SEW MOVIDYN ® Series servo controller

Overview

Name: MOVIDYN ®  Servo Controllers Operating Instructions

Core purpose: To guide the safe installation, start-up, operation, and maintenance of this series of servo controllers, suitable for driving permanent magnet synchronous servo motors in industrial and commercial systems (requiring adaptation to frequency converters)

Prohibited use scenarios:

Explosion-proof area

Exposure to harmful oils, acids, gases, dust, radiation, and other environments

Non fixed applications with mechanical vibrations and impacts exceeding the requirements of EN 50178

Undertaking equipment and personnel safety functions without a high-level security system

Safety and Equipment Fundamentals

Security level and consequences

Possible consequences of hazardous types

Serious electrical hazards or fatal injuries

Immediate danger, serious or fatal injury

Minor injury in dangerous scenarios

Harmful scenario equipment or environmental damage

Equipment classification and identification

Product Series:

MPR/MPB: Power module (MPB includes brake chopper, MPR is regenerative power unit)

MAS: Axis Module (Independent Axis Control)

MKS: Compact servo controller (integrated power and axis control functions)

Model interpretation: including information on rated current/power, voltage, design type, etc. (such as MAS51A005-503-00:5A, 380-500V, standard design)

Standard accessories:

Shielding clip (used for motor/braking resistor/signal cable shielding connection)

Tab slot (supporting AIO11/AFC11 and other functional extensions)

Status LED (3 LEDs for power module, 7-segment code display for shaft module/compact controller)

Installation requirements

Basic installation parameters

Specific standards for required types

Tightening torque MKS: 1.5 Nm; MPB/MPR/MAS：3.5 Nm

Installation spacing at top/bottom ≥ 100mm; multiple heat sinks need to be connected with bridging components

The installation posture is only vertical, and the module needs to be completely fixed on a single heat sink

The cable requirement is that the motor cable should be up to 100m long, and the resolver cable should be up to 100m long (0.25mm ² for ≤ 50m, 0.5mm ² for>50m)

Wiring and Protection

Grounding requirements: The PE conductor should have the same cross-section as the power line, and the module casing should be in metal contact with the switchgear mounting plate for grounding

Bus connection:

RS-485: Up to 32 units, cable length ≤ 200m, requires twisted pair shielded cable+0V5 reference potential line

EMC protection: NF series filters are required on the input side, and HD series reactors or shielded motor cables are required on the output side; Control cables and power cables are routed in separate slots, with both ends of the shielding layer grounded

UL Compliance Requirements

Cable specification: Only use 60/75 ℃ copper cable

Fuse selection: Suitable according to module type, maximum voltage 500VAC, current 30-10000AAC

Tightening torque: MKS is 1.5 Nm, other modules are 3.5 Nm

Start the process

Starting premise

Complete installation inspection, disconnect X21 terminal to prevent accidental motor start-up

Axis address setting: Set through the S1 button (0-59), multi axis systems need to avoid duplicate addresses

Initiate core steps

Step operation content

1. Connect PC to controller (MPB/MPR via RS-232, MKS via USS21A options)

Install and start the MD_SHELL software, configure the PC interface (COM port) and controller address

3. Enter motor parameters (model, rated voltage/speed/current, braking type, etc.)

4. Configure controller parameters (damping coefficient 0.5-2.0, stiffness coefficient 0.5-2.0, etc.)

5 programming terminal functions (binary input/output allocation, such as limit switches, brake control)

6. Transfer parameters to the controller and optimize control parameters through MD_SCOPE (optional)

Key Settings

Braking control: External relays/contactors need to be controlled through X21.9 terminals, and direct driving of braking is prohibited (maximum 150mA)

Limit switch: When not connected, X21.7/X21.8 should be short circuited to+24V, otherwise F27 fault will be triggered

Operation and maintenance

Operation display

Power module LED:

ON (green): ready; 24V (green): 24V power supply is normal; TRIP (red): Fault

7-segment code display: contains 16 states (such as “1”=speed control enabled, “F”=fault flashing, “b”=not ready)

Fault handling

Fault storage: Record fault codes and the operating status at the time of triggering (current, speed, etc.)

Reset method:

Power off and restart (waiting for ≥ 10 minutes)

Manual reset (P632, via terminal or software)

Automatic reset (P630, up to 5 times, restart time 3-30s)

Common faults and solutions:

Fault code description and handling measures

F01 overcurrent check motor/cable short circuit, replace module if damaged

F07 DC bus overvoltage extension deceleration ramp, check the brake resistor wiring

F14 Resolver fault check Resolver cable connection and shielding

F27 limit switch cable missing inspection limit switch wiring, if not in use, short-circuit the terminal

Parameter Settings

Core parameter category:

Set value/slope: speed range -5000~5000 rpm, slope time 0.00~30s

Controller parameters: Speed controller gain (0.10-32.00), time constant (0-300ms)

Monitoring function: speed monitoring (P510), current reference value (P410)

Special functions: Factory reset (P610), parameter locking (P640)

Technical data

General Parameters

Working temperature: 0-45 ℃ (without capacity reduction), with a capacity reduction of 3% for every 1K increase in temperature between 45-60 ℃

Storage temperature: -25~70 ℃

Protection level: IP20 (EN 60529)

Installation height: ≤ 1000m (over 1000m, capacity reduction of 1% per 100m)

Core module technical data (example)

Module type Rated power Rated current Weight (kg) Size (W × H × D, mm)

MAS51A005 – 5 AAC 3.5 70×380×250

MPB51A011 11 kW 16 AAC 5.5 105×380×250

MKS51A015 – 15 AAC 6.5 130×336×325