Overview of registers................................................................................................................................1975.2 Motor brake.............................................................................................................................................. 197

6 80SD100XD.C0XX-01 - Standard function model.........................................................................................1986.1 Overview of registers................................................................................................................................1986.2 Error: Error/Status.....................................................................................................................................1986.3 StatusOutput14: Error acknowledgment / Digital output of motor brake..................................................1996.4 StepperLatchStatus: Latch trigger status................................................................................................. 1996.5 StepperLatchConfig: Latch configuration................................................................................................. 1996.6 TriggerConfig: Trigger configuration.........................................................................................................199

7 80SD100XD.C0XX-01 - Ramp function model..............................................................................................2007.1 Overview of registers................................................................................................................................2007.2 Motor brake.............................................................................................................................................. 201

8 80SD100XD.C0XX-21 - Standard function model.........................................................................................2028.1 Overview of registers................................................................................................................................202

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8.2 Error: Error/Status.....................................................................................................................................2028.3 StatusOutput14: Error acknowledgment / Digital output of motor brake..................................................2038.4 StepperLatchStatus: Latch trigger status................................................................................................. 2038.5 StepperLatchConfig: Latch configuration................................................................................................. 2038.6 TriggerConfig: Trigger configuration.........................................................................................................2038.7 Status of the analog inputs...................................................................................................................... 2038.8 Trace control word....................................................................................................................................2048.9 Trace status.............................................................................................................................................. 2048.10 Trace trigger........................................................................................................................................... 204

9 80SD100XD.C0XX-21 - Ramp function model..............................................................................................2059.1 Overview of registers................................................................................................................................2059.2 Motor brake.............................................................................................................................................. 2059.3 Status of the analog inputs...................................................................................................................... 2059.4 Trace control word....................................................................................................................................2059.5 Trace status.............................................................................................................................................. 2069.6 Trace trigger............................................................................................................................................. 206

10 80SD100XS.C04X-01 - Standard function model....................................................................................... 20710.1 Overview of registers..............................................................................................................................20710.2 Error: Error/Status...................................................................................................................................20710.3 StatusOutput14: Error acknowledgment / Digital output of motor brake................................................20810.4 StepperLatchStatus: Latch trigger status............................................................................................... 20810.5 StepperLatchConfig: Latch configuration............................................................................................... 20810.6 TriggerConfig: Trigger configuration.......................................................................................................20810.7 StatusOutput15: ABR control register.................................................................................................... 208

11 80SD100XS.C04X-01 - Ramp function model.............................................................................................20911.1 Overview of registers..............................................................................................................................20911.2 Motor brake.............................................................................................................................................209

12 80SD100XS.C0XX-01 - Standard function model....................................................................................... 21012.1 Overview of registers..............................................................................................................................21012.2 Error: Error/Status...................................................................................................................................21012.3 StatusOutput14: Error acknowledgment / Digital output of motor brake................................................21012.4 StepperLatchStatus: Latch trigger status............................................................................................... 21112.5 StepperLatchConfig: Latch configuration............................................................................................... 21112.6 TriggerConfig: Trigger configuration.......................................................................................................211

13 80SD100XS.C0XX-01 - Ramp function model............................................................................................ 21213.1 Overview of registers..............................................................................................................................21213.2 Motor brake............................................................................................................................................ 212

Appendix C CE declaration of conformity.............................................................213

General information Safety notices

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Chapter 1 General information

1 Manual history

Information:B&R keeps the printed version of user's manuals as current as possible. If there is a newer versionavailable, it can be downloaded as a PDF file from the B&R website at www.br-automation.com.

Version Date Comment1.00 March 2013 Entire manual revised

Inverter modules added Safety technology for inverter modules added Note regarding "IFA EMC and functional safety" in safety technology chapter added Power supply module:

Technical data, parallel operation, block diagram and installation notes updated or addedRevision notes removed: Documentation applies beginning with hardware revision B7Description of phase failure updated

0.10 November 2009 First edition of the user's manual with stepper motor modules

Table 1: Manual history

2 Safety notices

Information:The safety notices, connection descriptions (type plate and documentation) and limit values listed inthe technical data are to be read carefully before installation and commissioning and must be observed.

