Anwenderhandbuch

ACOPOS

Perfection in Automation

MAACP2-0
ACOPOS
User´s Manual
 ACOPOS
USER'S MANUAL

Version: 1.0 (February 2002)

Mod. No.: MAACP2-E

We reserve the right to change the contents of this manual without warning. The information
contained herein is believed to be accurate as of the date of publication, however, Bernecker +
Rainer Industrie-Elektronik Ges.m.b.H. makes no warranty, expressed or implied, with regards
to the products or the documentation contained within this book. Bernecker + Rainer Industrie-
Elektronik Ges.m.b.H. shall not be liable in the event of incidental or consequential damages in
connection with or arising from the furnishing, performance or use of these products. The
software names, hardware names and trademarks used in this document are registered by the
respective companies.

ACOPOS User's Manual 1

2 ACOPOS User's Manual
 CHAPTER 1: GENERAL INFORMATION

CHAPTER 2: TECHNICAL DATA

CHAPTER 3: INSTALLATION

CHAPTER 4: DIMENSIONING

CHAPTER 5: WIRING

CHAPTER 6: GETTING STARTED

ACOPOS User's Manual 3

4 ACOPOS User's Manual
 CHAPTER 7: STANDARDS AND CERTIFICATIONS

INDEX

ACOPOS User's Manual 5

6 ACOPOS User's Manual
 Table of Contents

Chapter 1: General Information ..................................................... 13

1. ACOPOS Servo Family ...................................................................................................... 13
1.1 Secure Operation .......................................................................................................... 13
1.2 Taking it to the Limit ...................................................................................................... 14
1.3 Individual I/O Configurations ......................................................................................... 15
1.4 Configuring Instead of Programming ............................................................................. 15
1.5 Easy Service ................................................................................................................. 15
1.6 Software and Hardware as a Unit ................................................................................. 16
1.7 Plain Text for Functions ................................................................................................. 16
1.8 Simple Function Test ..................................................................................................... 17
1.9 Control Trigger .............................................................................................................. 18
1.10 Cam Profiles for Everyone .......................................................................................... 19
2. ACOPOS Configurations .................................................................................................... 20
2.1 CAN ............................................................................................................................... 20
2.1.1 Configuration 1 ........................................................................................................ 20
2.1.2 Configuration 2 ........................................................................................................ 21
2.2 Powerlink ....................................................................................................................... 22
2.2.1 Configuration 1 ........................................................................................................ 22
2.2.2 Configuration 2 ....................................................................................................... 23
3. Safety Guidelines ................................................................................................................ 24
3.1 General Information ....................................................................................................... 24
3.2 Intended Use ................................................................................................................. 24
3.3 Transport and Storage .................................................................................................. 25
3.4 Installation ..................................................................................................................... 25
3.5 Operation ....................................................................................................................... 25
3.5.1 Protection against Touching Electrical Parts .......................................................... 25
3.5.2 Protection from Dangerous Movements ................................................................. 26
3.6 Safety Notices ............................................................................................................... 27

Chapter 2: Technical Data .............................................................. 29

1. ACOPOS Servo Family ...................................................................................................... 29
1.1 Modular Servo Drive Concept ....................................................................................... 29
1.2 General Description ....................................................................................................... 30
1.3 Status LEDs .................................................................................................................. 31
1.3.1 LED Status .............................................................................................................. 32
1.4 ACOPOS 1022, 1045 and 1090 .................................................................................... 34
1.4.1 Order Data ............................................................................................................. 34
1.4.2 Technical Data ........................................................................................................ 34
1.5 ACOPOS 1180, 1320 .................................................................................................... 36
1.5.1 Order Data .............................................................................................................. 36
1.5.2 Technical Data ........................................................................................................ 36
1.6 ACOPOS 1640, 128M ................................................................................................... 38
1.6.1 Order Data .............................................................................................................. 38
1.6.2 Technical Data ........................................................................................................ 38
2. ACOPOS Plug-in Modules .................................................................................................. 40
2.1 General Information ....................................................................................................... 40

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2.2 Module Overview ........................................................................................................... 40

2.3 AC110 - CAN Interface .................................................................................................. 41
2.3.1 General Description ................................................................................................ 41
2.3.2 Order Data .............................................................................................................. 41
2.3.3 Technical Data ........................................................................................................ 41
2.3.4 CAN Node Number Settings ................................................................................... 42
2.3.5 Indications ............................................................................................................... 42
2.4 AC112 - Ethernet Powerlink Interface ........................................................................... 43
2.4.1 General Description ................................................................................................ 43
2.4.2 Order Data .............................................................................................................. 43
2.4.3 Technical Data ........................................................................................................ 43
2.4.4 Powerlink Node Number Setting ............................................................................. 44
2.4.5 Status LEDs ............................................................................................................ 45
2.5 AC120 - EnDat Encoder Interface ................................................................................. 47
2.5.1 General Description ................................................................................................ 47
2.5.2 Order Data .............................................................................................................. 48
2.5.3 Technical Data ........................................................................................................ 49
2.6 AC122 - Resolver Interface ........................................................................................... 50
2.6.1 General Description ................................................................................................ 50
2.6.2 Order Data .............................................................................................................. 51
2.6.3 Technical Data ........................................................................................................ 51
2.7 AC123 - Incremental Encoder and SSI Absolute Encoder Interface ............................. 53
2.7.1 General Description ................................................................................................ 53
2.7.2 Order Data .............................................................................................................. 53
2.7.3 Technical Data ........................................................................................................ 54
2.8 AC130 - Digital Mixed Module ....................................................................................... 56
2.8.1 General Description ................................................................................................ 56
2.8.2 Order Data .............................................................................................................. 56
2.8.3 Technical Data ........................................................................................................ 57
3. Cables ................................................................................................................................. 60
3.1 General Information ....................................................................................................... 60
3.1.1 Manufactured Cables .............................................................................................. 60
3.2 Motor Cables ................................................................................................................. 61
3.2.1 Order Data ............................................................................................................. 61
3.2.2 Cable Specification ............................................................................................... 63
3.3 EnDat Cables ................................................................................................................ 66
3.3.1 Order Data ............................................................................................................. 66
3.3.2 Cable Specification ................................................................................................. 66
3.4 Resolver Cables ............................................................................................................ 68
3.4.1 Order Data ............................................................................................................. 68
3.4.2 Cable Specification ................................................................................................. 69
4. Connectors ......................................................................................................................... 70
4.1 General Information ....................................................................................................... 70
4.2 Motor Connectors .......................................................................................................... 71
4.2.1 Order Data ............................................................................................................. 71
4.2.2 Specifications for 8PM001.00-1 and 8PM002.00-1 ............................................... 72
4.2.3 Specifications for 8PM003.00-1 ............................................................................. 73

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4.3 Encoder Connectors ...................................................................................................... 74

4.3.1 Order Data .............................................................................................................. 74
4.3.2 Specifications for EnDat Connector 8PE001.00-1 .................................................. 75
4.3.3 Specifications for Resolver Connector 8PR001.00-1 ............................................. 76

Chapter 3: Installation .................................................................... 77

1. General Information ............................................................................................................ 77
2. Dimensional Diagram and Installation Dimensions ............................................................ 79
2.1 ACOPOS 1022, 1045, 1090 ........................................................................................ 79
2.2 ACOPOS 1180, 1320 ................................................................................................... 80
2.3 ACOPOS 1640 ............................................................................................................. 81
2.4 ACOPOS 128M ............................................................................................................ 82
3. Installation and Removal of Plug-in Modules ...................................................................... 83
3.1 General Information ....................................................................................................... 83
3.1.1 Installation ............................................................................................................... 83
3.1.2 Removal .................................................................................................................. 84
4. Installing Various ACOPOS Series Devices Directly Next to Each Other .......................... 85
5. Using Cooling Aggregates in Switching Cabinets ............................................................... 87

Chapter 4: Dimensioning ............................................................... 91

1. Power Mains Connection .................................................................................................... 91
1.1 General Information ....................................................................................................... 91
1.1.1 System Configuration .............................................................................................. 91
1.1.2 Supply Voltage Range ............................................................................................ 91
1.1.3 Protective Ground Connection (PE) ........................................................................ 92
1.2 Dimensioning ................................................................................................................. 93
1.2.1 Individual ACOPOS Power Mains Connections ...................................................... 93
1.2.2 Implementing ACOPOS Power Mains Connections for Drive Groups .................... 96
1.3 Fault Current Protection ................................................................................................ 97
1.3.1 Rated Fault Current ................................................................................................ 97
1.3.2 Estimating the Discharge Current ........................................................................... 98
1.3.3 Manufacturer Used ................................................................................................. 98
2. DC Bus ............................................................................................................................... 99
2.1 General Information ....................................................................................................... 99
2.2 Wiring .......................................................................................................................... 100
2.3 Equal Distribution of the Applied Power via the Power Rectifiers ............................... 101
2.4 Equal Distribution of the Brake Power on the Braking Resistors ................................ 101
3. Motor Connection ............................................................................................................. 102
4. Braking Resistor ............................................................................................................... 104
4.1 General Information ..................................................................................................... 104
4.2 Braking Resistor Connection ....................................................................................... 105
4.3 Dimensioning the Brake Resistor ................................................................................ 106
4.4 Setting Brake Resistor Parameters ............................................................................. 109
5. Current Requirements of ACOPOS Plug-in Modules ....................................................... 110
6. Formula Variables Used .................................................................................................. 111

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 Table of Contents

Chapter 5: Wiring .......................................................................... 113

1. General Information .......................................................................................................... 113
1.1 Electromagnetic Compatibility of the Installation ......................................................... 113
1.1.1 General Information .............................................................................................. 113
1.1.2 Installation Notes .................................................................................................. 114
1.2 Secure Restart Inhibit .................................................................................................. 117
1.2.1 General Information .............................................................................................. 117
1.2.2 Principle - Realization of the Safety Function ....................................................... 118
1.2.3 External Wiring ...................................................................................................... 119
1.3 Overview of the Terminal Cross Sections ................................................................. 129
2. Connections ACOPOS 1022, 1045, 1090 ...................................................................... 130
2.1 Pin Assignments for Plug X1 ....................................................................................... 131
2.2 Pin Assignments for Plug X2 ....................................................................................... 131
2.3 Pin Assignments for Plug X3 ....................................................................................... 132
2.4 Pin Assignments for Plug X4 ....................................................................................... 132
2.5 Pin Assignments for Plug X5 ....................................................................................... 132
2.6 Protective Ground Connection (PE) ............................................................................ 133
3. Connections ACOPOS 1180, 1320 ................................................................................ 134
3.1 Pin Assignments for Plug X1 ....................................................................................... 135
3.2 Pin Assignments for Plug X2 ....................................................................................... 135
3.3 Pin Assignments for Plug X3 ....................................................................................... 136
3.4 Pin Assignments for Plug X4 ....................................................................................... 136
3.5 Pin Assignments for Plug X5 ....................................................................................... 137
3.6 Pin Assignments for Plug X6 ....................................................................................... 137
3.7 Protective Ground Connection (PE) ............................................................................ 138
4. Connections ACOPOS 1640, 128M ............................................................................... 139
4.1 Pin Assignments for Plug X1 ................................................................................... 140
4.2 Pin Assignments for X2 ............................................................................................. 141
4.3 Pin Assignments for X3 ............................................................................................. 141
4.4 Pin Assignments for Plug X4 .................................................................................... 142
4.5 Pin assignments for X5 ............................................................................................. 143
4.6 Pin Assignments for X6 ............................................................................................. 143
5. Plug-in Module Connections ............................................................................................. 144
5.1 AC110 - CAN Interface ................................................................................................ 144
5.1.1 Pin Assignments ................................................................................................... 144
5.2 AC112 - Ethernet Powerlink Interface ......................................................................... 145
5.2.1 Pin Assignments .................................................................................................. 145
5.3 AC120 - EnDat Encoder Interface ............................................................................... 146
5.3.1 Pin Assignments ................................................................................................... 146
5.4 AC122 - Resolver Interface ......................................................................................... 147
5.4.1 Pin Assignments ................................................................................................... 147
5.5 AC123 - Incremental Encoder and SSI Absolute Encoder Interface ........................... 148
5.5.1 Pin Assignments .................................................................................................. 148
5.6 AC130 - Digital Mixed Module ..................................................................................... 149
5.6.1 Pin Assignments ................................................................................................... 149
5.7 Connecting Cables to Plug-in Modules ....................................................................... 150
6. Cables ............................................................................................................................... 151

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 Table of Contents

6.1 Motor Cables ............................................................................................................... 151

6.1.1 Motor Cable Construction .................................................................................... 151
6.1.2 Pin Assignments 8CMxxx.12-1, 8CMxxx.12-3 ................................................... 152
6.1.3 Cable Schematic for 8CMxxx.12-1, 8CMxxx.12-3 .............................................. 152
6.1.4 Pin Assignments for 8CMxxx.12-5 ..................................................................... 153
6.1.5 Cable Schematic for 8CMxxx.12-5 ..................................................................... 153
6.2 EnDat Encoder Cables ................................................................................................ 154
6.2.1 EnDat Encoder Cable Construction ..................................................................... 154
6.2.2 Pin Assignments ................................................................................................... 154
6.2.3 Cable Schematic ................................................................................................... 155
6.3 Resolver Cables .......................................................................................................... 156
6.3.1 Resolver Cable Construction ................................................................................ 156
6.3.2 Pin Assignments ................................................................................................... 156
6.3.3 Cable Schematic ................................................................................................... 157

Chapter 6: Getting Started ........................................................... 159

1. Preparation ....................................................................................................................... 159
1.1 Unpacking the ACOPOS Servo Drive ......................................................................... 159
1.2 Installing and Connecting the ACOPOS Servo Drive .................................................. 159
1.3 Connecting the ACOPOS Servo Drive with a B&R PLC ............................................. 159
2. Starting Up an ACOPOS Servo Drive ............................................................................... 160
2.1 General Information ..................................................................................................... 160
2.1.1 Sample Project ...................................................................................................... 161
2.1.2 Preparing the Hardware for Sample Project acp10.gdm ...................................... 161
2.2 Start-up ........................................................................................................................ 162
2.2.1 Load Sample Project ............................................................................................. 162
2.2.2 Preset Values for the Sample Project ................................................................... 165
2.2.3 Preset Values Concerning Wiring ......................................................................... 170
2.2.4 Downloading the Project ....................................................................................... 176
2.2.5 Test Function ........................................................................................................ 179
2.2.6 Starting the Motor Movement .............................................................................. 181

Chapter 7: Standards and Certifications .................................... 189

1. Valid European Guidelines for ACOPOS Servo Drives .................................................... 189
2. Valid Standards for ACOPOS Servo Drives ..................................................................... 189
3. Electrical Limit Values for Immunity Tests according to IEC 61800-3 .............................. 190
4. Electrical Limit Values for Emission Tests according to IEC 61800-3 .............................. 191
5. Environmental Limit Values according to IEC 61800-2 .................................................... 192
6. International Certifications ................................................................................................ 193
7. Standards, Definitions for Safety Techniques ................................................................... 194

ACOPOS User's Manual 11

 Table of Contents

12 ACOPOS User's Manual

 General Information • ACOPOS Servo Family

General Information
Chapter 1
CHAPTER 1 • GENERAL INFORMATION

1. ACOPOS Servo Family

With the introduction of the ACOPOS product line - consisting of servo drive and motor
components - B&R has provided the basis for complete and uniform automation solutions.
Branch specific functions and intuitive tools allow for short development times and create more
room for innovation.

1.1 Secure Operation

The embedded parameter chip on the motor is one factor used to guarantee maximum security.
It contains all mechanical and electronic data relevant to the functionality of the motor.
Parameters no longer have to be set manually and start-up times are substantially reduced.
Secure operation also means that relevant data can be requested during service and the cause
of the problem can be determined.
EMC was given special attention in order to guarantee proper operation in an industrial
environment. Field tests have been carried out under difficult conditions in addition to the tests
defined in the standard. The results confirm the excellent values measured by the testing
laboratory and during operation. The filter required to meet the CE guidelines is also integrated
in the device. This simplifies installation considerably.

ACOPOS User's Manual 13

 General Information • ACOPOS Servo Family

Figure 1: Secure Operation

1.2 Taking it to the Limit

Operational security is also improved by monitoring high temperature components (IGBT

modules, brake resistor, motor windings). Models with computer support allow component
temperatures which cannot be measured directly to be calculated. One example is the junction
temperature. This is a decisive value for the maximum load of a semiconductor. Using these
models, a sufficiently precise value can be determined for each IGBT. Hot spots can be ruled out
and the full dynamic properties of the device can be used at low rpm values and when stalled.
The brake resistor and motor windings are monitored in the same way.
This form of monitoring allows better use of absolute limits on the drive and provides the user
with the advantages of higher performance at lower costs.

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 General Information • ACOPOS Servo Family

General Information
1.3 Individual I/O Configurations

Chapter 1
The I/O points needed to operate a servo axis are part of the standard equipment for ACOPOS
drives. The user is provided two trigger inputs for tasks requiring precise measurements or print
mark control. Sensor and actuator configurations are made using modular plug-in modules. This
modular concept allows the optimum configuration to be selected to meet the requirements of
the application.

Figure 2: Individual I/O Configurations

1.4 Configuring Instead of Programming

Long-term cooperation with our customers has provided us with fundamental knowledge in many
positioning application areas. This knowledge can be passed on to our customers in the form of
clear and easy to use function blocks. Industry specific functionality can be quickly and easily
implemented in an application program.

1.5 Easy Service

All necessary data is placed in application memory on the controller so that service is limited to
simply exchanging the device. The program does not have to be changed. After the system is
started again, the controller automatically (or when requested by the user) installs the operating
system used on the system. After this procedure is complete, the parameters are sent to the
servo drive again. Problems resulting from different software versions or parameters can be
ruled out.

ACOPOS User's Manual 15

 General Information • ACOPOS Servo Family

1.6 Software and Hardware as a Unit

B&R integrates all relevant technologies in one tool - B&R Automation Studio™.
Adding a B&R ACOPOS servo drive is done in a Windows Look & Feel environment which
becomes routine after using the program a few times. Wizards and selection boxes ease
configuration of servo axis parameters. The target system is shown in a clear tree structure.
Detailed information concerning the target system, with integrated hardware documentation
ranging from software to terminal assignments, reduces project development times
considerably.

Figure 3: Software and Hardware as a Unit

1.7 Plain Text for Functions

NC Objects that can be accessed by the application program are also stored on the CPU (like
the application program).
Creating NC Objects (for axes, a CNC system or a cam profile) takes place using dialog boxes
and special data module editors. The individual hardware and software channels are assigned
symbolic names. This eases use and increases clarity. The initial parameters are set in a
separate editor in plain text.

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 General Information • ACOPOS Servo Family

General Information
1.8 Simple Function Test

Chapter 1
The built-in NC test allows an axis to be used without a line of program code being written. As
seen in the picture, several editors are grouped together as a single window. All movements,
ranging from point-to-point movements to gear functions, can be carried out using an NC Action.
The reaction of the axis can be seen online in the monitor window. If the trace function is turned
on, relevant data - from position to motor temperature - is recorded on the drive. The multiple
curve display in the trace window allows simple evaluation of the movement results.

Figure 4: Simple Function Test

ACOPOS User's Manual 17

 General Information • ACOPOS Servo Family

1.9 Control Trigger

The oscilloscope in the drive allows movements to be monitored in real time. Many trigger
possibilities allow data required for analysis to be easily obtained. The graphic display of
diagnosis data supports the user when making fine adjustments and when optimizing the
movement. Measurement cursor and reference points allow µs precision.

Figure 5: Control Trigger

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 General Information • ACOPOS Servo Family

General Information
1.10 Cam Profiles for Everyone

Chapter 1
Modular technology plug-ins allow homogenous integration of high performance tools such as
the Cam Editor.
The mouse is used to define fixed points, synchronous sections or interpolations. Effects of
positioning behavior on speed, acceleration and jolt for the slaves axes connected can be
monitored directly.

Figure 6: Cam Profiles for Everyone

ACOPOS User's Manual 19

 General Information • ACOPOS Configurations

2. ACOPOS Configurations

2.1 CAN

2.1.1 Configuration 1

Functionality

The following ACOPOS functions are possible with this configuration:

• Point-to-Point
• Electronic Gears
• Electronic Compensation Gears
• Cross Cutter
• Electronic Cam Profiles
• Flying Saw
• Line Shaft

Figure 7: CAN Configuration 1

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 General Information • ACOPOS Configurations

General Information
2.1.2 Configuration 2

Chapter 1
Functionality
The following ACOPOS functions are possible with this configuration:
• Point-to-Point
• Electronic Gears
• Electronic Compensation Gears
• Cross Cutter
• Electronic Cam Profiles
• Flying Saw
• Line Shaft
• CNC

Figure 8: CAN Configuration 2

ACOPOS User's Manual 21

 General Information • ACOPOS Configurations

2.2 Powerlink

2.2.1 Configuration 1

Functionality

The following ACOPOS functions are possible with this configuration:

• Point-to-Point
• Electronic Gears
• Electronic Compensation Gears
• Cross Cutter
• Electronic Cam Profiles
• Flying Saw
• Line Shaft

Figure 9: Powerlink Configuration 1 - Star Topology

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 General Information • ACOPOS Configurations

2.2.2 Configuration 2 1)

General Information
Chapter 1
Functionality

The functionality is the same as in configuration 1. The advantage over configuration 1 is the low
cabling expenditure.

