Introduction The provide design criteria and specifications used in the procurement and application of motion control. Table of Contents 1. Introduction 2. Design 3. Installation 4. Documentation and Deliverable 5. Products or Material 6. Safety 7. Identification 8. Summaries 1. Introduction Consider all standards described in this document mandatory unless otherwise identified as optional or preferred. Any variance from GMI requirements or preferences requires prior GMI Engineering approval. Obtain approval from the engineer that issued this document or has been designated as responsible for project deliverables. GMI will provide and document specific project requirements and approvals. 2. Design Use the following general design guidelines. Maintain feedback power during a safety stop or e-stop to minimize the recovery time. Resynchronization might be required. Always include a method for locking out the servo motor s electric power. If needed, lockout the servo system as a group. Use an absolute multi-turn encoder for the feedback device. Furnish a homing method via a mechanical reference point, and include a method to jog the axis to the reference point from the HMI. Use overtravel sensors for all linear applications. CIS_303_Servo_Drive_Design_Guidelines_WHQ.doc, 0, October 2005 1
Installation Design all servo voltage levels at 480 Volt, 3 Phase, 60 Hertz. Use SERCOS for coordination from the servo controller to the axis modules. Connect speed reference encoder signals from remote or adjacent machines directly to the auxiliary port on the servo drives. Use appropriate vendor sizing software or similar sizing routines (performed by the OEM) to size each servo axis within the system. Provide documentation of the sizing application. Use a servo-class gear reducer with zero or minimal backlash. Whenever possible, use similar size axis modules and servo motors to minimize spare parts inventories. Plan for integration of motion controls with the human machine interface (HMI) including operations status displays on the HMI, fault handling routines, and trouble shooting features. GMI will provide HMI templates with diagnostics, alarms, and status indications during process design. 3. Installation In general, follow the manufacturer s suggested installation guidelines. Additional requirements include: GMI requires separation of the feedback cabling, and any other sensitive signal cabling, from any power cables. Use separate conduits to provide the cable separation Adjust servo cable lengths to the appropriate application with minimal coiling or looping of the cables. Refer to GMI installation wiring templates for typical installation requirements. High flex cables shall be used in all applications with cable flexing concerns (i.e. applications where the motion produces movement of the cables). CIS_303_Servo_Drive_Design_Guidelines_WHQ.doc, 0, October 2005 2
Documentation and Deliverable Install a local motor disconnect switch on all motors. Make each local motor disconnect switch lockable and suitable as a safety device in compliance with GMI s lockout tagout (LOTO) program. Furnish the local disconnect with an auxiliary contact wired to a PLC input. The preferred disconnect switch is either a Hubbell HBLDS#AC (where # is 3 [30A], 6 [60A], or 10 [100A]) or an Allen- Bradley 194E-CAxxE-P11 (where xx is related to the load size). Install the local disconnect upstream of the LIM (Kinetix) and the amplifiers/axis modules. 4. Documentation and Deliverable Refer to GMI s drawing templates for preferred documentation format and expected content. GMI will provide HMI templates during process design. 5. Products or Material For servo based motion control applications, refer to GMI architecture templates. GMI prefers the Allen-Bradley Kinetix 6000 System. Allen-Bradley ControlLogix 556X processor (RSLogix5000 version 13 or greater). All source code shall be provided. 1756-M0xSE SERCOS interface (where x=3, 8, or 16). For circuit protection, GMI prefers the Line Interface Module (LIM) (2094- BL75S). Follow the manufacturer s recommendations for short circuit protection of the LIM. Axis Modules Integrated Axis Module (IAM) Axis Module Use Allen-Bradley MP-Series motors. In washdown areas, use MP-Series Food Grade motors with motor shaft seal kit. CIS_303_Servo_Drive_Design_Guidelines_WHQ.doc, 0, October 2005 3