These safety notices must be kept and included with the device if it is passed on to anyone else (e.g. sold,rented, etc.).The user is responsible for observing all applicable international and national electrical standards.

2.1 Organization of safety notices

Safety notices in this manual are organized as follows:Safety notice DescriptionDanger! Disregarding these safety guidelines and notices can be life-threatening.Warning! Disregarding these safety guidelines and notices can result in severe injury or substantial damage to equipment.Caution! Disregarding these safety guidelines and notices can result in injury or damage to equipment.Information: This information is important for preventing errors.

Table 2: Description of the safety notices used in this documentation

2.2 General information

B&R drive systems and motors have been designed, developed and manufactured for conventional use in indus-trial environments. They were not designed, developed and manufactured for any use involving serious risks orhazards that could lead to death, injury, serious physical damage or loss of any kind without the implementationof exceptionally stringent safety precautions.In particular, such risks and hazards include the use of these devices to monitor nuclear reactions in nuclear powerplants, their use in flight control or flight safety systems as well as in the control of mass transportation systems,medical life support systems or weapons systems.



Danger!Drive systems and motors can have exposed parts that carry voltage (e.g. terminals) as well as hotsurfaces. Additional hazards include moving machine parts. Improperly removing required covers,inappropriate use of the devices or their improper installation or operation can result in severe personalinjury or damage to property.

All tasks such as the transport, installation, commissioning and servicing of devices are only permitted to be car-ried out by qualified personnel. Qualified personnel are those familiar with the transport, mounting, installation,commissioning and operation of devices who also have the appropriate qualifications (e.g. IEC 60364). Nationalaccident prevention regulations must be observed.The safety notices, connection descriptions (type plate and documentation) and limit values listed in the technicaldata are to be read carefully before installation and commissioning and must be observed.

Danger!The improper handling of drive systems and motors can cause severe personal injury or damage toproperty!

2.3 Intended use

Motor drives and motors are components designed to be installed in electrical systems or machines. They arenot permitted to be used unless the machine meets directive 2006/42/EC (machine directive) as well as directive2004/108/EC (EMC directive).

Danger!Before applying power, it is necessary to check if the B&R drive system being used is suitable forthe respective mains. The specifications and restrictions in the user documentation for the respectivedevice series must be observed completely!

When used in residential areas, shops or small businesses, additional measures must be implemented by the user.Technical data as well as connection and environmental specifications can be found on the type plate and in thisuser's manual. These specifications regarding connection and environmental conditions must be observed!

Danger!Electronic devices are never completely failsafe.If the drive systems fails, the user is responsible for ensuring that any connected motors are broughtto a secure state.

2.4 Protection against electrostatic discharge

Electrical components that can be damaged by electrostatic discharge (ESD) must be handled accordingly.

2.4.1 Packaging

Electrical components with a housing do not require any special ESD packaging, but they must still be handledproperly.

2.4.2 Guidelines for proper ESD handling

Do not touch the connector contacts on connected cables. Do not touch the contact tips on circuit boards.

2.5 Transport and storage

During transport and storage, devices must be protected against undue stress (mechanical loads, temperature,humidity, aggressive atmospheres, etc.).Drive systems contain components sensitive to electrostatic charges that can be damaged by inappropriate han-dling. It is therefore necessary to provide the required protective measures against electrostatic discharge wheninstalling or removing these drive systems.


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2.6 Handling and installation

Warning!B&R drive systems and motors may be very heavy.During handling and installation of B&R drive systems or motors, there exists the danger of personalinjury or damage to equipment (through shearing, impacts, cutting or crushing). Suitable protectiveequipment (e.g. safety glasses, protective gloves, safety shoes, etc.) should be used when necessary!

Installation must be performed according to this documentation using suitable equipment and tools.Devices may only be installed by qualified personnel without voltage applied. Before installation, voltage to thecontrol cabinet must be switched off and prevented from being switched on again.General safety guidelines and national accident prevention regulations (e.g. VBG 4) for working with high voltagesystems must be observed.Electrical installation must be carried out according to applicable guidelines (e.g. line cross section, fuses, protectiveground connections, see also "Dimensioning" on page 97).