Figure 10: Powerlink Configuration 2 - Line Topology

1) In preparation.

ACOPOS User's Manual 23

 General Information • Safety Guidelines

3. Safety Guidelines

3.1 General Information

Danger!
Servo drives and servo motors can have bare parts with voltages applied (e.g.
terminals) or hot surfaces. Additional sources of danger result from moving
machine parts. Improperly removing the required covers, inappropriate use,
incorrect installation or incorrect operation can result in severe personal injury or
damage to property.

All tasks, such as transport, installation, commissioning and service, are only allowed to be
carried out by qualified personnel. Qualified personnel are persons familiar with transport,
mounting, installation, commissioning and operation of the product and have the respective
qualifications (e.g. IEC 60364). Be sure to follow national accident prevention guidelines.
The safety guidelines, connection descriptions (type plate and documentation) and limit values
listed in the technical data are to be read carefully before installation and commissioning and
must be observed.

Danger!
Handling servo drives incorrectly can cause severe personal injury or damage to
property!

3.2 Intended Use

Servo drives are components designed to be installed in electrical systems or machines. They
are not being used as intended unless the machine meets EG regulation 98/37/EG (machine
regulation) as well as regulation 89/336/EWG (EMC regulation).
The servo drives are only allowed to be operated directly on grounded, three-phase industrial
mains (TN, TT power mains). When using the servo drives in living areas, shops and small
businesses, additional filtering measures must be implemented by the user.
The technical data as well as the values for connection and environmental guidelines can be
found on the type plate and in the documentation. The connection and environmental guidelines
must be met.
Electronic devices are generally not fail-safe. If the servo drive fails, the user is responsible for
making sure that the motor is placed in a secure state.

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 General Information • Safety Guidelines

General Information
3.3 Transport and Storage

Chapter 1
During transport and storage, the devices must be protected from excessive stress (mechanical
load, temperature, humidity, aggressive atmosphere).
Servo drives contain components sensitive to electrostatic charges which can be damaged by
inappropriate handling. During installation/removal of servo drives, provide the necessary safety
precautions against electrostatic discharges.

3.4 Installation

The installation must take place according to the documentation using suitable equipment and
tools.
The devices are only allowed to be installed without voltage applied and by qualified personnel.
Voltage to the switching cabinet should be switched off and prevented from being switched on
again.
The general safety regulations and national accident prevention guidelines (e.g. VBG 4) must be
observed when working with high voltage systems.
The electrical installation must be carried out according to the relevant guidelines (e.g. line cross
section, fuse, protective ground connection, also see chapter 4 "Dimensioning").

3.5 Operation

3.5.1 Protection against Touching Electrical Parts

Danger!
To operate servo drives, it is necessary that certain parts are carrying voltages over
42 VDC. A life-threatening electrical shock could occur if you touch these parts. This
could result in death, severe injury or material damage.

Before turning on the servo drive, make sure that the housing is properly connected to protective
ground (PE rail). The ground connection must be made, even when testing the servo drive or
when operating it for a short time!
Before turning the device on, make sure that all voltage carrying parts are securely covered.
During operation, all covers and switching cabinet doors must remain closed.
Control and high power contacts can have voltage applied, even when the motor is not turning.
Touching the contacts when the device is switched on is not permitted.

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 General Information • Safety Guidelines

Before working on servo drives, they must be disconnected from the power mains and prevented
from being switched on again.

Danger!
After switching off the device, wait until the DC bus discharge time of at least five
minutes has passed. The voltage currently on the DC bus must be measured with a
suitable measuring device before beginning work. This voltage must be less than 42
V DC to rule out danger. The Run LED going out does not indicate that voltage is not
present on the device!

The connections for the signal voltages (5 to 30 V) found on the servo drives are isolated circuits.
Therefore, the signal voltage connections and interfaces are only allowed to be connected to
devices or electrical components with sufficient isolation according to IEC 60364-4-41 or EN
50178.
Never remove the electrical connections from the servo drive with voltage applied. In unfavorable
conditions, arcs can occur causing personal injury and damage to contacts.

3.5.2 Protection from Dangerous Movements

Danger!
Incorrect control of motors can trigger unwanted and dangerous movements! Such
incorrect behavior can have various causes:
• Incorrect installation or an error when handling the components
• Incorrect or incomplete wiring
• Defective devices (servo drive, motor, position encoder, cable, brake)
• Incorrect control (e.g. caused by software error)

Some of these causes can be recognized and prevented by the servo drive using internal
monitoring. However, it is generally possible for the motor shaft to move every time the device
is switched on! Therefore protection of personnel and the machine can only be guaranteed using
higher level safety precautions.
The movement area of machines is must be protected to prevent accidental access. This type
of protection can be obtained by using stabile mechanical protection such as protective covers,
protective fences, protective gates or photocells.
Removing, bridging or bypassing these safety features and entering the movement area is
prohibited.
A sufficient number of emergency stop switches are to be installed directly next to the machine.
The emergency stop equipment must be checked before commissioning the machine.

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 General Information • Safety Guidelines

General Information
Remove shaft keys on free running motors or prevent them from being catapulted.

Chapter 1
The holding brake built into the motors cannot prevent hoists from allowing the load to sink.

3.6 Safety Notices

Safety notices are organized as follows:

Safety Notice Description

Danger! Disregarding the safety regulations and guidelines can be life-threatening.
Warning! Disregarding the safety regulations and guidelines can result in severe injury or heavy
damage to material.
Caution! Disregarding the safety regulations and guidelines can result in injury or damage to
material.
Information: Important information used to prevent errors.

Table 1: Description of the safety notices used in this manual

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 General Information • Safety Guidelines

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 Technical Data • ACOPOS Servo Family

CHAPTER 2 • TECHNICAL DATA

1. ACOPOS Servo Family

Technical Data
Chapter 2
1.1 Modular Servo Drive Concept

Controlling your power transmission system with the new B&R ACOPOS servo drives allows you
to fully use the advantages of an optimized system architecture. Applications that require
additional positioning tasks such as torque limitation or torque control can be created quickly and
elegantly.
The flexible system concept for B&R servo drives is achieved using matched hardware and
software components. You can select the optimal system configuration for your application and
increase your competitiveness.
• Perfect integration in the B&R 2000 product family
• Object-oriented axis programming minimizes development time and increases reusability
• Integrated technology functions for branch specific tasks
• Operation of synchronous and asynchronous motors possible
• Input voltage range from 400 - 480 VAC (±10 %) for use worldwide
• Four slots for plug-in modules
• Connection possibilities for all standard encoder systems
• Reduced commissioning and service times using “embedded motor parameter chip”
• Current regulator scan time up to 50 µs
• CAN and Powerlink fieldbus connection

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 Technical Data • ACOPOS Servo Family

1.2 General Description

The ACOPOS servo drive series covers a current range from 2.2 - 128 A and a power range
from 1 - 64 kW with 7 devices in 3 groups. The devices in a group are designed using the same
basic concept.

Group 8V1022.00-2 8V1180.00-2 8V1640.00-2

8V1045.00-2 8V1320.00-2 8V128M.00-2
8V1090.00-2
Power Connections Plug connection Plug connection Fixed
Integrated Power Filter Yes --- 1) --- 1)
Mains Failure Monitoring in preparation Yes Yes
DC Bus Connection Yes Yes Yes
24 VDC Supply External External or internal via DC bus External or internal via DC bus
24 VDC Output No 24 V / 0.5 A 24 V / 0.5 A
Integrated Brake Chopper Yes Yes Yes
Internal Braking Resistor Yes Yes Yes2)
Connection of External Braking No Yes Yes
Resistor Possible
Monitored Output for Motor Yes Yes Yes
Holding Brake
Monitored Input for Motor Yes Yes Yes
Temperature Sensor

Table 2: General description of the ACOPOS servo drive series

1) Integrated line filter in preparation

2) The braking resistor integrated in the ACOPOS servo drives 1640 and 128M are dimensioned so that it is possible to brake to a stop
(in a typical drive situation).

The integrated power supply concept starting with the ACOPOS 1180 allows the 24 VDC voltage
supply on the servo drive and the connected encoders and sensors (which can also be supplied
via the 24 VDC output) to remain for the entire stopping procedure if there is a power failure. In
may cases, it is not necessary to use a 24 VDC UPS which is otherwise needed.
In addition to connection possibilities for all standard encoder systems, the ACOPOS servo
drives also provide a modular fieldbus interface.
ACOPOS servo drives are suitable for both synchronous and asynchronous servo motors and
have a built-in line filter which meets the limit values for CISPR11, Group 2, Class A.

Caution!
ACOPOS Servo drives are suitable for use on a circuit capable of delivering not
more than 10000 RMS Symmetrical Amperes, 528 Volts maximum.

30 ACOPOS User's Manual

 Technical Data • ACOPOS Servo Family

1.3 Status LEDs

The ACOPOS servo drives are equipped with three LEDs for direct diagnosis:

LED Designation Color

1 Ready green
2 Run orange
3 Error Red

Technical Data
Chapter 2
Table 3: Status LEDs ACOPOS servo drives

If no LEDs are lit, the ACOPOS servo drive is not being supplied with 24 VDC.

Danger!
After switching off the device, wait until the DC bus discharge time of at least five
minutes has passed. The voltage currently on the DC bus must be measured with a
suitable measuring device before beginning work. This voltage must be less than
42 VDC to rule out danger. The Run LED going out does not indicate that voltage is
not present on the device!

Signal LED Description

Ready green Lit when the ACOPOS servo drive is ready for operation and the power level can be enabled (operating
system present and booted, no permanent or temporary errors).
Run orange Lit as soon as the power level is enabled for the ACOPOS servo drive.
Error Red Lit when an error occurs on the ACOPOS servo drive. After correcting the error, the LED is
automatically switched off.
Examples of permanent errors:
• Motor feedback not connected or defective
• Low level on the enable input
• Motor temperature sensor not connected or defective
• Internal error on the device (e.g. IGBT heat sink temperature sensor defective)
Examples of temporary errors:
• 24 VDC supply voltage exceeds the tolerance range
• DC bus voltage exceeds the tolerance range
• Internal 15 VDC control voltage exceeds the tolerance range
• IGBT current limit reached
• Over-temperature on the motor (temperature sensor)
• Over-temperature on the servo drive (IGBT junction, heat sink, conductive tracks)
• Over-temperature on the braking resistor
• CAN or Powerlink network faulty

Table 4: LED Status

ACOPOS User's Manual 31

 Technical Data • ACOPOS Servo Family

1.3.1 LED Status

The following timing is used for the indication diagrams:

Block size: 125 ms
Repeats after: 3000 ms

Status changes when booting the operating system loader

Status LED Indication

green
1. Boot procedure for basic hardware
orange
active
red
green
2. Configuration of CAN plug-in module
orange
active
red
green
3. Waiting for CAN telegram orange
red
green
4. CAN communication active orange
red

Table 5: Status changes when booting the operating system loader

Error status with reference to the CAN plug-in module AC110

Status LED Indication

green
Boot error on CAN basic hardware orange
red
green
Bus Off orange
red
green
CAN node number is 0 orange
red

Table 6: Error status with reference to the CAN plug-in module AC110

32 ACOPOS User's Manual

 Technical Data • ACOPOS Servo Family

Error status with reference to the Ethernet Powerlink plug-in module AC112

Status LED Indication

green
Boot error on Powerlink basic hardware orange
red
green
Error when booting the AC112-ARM orange

Technical Data
red

Chapter 2
green
Powerlink node number is 0 orange
red

Table 7: Error status with reference to the Ethernet Powerlink plug-in module AC112

ACOPOS User's Manual 33

 Technical Data • ACOPOS Servo Family

1.4 ACOPOS 1022, 1045 and 1090

1.4.1 Order Data

Model Number Short Description Image

Servo Drives
8V1022.00-2 Servo drive 3 x 400-480V 2.2A 1kW, line filter and
braking resistor integrated
8V1045.00-2 Servo drive 3 x 400-480V 4.4A 2kW, line filter and
braking resistor integrated
8V1090.00-2 Servo drive 3 x 400-480V 8.8A 4kW, line filter and
braking resistor integrated
Accessories
8AC110.60-2 ACOPOS plug-in module, CAN interface
8AC112.60-1 ACOPOS plug-in module, Ethernet Powerlink interface
8AC120.60-1 ACOPOS plug-in module, EnDat encoder interface
8AC122.60-1 ACOPOS plug-in module, resolver interface
8AC123.60-1 ACOPOS plug-in module, incremental encoder and
SSI absolute encoder interface
8AC130.60-1 ACOPOS plug-in module, 8 digital I/O configurable in
pairs as 24V input or as output 400/100mA, 2 digital
outputs 2A, Order TB712 terminal block separately

Table 8: Order data ACOPOS 1022, 1045 and 1090

1.4.2 Technical Data

Product ID 8V1022.00-2 8V1045.00-2 8V1090.00-2

General Information
C-UL-US Listed Yes
Power Mains Connection
Mains Input Voltage 3 x 400 VAC to 480 VAC ±10 %
Power filter according to IEC 61800-3-A11 second environment
(Limits from CISPR11, Group 2, Class A)
Frequency 48 Hz to 62 Hz
Installed Load Max. 3 kVA Max. 5 kVA Max. 10 kVA
Starting Current 13 A 13 A 20 A
Switch-on Interval >1 min
Power Loss at Max. Device Power 120 W 180 W 200 W
without Brake Resistor

Table 9: Technical data ACOPOS 1022, 1045 and 1090

34 ACOPOS User's Manual

 Technical Data • ACOPOS Servo Family

Product ID 8V1022.00-2 8V1045.00-2 8V1090.00-2

24 VDC Supply
Input Voltage
with motor holding brake 24 VDC +6 % / -2 %
without motor holding brake 24 VDC +30 % / -20 %
Current Requirements Max. 2.5 A + current for motor holding brake
Motor Connection
Maximum Switching Frequency 20 kHz 20 kHz 10 kHz

Technical Data
Continuous Current at 400 V 2.2 Aeff 4.4 Aeff 8.8 Aeff

Chapter 2
Continuous Current at 480 V 1.7 Aeff 3.3 Aeff 6.6 Aeff
Peak Current 14 Aeff 24 Aeff 24 Aeff
Maximum Motor Line Length 25 m
Protective Measures Short circuit and ground fault protection
Motor Holding Brake Connection
Maximum Output Current 1A
Protective Measures Short circuit and ground fault protection
Brake Resistance
Peak Power Output 3.5 kW 7 kW 7 kW
Continuous Power Output 130 W 200 W 200 W
Operational Conditions
Environmental Temperature during 0 to 45 °C
Operation
Relative Humidity during Operation 5 to 95 %, non-condensing
Power Reduction in Relation to 10 % per 1000 m installation altitude
Installation Altitude Max. 2,000 m above sea level
Degree of Pollution according to 2 (non-conductive material)
IEC 60664-1
Overvoltage Category according to II
IEC 60364-4-443:1999
Protection according to IEC 60529 IP20
Storage and Transport Conditions
Storage Temperature -25 to +55 °C
Relative Humidity for Storage 5 to 95 %, non-condensing
Transport Temperature -25 to +70 °C
Relative Humidity for Transport 95 % at 40 °C, non-condensing
Mechanical Characteristics
Dimensions
Width 70.5 mm
Height 375 mm
Depth 235.5 mm
Weight 4.0 kg 4.1 kg 4.4 kg

Table 9: Technical data ACOPOS 1022, 1045 and 1090 (cont.)

ACOPOS User's Manual 35

 Technical Data • ACOPOS Servo Family

1.5 ACOPOS 1180, 1320

1.5.1 Order Data

Model Number Short Description Image

Servo Drives
8V1180.00-2 Servo drive 3 x 400-480V 18A 9kW, line filter and
braking resistor integrated 1)
8V1320.00-2 Servo drive 3 x 400-480V 32A 16kW, line filter and
braking resistor integrated 1)
Accessories
8AC110.60-2 ACOPOS plug-in module, CAN interface
8AC112.60-1 ACOPOS plug-in module, Ethernet Powerlink interface
8AC120.60-1 ACOPOS plug-in module, EnDat encoder interface
8AC122.60-1 ACOPOS plug-in module, resolver interface
8AC123.60-1 ACOPOS plug-in module, incremental encoder and
SSI absolute encoder interface
8AC130.60-1 ACOPOS plug-in module, 8 digital I/O configurable in
pairs as 24V input or as output 400/100mA, 2 digital
outputs 2A, Order TB712 terminal block separately

Table 10: Order data ACOPOS 1180, 1320

1) Integrated line filter in preparation.

1.5.2 Technical Data

Product ID 8V1180.00-2 8V1320.00-2

General Information
C-UL-US Listed Yes
Power Mains Connection
Mains Input Voltage 3 x 400 VAC to 480 VAC ±10 %

Y
Power filter according to IEC 61800-3-A11 second environment

Frequency

INAR (Limits from CISPR11, Group 2, Class A) 1)

48 Hz to 62 Hz
Installed Load
Starting Current

ELIM Max. 17 kVA

13 A
Max. 30 kVA

Switch-on Interval

Brake Resistor PR
Power Loss at Max. Device Power without 500 W

Table 11: Technical data ACOPOS 1180, 1320

>10 sec
800 W

36 ACOPOS User's Manual

 Technical Data • ACOPOS Servo Family

Product ID 8V1180.00-2 8V1320.00-2

24 VDC Supply
Input Voltage 24 VDC +25 % / -25 %
Current Requirements

ARY Max. 4 A + current for motor holding brake

N
Motor Connection
Maximum Switching Frequency

LIMI 10 kHz

E
Continuous Current at 400 V 19 Aeff 34 Aeff

PR

Technical Data
Continuous Current at 480 V 14 Aeff 25 Aeff

Chapter 2
Peak Current 38 Aeff 60 Aeff
Maximum Motor Line Length 25 m
Protective Measures Short circuit and ground fault protection
Motor Holding Brake Connection
Maximum Output Current 1.5 A
Protective Measures Short circuit and ground fault protection
Brake Resistance
Peak Power Int. / Ext. 14 / 24 kW
Continuous Power Int. / Ext.

ARY 0.4 / 8 kW

IN
Operational Conditions

Operation

LIM
Environmental Temperature during 0 to 40 °C

PRE
Relative Humidity during Operation 5 to 95 %, non-condensing
Power Reduction in Relation to 10 % per 1000 m installation altitude
Installation Altitude Max. 2,000 m above sea level
Degree of Pollution according to IEC 2 (non-conductive material)
60664-1
Overvoltage Category according to II
IEC 60364-4-443:1999
Protection according to IEC 60529 IP20
Storage and Transport Conditions
Storage Temperature -25 to +55 °C
Relative Humidity for Storage
Transport Temperature

ARY 5 to 95 %, non-condensing
-25 to +70 °C
Relative Humidity for Transport

LIMIN 95 % at 40 °C, non-condensing

E
Mechanical Characteristics
Dimensions
Width
Height
Depth
Weight
PR 10.1 kg
200 mm
375 mm
234 mm
10.6 kg

Table 11: Technical data ACOPOS 1180, 1320 (cont.)

1) Integrated line filter in preparation.

ACOPOS User's Manual 37

 Technical Data • ACOPOS Servo Family

1.6 ACOPOS 1640, 128M

1.6.1 Order Data

Model Number Short Description Image

Servo Drives
8V1640.00-2 Servo drive 3 x 400-480V 64A 32kW, line filter and
braking resistor integrated 1)
8V128M.00-2 Servo drive 3 x 400-480V 128A 64kW, line filter and
braking resistor integrated 1)
Accessories
8AC110.60-2 ACOPOS plug-in module, CAN interface
8AC112.60-1 ACOPOS plug-in module, Ethernet Powerlink interface
8AC120.60-1 ACOPOS plug-in module, EnDat encoder interface
8AC122.60-1 ACOPOS plug-in module, resolver interface
8AC123.60-1 ACOPOS plug-in module, incremental encoder and
SSI absolute encoder interface
8AC130.60-1 ACOPOS plug-in module, 8 digital I/O configurable in
pairs as 24V input or as output 400/100mA, 2 digital
outputs 2A, Order TB712 terminal block separately

Table 12: Order data ACOPOS 1640, 128M

1) Integrated line filter in preparation.

1.6.2 Technical Data

Product ID 8V1640.00-2 8V128M.00-2

General Information
C-UL-US Listed Yes
Power Mains Connection
Mains Input Voltage 3 x 400 VAC to 480 VAC ±10 %

ARY Power filter according to IEC 61800-3-A11 second environment

(Limits from CISPR11, Group 2, Class A) 1)
Frequency
Installed Load

LIMIN Max. 54 kVA

48 Hz to 62 Hz
Max. 98 kVA

PRE
Starting Current 26 A (at 400 VAC)
Switch-on Interval Anywhere
Power Loss at Max. Device Power without ~1600 W ~3200 W
Brake Resistor
24 VDC Supply
Input Voltage 24 VDC +25 % / -25 %
Current Requirements Max. 6 A + 1.4 x current for motor holding brake

Table 13: Technical data ACOPOS 1640, 128M

38 ACOPOS User's Manual

 Technical Data • ACOPOS Servo Family

Product ID 8V1640.00-2 8V128M.00-2

Motor Connection
Maximum Switching Frequency 10 kHz 5 kHz

Y
Continuous Current at 400 V 64 Aeff 128 Aeff
Continuous Current at 480 V 48 Aeff 96 Aeff
Peak Current
Maximum Motor Line Length

AR200 Aeff (283 Apk)

25 m
300 Aeff (425 Apk)

Technical Data
Protective Measures Short circuit and ground fault protection

Chapter 2
Motor Holding Brake Connection
Maximum Output Current
Protective Measures
IM 3A
Short circuit and ground fault protection
Brake Resistance
Peak Power Int. / Ext.

