Installation and Maintenance Manual Stepper Motor Controller

Installation and Maintenance Manual Stepper Motor Controller
LECP6-TFM107 Draft
Installation and Maintenance Manual
Stepper Motor Controller (24VDC)
Series LECP6
Applicable model number
LEC*****-*
Safety Instructions
This manual contains essential information for the protection of users and
others from possible injury and/or equipment damage.
• Read this manual before using the product to ensure correct handling
and also read the manuals of related apparatus before use.
• Keep this manual in a safe place for future reference.
• These instructions indicate the level of potential hazard by label of
“Caution”, “Warning” or “Danger”, followed by important safety
information which must be carefully followed.
• To ensure safety of personnel and equipment the safety instructions in
this manual and the product catalogue must be observed, along with
other relevant safety practices.
Caution
Warning
Danger
Indicates a hazard with a low level of risk.
Which if not avoided, could result in minor or
moderate injury.
Indicates a hazard with a medium level of risk.
Which if not avoided, could result in death or
serious injury.
Indicates a hazard with a high level of risk.
Which if not avoided, will result in death or
serious injury.
• Electromagnetic compatibility: This product is class A equipment that is
intended for use in an industrial environment. There may be potential
difficulties in ensuring electromagnetic compatibility in other
environments due to conducted as well as radiated disturbances.
Warning
• Do not disassemble, modify (including change of printed circuit
board) or repair the product.
An injury or product failure may result.
• Do not operate the product beyond the specification range.
Fire, malfunction or equipment damage may result.
Use the product only after confirming the specifications.
• Do not use the product in the presence of flammable, explosive or
corrosive gas.
Fire, explosion or corrosion may result.
This product does not have an explosion proof construction.
• When using the product as part of an interlocking system:
Provide a double interlocking system, for example a mechanical system.
Check the product regularly to ensure correct operation.
• Before performing maintenance, be sure of the following:
Turn off the power supply.
Caution
• Always perform a system check after maintenance.
Do not use the product if any error occurs.
Safety cannot be assured if caused by un-intentional malfunction.
• Provide grounding to ensure correct operation and to improve
noise resistance of the product.
This product should be individually grounded using a short cable.
• Follow the instructions given below when handling the product.
Failing to do so may result in product damage.
• Maintenance space should always be provided around the product.
• Do not remove labels from the product.
• Do not drop, hit or apply excessive shock to the product.
• Unless stated otherwise, follow all specified tightening torques.
• Do not bend, apply tensile force, or apply force by placing heavy
loads on the cables.
1 Safety Instructions (continued)
2 General Instructions (continued)
• Connect wires and cables correctly and do not connect while the
power is turned on.
• Do not route input/output wires and cables together with power or
high-voltage cables.
• Check the insulation of wires and cables.
• Take appropriate measures against noise, such as noise filters,
when the product is incorporated into other equipment or devices.
• Take sufficient shielding measures when the product is to be used
in the following conditions:
• Where noise due to static electricity is generated.
• Where electro-magnetic field strength is high.
• Where radioactivity is present.
• Where power lines are located.
• Do not use the product in a place where electrical surges are
generated.
• Use suitable surge protection when a surge generating load such
as a solenoid valve is to be directly driven.
• Prevent any foreign matter from entering this product.
• Do not expose the product to vibration or impact.
• Use the product within the specified ambient temperature range.
• Do not expose the product to any heat radiation.
• Use a precision screwdriver with flat blade to adjust the DIP switch.
• Close the cover over the switches before power is turned on.
• Do not clean the product with chemicals such as benzene or
thinners.
• Confirm correct insulation of the product.
Poor insulation of wires, cables, connectors, terminals etc. can cause
interference with other circuits. Also there is the possibility that excessive
voltage or current may be applied to the product causing damage.
2 General Instructions
2.1 Wiring
Warning
• Adjusting, mounting or wiring change should not be done before
disconnecting the power supply to the product.
Electrical shock, malfunction and damage can result.
• Do not disassemble the cables.
• Use only specified cables.
• Do not connect or disconnect the wires, cables and connectors
when the power is turned on.
Caution
• Wire the connector correctly and securely.
Check the connector for polarity and do not apply any voltage to the
terminals other than those specified in the Operation Manual.
• Take appropriate measures against noise.
Noise in a signal line may cause malfunction. As a countermeasure
separate the high voltage and low voltage cables, and shorten the wiring
lengths, etc.
• Do not route input/output wires and cables together with power or
high voltage cables.
The product can malfunction due to interference of noise and surge
voltage from power and high voltage cables to the signal line. Route the
wires of the product separately from power or high voltage cables.