2.7 Operation

2.7.1 Protection against touching electrical parts

Danger!To operate drive systems, it is necessary for certain parts to carry dangerous voltages over 42 VDC.Touching one of these parts can result in a life-threatening electric shock. This could lead to death,severe injury or damage to equipment.

Before turning on a drive system, it is important to ensure that the housing is properly connected to ground (PE rail).The ground connection must be established even when testing the drive system or operating it for a short time!Before turning the device on, all parts that carry voltage must be securely covered. During operation, all coversand control cabinet doors must remain closed.Control and power connections can still carry voltage even if the motor is not turning. Touching these connectionswhen the device is switched on is prohibited.Before performing any work on drive systems, they must first be disconnected from the power mains and preventedfrom being switched on again.

Danger!Risk of electric shock!Remove the supply voltage, wait 5 minutes and make sure that the voltage on terminal X1 has droppedto below 42 VDC before beginning maintenance work.

Drive systems are labeled with the following warning:

Figure 1: Warning on the drive system

ACOPOSmicro units are provided with these warning stickers in different languages (see page 92).The connections for drive system signal voltages ranging from 5 to 30 V are safely isolated circuits. The signalvoltage connections and interfaces are therefore only permitted to be connected to devices or electrical componentsthat have sufficient isolation in accordance with IEC 60364-4-41 or EN 61800-5-1 and that correspond to SELV /PELV.Never remove the electrical connections from the drive system with voltage applied. In some cases, electric arcsmay occur that can cause personal injury and/or damage to contacts.



2.7.2 Protection against hazardous movements

Danger!Improper control of motors can result in unintended hazardous movements! Such incorrect behaviorcan have various causes:

Incorrect installation or a mistake when handling components Improper or incomplete wiring Defective devices (drive system, motor, position encoder, cables, brake) Incorrect control (e.g. caused by software error)

Some of the errors listed above can be detected and prevented by the drive system's internal monitoring. Never-theless, it is still possible for the motor shaft to move any time the device is switched on! For this reason, higher-levelsafety precautions need to be put in place to ensure that personnel and machines are protected.The moving parts on machines must be shielded in such a way as to prevent unintentional access by personnel.This type of protection can be achieved by using stable mechanical protective equipment such as protective covers,protective fences, protective gates or light barriers.Removing, bypassing or circumventing these protective measures and entering the area where movement takesplace is prohibited.A sufficient number of emergency stop switches must be installed in direct proximity to the machine and be easilyaccessible at all times. This emergency stop equipment must be checked before the machine is commissioned.On free running motors, the shaft key (if present) must be removed or measures taken to prevent its ejection.The holding brake built into motors cannot prevent hoisting equipment from dropping hanging loads.

2.7.3 Protection against burns

The surfaces of drive systems and motors can reach very high temperatures during operation.As a result, the included stickers must be affixed to drive systems and motors to indicate this danger (see page92):

Figure 2: Sticker for "Hot surface" (3 pcs. are included with the delivery of the ACOPOSmicro)

2.8 Specifications for functional safety

Specifications for functional safety are listed in the section "Safety technology" on page 169.Specifications are calculated based on a proof test interval of up to 20 years. Since a proof test cannot be carriedout for B&R drive systems, the proof test interval is the same as the system's mission time.In accordance with the EN ISO 13849, EN 62061 and IEC 61508 standards, the safety functions described in thesection "Safety technology" cannot be used beyond the specified mission time.

Danger!The user must ensure that all B&R drive systems that fulfill a safety function are replaced by new B&Rdrive systems or removed from operation before their mission time expires.

General information Terminology

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3 TerminologyTerm ExplanationSG3 System Generation 3 (SG3) - CPUs with Motorola processors

The following CPUs belong to this series: IF161, IP161 XP152 CP100, CP104, CP152, CP153, CP200, CP210, CP260, CP430, CP470, CP474, CP476, CP770, CP774 PP15, PP21, PP35, PP41

SG4 System Generation 4 (SG4) - CPUs with Intel processors

The following CPUs belong to this series: CP1583, CP1584, CP1585, CP1586, CP3583, CP3584, CP3585, CP3586 CP1483, CP1483-1, CP1484, CP1484-1, CP1485, CP1485-1, CP1486, CP3484, CP3484-1, CP3485, CP3485-1, CP3486 CP340, CP360, CP380, CP382, CP570 PP45, PP65 PP100/200, PP300/400 MP100/200 EC20, EC21 AC140, AC141 ARsim, ARwin, ARemb APC620, APC700, APC810