EL 7 / 250 kW 8.5 / 250 kW

PR
Continuous Power Int. / Ext. 0.2 / 24 kW 0.24 / 24 kW
Operational Conditions
Environmental Temperature during 0 to 40 °C
Operation
Relative Humidity during Operation 5 to 95 %, non-condensing
Power Reduction in Relation to 10 % per 1000 m installation altitude
Installation Altitude Max. 2,000 m above sea level
Degree of Pollution according to IEC 2 (non-conductive material)
60664-1
Overvoltage Category according to
IEC 60364-4-443:1999
R Y II

Protection according to IEC 60529

Storage and Transport Conditions

N A IP20

Storage Temperature
Relative Humidity for Storage

M I -25 to +55 °C
5 to 95 %, non-condensing
Transport Temperature
Relative Humidity for Transport

L I -25 to +70 °C
95 % at 40 °C, non-condensing
Mechanical Characteristics
Dimensions
Width
RE 276 mm 402 mm

P
Height 460 mm 460 mm
Depth 295 mm 295 mm
Weight 24.1 kg 33.8 kg

Table 13: Technical data ACOPOS 1640, 128M (cont.)

1) Integrated line filter in preparation.

ACOPOS User's Manual 39

 Technical Data • ACOPOS Plug-in Modules

2. ACOPOS Plug-in Modules

2.1 General Information

The ACOPOS drives are equipped with four plug-in module slots. You can select the plug-in
modules required for your application and insert them into the ACOPOS servo drive.

2.2 Module Overview

Model Number Short Description

8AC110.60-2 ACOPOS plug-in module, CAN interface
8AC112.60-1 ACOPOS plug-in module, Ethernet Powerlink interface
8AC120.60-1 ACOPOS plug-in module, EnDat encoder interface
8AC122.60-1 ACOPOS plug-in module, resolver interface
8AC123.60-1 ACOPOS plug-in module, incremental encoder and SSI absolute encoder interface
8AC130.60-1 ACOPOS plug-in module, 8 digital I/O configurable in pairs as 24V input or as output 400/100mA, 2 digital outputs 2A,
Order TB712 terminal block separately

Table 14: Module overview for plug-in modules

40 ACOPOS User's Manual

 Technical Data • ACOPOS Plug-in Modules

2.3 AC110 - CAN Interface

2.3.1 General Description

The AC110 plug-in module can be used in an ACOPOS slot. The module is equipped with a CAN
interface. This fieldbus interface is used for communication and setting parameters on the
ACOPOS servo drive for standard applications.

2.3.2 Order Data

Technical Data
Chapter 2
Model Number Short Description Image
Plug-in Module
8AC110.60-2 ACOPOS plug-in module, CAN interface
Accessories
7AC911.9 Bus Connector, CAN
0AC912.9 Bus Adapter, CAN, 1 CAN interface
0AC913.92 Bus Adapter, CAN, 2 CAN interfaces, including 30 cm
connection cable

Table 15: Order Data AC110

2.3.3 Technical Data

Product ID 8AC110.60-2
General Information
C-UL-US Listed Yes
Module Type ACOPOS plug-in module
Slot Currently limited to slot 1
Power Consumption Max. 0.7 W
CAN Interface
Connection, Module Side 9 pin DSUB plug
Indications RXD/TXD LEDs
Electrical Isolation Yes
CAN - ACOPOS

Table 16: Technical Data AC110

ACOPOS User's Manual 41

 Technical Data • ACOPOS Plug-in Modules

Product ID 8AC110.60-2
Maximum Distance 60 m
Baud Rate 500 kBit/s
Network Capable Yes
Bus Termination Resistor Externally wired
Operational Conditions
Environmental Temperature during 0 to 50 °C
Operation
Relative Humidity during Operation 5 to 95 %, non-condensing
Storage and Transport Conditions
Storage Temperature -25 to +55 °C
Relative Humidity for Storage 5 to 95 %, non-condensing
Transport Temperature -25 to +70 °C
Relative Humidity for Transport 95 % at 40 °C, non-condensing

Table 16: Technical Data AC110 (cont.)

2.3.4 CAN Node Number Settings

The CAN node number can be set using two HEX code switches: 1)

Code Switch CAN Node Number

Top 16s position (high)
Bottom 1s position (low)

Table 17: Setting the CAN node number with the two HEX code switches

Changing the node number becomes active the next time the ACOPOS servo drive is switched
on.
There must be a terminating resistor (120 Ω, 0.25 W) between CAN_H and CAN_L at the
beginning and end of the CAN bus.

2.3.5 Indications

The status LEDs show if data is being received (RXD) or sent (TXD).

1) Changing the node number using software is not possible (Basis CAN ID can be changed). The ACOPOS Manager only supports node
numbers from 1 - 32. When using the NC157 positioning module, only node numbers from 1 - 8 are possible.

42 ACOPOS User's Manual

 Technical Data • ACOPOS Plug-in Modules

2.4 AC112 - Ethernet Powerlink Interface

2.4.1 General Description

The AC112 plug-in module can be used in an ACOPOS slot. The module is equipped with an
Ethernet Powerlink interface. This fieldbus interface is used for communication and setting
parameters on the ACOPOS servo drive for complex and time critical applications.
The plug-in module is set up as a 2x hub. This makes it easy to establish a device to device
connection (line topology). 1)

Technical Data
Chapter 2
2.4.2 Order Data

Model Number Short Description Image

Plug-in Module
8AC112.60-1 ACOPOS plug-in module, Ethernet Powerlink interface

Table 18: Order Data AC112

2.4.3 Technical Data

Product ID 8AC112.60-1
General Information
C-UL-US Listed Yes
Module Type
Slot
Power Consumption PREL IM INARY ACOPOS plug-in module
Currently limited to slot 1
Max. 2.5 W

Table 19: Technical Data AC112

1) In preparation.

ACOPOS User's Manual 43

 Technical Data • ACOPOS Plug-in Modules

Product ID 8AC112.60-1
Powerlink Interface
Connection, Module Side 2 x RJ45 socket
Indications Status LEDs
Electrical Isolation
Ethernet - ACOPOS
Maximum Distance per Segment
R Y Yes

100 m 1)
Baud Rate

A 100 Mbit/s

IN
Network Capable Yes
Hub, 2x Yes2)

IM
Operational Conditions
Environmental Temperature during 0 to 50 °C

L
Operation
Relative Humidity during Operation 5 to 95 %, non-condensing
Storage and Transport Conditions
Storage Temperature

RE -25 to +55 °C

P
Relative Humidity for Storage 5 to 95 %, non-condensing
Transport Temperature -25 to +70 °C
Relative Humidity for Transport 95 % at 40 °C, non-condensing

Table 19: Technical Data AC112 (cont.)

1) With a cycle time of 400 µs and 10 ACOPOS servo drives, the maximum total cable length is 200 m.
2) In preparation.

2.4.4 Powerlink Node Number Setting

The Powerlink node number can be set using two HEX code switches:

Code Switch Powerlink Node Number

Top 16s position (high)
Bottom 1s position (low)

Table 20: Setting the Powerlink node number with the two HEX code switches

Changing the node number becomes active the next time the ACOPOS servo drive is switched
on.

44 ACOPOS User's Manual

 Technical Data • ACOPOS Plug-in Modules

2.4.5 Status LEDs

Technical Data
Chapter 2
Figure 11: Status LEDs AC112

The status is indicated on the AC112 using one green and one red LED.

LED Test

Immediately after resetting the module, both LEDs are switched off for 0.5 s, then switched on
for 1.5 s.
Then the green LED is cleared for one second and the following boot procedure. After proper
initialization, the red LED is switched off and the green LED is switched on.

Status of the LEDs

The following timing is used for the indication diagram:

Block size: 150 ms

Status LED Indication

Green
Error free operation
Red
Green
Fatal system error 1)
Red
Green
Master has dropped out
Red
Green
System stop 2)
Red see System Stop Error Codes

Table 21: Indication diagram for the AC112 status LEDs

1) This is a problem which cannot be repaired, the system can no longer carry out tasks correctly. This status can only be changed by
resetting the module.
2) The red LED blinks an error code, the output of the error code occurs in 4 short (150 ms) or long (600 ms) phases.

ACOPOS User's Manual 45

 Technical Data • ACOPOS Plug-in Modules

System Stop Error Codes

The following timing is used for the indication diagram:

Block size: 150 ms
Pause: 2000 ms

Error Indication
Stack overflow
RAM error
Undefined address 1)
Instruction fetch memory abort 2)
Data access memory abort 3)
Assertion failed 4)
Programming failed 5)

Table 22: System stop error codes

1) Access of non-existent address.

2) Invalid memory access during instruction fetch (e.g. WORD access of add numbered address).
3) Invalid memory access during data access (e.g. WORD access of add numbered address).
4) This system stop code only occurs in debug mode. The condition for a software assertion was not fulfilled.
5) Error during programming.

46 ACOPOS User's Manual

 Technical Data • ACOPOS Plug-in Modules

2.5 AC120 - EnDat Encoder Interface

2.5.1 General Description

The AC120 plug-in module can be used in an ACOPOS slot. The module is equipped with an
EnDat encoder interface.
The module handles the output from EnDat encoders which are built into B&R servo motors or
used as an encoder for external axes. The encoder input signals are monitored. In this way,

Technical Data
broken connections, shorted lines and encoder supply failure can be recognized.

Chapter 2
EnDat is a standard developed by Johanes Heidenhain GmbH (www.heidenhain.de),
incorporating the advantages of absolute and incremental position measurement and also offers
a read/write parameter memory in the encoder. With absolute position measurement (absolute
position is read in serially) the search home procedure is usually not required. Where necessary
a multi-turn encoder (4096 revolutions) should be installed. To save costs, a single turn encoder
and a reference switch can also be used. In this case, a search home procedure must be carried
out.
The incremental process allows the short delay times necessary for position measurement on
drives with exceptional dynamic properties. With the sinusoidal incremental signal and the fine
resolution in the EnDat module, a very high positioning resolution is achieved in spite of the
moderate signal frequencies used.
The parameter memory in the encoder is used by B&R to store motor data (among other things).
In this way, the ACOPOS servo drives are always automatically provided the correct motor
parameters and limit values.
During start-up, the AC120 module is automatically identified, configured and its parameters set
by the ACOPOS operating system. You only have to make sure that the maximum cable length
is not exceeded. When using a B&R EnDat cable, even this source of problems is avoided.

ACOPOS User's Manual 47

 Technical Data • ACOPOS Plug-in Modules

2.5.2 Order Data

Model Number Short Description Image

Plug-in Module
8AC120.60-1 ACOPOS plug-in module, EnDat encoder interface
Accessories
8CE005.12-1 EnDat cable, length 5m, 10 x 0.14mm² + 2 x 0.5mm²,
EnDat connector 17 pin Intercontec socket, servo
connector 15 pin DSUB plug, can be used in cable drag
chains, UL/CSA listed
8CE007.12-1 EnDat cable, length 7m, 10 x 0.14mm² + 2 x 0.5mm²,
EnDat connector 17 pin Intercontec socket, servo
connector 15 pin DSUB plug, can be used in cable drag
chains, UL/CSA listed
8CE010.12-1 EnDat cable, length 10m, 10 x 0.14mm² + 2 x 0.5mm²,
EnDat connector 17 pin Intercontec socket, servo
connector 15 pin DSUB plug, can be used in cable drag
chains, UL/CSA listed
8CE015.12-1 EnDat cable, length 15m, 10 x 0.14mm² + 2 x 0.5mm²,
EnDat connector 17 pin Intercontec socket, servo
connector 15 pin DSUB plug, can be used in cable drag
chains, UL/CSA listed
8CE020.12-1 EnDat cable, length 20m, 10 x 0.14mm² + 2 x 0.5mm²,
EnDat connector 17 pin Intercontec socket, servo
connector 15 pin DSUB plug, can be used in cable drag
chains, UL/CSA listed
8CE025.12-1 EnDat cable, length 25m, 10 x 0.14mm² + 2 x 0.5mm²,
EnDat connector 17 pin Intercontec socket, servo
connector 15 pin DSUB plug, can be used in cable drag
chains, UL/CSA listed

Table 23: Order Data AC120

48 ACOPOS User's Manual

 Technical Data • ACOPOS Plug-in Modules

2.5.3 Technical Data

Product ID 8AC120.60-1
General Information
C-UL-US Listed Yes
Module Type ACOPOS plug-in module
Slot 1) Currently limited to slots 2 and 3
Power Consumption

Technical Data
E0 ... EnDat single-turn, 512 lines Max. 1.7 W
E1 ... EnDat multi-turn, 512 lines Max. 2.3 W

Chapter 2
E2 ... EnDat single-turn, 32 lines (inductive) in preparation
E3 ... EnDat multi-turn, 32 lines (inductive) in preparation
Encoder Input
Connection, Module Side 15 pin DSUB socket
Indications UP/DN LEDs
Electrical Isolation No
EnDat Encoder - ACOPOS
Encoder Monitoring Yes
Resolution 2) 8000 * number of encoder lines
e.g. 4 million incr/rev for 512 line encoders
Precision 3) ---
Sine Cosine Inputs
Signal Transfer Differential Signals
Signal Frequency DC...400 kHz
Serial Interface
Signal Transfer RS485
Baud Rate 625 kBaud
Electrical Isolation Encoder-ACOPOS No, common-mode voltage max. ±7 V
Sense Lines 2, compensation of max. 1 V
Immunity 4)
IEC 61000-4-2 (ESD) 15 kV
IEC 61000-4-4 (Burst) 4 kV
Operational Conditions
Environmental Temperature during Operation 0 to 50 °C
Relative Humidity during Operation 5 to 95 %, non-condensing
Storage and Transport Conditions
Storage Temperature -25 to +55 °C
Relative Humidity for Storage 5 to 95 %, non-condensing
Transport Temperature -25 to +70 °C
Relative Humidity for Transport 95 % at 40 °C, non-condensing

Table 24: Technical Data AC120

1) Two EnDat modules can also be inserted. In this case, the module in slot 2 is automatically used for motor feedback.
2) Noise on the encoder signal reduces the resolution that can be used by approx. 3 bits (factor of 8).
3) The precision is actually limited by the encoder.
4) With B&R EnDat cable. Both screws on the module must be tightened!

ACOPOS User's Manual 49

 Technical Data • ACOPOS Plug-in Modules

2.6 AC122 - Resolver Interface

2.6.1 General Description

The AC122 plug-in module can be used in an ACOPOS slot. The module is equipped with a
resolver interface.
The plug-in module handles the output from resolvers which are built into B&R servo motors or
used as an encoder for external axes. This resolver delivers the absolute position over one
revolution. Normally, the movement path is longer than one revolution. In this case, a reference
switch must be used and a search home procedure carried out.
The encoder input signals are monitored. In this way, broken connections, shorted lines and
encoder supply failure can be recognized. 1)
The module is designed for the evaluation of BRX resolvers. These resolvers are fed with a
single sinusoidal signal (reference signal) and deliver two sinusoidal signals as the result. The
amplitude of these signals change with the angular position (sine or cosine form).
Unlike BRX resolvers, BRT resolvers can be fed with two sine signals which are offset by 90°. A
single sine signal with constant amplitude is returned. The phase position of this signal depends
on the angular position.
During start-up, the AC122 module is automatically identified by the ACOPOS operating system.
Making automatic adjustments to the motor (resolution parameter) and reading the motor
parameters and limit values is not possible because the resolver does not have parameter
memory like the EnDat encoder.
If the precision, resolution, bandwidth or ease of setting parameters is not sufficient with the
resolver, the EnDat system should be used (see Section 2.5 "AC120 - EnDat Encoder
Interface").

1) In preparation.

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 Technical Data • ACOPOS Plug-in Modules

2.6.2 Order Data

Model Number Short Description Image

8AC122.60-1 ACOPOS plug-in module, resolver interface
Accessories
8CR005.12-1 Resolver cable, length 5m, 3 x 2 x 24 AWG/19,
resolver connector 12 pin Intercontec socket, servo
connector 9 pin DSUB plug, can be used in cable drag
chains, UL/CSA listed

Technical Data
8CR007.12-1 Resolver cable, length 7m, 3 x 2 x 24 AWG/19,

Chapter 2
resolver connector 12 pin Intercontec socket, servo
connector 9 pin DSUB plug, can be used in cable drag
chains, UL/CSA listed
8CR010.12-1 Resolver cable, length 10m, 3 x 2 x 24 AWG/19,
resolver connector 12 pin Intercontec socket, servo
connector 9 pin DSUB plug, can be used in cable drag
chains, UL/CSA listed
8CR015.12-1 Resolver cable, length 15m, 3 x 2 x 24 AWG/19,
resolver connector 12 pin Intercontec socket, servo
connector 9 pin DSUB plug, can be used in cable drag
chains, UL/CSA listed
8CR020.12-1 Resolver cable, length 20m, 3 x 2 x 24 AWG/19,
resolver connector 12 pin Intercontec socket, servo
connector 9 pin DSUB plug, can be used in cable drag
chains, UL/CSA listed
8CR025.12-1 Resolver cable, length 25m, 3 x 2 x 24 AWG/19,
resolver connector 12 pin Intercontec socket, servo
connector 9 pin DSUB plug, can be used in cable drag
chains, UL/CSA listed

Table 25: Order Data AC122

2.6.3 Technical Data

Product ID 8AC122.60-1
General Information
C-UL-US Listed Yes
Module Type ACOPOS plug-in module
Slot 1) Currently limited to slots 2 and 3
Power Consumption Max. 1.2 W
Resolver Input
Resolver Type BRX 2)
Connection, Module Side 9 pin DSUB socket
Indications UP/DN LEDs
Electrical Isolation No
Resolver - ACOPOS
Encoder Monitoring Yes3)

Table 26: Technical Data AC122

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 Technical Data • ACOPOS Plug-in Modules

Product ID 8AC122.60-1
Resolution Depends on the maximum speed
14 bits/rev for n<3900 min-1
12 bits/rev for n<15600 min-1
Bandwidth 1.7 kHz for n<3900 min-1
2.5 kHz for n<15600 min-1
Precision ±8 angular minutes
Reference Output
Signal Transfer Differential Signals
Differential Voltage Typically 3.4 V eff
Output Current Max. 50 mA eff
Frequency 10 kHz
Sine Cosine Inputs
Signal Transfer Differential Signals
Differential Voltage Nom. 1.7 V eff max. 1.9 Veff
Possible Phase Shift to Ref. ±10°
Input Impedance at 10 kHz (per pin) 10.4 kΩ - j 11.1 kΩ
Electrical Isolation Encoder-ACOPOS No, common-mode voltage on the sine cosine inputs max ±20 V
Immunity 4)
IEC 61000-4-2 (ESD) 15 kV
IEC 61000-4-4 (Burst) 4 kV
Operational Conditions
Environmental Temperature during 0 to 50 °C
Operation
Relative Humidity during Operation 5 to 95 %, non-condensing
Storage and Transport Conditions
Storage Temperature -25 to +55 °C
Relative Humidity for Storage 5 to 95 %, non-condensing
Transport Temperature -25 to +70 °C
Relative Humidity for Transport 95 % at 40 °C, non-condensing

Table 26: Technical Data AC122 (cont.)

1) Two resolver modules can also be inserted. In this case, the module in slot 2 is automatically used for motor feedback.
2) BRX resolvers have 1 primary winding and 2 secondary windings. The primary winding is supplied with the reference output.
Sinusoidial voltages are induced into the secondary windings with amplitudes corresponding to the sine or cosine of the angle of
rotation.
3) In preparation.
4) With B&R resolver cable. Both screws on the module must be tightened!

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 Technical Data • ACOPOS Plug-in Modules

2.7 AC123 - Incremental Encoder and SSI Absolute Encoder Interface

2.7.1 General Description

The ACOPOS plug-in module AC123 is used to connect standard industrial incremental or
absolute encoders with a synchronous serial interface (SSI) to ACOPOS servo drives. For
example, this allows electronic gears to be configured which read master movements using
external encoders. If the encoder resolution is high enough, motor feedback for asynchronous
motors is also possible.

Technical Data
Chapter 2
With incremental encoders, the maximum counter frequency is 200 kHz. Single and multi-turn
encoders with a maximum of 31 bits at 200 kBaud can be read as absolute SSI encoders.
The position is determined cyclically (initiated by the module) and is exactly synchronized with
the ACOPOS controller clock. The input signals are monitored for both encoder types. In this
way, broken connections, shorted lines and encoder supply failure can be recognized.
With incremental encoders the count frequency and distance between edges is also monitored.
With absolute encoders, the parity bit is evaluated and a plausibility check carried out.