• Take care that actuator movement does not catch cables.
• Operate with all wires and cables secured.
• Avoid bending cables at sharp angles where they enter the product.
• Avoid twisting, folding, rotating or applying an external force to the
cable.
Risk of electric shock, wire breakage, contact failure and loss of control
of the product can happen.
• Fix the motor cables protruding from the actuator in place before
use.
The motor and lock cables are not robotic type cables and can be
damaged when moved.
• The actuator cables connecting the actuator and the controller are
robotic type cables. But should not be placed in a flexible moving
tube with a radius smaller than the specified value. (Min. 50 mm)
2.2 Transportation
Caution
• Do not carry or swing the product by the cables.
2.3 Mounting
Warning
• Observe the tightening torque for screws.
Unless stated otherwise, tighten the screws to the recommended torque
for mounting the product.
• Do not make any alterations to this product.
Alterations made to this product may lead to a loss of durability and
damage to the product, which can lead to human injury and damage to
other equipment and machinery.
• When an external guide is used, connect the moving parts of the
product and the load in such a way that there is no interference at
any point within the stroke.
Do not scratch or dent the sliding parts of the table or mounting face etc.,
by striking or holding them with other objects. The components are
manufactured to precise tolerances, so that even a slight deformation
may cause faulty operation or seizure.
• Do not use the product until you verify that the equipment can be
operated correctly.
After mounting or repair, connect the power supply to the product and
perform appropriate functional inspections to check it is mounted
correctly.
• When attaching to the work piece, do not apply strong impact or
large moment.
If an external force over the allowable moment is applied, it may cause
looseness in the guide unit, an increase in sliding resistance or other
problems.
• Maintenance space
Allow sufficient space for maintenance and inspection.
2.4 Handling
Warning
• Do not touch the motor while in operation.
The surface temperature of the motor can increase to approx. 90°C to
100°C due to operating conditions.
Energizing alone may also cause this temperature increase.
As it may cause burns, do not touch the motor when in operation.
• If abnormal heating, smoking or fire, etc. occurs in the product,
immediately turn off the power supply.
• Immediately stop operation if abnormal operation noise or vibration
occurs.
If abnormal operation noise or vibration occurs, the product may have
been mounted incorrectly. Unless operation of the product is stopped for
inspection, the product can be seriously damaged.
• Never touch the rotating part of the motor or the moving part of the
actuator while in operation.
There is a serious risk of injury.
• When installing, adjusting, inspecting or performing maintenance
on the product, controller and related equipment, be sure to turn off
the power supply to each of them. Then, lock it so that no one other
than the person working can turn the power on, or implement
measures such as a safety plug.
• In the case of the actuator that has a servo motor (24VDC), the
“motor phase detection step" is done by inputting the servo on
signal just after the controller power is turned on.
The “motor phase detection step” operates the table/rod to the
maximum distance of the lead screw. (The motor rotates in the
reverse direction if the table hits an obstacle such as the end stop
damper.) Take the “motor phase detection step” into consideration
for the installation and operation of this actuator
2 General Instructions (continued)
Caution
• Keep the controller and product combined as delivered for use.
The product is set in parameters for shipment.
If it is combined with a different product parameter, failure can result.
• Check the product for the following points before operation.
• Damage to electric driving line and signal lines.
• Looseness of the connector to each power line and signal line.
• Looseness of the actuator/cylinder and controller/driver mounting.
• Abnormal operation.
• Stop function
• When more than one person is performing work, decide on the
procedures, signals, measures and resolution for abnormal
conditions before beginning the work.
• Also designate a person to supervise the work, other than those
performing the work.
• An operation test should be performed at low speed, start the test
at a predefined speed, after confirming there are no problems.
• Actual speed of the product will be changed by the workload.
Before selecting a product, check the catalogue for the instructions
regarding selection and specifications.
• Do not apply a load, impact or resistance in addition to a
transferred load during return to origin.
In the case of the return to origin by pushing force, additional force will
cause displacement of the origin position since it is based on detected
motor torque.
• Do not remove the nameplate.
2.5 Actuator with lock
Warning
• Do not use the lock as a safety lock or a control that requires a
locking force.
The lock used for the product with a lock is designed to prevent dropping
of work piece.
• For vertical mounting, use the product with a lock.
If the product is not equipped with a lock, the product will move and drop
the work piece when the power is removed.
• "Measures against drops” means preventing a work piece from
dropping due to its weight when the product operation is stopped
and the power supply is turned off.
• Do not apply an impact load or strong vibration while the lock is
activated.