SGC System Generation Compact CPUs (SGC) - CPUs with Motorola processors (Embedded P)

The following CPUs belong to this series: CP0201, CP0291, CP0292 XC0201, XC0202, XC0292

Table 3: Terminology

System features The ACOPOSmicro drive system

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Chapter 2 System features

1 The ACOPOSmicro drive system

Compact design Flexible application Low heat dissipation Uniform design for inverter and stepper motor modules Optional expansions

ACOPOSmicro with encoder interface and heat spreader ACOPOSmicro with heat spreader

1.1 One solution for all applications

The main goal when developing the ACOPOSmicro was to provide cost-effective drive solutions that also includedthe lower power ranges. Nevertheless, the technical capabilities of the ACOPOSmicro still allow it to compete withlarger devices. The ACOPOSmicro is designed to control both stepper motors and servo motors. Despite its smalldimensions, it can support up to two axes on one module.

1.2 Flexibility

Ever-changing fields of application and the necessity to integrate different types of drives in one machine oftencreate large challenges for the developers of an application. Creating projects with B&R Automation Studio makes itpossible to handle a wide range of drive concepts using the same tools. This means that flexible drive architecturescan be implemented by either combining these concepts together or maintaining their independence from oneanother.It is possible to plan for various machine variants during project development and to account for different configu-rations that use various drive types. This makes it easy to switch from a stepper motor to a servo motor variant(and vice versa) without problems. As a result, machine manufacturers are able to enjoy unprecedented flexibility.

1.3 Integrated I/O

In addition to trigger inputs, this device also includes a 24 VDC output. It can be used, for example, to controlexternal brakes in addition to being available for other tasks.If required, additional functionality can be added via optional modules at a minimum cost and without taking upextra space.This makes it possible to meet even extraordinary customer-specific requirements. The optional support of manydifferent encoder systems, even with the stepper motor variant, illustrates this product line's high degree of flexibility.



1.4 Compact dimensions

The two-channel variant clearly highlights this module's extremely compact design. The ACOPOSmicro requiresan area of less than 50 cm per axis.This not only saves space in the control cabinet for applications with multiple axes, but also provides advantagesin wiring since the bus and supply voltage connection is only needed for every second motor.Such high power density in such a small space is indeed extraordinary.

1.5 Keying and identification

The possibility of using keyed connection terminals is extremely useful, especially for the two-channel variant. Inparticular, this prevents serious errors that can occur by connecting the wrong drive axis during commissioning.Being able to easily label the ACOPOSmicro also helps to avoid errors.

1.6 Variable nominal voltage ranges

To achieve higher torque values at high speeds, the first voltage variant was designed for a nominal voltage of80 VDC. The ability to withstand overvoltage up to 95 VDC also allows for increases in the DC link voltage such asthose that occur during braking procedures. Nevertheless, the drive can also be utilized in the low voltage rangewith nearly no limitations. This means that the ACOPOSmicro product line can be operated down to a voltage of18 VDC.

1.7 ACOPOSmicro stepper motor modules

Whereas earlier stepper motors were mainly reserved for simpler tasks, today they are used to meet even complexCNC demands. The particular advantage offered by these motors is their high level of torque in the low to middlespeed range that can be implemented with even very small motor designs. The use of this technology is a trulyeconomical solution within its torque limits.

Ease of handling

It goes without saying with this device that no switches are needed to select the motor current. All module settingsare software-based. The default values of all parameters can be quickly and easily adapted to the project andoverwritten at runtime. Current resolution down to approximately one percent of the nominal current meets everyneed in regard to selecting a current value. The module's main feature is that holding current, nominal current andmaximum current (boost current) can each be defined separately. This keeps thermal loss in the stepper motor toa minimum, and the maximum torque is available exactly when it is needed. All of this leads to noticeable savingsin energy and reduces power loss in the motor, which further extends the service life of all of the components.