2.7.2 Order Data

Model Number Short Description Image

8AC123.60-1 ACOPOS plug-in module, incremental encoder and
SSI absolute encoder interface

Table 27: Order Data AC123

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 Technical Data • ACOPOS Plug-in Modules

2.7.3 Technical Data

Product ID 8AC123.60-1
General Information
C-UL-US Listed Yes
Module Type ACOPOS plug-in module
Slot 1) Currently limited to slots 2 and 3
Power Consumption Max. 7.5 W
Depends on the current requirements for the encoder connected 2)
Encoder Input
Connection, Module Side 15 pin DSUB socket
Indications UP/DN LEDs
Electrical Isolation Yes
Encoder - ACOPOS
Encoder Monitoring Yes
Signal Transfer Differential signal transfer
Cable Length 3) Max. 50 m
Immunity 4)
IEC 61000-4-2 (ESD) 15 kV
IEC 61000-4-4 (Burst) 4 kV
Encoder Supply
Supply Voltages Internal, select between 5 V/15 V
Sense Lines
for 5 V Yes, 2, compensation of max. 2 V
for 15 V No
Load
5V 350 mA
15 V 350 mA
Short Circuit, Overload Protection Yes
Incremental Encoder 5)
Signal Form Square wave pulse
Evaluation 4-fold
Input Frequency Max. 200 kHz
Count Frequency Max. 800 kHz
Reference Frequency Max. 200 kHz
Distance between Edges Min. 0.6 µs
Counter Size 32 bit
Inputs A, A\, B, B\, R, R\
Differential Voltage Inputs A, B, R
Minimum 2.5 V
Maximum 6V

Table 28: Technical Data AC123

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 Technical Data • ACOPOS Plug-in Modules

Product ID 8AC123.60-1
SSI Absolute Encoder
Baud Rate 200 kBaud
Word Size Max. 31 bit
Differential Voltage Clock Output - 120 Ω
Minimum 2.5 V
Maximum 5V
Differential Voltage Data Input
Minimum 2.5 V

Technical Data
Maximum 6V

Chapter 2
Operational Conditions
Environmental Temperature during 0 to 50 °C
Operation
Relative Humidity during Operation 5 to 95 %, non-condensing
Storage and Transport Conditions
Storage Temperature -25 to +55 °C
Relative Humidity for Storage 5 to 95 %, non-condensing
Transport Temperature -25 to +70 °C
Relative Humidity for Transport 95 % at 40 °C, non-condensing

Table 28: Technical Data AC123 (cont.)

1) Two modules can also be inserted. In this case, the module in slot 2 is automatically used for motor feedback.
2) The power consumption of the plug-in module can be approximated using the following formula:
PModule [W] = P Encoder [W] * k + 0.6 W
The power consumed by the encoder PEncoder is calculated from the selected encoder supply voltage (5 V/15 V) and the current
required:
PEncoder [W] = UEncoder [V] * IEncoder [A]
The following values must be used for k:
k = 1.2 (for 15 V encoder supply)
k = 1.75 (for 5 V encoder supply)
3) A cable with at least 4 x 2 x 0.14 mm² + 2 x 0.5 mm² is required for the maximum cable length. The sense lines must be used.
4) With shielded cable (single shield) and twisted pair signal lines (e.g. 4 x 2 x 0.14 mm² + 2 x 0.5 mm²). Both screws on the module must
be tightened!
5) Incremental encoders can be used as motor feedback only for asynchronous motors, but can only provide limited control quality for
this purpose. An encoder with at least 1000 lines must be used for motor feedback.

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 Technical Data • ACOPOS Plug-in Modules

2.8 AC130 - Digital Mixed Module

2.8.1 General Description

The AC130 plug-in module can be used in an ACOPOS slot. A maximum of 8 digital inputs or
10 digital outputs are available.
I/O points can be configured in pairs as inputs or outputs. The first three inputs have incremental
encoder functionality (A, B, R). The first two outputs can be operated in pulse width modulation
(PWM) mode.
The inputs are divided into 4 standard (max. 10 kHz) and 4 high speed (max. 100 kHz) inputs.
The outputs include 4 high speed (push-pull) outputs with a maximum current of 100 mA,
4 standard (high-side) outputs with a maximum current of 400 mA and 2 low speed (high-side)
outputs with a maximum current of 2 A. All outputs can be read.

2.8.2 Order Data

Model Number Short Description Image

8AC130.60-1 ACOPOS plug-in module, 8 digital I/O configurable in
pairs as 24V input or as output 400/100mA, 2 digital
outputs 2A, Order TB712 terminal block separately
Accessories
7TB712.9 Terminal block, 12 pin, screw clamps
7TB712.91 Terminal block, 12 pin, cage clamps
7TB712:90-02 Terminal block, 12 pin, 20 pcs., screw clamps
7TB712:91-02 Terminal block, 12 pin, 20 pcs., cage clamps

Table 29: Order Data AC130

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 Technical Data • ACOPOS Plug-in Modules

2.8.3 Technical Data

Product ID 8AC130.60-1
General Information
C-UL-US Listed Yes
Module Type ACOPOS plug-in module
Slot Currently limited to slots 3 and 4
Power Consumption Max. 0.8 W

Technical Data
Inputs/Outputs

Chapter 2
Connection, Module Side 12 conductor pin-connector
Configuration of the Inputs/Outputs Configured in pairs as input or output
Indication 24 V - LED
Immunity 1)
IEC 61000-4-2 (ESD) 15 kV
IEC 61000-4-4 (Burst) 2 kV
Power Supply
Power Supply
Minimum 18 VDC
Nominal 24 VDC
Maximum 30 VDC
Reverse Polarity Protection Yes
Voltage Monitoring (24 V - LED) Yes, supply voltage >18 V
Inputs
Number of Inputs Max. 8
Wiring Sink
Electrical Isolation
Input - ACOPOS Yes
Input - Input No
Input Voltage
Minimum 18 VDC
Nominal 24 VDC
Maximum 30 VDC
Switching Threshold
LOW <5V
HIGH > 15 V
Input Current at Nominal Voltage
Inputs 1 - 4 Approx. 10 mA
Inputs 5 - 8 Approx. 5.5 mA
Switching Delay
Inputs 1 - 4 Max. 5 µs
Inputs 5 - 8 Max. 35 µs
Event Counter
Signal Form Square wave pulse
Input Frequency Max. 100 kHz

Table 30: Technical Data AC130

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 Technical Data • ACOPOS Plug-in Modules

Product ID 8AC130.60-1
Counter Size 16 bit
Inputs
Input 1 Counter 1
Input 2 Counter 2
Incremental Encoder
Signal Form Square wave pulse
Evaluation 4-fold
Encoder Monitoring No
Input Frequency Max. 62.5 kHz
Count Frequency Max. 250 kHz
Reference Frequency Max. 62.5 kHz
Distance between Edges Min. 2.5 µs
Counter Size 16 bit
Inputs
Input 1 Channel A
Input 2 Channel B
Input 3 Reference Pulse R
Outputs
Number of Outputs Max. 10
Type Transistor Outputs
Outputs 1 - 4 push-pull
Outputs 5 - 10 high-side
Electrical Isolation
Output - ACOPOS Yes
Output - Output No
Switching Voltage
Minimum 18 VDC
Nominal 24 VDC
Maximum 30 VDC
Continuous Current
Outputs 1 - 4 Max. 100 mA
Outputs 5 - 8 Max. 400 mA
Outputs 9 - 10 Max. 2 A
Switching Delay
Outputs 1 - 4 Max. 5 µs
Outputs 5 - 8 Max. 50 µs
Outputs 9 - 10 Max. 500 µs
Switching Frequency (resistive load)
Outputs 1 - 2 Max. 10 kHz (max. 20 kHz in PWM mode)
Outputs 3 - 4 Max. 10 kHz
Outputs 5 - 8 Max. 5 kHz
Outputs 9 - 10 Max. 100 Hz
PWM Outputs 1 - 2
Resolution of the Pulse Width 13 bit
Period Duration 50 µs - 400 µs

Table 30: Technical Data AC130 (cont.)

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 Technical Data • ACOPOS Plug-in Modules

Product ID 8AC130.60-1
Protection
Short Circuit Protection Yes
Overload Protection Yes
Short Circuit Current at 24 V (until cut-off)
Outputs 1 - 4 Approx. 1 A
Outputs 5 - 8 Approx. 1.2 A
Outputs 9 - 10 Approx. 24 A
Readable Outputs Yes

Technical Data
Operational Conditions

Chapter 2
Environmental Temperature during 0 to 50 °C
Operation
Relative Humidity during Operation 5 to 95 %, non-condensing
Storage and Transport Conditions
Storage Temperature -25 to +55 °C
Relative Humidity for Storage 5 to 95 %, non-condensing
Transport Temperature -25 to +70 °C
Relative Humidity for Transport 95 % at 40 °C, non-condensing

Table 30: Technical Data AC130 (cont.)

1) Shielded cables must be used for inputs 1 - 4. Both screws on the module must be tightened!

ACOPOS User's Manual 59

 Technical Data • Cables

3. Cables

3.1 General Information

B&R offers the cables for ACOPOS servo drives in six different lengths. All cables can be used
for drag chain installations.
To prevent disturbances to encoder signals, the holding brake and temperature sensor wires are
in the motor cable and not in the EnDat or resolver cable.

3.1.1 Manufactured Cables

Using the B&R cable guarantees that the EMC limits are not exceeded. The cables are
manufactured in the EU and are therefore subject to the strictest quality standards.

Information:
If other cables are used, make sure that they have the same wave parameters. If
deviations exist, additional measures are necessary to ensure that EMC guidelines
are met.

60 ACOPOS User's Manual

 Technical Data • Cables

3.2 Motor Cables

3.2.1 Order Data

Model Number Short Description Image

Motor Cables 1.5 mm²
8CM005.12-1 Motor cable, length 5m, 4 x 1.5mm² + 2 x 2 x 0.75mm²,
motor connector 8 pin Intercontec socket, can be used
in cable drag chains, UL/CSA listed

Technical Data
8CM007.12-1 Motor cable, length 7m, 4 x 1.5mm² + 2 x 2 x 0.75mm²,

Chapter 2
motor connector 8 pin Intercontec socket, can be used
in cable drag chains, UL/CSA listed
8CM010.12-1 Motor cable, length 10m, 4 x 1.5mm² +
2 x 2 x 0.75mm², motor connector 8 pin Intercontec
socket, can be used in cable drag chains, UL/CSA
listed
8CM015.12-1 Motor cable, length 15m, 4 x 1.5mm² +
2 x 2 x 0.75mm², motor connector 8 pin Intercontec
socket, can be used in cable drag chains, UL/CSA
listed
8CM020.12-1 Motor cable, length 20m, 4 x 1.5mm² +
2 x 2 x 0.75mm², motor connector 8 pin Intercontec
socket, can be used in cable drag chains, UL/CSA
listed
8CM025.12-1 Motor cable, length 25m, 4 x 1.5mm² +
2 x 2 x 0.75mm², motor connector 8 pin Intercontec
socket, can be used in cable drag chains, UL/CSA
listed
Motor Cables 4 mm²
8CM005.12-3 Motor cable, length 5m, 4 x 4mm² + 2 x 2 x 1mm²,
motor connector 8 pin Intercontec socket, can be used
in cable drag chains, UL/CSA listed
8CM007.12-3 Motor cable, length 7m, 4 x 4mm² + 2 x 2 x 1mm²,
motor connector 8 pin Intercontec socket, can be used
in cable drag chains, UL/CSA listed
8CM010.12-3 Motor cable, length 10m, 4 x 4mm² + 2 x 2 x 1mm²,
motor connector 8 pin Intercontec socket, can be used
in cable drag chains, UL/CSA listed
8CM015.12-3 Motor cable, length 15m, 4 x 4mm² + 2 x 2 x 1mm²,
motor connector 8 pin Intercontec socket, can be used
in cable drag chains, UL/CSA listed
8CM020.12-3 Motor cable, length 20m, 4 x 4mm² + 2 x 2 x 1mm²,
motor connector 8 pin Intercontec socket, can be used
in cable drag chains, UL/CSA listed
8CM025.12-3 Motor cable, length 25m, 4 x 4mm² + 2 x 2 x 1mm²,
motor connector 8 pin Intercontec socket, can be used
in cable drag chains, UL/CSA listed

Table 31: Order data for motor cables

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 Technical Data • Cables

Model Number Short Description Image

Motor Cables 10 mm²
8CM005.12-5 Motor cable, length 5m, 4 x 10mm² + 2 x 2 x 1.5mm²,
motor connector 8 pin Intercontec socket, can be used
in cable drag chains, UL/CSA listed
8CM007.12-5 Motor cable, length 7m, 4 x 10mm² + 2 x 2 x 1.5mm²,
motor connector 8 pin Intercontec socket, can be used
in cable drag chains, UL/CSA listed
8CM010.12-5 Motor cable, length 10m, 4 x 10mm² + 2 x 2 x 1.5mm²,
motor connector 8 pin Intercontec socket, can be used
in cable drag chains, UL/CSA listed
8CM015.12-5 Motor cable, length 15m, 4 x 10mm² + 2 x 2 x 1.5mm²,
motor connector 8 pin Intercontec socket, can be used
in cable drag chains, UL/CSA listed
8CM020.12-5 Motor cable, length 20m, 4 x 10mm² + 2 x 2 x 1.5mm²,
motor connector 8 pin Intercontec socket, can be used
in cable drag chains, UL/CSA listed
8CM025.12-5 Motor cable, length 25m, 4 x 10mm² + 2 x 2 x 1.5mm²,
motor connector 8 pin Intercontec socket, can be used
in cable drag chains, UL/CSA listed
Motor Cables 35 mm²
8CM005.12-8 Motor cable, length 5m, 4 x 35mm² + 2 x 2 x 1.5mm²,
can be used in cable drag chains, UL/CSA listed
8CM007.12-8 Motor cable, length 7m, 4 x 35mm² + 2 x 2 x 1.5mm²,
can be used in cable drag chains, UL/CSA listed
8CM010.12-8 Motor cable, length 10m, 4 x 35mm² + 2 x 2 x 1.5mm²,
can be used in cable drag chains, UL/CSA listed
8CM015.12-8 Motor cable, length 15m, 4 x 35mm² + 2 x 2 x 1.5mm²,
can be used in cable drag chains, UL/CSA listed
8CM020.12-8 Motor cable, length 20m, 4 x 35mm² + 2 x 2 x 1.5mm²,
can be used in cable drag chains, UL/CSA listed
8CM025.12-8 Motor cable, length 25m, 4 x 35mm² + 2 x 2 x 1.5mm²,
can be used in cable drag chains, UL/CSA listed

Table 31: Order data for motor cables (cont.)

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 Technical Data • Cables

3.2.2 Cable Specification

Product ID Motor Cables 1.5 mm² Motor Cables 4 mm²

General Information
Cable Cross Section 4 x 1.5 mm² + 2 x 2 x 0.75 mm² 4 x 4 mm² + 2 x 2 x 1 mm²
Durability Oil resistant according to VDE 0472 part 803, as well as standard hydraulic oil
Certification UL AWM Style 20669, 90 °C, 600 V, E63216 and CSA AWM I/II A/B, 90 °C, 600 V, FT1 LL46064
Conductor

Technical Data
Power Lines 1.5 mm², tinned Cu wire 4 mm², tinned Cu wire

Chapter 2
Wire Insulation Special thermoplastic material
Wire Colors Black, brown, blue, yellow/green
Signal Lines 0.75 mm², tinned Cu wire 1 mm², tinned Cu wire
Wire Insulation Special thermoplastic material
Wire Colors White, white/red, white/blue, white/green
Cable Construction
Power Lines
Stranding No
Shield No
Signal Lines
Stranding White with white/red and white/blue with white/green
Shield Separate shielding for pairs, tinned Cu mesh, optical coverage >85 % and foil banding
Cable Stranding With filler elements and foil banding
Cable Shielding Tinned Cu mesh, optical coverage >85 % and wrapped in isolating fabric
Outer Sheathing
Material PUR
Color Orange, similar to RAL 2003 flat
Labeling BERNECKER + RAINER 4x1.5+2x2x0.75 FLEX BERNECKER + RAINER 4x4.0+2x2x1.5 FLEX
Electrical Characteristics
Conductor Resistance
Power Lines ≤ 14 Ω/km ≤ 5.2 Ω/km
Signal Lines ≤ 29 Ω/km ≤ 14 Ω/km
Insulation Resistance >200 MΩ per km
Isolation Voltage
Wire/wire 3 kV
Wire/shield 1 kV
Operating Voltage Max. 600 V
Mechanical Characteristics
Temperature Range
Moving -10 °C to 70 °C
Still -20 °C to 90 °C
Outer Diameter 12.8 mm ±0,4 mm 15.8 mm ±0.5 mm
Flex Radius >96 mm >118.5 mm
Speed ≤ 4 m/s
Acceleration <60 m/s²

Table 32: Cable specifications for 1.5 and 4 mm² motor cables

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 Technical Data • Cables

Product ID Motor Cables 1.5 mm² Motor Cables 4 mm²

Flex Cycles ≥ 3,000,000
Weight 0.26 kg/m 0.45 kg/m

Table 32: Cable specifications for 1.5 and 4 mm² motor cables (cont.)

Product ID Motor Cables 10 mm² Motor Cables 35 mm²

General Information
Cable Cross Section 4 x 10 mm² + 2 x 2 x 1.5 mm² 4 x 35 mm² + 2 x 2 x 1.5 mm²
Durability Oil resistant according to VDE 0472 part 803, as well as standard hydraulic oil
Certification UL AWM Style 20669, 90 °C, 600 V, E63216 and CSA AWM I/II A/B, 90 °C, 600 V, FT1 LL46064
Conductor
Power Lines 10 mm², tinned Cu wire 35 mm², tinned Cu wire
Wire Insulation Special thermoplastic material
Wire Colors Black, brown, blue, yellow/green
Signal Lines 1.5 mm², tinned Cu wire
Wire Insulation Special thermoplastic material
Wire Colors White, white/red, white/blue, white/green
Cable Construction
Power Lines
Stranding No
Shield No
Signal Lines
Stranding White with white/red and white/blue with white/green
Shield Separate shielding for pairs, tinned Cu mesh, optical coverage >85 % and foil banding
Cable Stranding With filler elements and foil banding
Cable Shielding Tinned Cu mesh, optical coverage >85 % and wrapped in isolating fabric
Outer Sheathing
Material PUR
Color Orange, similar to RAL 2003 flat
Labeling BERNECKER + RAINER 4x10.0+2x2x1.5 FLEX BERNECKER + RAINER 4x35.0+2x2x1.5 FLEX
Electrical Characteristics
Conductor Resistance
Power Lines ≤ 2.1 Ω/km ≤ 0.6 Ω/km
Signal Lines ≤ 14 Ω/km ≤ 14 Ω/km
Insulation Resistance >200 MΩ per km
Isolation Voltage
Wire/wire 3 kV
Wire/shield 1 kV
Operating Voltage Max. 600 V

Table 33: Cable specifications for 10 and 35 mm² motor cables

64 ACOPOS User's Manual

 Technical Data • Cables

Product ID Motor Cables 10 mm² Motor Cables 35 mm²

Mechanical Characteristics
Temperature Range
Moving -10 °C to 70 °C
Still -20 °C to 90 °C
Outer Diameter 20.1 mm ±0.7 mm 32.5 mm ±1 mm
Flex Radius >150.8 mm >243.8 mm
Speed ≤ 4 m/s

Technical Data
Acceleration <60 m/s²

Chapter 2
Flex Cycles ≥ 3,000,000
Weight 0.77 kg/m 2.2 kg/m

Table 33: Cable specifications for 10 and 35 mm² motor cables (cont.)

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 Technical Data • Cables

3.3 EnDat Cables

3.3.1 Order Data

Model Number Short Description Image

8CE005.12-1 EnDat cable, length 5m, 10 x 0.14mm² + 2 x 0.5mm²,
EnDat connector 17 pin Intercontec socket, servo
connector 15 pin DSUB plug, can be used in cable drag
chains, UL/CSA listed
8CE007.12-1 EnDat cable, length 7m, 10 x 0.14mm² + 2 x 0.5mm²,
EnDat connector 17 pin Intercontec socket, servo
connector 15 pin DSUB plug, can be used in cable drag
chains, UL/CSA listed
8CE010.12-1 EnDat cable, length 10m, 10 x 0.14mm² + 2 x 0.5mm²,
EnDat connector 17 pin Intercontec socket, servo
connector 15 pin DSUB plug, can be used in cable drag
chains, UL/CSA listed
8CE015.12-1 EnDat cable, length 15m, 10 x 0.14mm² + 2 x 0.5mm²,
EnDat connector 17 pin Intercontec socket, servo
connector 15 pin DSUB plug, can be used in cable drag
chains, UL/CSA listed
8CE020.12-1 EnDat cable, length 20m, 10 x 0.14mm² + 2 x 0.5mm²,
EnDat connector 17 pin Intercontec socket, servo
connector 15 pin DSUB plug, can be used in cable drag
chains, UL/CSA listed
8CE025.12-1 EnDat cable, length 25m, 10 x 0.14mm² + 2 x 0.5mm²,
EnDat connector 17 pin Intercontec socket, servo
connector 15 pin DSUB plug, can be used in cable drag
chains, UL/CSA listed

Table 34: Order data for EnDat cables

3.3.2 Cable Specification

Product ID EnDat Cables

General Information
Cable Cross Section 10 x 0.14 mm² + 2 x 0.50 mm²
Durability Oil resistant according to VDE 0472 part 803, as well as standard hydraulic oil
Certification UL AWM Style 20963, 80 °C, 30 V, E63216 and CSA AWM I/II A/B, 90 °C, 30 V,
FT1 LL46064
Conductor
Signal Lines 0.14 mm², tinned Cu wire
Wire Insulation Special thermoplastic material
Wire Colors Blue, brown, yellow, gray, green, pink, red, black, violet, white
Supply Lines 0.5 mm², tinned Cu wire
Wire Insulation Special thermoplastic material
Wire Colors White/green, white/red

Table 35: Cable specifications for EnDat cables

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 Technical Data • Cables

Product ID EnDat Cables

Cable Construction
Signal Lines
Stranding No
Shield No
Supply Lines
Stranding White/red with white/green and filler elements
Shield No
Cable Stranding with foil banding

Technical Data
Cable Shielding Cu mesh, optical coverage >85 % and wrapped in isolating fabric

Chapter 2
Outer Sheathing
Material PUR
Color Orange, similar to RAL 2003 flat
Labeling BERNECKER + RAINER 10x0.14+2x0.50 FLEX
Electrical Characteristics
Conductor Resistance
Signal Lines ≤ 140 Ω/km
Supply Lines ≤ 40 Ω/km
Insulation Resistance >200 MΩ per km
Isolation Voltage
Wire/wire 1.5 kV
Wire/shield 0.8 kV
Operating Voltage Max. 30 V
Mechanical Characteristics
Temperature Range
Moving -10 °C to 70 °C
Still -20 °C to 90 °C
Outer Diameter 7.3 mm ±0.25 mm
Flex Radius >55 mm
Speed ≤ 4 m/s
Acceleration <60 m/s²
Flex Cycles ≥ 3,000,000
Weight 0.08 kg/m

Table 35: Cable specifications for EnDat cables (cont.)