Products or Material Figure 1: Allen-Bradley/Kinetix 6000 Hardware ControlLogix Ethernet Kinetix 6000 SERCOS Control the Motion Axis Configuration Diagnostics Servo Motors MPF CIS_303_Servo_Drive_Design_Guidelines_WHQ.doc, 0, October 2005 4
Products or Material The following Bosch-Rexroth (Indramat) System devices may be used with prior approval from GMI Corporate Engineering: PowerPC (PPC) Software: Visual Motion version 10. SERCOS for motion communication coordination. ControlNet/DeviceNet to ControlLogix (machine interface communications) EtherNet for diagnostic purposes. Amplifiers Software: DriveTop version 9. Ecodrive Indradrive MKD-Series motors. Figure 2: Bosch Rexroth Motion Hardware ControlLogix Machine Control Communication Ethernet* 1 or ControlNet Scheduled/Unscheduled High speed machine control Power PC (PPC) * Ethernet TCP/IP Ethernet* 2 PPC Application Programming Backup/Restore App. Drive Configuration Controller Diagnostics OPC Server to HIM EcoDrive SERCOS Control the Motion Axis Configuration Diagnostics Servo Motors MKD CIS_303_Servo_Drive_Design_Guidelines_WHQ.doc, 0, October 2005 5
Safety 6. Safety Refer to GMI templates and typical examples of the safety circuits to meet the requirements of a NFPA Category 0 Stop (immediate removal of power to the motor) or Category 1 stop (controlled stop, then removal of power to the motor). In addition, design E-stops to meet the requirements of EN 954-1:1997; Risk Category 3. Remove power by electromechanical components (NFPA-79). Make sure that resetting of any safety circuit device does not initiate any hazardous conditions. Avoid automatic equipment restart when an e-stop button is pulled out or a safety gate is closed. Refer to the servo manufacturer s documentation for additional safety considerations. The following drawings show a typical safety circuit installation using a servo system: CIS_303_Servo_Drive_Design_Guidelines_WHQ.doc, 0, October 2005 6
Safety CIS_303_Servo_Drive_Design_Guidelines_WHQ.doc, 0, October 2005 7
Identification 7. Identification Label all motors at a permanent location near, but not on, the motor or gear reducer. Make sure the label contains motor tag number (refer to the equipment tagging guidelines), the common name (such as PRODUCT PUMP 3), and starter location. Label cabinets or enclosures that house contactors, starters, or other control devices on the outside with the source of the electrical power used. This might be the number of a specific MCC or a breaker number from a lighting distribution panel or general utility power panel. Label all major components (such as axis modules, motor starters, or local disconnects) as identified on the schematic diagrams. Identify all wires at each termination. Use wire markers to identify a unique number that corresponds to the schematic diagram. When the wires are part of a PLC system, label them with the same number as the input or output points of the PLC. CIS_303_Servo_Drive_Design_Guidelines_WHQ.doc, 0, October 2005 8
Summaries 8. Summaries Enter information in these tables to track revisions to the master document. NOTE: In the Entry column, enter your information between the dashes. The entries automatically update matching document properties. Document Property Entry Master Owner Master Number -0- -Daniel Migliori- Increment revision numbers by one. Master Date -4/22/05- Number Date Owner Summary (Brief description of major changes) 0 4/22/2005 Daniel Migliori Original Development CIS_303_Servo_Drive_Design_Guidelines_WHQ.doc, 0, October 2005 9
Summaries 8.1 Plant Customization Tracking Enter information in these tables to track revisions to plant customized documents. NOTE: In the Entry column, enter your information between the dashes. The entries automatically update document properties. Document Property Entry Plant Code -XXX- Plant Owner -Enter Name- Plant Number -0.0- Plant Date -3/29/05- Use the following format for the Plant Number: <Master Number>.<Plant Number> Number Date Owner Summary (Brief description of major changes) 0 CIS_303_Servo_Drive_Design_Guidelines_WHQ.doc, 0, October 2005 10