If an external impact load or strong vibration is applied to the product, the
lock will lose its holding force and damage to the sliding part of the lock
or reduced lifetime can result. The same situation will happen when the
lock slips due to a force higher than its holding force, as this will
accelerate the wear to the lock.
• Do not apply liquid, oil or grease to the lock or its surroundings.
When liquid, oil or grease is applied to the sliding part of the lock, its
holding force will be reduced significantly.
• Take “measures against drops” and check that safety is assured
before mounting, adjustment and inspection of the product.
If the lock is released with the product mounted vertically, a work piece
can drop due to its weight.
2.6 Please refer to the auto switch references in “Best Pneumatics “
when an auto switch is to be used.
2.7 Unpacking
Caution
• Check the received product is as ordered.
If a different product is installed from the one ordered, injury or damage
could result.
LECP6-TFM107 Draft
4 Installation (continued)
3 Specifications
Item
Compatible motor
Controller power supply Note1)
Parallel input
Parallel output
Compatible encoder
Serial communication
Memory
LED indicator
Lock control
Cable length (m)
Cooling system
Operating temperature range
(oC)
Operating humidity range (%)
Storage temperature range ( oC)
Storage humidity range (%)
Insulation resistance
Weight (kg)
Specifications
Step motor (Servo 24VDC)
Rated voltage: 24VDC ±10%
Max current consumption: 3A (Peak 5A) Note2)
(For powering the motor drive, controller, stop
and lock release)
11 inputs (photo-coupler isolation)
13 outputs (photo-coupler isolation)
A/B phase, Line receiver input
Resolution: 800 pulse/rev
Conforming to RS485.
EEPROM
2 off LED’s (green and red):
Forced lock-release terminal
I/O cable: 5 or less
Actuator cable: 20 or less
Natural air cooling
6 Wiring
6 Wiring (continued)
• Grounding the controller
As shown in the diagram, connect the grounding wire with a screw.
The controller must be grounded to shield it from electrical noise.
The M4 screw, cable with crimping terminal and toothed washer should
be obtained separately by the customer.
Parallel I/O cable wiring for connection to controller CN5 connector
M4 screw
Toothed
washer
ble with
c
• Parallel I/O wiring for NPN and PNP connection
0 to 40 (without condensation or freezing)
35 to 85 (without condensation or freezing)
-10 to 60 (without condensation or freezing)
35 to 85 (without condensation or freezing)
Between the housing (radiation fin) and FG
50MΩ
Ω (500VDC)
0.15 (screw mounting type)
0.17 (DIN rail mounting type)
Controller
Caution
Warning
The product should be connected to a ground. The cross-sectional area of
2
this wire shall be a minimum of 2 mm . The grounding point should be as
near to the controller as possible to keep the wire length short.
Note1) Do not use a power supply with “inrush-current control” for the controller
power supply.
Note2) The power consumption changes depending on the actuator model.
Please refer to the specifications of actuator for more details.
Recommended: Functional ground
4 Installation
• Do not use the stop signal, "EMG" of controller and stop switch on
the teaching box as the emergency stop of system.
The stop signal, "EMG" of controller and the stop switch on the teaching
box are for decelerating and stopping the actuator.
Design the system with an emergency stop circuit, which complies with
safety standards.
Not recommended: Ground scheme
5 Names and Functions of individual parts
• How to install
•Screw mounting type (LECP6**-*) installation using two M4 screws
Caution
• Wiring of power supply plug for controller connector CN1
Connect the positive terminal of the 24 VDC controller power supply to
the C24V and M24V terminals of the power supply plug and connect the
negative terminal of the 24 VDC controller power supply to the 0V
terminal of the power supply plug.
• For actuators fitted with a lock, fit a lock release switch
Connect the lock release switch to the supply plug BK RLS terminal.
Caution
The 24 VDC power supply for the I/O connector CN5 should be separate
from the 24 VDC power supply for the controller connector CN1.
When connecting a PLC etc. to the controller parallel I/O CN5 connector,
use the I/O cable LEC-CN5-*.
• Pin out for I/O cable LEC-CN5-*
• See the power supply plug drawing below for connection details
• DIN-rail mounting type (LECP6**D-*) installation onto the DIN rail
Controller to DIN rail is unlocked
Controller to DIN rail is locked
No.
Label
Name
1
PWR
Power LED (green)
2
ALM
3
CN5
4
CN4
5
CN3
6
CN2
Power LED (red)
Parallel I/O
Connector (26 pins)
Serial I/O
Connector (9 pins)
Encoder connector (16 pins)
Motor power connector
(6 pins)
7
8
9
10
CN1
-
Power connector
(5 pins)
Compatible actuator label
Product label
FG
Description
Power ON/No alarm: Green light.