ACOPOS User's Manual 67

 Technical Data • Cables

3.4 Resolver Cables

3.4.1 Order Data

Model Number Short Description Image

8CR005.12-1 Resolver cable, length 5m, 3 x 2 x 24 AWG/19,
resolver connector 12 pin Intercontec socket, servo
connector 9 pin DSUB plug, can be used in cable drag
chains, UL/CSA listed
8CR007.12-1 Resolver cable, length 7m, 3 x 2 x 24 AWG/19,
resolver connector 12 pin Intercontec socket, servo
connector 9 pin DSUB plug, can be used in cable drag
chains, UL/CSA listed
8CR010.12-1 Resolver cable, length 10m, 3 x 2 x 24 AWG/19,
resolver connector 12 pin Intercontec socket, servo
connector 9 pin DSUB plug, can be used in cable drag
chains, UL/CSA listed
8CR015.12-1 Resolver cable, length 15m, 3 x 2 x 24 AWG/19,
resolver connector 12 pin Intercontec socket, servo
connector 9 pin DSUB plug, can be used in cable drag
chains, UL/CSA listed
8CR020.12-1 Resolver cable, length 20m, 3 x 2 x 24 AWG/19,
resolver connector 12 pin Intercontec socket, servo
connector 9 pin DSUB plug, can be used in cable drag
chains, UL/CSA listed
8CR025.12-1 Resolver cable, length 25m, 3 x 2 x 24 AWG/19,
resolver connector 12 pin Intercontec socket, servo
connector 9 pin DSUB plug, can be used in cable drag
chains, UL/CSA listed

Table 36: Order data for resolver cables

68 ACOPOS User's Manual

 Technical Data • Cables

3.4.2 Cable Specification

Product ID Resolver Cables

General Information
Cable Cross Section 3 x 2 x 24 AWG/19
Durability Oil resistant according to VDE 0472 part 803, as well as standard hydraulic oil
Certification UL AWM Style 20671, 90 °C, 30 V, E63216 and CSA AWM, 90 °C, 30 V, I/II A/B FT1 LL46064
Conductor

Technical Data
Signal Lines 24 AWG/19, tinned Cu wire

Chapter 2
Wire Insulation Special thermoplastic material
Wire Colors White, brown, green, yellow, gray, pink
Cable Construction
Signal Lines
Stranding White with brown, green with yellow, gray with pink
Shield No
Cable Stranding The 3 pairs together covered by foil banding
Cable Shielding Cu mesh, optical coverage ≥90 % and wrapped in isolating fabric
Outer Sheathing
Material PUR
Color Orange, similar to RAL 2003 flat
Labeling BERNECKER + RAINER 3x2x24 AWG FLEX
Electrical Characteristics
Conductor Resistance 24 AWG ≤ 86 Ω/km
Insulation Resistance >200 MΩ per km
Isolation Voltage
Wire/wire 1.5 kV
Wire/shield 0.8 kV
Operating Voltage Max. 30 V
Mechanical Characteristics
Temperature Range
Moving -10 °C to 80 °C
Still -40 °C to 90 °C
Outer Diameter 6.5 mm ±0.2 mm
Flex Radius ≥50 mm
Speed ≤ 4 m/s
Acceleration <60 m/s²
Flex Cycles ≥ 3,000,000
Weight 0.07 kg/m

Table 37: Cable specifications for resolver cables

ACOPOS User's Manual 69

 Technical Data • Connectors

4. Connectors

4.1 General Information

B&R offers five different motor/encoder connectors for AC servo motors. All connectors have
IP67 protection. The metallic housing provides a protective ground connection on the housing
according to VDE 0627. All plastic used in the connector is UL94/V0 listed. High quality, gold
plated cage connector contacts guarantee a high level of contact security even when reinserted
many times.
Using the B&R connector guarantees that the EMC limits for the connection are not exceeded.
Make sure that connectors are put together correctly including a proper shield connection.

70 ACOPOS User's Manual

 Technical Data • Connectors

4.2 Motor Connectors

4.2.1 Order Data

Model Number Short Description Image

Cable Diameter 9 - 17 mm
8PM001.00-1 Motor connector 8 pin Intercontec socket, crimp range
4 x 0.5-2.5mm² + 4 x 0.06-1.0mm², for cable ø
9-14mm, IP67, UL/CSA listed

Technical Data
8PM002.00-1 Motor connector 8 pin Intercontec socket, crimp range

Chapter 2
4 x 0.5-4.0mm² + 4 x 0.06-1.0mm², for cable ø
14-17mm, IP67, UL/CSA listed

Cable Diameter 17 - 26 mm
8PM003.00-1 Motor connector 8 pin Intercontec socket, crimp range
4 x 1.5-10mm² + 4 x 0.5-2.5mm², for cable ø 17-26mm,
IP67, UL/CSA listed

Table 38: Order data for motor connectors

ACOPOS User's Manual 71

 Technical Data • Connectors

4.2.2 Specifications for 8PM001.00-1 and 8PM002.00-1

Product ID 8PM001.00-1 8PM002.00-1

General Information
Contacts 8 (4 power and 4 signal contacts)
Degree of Pollution 3
Installation Altitude up to 4,000 m
Insulator PA, UL94/V0 listed
Contacts Gold plated brass
Protective Ground Connection on Housing According to VDE 0627
Protection according to DIN 40050 IP67 when connected
Certifications UL/CSA
Electrical Characteristics
Overvoltage Category 3
Power Contacts
Nominal Current 25 A
Nominal Voltage 800 VAC / VDC
Isolation Voltage (L-L) 6000 V
Contact Resistance <3 mΩ
Signal Contacts
Nominal Current 9A
Nominal Voltage 250 VAC / VDC
Isolation Voltage (L-L) 2500 V
Contact Resistance <5 mΩ
Mechanical Characteristics
Temperature Range -40 °C to 125 °C
Housing Material Zinc casting, nickel plated
Gaskets Viton, H-NBR
Crimp Range 4 x 0.5 -2.5 mm² + 4 x 0.06 - 1 mm² 4 x 0.5 -4 mm² + 4 x 0.06 - 1 mm²
Cable ø 9 -14 mm 14 -17 mm
Manufacturer Information
Manufacturer INTERCONTEC
Internet Address http://www.intercontec.com
Manufacturer’s Product ID BSTA 108 FR 19 08 0006 000 BSTA 108 FR 35 16 0006 000

Table 39: Specifications for motor connectors 8PM001.00-1 and 8PM002.00-1

72 ACOPOS User's Manual

 Technical Data • Connectors

4.2.3 Specifications for 8PM003.00-1

Product ID 8PM003.00-1
General Information
Contacts 8 (4 power and 4 signal contacts)
Degree of Pollution 3
Installation Altitude up to 4,000 m
Insulator PA, UL94/V0 listed

Technical Data
Contacts Gold plated brass

Chapter 2
Protective Ground Connection on Housing According to VDE 0627
Protection according to DIN 40050 IP67 when connected
Certifications UL/CSA
Electrical Characteristics
Overvoltage Category 3
Power Contacts
Nominal Current 75 A
Nominal Voltage 630 VAC / VDC
Isolation Voltage (L-L) 6000 V
Contact Resistance <1 mΩ
Signal Contacts
Nominal Current 30 A
Nominal Voltage 250 VAC / VDC
Isolation Voltage (L-L) 4000 V
Contact Resistance <3 mΩ
Mechanical Characteristics
Temperature Range -40 °C to 130 °C
Housing Material Aluminum, nickel plated
Gaskets Viton
Crimp Range 4 x 1.5 -10 mm² + 4 x 0.5 -2.5 mm²
Cable ø 17 -26 mm
Manufacturer Information
Manufacturer INTERCONTEC
Internet Address http://www.intercontec.com
Manufacturer’s Product ID CSTA 264 FR 48 25 0001 000

Table 40: Specifications for motor connector 8PM003.00-1

ACOPOS User's Manual 73

 Technical Data • Connectors

4.3 Encoder Connectors

4.3.1 Order Data

Model Number Short Description Image

EnDat Connector
8PE001.00-1 EnDat Connector 17 pin Intercontec socket, crimp
range 17 x 0.06-1,0mm², for cable ø 9-12mm, IP67,
UL/CSA listed

Resolver Connector
8PR001.00-1 Resolver connector 12 pin Intercontec socket, crimp
range 12 x 0.06-1,0mm², for cable ø 5.5-10.5mm,
IP67, UL/CSA listed

Table 41: Order data for encoder connectors

74 ACOPOS User's Manual

 Technical Data • Connectors

4.3.2 Specifications for EnDat Connector 8PE001.00-1

Product ID 8PE001.00-1
General Information
Contacts 17 signal contacts
Degree of Pollution 3
Installation Altitude up to 2,000 m
Insulator PBT, UL94/V0 listed

Technical Data
Contacts Gold plated brass

Chapter 2
Protective Ground Connection on Housing According to VDE 0627
Protection according to DIN 40050 IP67 when connected
Certifications UL/CSA
Electrical Characteristics
Signal Contacts
Nominal Current 9A
Nominal Voltage 32 V
Isolation Voltage (L-L) 1500 V
Contact Resistance <5 mΩ
Mechanical Characteristics
Temperature Range -40 °C to 125 °C
Housing Material Zinc casting, nickel plated
Gaskets Viton, H-NBR
Crimp Range 17 x 0.06 - 1 mm²
Cable ø 9 -12 mm
Manufacturer Information
Manufacturer INTERCONTEC
Internet Address http://www.intercontec.com
Manufacturer’s Product ID ASTA 035 FR 11 12 0005 000

Table 42: Specifications for EnDat Connector 8PE001.00-1

ACOPOS User's Manual 75

 Technical Data • Connectors

4.3.3 Specifications for Resolver Connector 8PR001.00-1

Product ID 8PR001.00-1
General Information
Contacts 12 signal contacts
Degree of Pollution 3
Installation Altitude up to 2,000 m
Insulator PBT, UL94/V0 listed
Contacts Gold plated brass
Protective Ground Connection on Housing According to VDE 0627
Protection according to DIN 40050 IP67 when connected
Certifications UL/CSA
Electrical Characteristics
Signal Contacts
Nominal Current 9A
Nominal Voltage 160 V
Isolation Voltage (L-L) 2500 V
Contact Resistance <5 mΩ
Mechanical Characteristics
Temperature Range -40 °C to 125 °C
Housing Material Zinc casting, nickel plated
Gaskets Viton, H-NBR
Crimp Range 12 x 0.06 - 1 mm²
Cable ø 5.5 - 10.5 mm
Manufacturer Information
Manufacturer INTERCONTEC
Internet Address http://www.intercontec.com
Manufacturer’s Product ID ASTA 021 FR 11 10 0005 000

Table 43: Specifications for Resolver Connector 8PR001.00-1

76 ACOPOS User's Manual

 Installation • General Information

CHAPTER 3 • INSTALLATION

1. General Information

Make sure that installation takes place on a flat surface which is correctly dimensioned. The
dimensional diagram lists the number and type of mounting screws to be used.
The ring screws contained in the delivery can be attached to the device to lift ACOPOS 1640 and
ACOPOS 128M drives:

Installation
Chapter 3

Figure 12: Attaching the ring screws contained in the delivery to ACOPOS 1640 and 128M drives

ACOPOS User's Manual 77

 Installation • General Information

ACOPOS servo drives can only be installed in an environment which corresponds to pollution
degree II (non-conductive material). When installing the device, make sure that the maximum
operating temperature (40 °C) is not exceeded and IP20 protection is provided as specified in
the technical data.
For proper air circulation, at least 80 mm has to be left free above and below the ACOPOS servo
drive. ACOPOS servo drives can be mounted directly next to each other; the required distance
between devices can be found in the respective dimensional diagram.

78 ACOPOS User's Manual

 Installation • Dimensional Diagram and Installation Dimensions

2. Dimensional Diagram and Installation Dimensions

2.1 ACOPOS 1022, 1045, 1090

Installation
Chapter 3

Figure 13: Dimensional diagram and installation dimensions for ACOPOS 1022, 1045, 1090

1) For proper air circulation, at least 80 mm has to be left free above and below the ACOPOS servo drive.

ACOPOS User's Manual 79

 Installation • Dimensional Diagram and Installation Dimensions

2.2 ACOPOS 1180, 1320

Figure 14: Dimensional diagram and installation dimensions for ACOPOS 1180, 1320

1) For proper air circulation, at least 80 mm has to be left free above and below the ACOPOS servo drive. Approximately 100 mm free
space is required under the ACOPOS servo drive to prevent cabling problems.

80 ACOPOS User's Manual

 Installation • Dimensional Diagram and Installation Dimensions

2.3 ACOPOS 1640

Installation
Chapter 3

Figure 15: Dimensional diagram and installation dimensions for ACOPOS 1640

1) For proper air circulation, at least 80 mm has to be left free above and below the ACOPOS servo drive. Approximately 160 mm free
space is required under the ACOPOS servo drive to prevent cabling problems.

ACOPOS User's Manual 81

 Installation • Dimensional Diagram and Installation Dimensions

2.4 ACOPOS 128M

Figure 16: Dimensional diagram and installation dimensions for ACOPOS 128M

1) For proper air circulation, at least 80 mm has to be left free above and below the ACOPOS servo drive. Approximately 160 mm free space is
required under the ACOPOS servo drive to prevent cabling problems.

82 ACOPOS User's Manual

 Installation • Installation and Removal of Plug-in Modules

3. Installation and Removal of Plug-in Modules

3.1 General Information

All ACOPOS servo drives are equipped with four slots for plug-in modules. At present, the
following module arrangements must be used:

Plug-in Module Operation Possible in this Slot

1 2 3 4
8AC110.60-2 ✓ x x x
8AC112.60-1 ✓ x x x
8AC120.60-1 x ✓ ✓ x
8AC122.60-1 x ✓ ✓ x
8AC123.60-1 x ✓ ✓ x
8AC130.60-1 x x ✓ ✓

Installation
Chapter 3
Table 44: Slot overview for ACOPOS plug-in modules

Caution!
• Keep the plug-in modules in the original packaging and only take them out
immediately before installation.
• Avoid touching the plug-in modules anywhere but on the front cover.
• Take the necessary steps to protect against electrostatic discharges.

3.1.1 Installation

1) Disconnect the ACOPOS servo drive from the power mains and prevent reconnection.
2) Switch off 24 VDC supply voltage.
3) Remove screw from the bottom of the slot cover.
4) Loosen screw on the front (don't remove it completely, the screw could fall into the
ACOPOS servo drive!).

ACOPOS User's Manual 83

 Installation • Installation and Removal of Plug-in Modules

5) Remove slot cover.

Figure 17: Installing ACOPOS plug-in modules

6) Insert plug-in module in the free slot (see diagram shown above).
7) Fasten the plug-in module with the two screws.
8) Switch on 24 VDC supply voltage.
9) Connect ACOPOS servo drive to the power mains.

3.1.2 Removal

1) Disconnect the ACOPOS servo drive from the power mains and prevent reconnection.
2) Switch off 24 VDC supply voltage.
3) Remove screw from the bottom of the plug-in module.
4) Loosen screw on the front (don't remove it completely, the screw could fall into the
ACOPOS servo drive!).
5) Remove plug-in module.
6) Insert slot cover in free slot.
7) Fasten the slot cover with the two screws.
8) Switch on 24 VDC supply voltage.
9) Connect ACOPOS servo drive to the power mains.

84 ACOPOS User's Manual

 Installation • Installing Various ACOPOS Series Devices Directly Next to Each Other

4. Installing Various ACOPOS Series Devices Directly Next to Each

Other

When installing various ACOPOS series devices directly next to each other, we recommend
aligning the vertical position so that the LED displays of the respective devices are lined up.

Installation
Chapter 3
Figure 18: Installing various ACOPOS series devices directly next to each other

You can see from the image above that the vertical offset of the upper mounting holes is 10 mm.
The distances for the lower mounting holes and the number and size of the screws required can
be taken from the dimensional diagrams for the respective ACOPOS servo drives.

ACOPOS User's Manual 85

 Installation • Installing Various ACOPOS Series Devices Directly Next to Each Other

Overview of the vertical offsets:

ACOPOS
Installed next to
1022 1045 1090 1180 1320 1640 128M
1022
1045
1090 No offset 10 mm
ACOPOS 1180
1320
1640
10 mm No offset
128M

Table 45: Overview of the vertical offsets (ACOPOS - ACOPOS)

86 ACOPOS User's Manual

 Installation • Using Cooling Aggregates in Switching Cabinets

5. Using Cooling Aggregates in Switching Cabinets

To prevent exceeding the required environmental temperatures, it may be necessary to cool the
air inside of a switching cabinet.

Caution!
Incorrect installation of cooling aggregates may cause condensation which can
damage the ACOPOS servo drives installed there!
Condensation can enter the ACOPOS servo drives with the cooled air stream!

Make sure that only well sealed switching cabinets are used (condensation caused by outside
air entering the switching cabinet).
During operation with the switching cabinet doors open (e.g. service), the ACOPOS servo drives
are not allowed to be cooler than the air in the switching cabinet at any time after the doors are

Installation
Chapter 3
closed.
To keep the temperature of the ACOPOS servo drives and the switching cabinet at the same
level, the cooling aggregate must remain in operation even when the system is switched off.
Cooling aggregates must be installed in a way that prevents condensation from dripping into the
ACOPOS servo drives. This should be considered when selecting the switching cabinet (special
construction for use of cooling aggregates on top of the switching cabinet).
Also make sure that condensed water which forms in the cooling aggregate fan when it is
switched off cannot sprinkle into the ACOPOS servo drives.
Make sure the temperature setting of the cooling aggregates is correct!

ACOPOS User's Manual 87

 Installation • Using Cooling Aggregates in Switching Cabinets

Cooling aggregate on top of the switching cabinet

Figure 19: Cooling aggregate on top of the switching cabinet

88 ACOPOS User's Manual

 Installation • Using Cooling Aggregates in Switching Cabinets

Cooling aggregate on the front of the switching cabinet

Installation
Chapter 3

Figure 20: Cooling aggregate on the front of the switching cabinet

ACOPOS User's Manual 89

 Installation • Using Cooling Aggregates in Switching Cabinets

90 ACOPOS User's Manual

 Dimensioning • Power Mains Connection

CHAPTER 4 • DIMENSIONING

1. Power Mains Connection

1.1 General Information

1.1.1 System Configuration

The power mains connection is made using terminals X3 / L1, L2, L3 and PE. The ACOPOS
servo drives can be directly connected to TT and TN systems (these are three-phase systems
with grounded neutral).
When using ungrounded IT systems (three-phase systems without grounded neutral), isolation
transformers must be used. The secondary neutral must be grounded and connected to the
ACOPOS protective ground conductor. In this way, it is possible to prevent overvoltages
between external conductors and the ACOPOS housing. Three-phase isolation transformers
with the corresponding input and output voltages and a vector group with secondary neutral can
be used (e.g. 3 x 400 V / 3 x 400 V, Dyn3).

Dimensioning
Danger!

Chapter 4
The ACOPOS servo drives are only allowed to be operated directly on grounded,
three-phase industrial mains (TN, TT systems). When using the servo drives in living
areas, shops and small businesses, additional filtering measures must be
implemented by the user.

1.1.2 Supply Voltage Range

The permissible supply voltage range for ACOPOS servo drives is 3 x 400 VAC to
3 x 480 VAC ±10 %. Respective intermediate transformers must be used for other supply
voltages. With grounded power mains, autotransformers can also be used to adjust the voltage.
Neutral does not have to be connected for this type of transformer.

ACOPOS User's Manual 91

 Dimensioning • Power Mains Connection

1.1.3 Protective Ground Connection (PE)

The following information concerning the protective ground connection corresponds to

IEC 61800-5 (draft), Item 3.2.5.3 "Connection elements for the protective ground conductor" and
must be followed.