Maximum resolution

Depending on the stepper motor being used, the ACOPOSmicro can break a motor revolution down into 102,400partial steps. This is possible due to the 256 microsteps supported by the system. The basic step angle is auto-matically divided into the maximum possible microsteps based on the speed. In addition to the possibility for in-creased positioning accuracy, this also enables much smoother operation. The common problem of accumulatingresonance frequencies is significantly minimized by the fine grading of current changes. The current controller'shigh frequency also plays a role in this. Optional encoder feedback can help stepper motors achieve highly accu-rate positioning under a wide range of load torques.

1.8 ACOPOSmicro inverter modules

Powerful solutions across the board

Reduced energy, service and maintenance costs thanks to a longer lifespan and fewer components per axis allof this is made possible through the use of ACOPOSmicro inverter modules instead of pneumatic cylinders.In particular, the large amount of energy required to generate compressed air due to significant energy loss (e.g.motor and compressor loss, pressure loss through reduction valves and leaks) has a negative impact on the totalcost of ownership of a machine and increases the demand for electric linear axes.Linear motors provide more precise positioning, thus improving the accuracy of repeated machine movements.Higher clock speeds, by up to a factor of 2, increase the production capacity of the plant and reduce productioncosts. Packaging machines, handling devices pick-and-place applications are just a few examples where pneu-matic cylinders, linear axes driven by servo motors, cam gears or multi-jointed applications can be replaced bylinear motors.


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In short, the integration of electrically driven linear axes into B&R's automation technology catalog opens up a newworld of innovative and flexible machine designs.

1.9 Modular cooling design

The majority of the heat generated in the device is emitted to the heat spreader integrated in the ACOPOSmicro.This excessive heat can then be dissipated in various ways, such as through a conventional heat sink on thecooling medium of an external (water or oil-cooled) cold plate or passed on to the machine parts.

1.10 Control and connection elements

ACOPOSmicro stepper motor modules

View from front View from below

Power unit supply

PE (ground connection)

Insert for labeling

Status indicators

Incremental encoders(only one/two channel encoder types)

24 V connection and digital I/OOptional I/O

X2X Link

Motor connections

Figure 3: ACOPOSmicro stepper motor modules - Operating and connection elements

ACOPOSmicro inverter modules

View from front View from below

Power unit supply

PE (ground connection)

Insert for labeling

Status indicators

Encoder inputs(only one/two channel encoder types)

24 V connection and digital I/OOptional I/O

POWERLINK

Motor connections

Figure 4: ACOPOSmicro inverter modules - Operating and connection elements



1.11 Dimensions

65

56895

149

158

134

4.5

Figure 5: Dimensions

1.12 Software

1.12.1 PLCopen motion control function blocks

Motion control is one of the central topics in automation technology. This is due in part to the fact that this areabears a relatively high share of the costs of an entire automation solution. As a result, the potential for savingsare high as well.PLCopen motion control function blocks comply with the IEC 61131-3 standard and support users in this endeavorby offering vendor-independence and reducing overall development times. They provide additional support in thatthey can be used with a wide variety of programming languages, including Ladder Diagram (LD), Structured Text(ST) and the high-level language C.


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The range of functions offered by these blocks are grouped according to single and multi-axis movements. Inaddition to conventional relative and absolute movements, the first of these two groups also includes the possibilityof overlapping movements. With multi-axis movements, functions such as gears, cam profile functions, up/downsynchronization and differential gears (changing the phase angle) are also supported.

1.12.2 Higher productivity with Smart Process Technology

Smart Process Technology meets customer needs for cost-effective solutions and high production speeds. Thisfreely configurable technology library is uniformly integrated into existing motion control products.The use of indirect process parameters makes it possible to eliminate sensors, which are often not fast enoughto keep up with high production speeds. Synchronous processing and short response times make it possible toachieve excellent productivity and precision. In addition, powerful and intelligent decentralized units allow seamlessquality control. In the field, this significantly reduces cycle times while improving component quality.As a result, the demands placed on advanced motion control components high product quality, machine produc-tivity, short maintenan

maacpmicro1-eng.pdf

Documents

manual history

operation inverter modules

safety technologychapter

general informationchapter

maacpmicro1engall information

organization of safety

software names

intended use