The green LED flashes while data (step data/
parameters) is being written.
Power ON/Alarm: Red light.
Used to connect PLC, etc. with the I/O cable.
(11 inputs and COM, 13 outputs and COM)
Do not wire the power supply plug incorrectly as this will result in
damage to the controller.
Used to connect the teaching box, PC, etc.
Used to connect the actuator cable.
Used to connect the controller input power
supply with the power supply plug:
Common power (-),
Motor power (+),
Control power (+),
Stop signal (+),
Lock release (+)
The label indicating the applicable actuator
model.
It also indicates the type of the parallel I/O
(PNP/NPN).
The label indicating the part number of the
controller.
Functional ground
Caution
Hook the controller onto the DIN rail and
press the lever in the direction of the arrow
to lock the controller to the DIN rail.
Warning
The green LED flashes while the data (step data/ parameters) is being
written.
Do not turn off the controller input power supply or remove the cable
while the data is being written (while the green LED is flashing).
* The data (step data/ parameters) may not be written correctly.
7 Maintenance
• Perform a maintenance check periodically
Confirm wiring and screws are not loose.
Warning
• Do not disassemble or repair the product.
Fire or electric shock can result.
• Before modifying or checking the wiring, the voltage should be
checked with a tester 5 minutes after the power supply is turned
off.
Electrical shock can result.
LECP6-TFM107 Draft
8 CE Directive
8 CE Directive (continued)
The LE series of actuators, motor controllers and teaching box
conform to the EU EMC directive, if they are installed in accordance
with the following instructions.
These components are intended for incorporation into machinery and
assemblies forming part of a larger system.
The CE compliance was achieved when the above three components
were connected as shown in the diagram below.
• P-Clip or U-Clip installation
The function of the P-clip or U-clip is to provide a 360° metallic contact
and is a convenient method of ensuring an effective RF ground.
When dealing with EMI issues it is important to know that the DC
connection does not maintain the integrity of an AC high frequency
connection. High frequency bonding typically involves using wide flat
cabling to establish an effective system ground. When applied correctly
the P-clip or the U-clip will provide a high frequency connection.
When installing a P-clip or U-clip (see figure below) install the clips as
close to the cable ends as possible. In order to provide a suitable ground
connection surface, it may be necessary to remove the paint from the
panel or the cabinet, an earth stud or a bus bar are also acceptable.
Remove only the outer vinyl jacket of the braided screened cable (this
allows the cable braid to connect to the P-clip or U clip). Take care not to
damage the braiding. Snap the P-Clip or the U-Clip over the exposed
braiding and adjust for a tight fit. Secure the clip to the designated
ground with a machine screw and lock washer. The use of a brass or
other conductive insert is recommended. Soldering a pigtail to the cable
shield is not a suitable method for providing good RF ground.
Please note that the EMC changes according to the configuration of
the customers control panel and the relationship with other electrical
equipment and wiring. Therefore conformity to the EMC directive
cannot be certified for SMC components incorporated into the
customer’s equipment under actual operating conditions. As a result
it is necessary for the customer to verify conformity to the EMC
directive for the machinery and equipment as a whole.
(1)
(7)
(3)
(8)
(4)
(9)
(7)
(9)
(7)
(5)
(7)
(6)
Frame Ground
Ground
(2)
• Grounding the actuator
Please refer to the IMM of the actuator being used, for information on
actuator grounding.
• Machinery parts list
Part no./Material
No. Part name
1 Motor controller
LECP6 Series
2 Actuator
LE Series
3 Teaching box
LEC-T1 Series
4 I/O cable (with shield)
LEC-CN5-[]
5 Power supply cable
5 wire with shield
(with shield)
(5 m)
6 Actuator cable
LEC-CP-[]
7 P-clip (for shield ground)
Metal
8 Programmable controller
–
9 Switching power supply
–
The LECP6** controller should be mounted in an IP54 rated metal cabinet
for protection from ESD.
Caution
Note: During installation and maintenance protect the LEC controller
from electrostatic discharge (ESD)
The metal cabinet should be grounded with a short grounding cable.
Contacts
All shielded cables must be grounded inside the cabinet using suitable
metal P-Clip or U-Clip as shown.
The shielded cables are:
• 24 VDC Power cable from power supply to LECP6** series controller
• The Input/output cable from controller to PLC
• Grounding the controller
Please refer to the “Installation” section
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URL :
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http// www.smceu.com (Europe)
Specifications are subject to change without prior notice from the manufacturer.
© 2009 SMC Corporation All Rights Reserved.
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