Wire Cross Section

The wire cross section for the protective ground conductor is oriented to the external conductors
and must be selected according to the following table:

Wire Cross Section for External Line A Minimum Wire Cross Section for Protective Ground Connection
APE
[mm²] [mm²]
A ≤ 16 A
16 < A ≤ 35 16
35 < A A/2

Table 46: Selection of the protective ground conductor cross section

Increased Discharge Current

ACOPOS servo drives are devices with increased discharge current (larger than 3.5 mA AC or
10 mA DC). Therefore a fixed (immobile) protective ground connection is required on the servo
drives.
The following conditions must be met, depending on the ACOPOS device being used:

ACOPOS Conditions Image

1022 In addition to the connection of the first protective ground
1045 conductor on terminal X3 / PE, a second protective ground
1090 conductor with the same cross section must be connected on
the designated terminal (threaded bolt M4).

Table 47: Protective ground conditions according to ACOPOS device

92 ACOPOS User's Manual

 Dimensioning • Power Mains Connection

ACOPOS Conditions Image

1180 In addition to the connection of the first protective ground
1320 conductor on terminal X3 / PE, a second protective ground
conductor with the same cross section must be connected on
the designated terminal (threaded bolt M5).

1640 The cross section of the protective ground conductor

128M connected to terminal X3 / PE must be at least 10 mm² Cu.

Table 47: Protective ground conditions according to ACOPOS device (cont.)

1.2 Dimensioning

In general, dimensioning the power mains, the overcurrent protection and the line contactors
depend on the structure of the power mains connection. The ACOPOS servo drives can be
connected individually (each drive has separate overcurrent protection and, if necessary, a
separate line contactor) or together in groups.

Dimensioning
1.2.1 Individual ACOPOS Power Mains Connections

Chapter 4
The structure of an individual power mains connection with line contactor and circuit breaker can
be seen in the following diagram:

Figure 21: Circuit diagram for ACOPOS X3, individual power mains connection

ACOPOS User's Manual 93

 Dimensioning • Power Mains Connection

Dimensioning the Power Mains and Overcurrent Protection

The cross section of the power mains and the rated current for overcurrent protection should be
dimensioned for the average current load to be expected.
The power mains are to be equipped with overcurrent protection in the form of a circuit breaker
or a fuse. Circuit breakers (time lag) with type C tripping characteristics (according to IEC 60898)
or fuses (time lag) with type gM tripping characteristics (according to IEC60269-1) are to be
used. 1)
The average current load to be expected can be calculated as follows:
S [ VA ]
Imains [ A ] = ---------------------------------------
3 ⋅ Umains [ V ]

The apparent power S can be calculated as follows:

2 ⋅ π ⋅ n aver [ min – 1 ] 2)
S [ VA ] = Meff [ Nm ] ⋅ k ⋅ -------------------------------------------------
-
60

ACOPOS k
1022 2.8
1045 2.4
1090 2.4
1180 2.1
1320 1.9
1640 1.7
128M 1.5

Table 48: Constant k

1) Circuit breakers are available on the market with rated currents from 6 A to 63 A. Outside of this range, fuses must be used.

2) If information concerning load torque, inertia and friction are available, the effective torque is calculated as follows:

1
M ef f [ Nm ] = -----------------------
T cycle [ s ] ∑
i
Mi [ N m] 2 ⋅ ti [ s ]

If the motor is dimensioned correctly, the nominal torque for the selected motor can also be used here.

94 ACOPOS User's Manual

 Dimensioning • Power Mains Connection

The cross section of the power mains and the rated current of the overcurrent protection used
are chosen according to Table 49, "Maximum current load for PVC insulated three-phase cables
or individual wires", on page 95 so that the maximum current load for the cable cross section
selected is greater than or equal to the calculated mains current.

I Z ≥ I mains

The rated current of the overcurrent protection must be less than or equal to the maximum
current load for the cable cross section selected (see Table 49, "Maximum current load for PVC
insulated three-phase cables or individual wires", on page 95).

IB ≤ I Z

The following table shows the maximum current load of PVC insulated three-phase cables (or
three current-carrying wires) according to IEC60204-1 at 40 °C environmental temperature 1)
and 70 °C maximum conductor temperature (maximum current load for installation type F and
cross sections greater than 35 mm², IEC60364-5-523 is used for installation types B1 and B2).

Installation Types
Wire Cross Section Three individual Three-phase cable Three-phase cable Three-phase cable Three individual
wires in insulating in insulating on walls in a cable tray wires in a cable tray
conduit or cable conduit or cable
duct duct
B1 B2 C E F

Dimensioning
Maximum current load for the cable cross section IZ / rated current for the overcurrent protection IR

Chapter 4
[mm²] [A]
1.5 13.5 / 13 12.2 / 10 15.2 / 13 16.1 / 16 ---
2.5 18.3 / 16 16.5 /16 21 / 20 22 / 20 ---
4 25 / 25 23 / 16 28 / 25 30 / 25 ---
6 32 / 32 29 / 25 36 / 32 37 / 32 ---
10 44 / 32 40 / 32 50 / 50 52 / 50 ---
16 60 / 50 53 / 63 66 / 63 70 / 63 ---
25 77 / 63 67 / 63 84 / 80 88 / 80 96 / 80
35 97 / 80 83 / 80 104 / 100 114 / 100 119 / 100
50 117 / 100 103 / 100 123 / 100 123 / 100 145 / 125
70 149 / 125 130 / 125 155 / 125 155 / 125 188 / 160
95 180 / 160 156 / 125 192 / 160 192 / 160 230 / 200

Table 49: Maximum current load for PVC insulated three-phase cables or individual wires

1) The maximum current load value in IEC60204-1 is for an environmental temperature of 40 °C. In IEC60364-5-523, this reference
temperature is 30 °C. The values in Table 49, "Maximum current load for PVC insulated three-phase cables or individual wires", on
page 95 from IEC60364-5-523 are calculated with the factor kTemp = 0.87 given in the standard and also at 40 °C.

ACOPOS User's Manual 95

 Dimensioning • Power Mains Connection

When determining the cross section for the power mains, make sure that the cross section
selected is within the range that can be used with power mains terminal X3 (see Chapter 5
"Wiring", Table 56, "Terminal cross sections for ACOPOS servo drives", on page 129).

Dimensioning the Line Contactor

The rated current of the line contactor is oriented to the overcurrent protection for the power
mains connection. The line contactor is selected so that the maximum current load is
approximately 1.3 times the rated current of the overcurrent protection.

1.2.2 Implementing ACOPOS Power Mains Connections for Drive Groups

The structure of the power mains connection for a drive group with line contactor and circuit
breaker can be seen in the following diagram:

Figure 22: Circuit diagram for ACOPOS X3, power mains connection for a drive group

Dimensioning the Power Mains and Overcurrent Protection

The cross section of the distribution point and all power mains connections are chosen according
to Table 49, "Maximum current load for PVC insulated three-phase cables or individual wires",
on page 95 so that the maximum current load for the cable cross section selected 1) is greater
than or equal to the sum of the calculated mains current.

Z ≥ ∑ I mains

The rated current of the overcurrent protection must be less than or equal to the maximum
current load for the cable cross section selected (see Table 49, "Maximum current load for PVC
insulated three-phase cables or individual wires", on page 95).

IB ≤ I Z

1) When determining a common cross section for several drives (especially with different sized ACOPOS modules), make sure that the
cross section selected is within the range that can be used with the power mains terminals (see Chapter 5 "Wiring", Table 56, "Terminal
cross sections for ACOPOS servo drives", on page 129).

96 ACOPOS User's Manual

 Dimensioning • Power Mains Connection

Dimensioning the Line Contactor

The rated current of a common line contactor is oriented to the overcurrent protection for the
power mains connection. The line contactor is selected so that the maximum current load is
approximately 1.3 times the rated current of the overcurrent protection.

1.3 Fault Current Protection

Fault current protection (RCD - residual current-operated protective device) can be used with
ACOPOS servo drives. However the following points must be noted:
ACOPOS servo drives have a power rectifier. If a short-circuit to the frame occurs, a flat DC fault
current can be created which prevents an AC current or pulse current sensitive RCD (Type A or
AC) from being activated, therefore canceling the protective function for all connected devices.

Danger!
If used for protection during direct or indirect contact of the fault current protection
(RCD), only a Type B RCD (AC-DC sensitive, according to IEC 60755) can be used
for the ACOPOS power mains connection. Otherwise additional protective
measures must be used, such as neutralization or isolation from the power mains
using an isolation transformer.

1.3.1 Rated Fault Current

Dimensioning
Chapter 4
On ACOPOS servo drives, fault current protection with a rated fault current 1) of ≥100 mA can
be used. However, errors can occur:
• When connecting servo drives to the power mains (short-term single-phase or two-phase
operation because of contact chatter on the line contactor).
• Because of high frequency discharge currents occurring during operation when using
long motor cables.
• Because of an extreme unbalance factor for the three-phase system.

1) The rated fault current listed by the manufacturer are maximum values which will definitely trip the protective device. Normally, the
protective device is tripped at approximately 60 % of the rated fault current.

ACOPOS User's Manual 97

 Dimensioning • Power Mains Connection

1.3.2 Estimating the Discharge Current

Depending on the connection of the ACOPOS servo drive, different discharge currents flow to
ground on the protective ground conductor (PE):
Single-phase or two-phase operation (as intermediate state when switching on the line
contactor):

U mains [ V ] ⋅ 2 ⋅ π ⋅ f mains [ Hz ] ⋅ C D [ F ]
I A [ A] = -------------------------------------------------------------------------------------------------
3

Single-phase operation with neutral (lab or test operation):

U mains [ V ] ⋅ 2 ⋅ π ⋅ f mains [ Hz ] ⋅ C D [ F ]
I A [ A] = -------------------------------------------------------------------------------------------------
2⋅ 3

ACOPOS CD
[nF]
1022, 1045, 1090 660
1180, 1320 --- 1)
1640, 128M --- 1)

Table 50: Discharge capacitance CD

1) Integrated line filter in preparation

1.3.3 Manufacturer Used

For example, the AC-DC sensitive, 4 pin fault current protective device F 804 from ABB (fault
current: 300 mA; nominal current: 63 A) can be used. Using this fault current protective device,
approximately 5 ACOPOS 1022 (or 1045, 1090) can be connected in parallel.

98 ACOPOS User's Manual

 Dimensioning • DC Bus

2. DC Bus

2.1 General Information

With ACOPOS servo drives, it is possible to connect several servo drives via the DC bus 1) . This
connection allows compensation of brake and drive energy of several axes or the distribution of
brake energy to several braking resistors.
The connection is made using terminals X2 / +DC and -DC. The structure of the DC bus
connections can be seen in the following diagram:

Figure 23: ACOPOS X2 circuit diagram, DC bus connections

Dimensioning
Caution!

Chapter 4
To prevent excessively high discharge currents from flowing over the individual
servo drives, make sure that smaller servo drives are not connected between two
larger servo drives.

1) The connection of the DC bus for several ACOPOS 1022, 1045 or 1090 modules is only possible within combined groups (also see
Section 1.2.2 "Implementing ACOPOS Power Mains Connections for Drive Groups"). With ACOPOS 1180, 1320, 1640 and 128M
modules, it is also possible to connect individual ACOPOS servo drives because of built-in phase and power mains monitoring.

ACOPOS User's Manual 99

 Dimensioning • DC Bus

2.2 Wiring

The DC bus connections on the ACOPOS servo drives do not have short circuit and ground fault
protection and are not protected against reverse polarity. Therefore the DC bus connections
must be wired correctly.

Caution!
The DC bus connections must be wired correctly (no short circuits, ground faults or
reverse polarity).

A suitable measure to ensure that the wiring is secure against short circuits and ground faults 1)
is the use of corresponding cabling. Special rubber-insulated wires with increased resistance to
heat (90 °C) of types
• NSGAÖU
• NSGAFÖU
• NSGAFCMÖU
with a nominal voltage Uo/U of at least 1.7/3 kV are considered to be secure against short circuits
and ground faults in switchgear and distribution systems up to 1000 V 2) .

1) Cabling e.g. according to DIN VDE 0100, part 200 "Electrical systems for buildings - terms", item A.7.6.
2) See e.g. DIN VDE 0298, part 3 "Use of cables and insulated wires for high-voltage systems", item 9.2.8.

100 ACOPOS User's Manual

 Dimensioning • DC Bus

2.3 Equal Distribution of the Applied Power via the Power Rectifiers

When creating a DC bus connection between several servo drives, it is possible that the parallel
connection of the power rectifiers causes incorrect distribution of the applied power. To prevent
this undesired effect, appropriately dimensioned shunt resistors are integrated in the ACOPOS
servo drives.
The following rules must be observed so that the effect of these shunt resistors is not cancelled
out:
• The length of the DC bus wiring is not allowed to exceed a total length of 3 m and must
be within a single switching cabinet.
• Dimensioning the cross section of the ACOPOS servo drive power mains must be done
according to Section "Dimensioning the Power Mains and Overcurrent Protection".
• The cross section of the DC bus wiring 1) on the respective ACOPOS servo drives must
be less than or equal to the cross section of the servo drive power mains.
• The selected cross section must be within the range possible for the DC bus connection
terminal X2 (see chapter 5 "Wiring", Table 56, "Terminal cross sections for ACOPOS
servo drives", on page 129).

2.4 Equal Distribution of the Brake Power on the Braking Resistors

The braking resistors integrated in the ACOPOS servo drives as well as braking resistors which
can be connected externally are controlled using a specially developed procedure. This
guarantees that the brake power is optimally and equally distributed on the braking resistors

Dimensioning
Chapter 4
when a DC bus connection is made between several units.
When using the integrated braking resistors, additional configuration is not required. When using
external braking resistors, the corresponding parameters must be defined (see Section 4.4
"Setting Brake Resistor Parameters").

1) The cross section of the individual segments of the DC bus wiring must be dimensioned for the thermal equivalent effective value of
the respective compensation current. If information concerning the flow of the compensation current is available, calculate the thermal
equivalent effective value of the compensation current using

1
Iq [ A ] = -----------------------
T cycle [ s ] ∑
i
Ii [ A ] 2 ⋅ ti [ s ]

The cross section of the DC bus wiring should then be selected as described in chapter 5 "Wiring", Table 56, "Terminal cross sections
for ACOPOS servo drives", on page 129 so that the maximum current load of the cable cross section is greater than or equal to the
thermal equivalent effective value of the compensation current (IZ ≥ Iq).

ACOPOS User's Manual 101

 Dimensioning • Motor Connection

3. Motor Connection

On B&R motors, the power connections, the connections for the holding brake and the
connections for the motor temperature sensor are all made using the same motor plug. On the
servo drive, the motor connection is made using terminals X5 / U, V, W and PE as well as
terminals X4 / B+, B-, T+ and T-. The motor connection must be shielded correctly (see chapter 5
"Wiring", Section 1.1 "Electromagnetic Compatibility of the Installation").
The structure of the motor connection can be seen in the following diagram:

Figure 24: ACOPOS X4/X5 circuit diagram, motor connection

The cross section of the motor cable must be dimensioned for the thermal equivalent effective
value of the motor current 1) . If the motor is dimensioned correctly, the nominal current for the
motor can also be used here.

1) If information concerning load torque, inertia and friction are available, the thermal equivalent effective value for the motor current of
the motor used is calculated as follows:

1
Iq [ A ] = -----------------------
T cycle [ s ] ∑
i
Ii [ A ] 2 ⋅ ti [ s ]

102 ACOPOS User's Manual

 Dimensioning • Motor Connection

The cross section of the motor cable is chosen for B&R motor cables according to the following
table so that the maximum current load for the cable cross section selected is greater than or
equal to the thermal equivalent effective value of the motor current.

IZ ≥ Iq

The following table shows the maximum current load for special insulated three-phase cables
according to IEC60364-5-523 at 40 °C environmental temperature 1) and 90 °C maximum cable
temperature.

Installation Types
Wire Cross Section Three-phase cable in insulating Three-phase cable on walls Three-phase cable in a cable
conduit or cable duct tray
B2 C E
Maximum current load of the cable IZ
[mm²] [A]
1.5 17.8 20 20.9
4 31.9 36.4 38.2
10 54.6 64.6 68.3
35 116.5 133.8 143.8

Table 51: Maximum current load for special insulated three-phase cables

Dimensioning
When determining the cross section for the motor cable, make sure that the cross section

Chapter 4
selected is within the range that can be used with motor connection terminal X5 (see Chapter 5
"Wiring", Table 56, "Terminal cross sections for ACOPOS servo drives", on page 129).

1) The entry for the maximum current load in IEC60364-5-523 is for an environmental temperature of 30 °C. The values in Table 51,
"Maximum current load for special insulated three-phase cables", on page 103 are calculated with the factor kTemp = 0.91 given in the
standard for use at 40 °C environmental temperature.

ACOPOS User's Manual 103

 Dimensioning • Braking Resistor

4. Braking Resistor

4.1 General Information

When braking servo motors, power is returned to the servo drive. This causes the capacitors in
the DC bus to be charged to higher voltages. Starting with a DC bus voltage of approx. 800 V,
the ACOPOS servo drive links the braking resistor to the DC bus using the brake chopper and
converts the braking power to heat.
For ACOPOS servo drives, braking resistors are integrated for this purpose or external braking
resistors can be connected. The equipment differences can be found in the following table:

8V1022.00-2 8V1045.00-2 8V1180.00-2 8V1640.00-2 8V128M.00-2

8V1090.00-2 8V1320.00-2
Integrated Brake Chopper Yes Yes Yes Yes Yes
Internal Braking Resistor Yes Yes Yes Yes 1) Yes 1)
Continuous Power Output 130 W 200 W 400 W 200 W 240 W
Maximum Power 3.5 kW 7 kW 14 kW 7 kW 8.5 kW
Connection of External Braking Resistor No 4) No 4) Yes Yes Yes
Possible 2)
Continuous Power Output --- --- 8 kW 24 kW 24 kW
Maximum Power --- --- 24 kW 250 kW 250 kW
Minimum Braking Resistor Value ( R BR ) --- --- 26 Ω 2.5 Ω 2.5 Ω
min
Rated Current of the Built-in Fuse 3) --- --- 10 A (fast- 30 A (fast- 30 A (fast-
( IB ) acting) acting) acting)

Table 52: Braking resistors for ACOPOS servo drives

1) The braking resistor integrated in the ACOPOS servo drives 1640 and 128M is dimensioned so that it is possible to brake to a stop (in
a typical drive situation).

2) The ACOPOS servo drives are designed so that either the integrated braking resistor or the external braking resistor can be activated.
Braking with both braking resistors at the same time is not possible. Switching takes place using the software and is only possible during
the servo drive initialization phase:

ParID 398: Switching to internal / external braking resistor

1 ... external
0 ... internal (default)

3) The fuses used must be fast-acting fuses ∅10 x 38 mm for 600 V AC/DC. For example, type KLKD0xx (xx is the rated current of the
fuse in amperes e.g. KLKD030) from Littelfuse (www.littelfuse.com) can be used.

4) The braking resistors integrated in ACOPOS servo drives 1022, 1045 and 1090 are optimally dimensioned for the respective sizes.

104 ACOPOS User's Manual

 Dimensioning • Braking Resistor

4.2 Braking Resistor Connection

The external braking resistors are connected using terminals X6 / RB+, RB- and PE. The
structure of the braking resistor connection can be seen in the following diagram:

Figure 25: Circuit diagram for ACOPOS X6, external braking resistor on ACOPOS 1180, 1320, 1640 and
128M

Dimensioning
When determining the cross section 1) for the braking resistor connection, make sure that the

Chapter 4
cross section selected is within the range that can be used with braking resistor connection
terminal X6 (see Chapter 5 "Wiring", Table 56, "Terminal cross sections for ACOPOS servo
drives", on page 129).

1) The cross section of the braking resistor cable must be dimensioned for the thermal equivalent effective value of the respective brake
current. If information concerning the flow of the brake current is available, calculate the thermal equivalent effective value of the brake
current using

1
Iq [ A ] = -----------------------
Tcycl e [ s ] ∑
i
Ii [ A ] 2 ⋅ ti [ s ]

The cross section of the braking resistor connection should then be selected as described in Table 49, "Maximum current load for PVC
insulated three-phase cables or individual wires", on page 95, so that the maximum current load of the cable cross section is greater
than or equal to the thermal equivalent effective value of the brake current (IZ ≥ Iq).

ACOPOS User's Manual 105

 Dimensioning • Braking Resistor

4.3 Dimensioning the Brake Resistor

Like other drive components, the externally connected braking resistors must be dimensioned
according to the requirements of the application.
To determine the required braking power (PBr max and PBr aver), the mechanical values M(t), ω(t),
Tcycle must be known. The following formulas are used to determine the drive power curve.

P ( t ) [ W ] = M ( t ) [ Nm ] ⋅ ω ( t ) [ rad ⋅ s – 1 ]

n ( t ) [ min – 1 ]
ω ( t ) [ rad ⋅ s– 1 ] = 2 ⋅ π ⋅ -----------------------------------
60 [ s ⋅ min– 1 ]

Figure 26: Diagram of a typical movement with the brake power curve P Br(t) 1)

1) If - as shown - a typical triangular brake power curve occurs, then the average brake power can be calculated directly with the following
formula:

1 P Br ⋅ t Br
PBR [ W ] = ----------------------- ⋅ --------------------------
max
-
aver T cycle [ s ] 2

106 ACOPOS User's Manual

 Dimensioning • Braking Resistor

The calculation is continued by deriving the brake power curve PBr(t) from the drive power curve.
The power must be set to zero in areas where it is positive (P(t) > 0). This results in the following
maximum brake power

PBr [ W ] = abs ( max ( P Br ( t ) [ W ] ) )

max

Then the average brake power is calculated over the given cycle
1
PBr
aver
[ W ] = ------------------------
Tcycle [ s ] ∑
i
P Br ( t ) [ W ] ⋅ t i [ s ]
i

In order to use an external braking resistor 1) , the following parameters must be calculated:
• the resistance (RBr)
• the maximum power ( PR )
Br
max
• the nominal power ( P R )
Br N

Resistance of the Braking Resistor

The resistance of the braking resistor RBr can be calculated as follows:

U DC [ V ] 2 800 [ V ] 2 -
RBr [ Ω ] = --------------------------
- = --------------------------
PBr [ W ] P Br [ W ]
max max

Dimensioning
Chapter 4
The selected resistance is not allowed to be less than the minimum resistance for the respective
ACOPOS servo drive (see Table 52, "Braking resistors for ACOPOS servo drives", on
page 104).

RBr [ Ω ] ≥ R Br [Ω ]
mi n

If this condition is not met, the maximum brake power required cannot be reached! Typical
resistances are 4 - 50 Ω depending on the size of the ACOPOS device.

Caution!
If a resistance less than the minimum resistance is used, the brake chopper built
into the ACOPOS device could be destroyed!

1) Reliable braking resistors are available from Danotherm (www.danotherm.com).

ACOPOS User's Manual 107

 Dimensioning • Braking Resistor

Then the following calculation

PBr [ W ] ≤ R Br [ Ω ] ⋅ IB [ A ] 2
ave r

must be made to check if the average continuous power for the brake can be reached with the
selected braking resistor on the ACOPOS servo drive. The brake power which can be continually
output by the ACOPOS device is limited by the built-in fuse (rated current of the built-in fuse, see
Table 52, "Braking resistors for ACOPOS servo drives", on page 104).

Power Data for the Braking Resistor

The maximum power that the braking resistor must be able to dissipate is calculated as follows:

PR [ W ] ≥ P Br [W]
Brmax max

The nominal power (the power which can be continually dissipated) for the braking resistor is
calculated using the following formulas:

PR [ W ] ≥ P Br
Br aver
N

1
PR [ W ] ≥ ------ ⋅ PR [W]
Br N 30 Br max

The second condition depends on ACOPOS internal relationships.

108 ACOPOS User's Manual

 Dimensioning • Braking Resistor

4.4 Setting Brake Resistor Parameters

The braking resistors integrated in the ACOPOS servo drives as well as braking resistors which
can be connected externally are controlled using a specially developed procedure. This
guarantees that the brake power is optimally and equally distributed on the braking resistors
when a DC bus connection is make between several units.
When using the integrated braking resistors, additional configuration is not required. When using
external braking resistors, the following resistor data must be known:

Resistor Data Term Unit

Continuous power for the resistance PR [W]
BrN

Maximum power for the resistance PR [W]

Brmax

Ohmic resistance RBr [Ω]

Maximum switch on time at maximum power [s]
Maximum temperature of the resistor 1) [°C]

Table 53: Resistor data when using external braking resistors

1) If available.

Then the parameters to be set on the ACOPOS servo drive can be determined with the
configuration tool RESISTPARAM.XLS.
ParID 10: Ohmic resistance [W]

Dimensioning
ParID 11: Max. temperature of the resistor [°C]

Chapter 4
ParID 12: Thermal resistance [°C/W]
ParID 13: Heat capacity of the resistor [Ws/°C]

ACOPOS User's Manual 109

 Dimensioning • Current Requirements of ACOPOS Plug-in Modules

5. Current Requirements of ACOPOS Plug-in Modules

The plug-in modules for ACOPOS servo drives allow the servo drives to be individually
configured according to the requirements of the application. When putting together plug-in
module combinations, the power consumption must be checked.
The maximum power output for all 4 slots is 22 W. The total power consumption for all plug-in
modules must be less than or equal to the maximum power output.

Pmax = 22W ≥ ∑ P module

The power consumption of the individual modules can be found in the technical data for the
modules (see chapter 2 "Technical Data").

110 ACOPOS User's Manual

 Dimensioning • Formula Variables Used

6. Formula Variables Used

Term Unit Description

CD F Discharge capacitance
for ACOPOS 1022, 1045, 1090 CD = 660 nF
for ACOPOS 1180, 1320 --- 1)
for ACOPOS 1064, 128M --- 1)
fmains Hz Mains frequency
IA A Discharge current via protective ground conductor (PE)
IB A Rated current for overcurrent protection
Imains A Mains current (phase current)
Iq A Thermal equivalent current effective value
IZ A Maximum current load on a cable
M Nm Torque (general)
Meff Nm Effective load torque
n min-1 Speed (general)
naver min-1 Average speed
ω rad/s Angular speed
P W Power or true power (general)
PBr W Brake power
P Br W Maximum brake power
max

P Br W Average brake power

aver

Dimensioning
Chapter 4
PR W Maximum load on the external braking resistor
Brmax

PR W Nominal power of the external braking resistor

BrN

Pmax W Maximum power

Pmodule W Power consumption of the plug-in modules
π --- Pi (3.1415)
RBr Ω Braking resistance
R Br Ω Minimum braking resistance
min

S VA Apparent power
t s Time (general)
tBr s Brake time
Tcycle s Cycle time
UDC V DC bus voltage
Umains V Supply voltage (phase to phase)

Table 54: Formula variables used

1) Integrated line filter in preparation.

ACOPOS User's Manual 111

 Dimensioning • Formula Variables Used

112 ACOPOS User's Manual

 Wiring • General Information

CHAPTER 5 • WIRING

1. General Information

1.1 Electromagnetic Compatibility of the Installation

1.1.1 General Information

Servo drives are electrical equipment intended for use in industrial and commercial systems.
ACOPOS servo drives meet the requirements for adherence to the EMC guideline 89/336/EWG
regarding electromagnetic compatibility of the installation. Under the terms of the EMC
guidelines, such devices do not require certification because they are intended to be further
processed by the competent, machine and equipment manufacturer in compliance with the
EMCG components and cannot be operated independently.
Evidence of compliance with the limit values required in the EMC guidelines must be provided
by the manufacturer or the machine or system operator.
ACOPOS servo drives fulfill the requirements of IEC 61800-3 (industry – 2nd environment) in
regard to disturbance immunity and emitted disturbance.
When using the servo drives in living areas, shops and small businesses, additional filtering
measures must be implemented by the user.

Chapter 5
Wiring

ACOPOS User's Manual 113

 Wiring • General Information

1.1.2 Installation Notes

• The switching cabinet or the system must be constructed appropriately.

• In order to avoid disturbances,
- motor cables
- encoder cables
- control cables
- data cables
are to be properly shielded.
• Inductive switching elements such as contactors or relays are to be equipped with
corresponding suppressor elements such as varistors, RC elements or damping diodes.
• All electrical connections are to be kept as short as possible.
• Cable shields are to be attached to the designated shield terminals and the plug housing.
• Shielded cables with copper mesh or tinned copper mesh are to be used. Twisting or
extending the protective mesh using single conductors is not allowed.
• Unused cable conductors are to be grounded on both sides if possible.

114 ACOPOS User's Manual

 Wiring • General Information

The ground connections and shield connections have to be made as illustrated in the following
diagram.

Chapter 5
Wiring

Figure 27: Connection diagram for ground and shield connections

ACOPOS User's Manual 115

 Wiring • General Information

➊ The protective ground conductor for the power mains (PE) and the protective ground
conductor for the motor lines are internally connected with the housing of the ACOPOS
servo drive.
➋ The second protective ground conductor connection is required because of the increased
discharge current (>3.5 mA) on the ACOPOS servo drives 1022, 1045, 1090, 1180 and
1320. The same cross section as the protective ground conductor for the power mains must
be used.
➌ The two trigger inputs only internally filter disturbances up to approx. 50 µs, therefore
proper grounding of the cable shields is important.
➍ The cable shield must be connected to the designated terminal.
➎ On all plug-in modules, the two screws used to fasten the module must be tightened so that
the mounting bracket is connected to ground.
➏ Cable connection via DSUB plug:
The cable shield must be connected using the designated clamp in the metallic or metal
plated plug housing. The plug housing must be fastened to the designated device connector
using safety screws.

Cable connection via terminals:

The cable shield must be connected to the designated terminal.
➐ The cable shield for the motor line is connected with the ACOPOS housing via the
grounding plate using the grounding clamp provided:

Shield connection for the motor cable using grounding clamps

1022, 1045, 1090 1180, 1320 1640, 128M

Table 55: Grounding the motor cable

116 ACOPOS User's Manual

 Wiring • General Information

➑ On the motor side, the cable shield is connected to the motor housing using the motor plug
and connected to ground via the machine.
➒ On the motor side, the encoder cable shield is connected to the motor housing using the
encoder plug and connected to ground via the machine.

1.2 Secure Restart Inhibit

1.2.1 General Information

ACOPOS servo drives have a built-in secure restart inhibit to guarantee that the device is
stopped securely and to prevent it from restarting unexpectedly. It is designed to correspond to
safety category 3 according to EN954-1. 1)
In addition to preventing the device from restarting unexpectedly according to EN1037, this
safety function also meets the requirements of EN60204-1 regarding the stop function for
categories 0 and 1. Both stop functions require the supply to the machine drives to be switched
off (immediately for category 0 and after stopping for category 1).
The restart inhibit interrupts the supply to the motor by preventing the pulses to the IGBTs. In this
way, a rotating field can no longer be creating in synchronous and asynchronous motors
controlled by the ACOPOS servo drives. This fulfills the requirements of EN1037 regarding
preventing the device from starting unexpectedly and EN60204-1 regarding the stop function for
categories 0 and 1. 2)

Danger!
Take note that multiple errors in the IGBT bridge can cause a short advancing
movement. The maximum rotary angle of the advancing movement ϕ on the motor
shaft depends on the motor used. For permanently excited synchronous motors,
ϕ = 360°/2p (for B&R standard motors, p = 3 and the angle is therefore 60°). For
three-phase current asynchronous motors, there is a relatively small angle of
Chapter 5

rotation, between 5° and 15°.

Wiring

For applications, where this can be dangerous, the goal for protection cannot be
obtained.

1) Testing of a sample device for the FS certification from TÜV for safety category 3 is in preparation.
2) A detailed explanation of the standards and categories can be found in chapter 7 "Standards and Certifications".

ACOPOS User's Manual 117

 Wiring • General Information

1.2.2 Principle - Realization of the Safety Function

Secure restart inhibit is obtained by removing the IGBT driver supply. Terminals X1 / Enable and
X1 / COM(9) are used to supply an integrated DC-DC converter with 24 VDC. The converter
creates the supply voltage for the IGBT driver from this voltage.

Figure 28: Block diagram of secure restart inhibit

If the 24 VDC voltage supply for the DC-DC converter is interrupted, the IGBT driver is also no
longer supplied. Then it is no longer possible to transfer the modulation pattern needed to
generate the rotating field on the IGBT output stage.

118 ACOPOS User's Manual

 Wiring • General Information

Additional Function

The availability of the DC-DC converter output voltage can be requested from the
microprocessor. If a voltage is not present, the generation of the modulation pattern is
suppressed by the microprocessor.

Danger!
After activating the restart inhibit using terminals X1 / Enable and X1 / COM(9), the
motor is de-energized and therefore torque-free. If the motor was moving before
activation of the restart inhibit, it is only stopped by an operational brake which is
sometimes available or from the friction of the entire system. Therefore, the motor
is not able to hold hanging loads. Holding brakes must be used for this purpose.
For applications, where this can be dangerous, the goal for protection cannot be
obtained.

1.2.3 External Wiring

The following section contains four wiring suggestions for the external wiring of the secure restart
inhibit. They are divided corresponding to the three stop functions (categories 0, 1 and 2)
according to IEC 60204-1.
With the wiring shown, you can obtain safety category 3 according to EN954-1 for the emergency
stop function (for regular checks of the emergency stop function) and for secure restart inhibit.
In order for the wiring to meet the requirements of the respective application and the listed safety
category according to EN954-1, suitable switching devices – 1 pin e-stop switching devices from
safety category 2 (reliable switching devices) - and cabling concepts must be used.

Danger!
To set up the e-stop function, single or double pole switching devices from safety
Chapter 5

category 2 (reliable switching devices) must be used in the e-stop chain. To obtain
Wiring

safety category 3 according to EN954-1, the e-stop function must be checked once
a day.
For applications where this is not possible, the goal for protection cannot be
obtained.

ACOPOS User's Manual 119

 Wiring • General Information

Stop Function for Category 0 – Safety Category 3

Figure 29: External wiring for the stop function in category 0 – safety category 3

1) For servo drives which have no 24 VDC output (ACOPOS 1022/1045/1090), the control voltage must be provided externally.

120 ACOPOS User's Manual

 Wiring • General Information

Description:

By pressing the e-stop switch S1 or the stop switch S2, the drive has no torque and spins out.
This guarantees that the energy feed to the motor is immediately switched off.
If you open and lock stop switch S2, restart is inhibited.

Chapter 5
Wiring

ACOPOS User's Manual 121

 Wiring • General Information

Stop Function for Category 1 – Safety Category 3

Figure 30: Type 1 – Starting active braking over the network

1) Opened at n = 0 min-1.
2) The drop-out time lag corresponds to the requirements of the application.
3) The network connection is used to transfer the interruption command for active braking, for diagnosis and setting parameters.
4) For servo drives which have no 24 VDC output (ACOPOS 1022/1045/1090), the control voltage must be provided externally.

122 ACOPOS User's Manual

 Wiring • General Information

Description:

When the e-stop switch S1 is pressed, the "EmergencyStop" control input on the controller
triggers active braking (see following code example). Relay K2 also releases at the same time.
After stopping (n = 0 min-1), speed switch S3 opens and switches off the energy feed to the drive.
If the controller, the network, etc. is faulty, then auxiliary relay K3 is released after a defined delay
and causes the energy feed to the motor to be cut off.
Pressing stop switch S2 basically triggers the same procedure, but is handled differently by the
software (separate digital input "Stop").
This guarantees that the energy feed to the motor is definitely switched off afterwards.
If you open and lock stop switch S2, restart is inhibited.

Code example:

Trigger the interruption command (via CAN bus or Powerlink).

switch(step)
{
if ( (EmergencyStop == FALSE) and (stop_step == 0) )
{
/* stop movement with the defined interrupt parameters */
if( (status = ncaction(<ax_obj>, ncMOVE, ncSTOP)) == ncOK)
{
step = EMERGENCY;
stop_step = step; /* Blocking the transfer of instructions*/
}
}
if ( (Stop == FALSE) and (stop_step == 0) )
{
/* stop movement with the movement parameters */
if( (status = ncaction(<ax_obj>, ncMOVE, ncHALT)) == ncOK)
{
step = STOP;
Chapter 5

stop_step = step; /* Blocking the transfer of instructions*/

Wiring

}
}

...

ACOPOS User's Manual 123

 Wiring • General Information

case EMERGENCY:

...

if (EmergencyStop == TRUE) /* Reset emergency stop switch? */

{
step = BACK_TO_NORMAL;
}
break;

case STOP:

...

if (Stop == TRUE) /* Reset stop switch? */

{
step = BACK_TO_NORMAL;
}
break;

case BACK_TO_NORMAL:
/* if the e-stop situation is corrected, the axis
can be started again */
wait_for_restart();
stop_step = 0;
break;

124 ACOPOS User's Manual

 Wiring • General Information

Chapter 5
Wiring

Figure 31: Type 2 – Starting active braking using the Quickstop-input on the ACOPOS

1) Opens if n = 0 min-1.
2) The drop-out time lag corresponds to the requirements of the application.
3) The network connection is used for diagnosis and setting parameters.
4) For servo drives which have no 24 VDC output (ACOPOS 1022/1045/1090), the control voltage must be provided externally.

ACOPOS User's Manual 125

 Wiring • General Information

Description:

Pressing e-stop switch S1 causes relay K2 to be released. In this way, the ACOPOS input
"Quickstop" triggers active braking. After stopping (n = 0 min-1), speed switch S3 opens and
switches off the energy feed to the drive. If the drive, etc. is faulty, then auxiliary relay K3 is
released after a defined delay and causes the energy feed to the motor to be cut off.
Pressing stop switch S2 starts the same procedure as for type 1.
This guarantees that the energy feed to the motor is definitely switched off afterwards.
If you open and lock stop switch S2, restart is inhibited.

126 ACOPOS User's Manual

 Wiring • General Information

Stop Function for Category 2 – Safety Category 3

Chapter 5
Wiring

Figure 32: External wiring for the stop function in category 2 – safety category 3

1) The drop-out time lag corresponds to the requirements of the application.

2) The network connection is used to transfer the interruption command for active braking, for diagnosis and setting parameters.
3) For servo drives which have no 24 VDC output (ACOPOS 1022/1045/1090), the control voltage must be provided externally.

ACOPOS User's Manual 127

 Wiring • General Information

Description:

When the e-stop switch S1 is pressed, the "EmergencyStop" control input on the controller
triggers active braking (see "Code example:", on page 123). If the controller, the network, etc. is
faulty, then auxiliary relay K3 is released after a defined delay and causes the energy feed to the
motor to be cut off.
Pressing stop switch S2 basically triggers the same procedure, but is handled differently by the
software (separate digital input "Stop"). However, the energy feed to the motor is not switched
off after stopping.
If you open and lock e-stop switch S1, restart is inhibited.

128 ACOPOS User's Manual

 Wiring • General Information

1.3 Overview of the Terminal Cross Sections

Terminal Cross Sections 8V1022.00-2 8V1180.00-2 8V1640.00-2 8V128M.00-2

8V1045.00-2 8V1320.00-2
8V1090.00-2

[mm²] [AWG] [mm²] [AWG] [mm²] [AWG] [mm²] [AWG]

Solid core and multiple conductor 0.5 - 1.5 20 - 14 0.5 - 1.5 20 - 14 0.5 - 1.5 20 - 14 0.5 - 1.5 20 - 14
lines

Flexible and fine wire lines

without Wire Tip Sleeves 0.5 - 1.5 20 - 14 0.5 - 1.5 20 - 14 0.5 - 1.5 20 - 14 0.5 - 1.5 20 - 14
X1 with Wire Tip Sleeves 0.5 - 1.5 20 - 14 0.5 - 1.5 20 - 14 0.5 - 1.5 20 - 14 0.5 - 1.5 20 - 14

Approbation Data
UL/C-UL-US --- 26 - 14 --- 26 - 14 --- 26 - 14 --- 26 - 14
CSA --- 26 - 14 --- 26 - 14 --- 26 - 14 --- 26 - 14

Terminal tightening torque value [Nm] 0.2 ... 0.25 0.2 ... 0.25 0.2 ... 0.25 0.2 ... 0.25

Solid core and multiple conductor 0.2 - 4 24 - 10 0.5 - 10 20 - 7 10 - 25 7-3 10 - 50 7-0

lines

Flexible and fine wire lines

X2 without Wire Tip Sleeves 0.2 - 4 24 - 10 0.5 - 6 20 - 9 4 - 16 11 - 5 10 - 35 7-2
DC Bus with Wire Tip Sleeves 0.25 - 4 23 - 10 0.5 - 6 20 - 9 4 - 16 11 - 5 10 - 35 7-2

Approbation Data
UL/C-UL-US --- 30 - 10 --- 20 - 8 --- 12 - 4 --- 10 - 2
CSA --- 28 - 10 --- 20 - 8 --- 14 - 4 --- 12 - 2

Terminal tightening torque value [Nm] 0.5 ... 0.6 1.2 ... 1.5 2.5 ... 3 2.5 ... 3

Solid core and multiple conductor 0.2 - 4 24 - 10 0.5 - 10 20 - 7 10 - 25 7-3 10 - 50 7-0

lines

Flexible and fine wire lines

X3 without Wire Tip Sleeves 0.2 - 4 24 - 10 0.5 - 6 20 - 9 4 - 16 11 - 5 10 - 35 7-2
Power Mains with Wire Tip Sleeves 0.25 - 4 23 - 10 0.5 - 6 20 - 9 4 - 16 11 - 5 10 - 35 7-2

Approbation Data
UL/C-UL-US --- 30 - 10 --- 20 - 8 --- 12 - 4 --- 10 - 2
CSA --- 28 - 10 --- 20 - 8 --- 14 - 4 --- 12 - 2

Terminal tightening torque value [Nm] 0.5 ... 0.6 1.2 ... 1.5 2.5 ... 3 2.5 ... 3

Solid core and multiple conductor 0.14 - 1.5 28 - 16 0.2 - 2.5 24 - 12 0.14 - 1.5 28 - 16 0.14 - 1.5 28 - 16
lines
X4
Motor Flexible and fine wire lines
(holding without Wire Tip Sleeves 0.14 - 1.5 28 - 16 0.2 - 2.5 24 - 12 0.14 - 1.5 28 - 16 0.14 - 1.5 28 - 16
brake, with Wire Tip Sleeves 0.25 - 0.5 23 - 20 0.25 - 2.5 23 - 12 0.25 - 0.5 23 - 20 0.25 - 0.5 23 - 20
temperature
Approbation Data
sensor) UL/C-UL-US --- 30 - 14 --- 30 - 12 --- 30 - 16 --- 30 - 16
CSA --- 28 - 16 --- 28 - 12 --- 28 - 16 --- 28 - 16

Terminal tightening torque value [Nm] 0.22 ... 0.25 0.5 ... 0.6 0.22 ... 0.25 0.22 ... 0.25

Solid core and multiple conductor 0.2 - 4 24 - 10 0.5 - 10 20 - 7 10 - 25 7-3 10 - 50 7-0

lines
Chapter 5
Wiring

X5 Flexible and fine wire lines

without Wire Tip Sleeves 0.2 - 4 24 - 10 0.5 - 6 20 - 9 4 - 16 11 - 5 10 - 35 7-2
Motor with Wire Tip Sleeves 0.25 - 4 23 - 10 0.5 - 6 20 - 9 4 - 16 11 - 5 10 - 35 7-2
(power)
Approbation Data
UL/C-UL-US --- 30 - 10 --- 20 - 8 --- 12 - 4 --- 10 - 2
CSA --- 28 - 10 --- 20 - 8 --- 14 - 4 --- 12 - 2

Terminal tightening torque value [Nm] 0.5 ... 0.6 1.2 ... 1.5 2.5 ... 3 2.5 ... 3

Solid core and multiple conductor --- --- 0.2 - 4 24 - 10 2.5 - 10 13 - 7 2.5 - 10 13 - 7
lines
X6 Flexible and fine wire lines
External without Wire Tip Sleeves --- --- 0.2 - 4 24 - 10 0.5 - 6 20 - 9 0.5 - 6 20 - 9
Braking with Wire Tip Sleeves --- --- 0.25 - 4 23 - 10 0.5 - 6 20 - 9 0.5 - 6 20 - 9
Resistor
Approbation Data
UL/C-UL-US --- --- --- 30 - 10 --- 22 - 8 --- 22 - 8
CSA --- --- --- 28 - 10 --- 20 - 8 --- 20 - 8

Terminal tightening torque value [Nm] --- 0.5 ... 0.6 1.2 ... 1.6 1.2 ... 1.6

Table 56: Terminal cross sections for ACOPOS servo drives

ACOPOS User's Manual 129

 Wiring • Connections ACOPOS 1022, 1045, 1090

2. Connections ACOPOS 1022, 1045, 1090

Figure 33: Connection overview ACOPOS 1022, 1045, 1090

130 ACOPOS User's Manual

 Wiring • Connections ACOPOS 1022, 1045, 1090

2.1 Pin Assignments for Plug X1

X1 Pin Description Function

1 Trigger1 Trigger 1
2 Quickstop/Trigger2 Quickstop/Trigger 2
3 COM (1, 2) Trigger 1, Quickstop/Trigger 2 - 0 V
4 Shield Shield
5 End+ Positive HW limit
6 End- Negative HW limit
7 Ref Reference switch
8 --- ---
9 Enable Enable
10 COM (9) Enable 0 V
11 --- ---
12 --- ---
13 --- ---
14 +24V Supply +24 V
15 +24V Supply +24 V
16 COM (5-7, 14, 15) Supply 0 V
17 COM (5-7, 14, 15) Supply 0 V
18 COM (5-7, 14, 15) Supply 0 V

Terminal Cross Sections see Table 56, "Terminal cross sections for ACOPOS servo
drives", on page 129

Table 57: Pin assignments for plug X1 ACOPOS 1022, 1045, 1090

2.2 Pin Assignments for Plug X2

X2 Pin Description Function

1 -DC1 U DC bus -
Chapter 5
Wiring

2 +DC1 U DC bus +
3 +DC2 U DC bus +
4 -DC2 U DC bus -

Terminal Cross Sections see Table 56, "Terminal cross sections for ACOPOS servo
drives", on page 129

Table 58: Pin assignments for plug X2 ACOPOS 1022, 1045, 1090

ACOPOS User's Manual 131

 Wiring • Connections ACOPOS 1022, 1045, 1090

2.3 Pin Assignments for Plug X3

X3 Pin Description Function

1 L1 Power Mains Connection L1
2 L2 Power Mains Connection L2
3 L3 Power Mains Connection L3
4 PE Protective Ground Conductor

Terminal Cross Sections see Table 56, "Terminal cross sections for ACOPOS servo
drives", on page 129

Table 59: Pin assignments for plug X3 ACOPOS 1022, 1045, 1090

2.4 Pin Assignments for Plug X4

X4 Pin Description Function

1 T- Temperature Sensor -
2 T+ Temperature Sensor +
3 B- Brake -
4 B+ Brake +

Terminal Cross Sections see Table 56, "Terminal cross sections for ACOPOS servo
drives", on page 129

Table 60: Pin assignments for plug X4 ACOPOS 1022, 1045, 1090

2.5 Pin Assignments for Plug X5

X5 Pin Description Function

1 PE Protective Ground Conductor
2 W Motor Connection W
3 V Motor Connection V
4 U Motor Connection U

Terminal Cross Sections see Table 56, "Terminal cross sections for ACOPOS servo
drives", on page 129

Table 61: Pin assignments for plug X5 ACOPOS 1022, 1045, 1090

132 ACOPOS User's Manual

 Wiring • Connections ACOPOS 1022, 1045, 1090

2.6 Protective Ground Connection (PE)

The protective ground conductor is connected to the threaded bolt M4 provided using a cable
lug. For information concerning dimensioning see Chapter 4 "Dimensioning", Section 1.1.3
"Protective Ground Connection (PE)".

Image Pin Description Function

--- PE Protective Ground Conductor

Terminal Cross Sections [mm²] AWG

Cable lug for threaded bolt M4 0.25 - 6 23 - 9

Table 62: Protective ground conductor (PE) ACOPOS 1022, 1045, 1090

Danger!
Before turning on the servo drive, make sure that the housing is properly connected
to ground (PE rail). The ground connection must be made, even when testing the
servo drive or when operating it for a short time!
Chapter 5
Wiring

ACOPOS User's Manual 133

 Wiring • Connections ACOPOS 1180, 1320

3. Connections ACOPOS 1180, 1320

Figure 34: Connection overview ACOPOS 1180, 1320

134 ACOPOS User's Manual

 Wiring • Connections ACOPOS 1180, 1320

3.1 Pin Assignments for Plug X1

X1 Pin Description Function

1 Trigger1 Trigger 1
2 Quickstop/Trigger2 Quickstop/Trigger 2
3 COM (1, 2) Trigger 1, Quickstop/Trigger 2 - 0 V
4 Shield Shield
5 End+ Positive HW limit
6 End- Negative HW limit
7 Ref Reference switch
8 --- ---
9 Enable Enable
10 COM (9) Enable 0 V
11 --- ---
12 --- ---
13 +24V out / 0.5A +24 V output / 0.5 A
14 +24V Supply +24 V
15 +24V Supply +24 V
16 COM (5-7, 13-15) Supply 0 V
17 COM (5-7, 13-15) Supply 0 V
18 COM (5-7, 13-15) Supply 0 V

Terminal Cross Sections see Table 56, "Terminal cross sections for ACOPOS servo
drives", on page 129

Table 63: Pin assignments for plug X1 ACOPOS 1180, 1320

3.2 Pin Assignments for Plug X2

X2 Pin Description Function

1 -DC1 U DC bus -
Chapter 5
Wiring

2 +DC1 U DC bus +
3 +DC2 U DC bus +
4 -DC2 U DC bus -

Terminal Cross Sections see Table 56, "Terminal cross sections for ACOPOS servo
drives", on page 129

Table 64: Pin assignments for plug X2 ACOPOS 1180, 1320

ACOPOS User's Manual 135

 Wiring • Connections ACOPOS 1180, 1320

3.3 Pin Assignments for Plug X3

X3 Pin Description Function

1 L1 Power Mains Connection L1
2 L2 Power Mains Connection L2
3 L3 Power Mains Connection L3
4 PE Protective Ground Conductor

Terminal Cross Sections see Table 56, "Terminal cross sections for ACOPOS servo
drives", on page 129

Table 65: Pin assignments for plug X3 ACOPOS 1180, 1320

3.4 Pin Assignments for Plug X4

X4 Pin Description Function

1 T- Temperature Sensor -
2 T+ Temperature Sensor +
3 B- Brake -
4 B+ Brake +
5 S2 External activation of the holding brake 1)
6 S1 External activation of the holding brake 1)

Terminal Cross Sections see Table 56, "Terminal cross sections for ACOPOS servo
drives", on page 129

Table 66: Pin assignments for plug X4 ACOPOS 1180, 1320

1) S1 and S2 can be used to connect an external potential free contact (typically normally closed). This makes it possible to activate the
holding brake using an external safety circuit independent of the control integrated in the ACOPOS servo drive. If this function is not
used, a jumper must be placed between S1 and S2.

136 ACOPOS User's Manual

 Wiring • Connections ACOPOS 1180, 1320

3.5 Pin Assignments for Plug X5

X5 Pin Description Function

1 PE Protective Ground Conductor
2 W Motor Connection W
3 V Motor Connection V
4 U Motor Connection U

Terminal Cross Sections see Table 56, "Terminal cross sections for ACOPOS servo
drives", on page 129

Table 67: Pin assignments for plug X5 ACOPOS 1180, 1320

3.6 Pin Assignments for Plug X6

X6 Pin Description Function

1 PE Protective Ground Conductor
2 RB- Brake Resistance -
3 RB+ Brake Resistance +

Terminal Cross Sections see Table 56, "Terminal cross sections for ACOPOS servo
drives", on page 129

Table 68: Pin assignments for plug X6 ACOPOS 1180, 1320

Chapter 5
Wiring

ACOPOS User's Manual 137

 Wiring • Connections ACOPOS 1180, 1320

3.7 Protective Ground Connection (PE)

The protective ground conductor is connected to the threaded bolt M5 provided using a cable
lug. For information concerning dimensioning see Chapter 4 "Dimensioning", Section 1.1.3
"Protective Ground Connection (PE)".

Image Pin Description Function

--- PE Protective Ground Conductor

Terminal Cross Sections [mm²] AWG

Cable lug for threaded bolt M5 0.25 - 16 23 - 5

Table 69: Protective ground conductor (PE) ACOPOS 1180, 1320

Danger!
Before turning on the servo drive, make sure that the housing is properly connected
to ground (PE rail). The ground connection must be made, even when testing the
servo drive or when operating it for a short time!

138 ACOPOS User's Manual

 Wiring • Connections ACOPOS 1640, 128M

4. Connections ACOPOS 1640, 128M

Chapter 5
Wiring

Figure 35: Connection overview ACOPOS 1640, 128M

1) See Section 4.1 "Pin Assignments for Plug X1" and Section 4.4 "Pin Assignments for Plug X4".

ACOPOS User's Manual 139

 Wiring • Connections ACOPOS 1640, 128M

4.1 Pin Assignments for Plug X1 1)

X1 Pin Description Function

1 Trigger1 Trigger 1
2 Quickstop/Trigger2 Quickstop/Trigger 2
3 COM (1, 2) Trigger 1, Quickstop/Trigger 2 - 0 V
4 Shield Shield
5 End+ Positive HW limit
6 End- Negative HW limit
7 Ref Reference switch
8 --- ---
9 Enable Enable
10 COM (9) Enable 0 V
11 --- ---
12 --- ---
13 +24V out / 0.5A +24 V output / 0.5 A
14 +24V Supply +24 V
15 +24V Supply +24 V
16 COM (5-7, 13-15) Supply 0 V
17 COM (5-7, 13-15) Supply 0 V
18 COM (5-7, 13-15) Supply 0 V

Terminal Cross Sections see Table 56, "Terminal cross sections for ACOPOS servo
drives", on page 129

Table 70: Pin assignments for plug X1 ACOPOS 1640, 128M

1) For ACOPOS 8V1640.00-2 up to and including Rev. B5, connections X1 / 13, 14, 15 have no function (---).

140 ACOPOS User's Manual

 Wiring • Connections ACOPOS 1640, 128M

4.2 Pin Assignments for X2

X2 Pin Description Function

1 +DC2 U DC bus +
2 +DC1 U DC bus +
3 -DC2 U DC bus -
4 -DC1 U DC bus -

Terminal Cross Sections see Table 56, "Terminal cross sections for ACOPOS servo
drives", on page 129

Table 71: Pin assignments for X2 ACOPOS 1640, 128M

4.3 Pin Assignments for X3

X3 Pin Description Function

1 L1 Power Mains Connection L1
2 L2 Power Mains Connection L2
3 L3 Power Mains Connection L3
4 PE Protective Ground Conductor

Terminal Cross Sections see Table 56, "Terminal cross sections for ACOPOS servo
drives", on page 129

Table 72: Pin assignments for X3 ACOPOS 1640, 128M

Chapter 5
Wiring

ACOPOS User's Manual 141

 Wiring • Connections ACOPOS 1640, 128M

4.4 Pin Assignments for Plug X4 1)

X4 Pin Description Function

1 S1 External activation of the holding brake *)
2 S2 External activation of the holding brake *)
3 B+ Brake +
4 B- Brake -
5 T+ Temperature +
6 T- Temperature -
7 --- ---
8 --- ---
9 --- ---
10 --- ---
11 --- ---
12 --- ---

Terminal Cross Sections see Table 56, "Terminal cross sections for ACOPOS servo
drives", on page 129

Table 73: Pin assignments for plug X4 ACOPOS 1640, 128M

*) S1 and S2 can be used to connect an external potential free contact (typically normally closed). This makes it possible to activate the
holding brake using an external safety circuit independent of the control integrated in the ACOPOS servo drive. If this function is not
used, a jumper must be placed between S1 and S2.

1) For ACOPOS 8V1640.00-2 up to and including Rev. B5:

Connections X1 / 16, 17, 18 and X4 / 8, 11, 12 are internally connected in the device.

142 ACOPOS User's Manual

 Wiring • Connections ACOPOS 1640, 128M

4.5 Pin Assignments for X5

X5 Pin Description Function

1 PE Protective Ground Conductor
2 W Motor Connection W
3 V Motor Connection V
4 U Motor Connection U

Terminal Cross Sections see Table 56, "Terminal cross sections for ACOPOS servo
drives", on page 129

Table 74: Pin assignments for X5 ACOPOS 1640, 128M

4.6 Pin Assignments for X6

X6 Pin Description Function

1 RB+ Brake Resistance +
2 RB- Brake Resistance -
3 PE Protective Ground Conductor

Chapter 5
Wiring

Terminal Cross Sections see Table 56, "Terminal cross sections for ACOPOS servo
drives", on page 129

Table 75: Pin assignments for X6 ACOPOS 1640, 128M

ACOPOS User's Manual 143

 Wiring • Plug-in Module Connections

5. Plug-in Module Connections

5.1 AC110 - CAN Interface

5.1.1 Pin Assignments

Image Connection Pin Description Function

1 --- ---
2 CAN_L CAN Low
3 COM (2, 7) CAN 0 V
4 --- ---
5 --- ---
6 --- ---
7 CAN_H CAN High
8 --- ---
9 --- ---

Table 76: Pin assignments for AC110 - CAN Interface

144 ACOPOS User's Manual

 Wiring • Plug-in Module Connections

5.2 AC112 - Ethernet Powerlink Interface

5.2.1 Pin Assignments

Image Connector 1 Pin Description Function

1 RXD Receive Signal
2 RXD\ Receive Signal Inverted
3 TXD Transmit Signal
4 Shield Shield
5 Shield Shield
6 TXD\ Transmit Signal Inverted
7 Shield Shield
8 Shield Shield
Connector 2 Pin Description Function
1 RXD Receive Signal
2 RXD\ Receive Signal Inverted
3 TXD Transmit Signal
4 Shield Shield
5 Shield Shield
6 TXD\ Transmit Signal Inverted
7 Shield Shield
8 Shield Shield

Table 77: Pin assignments for AC112 - Ethernet Powerlink Interface

Information:
In general, crossover Ethernet cables must be used for Powerlink Ethernet
connections!
Chapter 5
Wiring

ACOPOS User's Manual 145

 Wiring • Plug-in Module Connections

5.3 AC120 - EnDat Encoder Interface

5.3.1 Pin Assignments

Image Connector Pin Description Function

1 A Channel A
2 COM (1, 3 - 9, 11, 13 - 15) Encoder supply 0 V
3 B Channel B
4 +5V out / 0.25A Encoder supply +5 V
5 D Data input
6 --- ---
7 R\ Reference pulse inverted
8 T Clock output
9 A\ Channel A inverted
10 Sense COM Sense input 0 V
11 B\ Channel B inverted
12 Sense +5V Sense input +5 V
13 D\ Data inverted
14 R Reference pulse
15 T\ Clock output inverted

Table 78: Pin assignments for AC120 - EnDat Encoder Interface

146 ACOPOS User's Manual

 Wiring • Plug-in Module Connections

5.4 AC122 - Resolver Interface

5.4.1 Pin Assignments

Image Connector Pin Description Function

1 --- ---
2 --- ---
3 Cos Cosine input
4 Sin Sine input
5 Ref Reference Output
6 --- ---
7 Cos\ Cosine input inverted
8 Sin\ Sine input inverted
9 Ref \ Reference output inverted

Table 79: Pin assignments for AC122 - Resolver Interface

Chapter 5
Wiring

ACOPOS User's Manual 147

 Wiring • Plug-in Module Connections

5.5 AC123 - Incremental Encoder and SSI Absolute Encoder Interface

5.5.1 Pin Assignments

Image Connector Pin Description Function in Function in SSI

Incremental Mode Mode
1 A Channel A ---
2 A\ Channel A inverted ---
3 B Channel B ---
4 B\ Channel B inverted ---
5 RD Reference pulse Data input
6 RD\ Reference pulse Data input inverted
inverted
7 T --- Clock output
8 T\ --- Clock output
inverted
9 +5V out / 0.35A Encoder supply +5 V
10 Sense +5V Sense +5 V
11 Sense COM Sense 0 V
12 COM (7 - 9, 13) Encoder supply 0 V
13 +15V out / 0.35A Encoder supply +15 V
14 A1 Activate encoder supply 1)
15 A2 Activate encoder supply 1)

Table 80: Pin assignments AC123 - incremental encoder and SSI absolute encoder interface

1) To activate the encoder supply, pins 14 and 15 must be connected in the encoder cable plug.

148 ACOPOS User's Manual

 Wiring • Plug-in Module Connections

5.6 AC130 - Digital Mixed Module

5.6.1 Pin Assignments

Image Connector Pin Description Function

1 Dig. I/O 1 Digital input / output 1
2 Dig. I/O 2 Digital input / output 2
3 Dig. I/O 3 Digital input / output 3
4 Dig. I/O 4 Digital input / output 4
5 Dig. I/O 5 Digital input / output 5
6 Dig. I/O 6 Digital input / output 6
7 Dig. I/O 7 Digital input / output 7
8 Dig. I/O 8 Digital input / output 8
9 Dig. O 9 Digital output 9
10 Dig. O 10 Digital output 10
11 +24V Supply +24 V
12 COM (1-11) Supply 0 V

Terminal Cross Sections [mm²] [AWG]

Solid core and multiple conductor lines 0.5 - 1.5 20 - 14
Flexible, multiple wire line
without Wire Tip Sleeves 0.5 - 1.5 20 - 14
with Wire Tip Sleeves 0.5 - 1.5 20 - 14
Approbation Data (UL/C-UL-US- and CSA)
UL/C-UL-US --- 26 - 14
CSA --- 26 - 14

Table 81: Pin assignments AC130 - digital mixed module Chapter 5

Wiring

ACOPOS User's Manual 149

 Wiring • Plug-in Module Connections

5.7 Connecting Cables to Plug-in Modules

Figure 36: Connecting Cables to Plug-in Modules

Stress relief for the cable is implemented using a cable tie. The cable tie is to be run through the
eye on the bottom of the plug-in module.
Make sure that the ventilation slots on the bottom of the ACOPOS drive are not blocked.

150 ACOPOS User's Manual

 Wiring • Cables

6. Cables

6.1 Motor Cables

6.1.1 Motor Cable Construction

Pos. Amount Description Remark

1 1 Motor lines 4 x 1.5 mm² + 2 x 2 x 0.75 mm²
4 x 4 mm² + 2 x 2 x 1 mm²
4 x 10 mm² + 2 x 2 x 1.5 mm²
4 x 35 mm² + 2 x 2 x 1.5 mm² (not prefabricated)
2 1 Circular connector BSTA 108 FR 19 08 0006 000 (for 8CMxxx.12-1 and 8CMxxx.12-3)
BSTA 108 FR 35 16 0006 000 (for 8CMxxx.12-5)
3 1 Shrink wrap
4 8 Wire tip sleeve

Table 82: Motor cable construction

Chapter 5
Wiring

ACOPOS User's Manual 151

 Wiring • Cables

6.1.2 Pin Assignments 8CMxxx.12-1, 8CMxxx.12-3

Circular connector Pin Description Function

1 U Motor Connection U
2 PE Protective Ground Conductor
3 W Motor Connection W
4 V Motor Connection V
A T+ Temperature +
B T- Temperature -
C B+ Brake +
D B- Brake -

Table 83: Pin assignments for motor cables 8CMxxx.12-1, 8CMxxx.12-3

6.1.3 Cable Schematic for 8CMxxx.12-1, 8CMxxx.12-3

Figure 37: Cable schematic for motor cables 8CMxxx.12-1, 8CMxxx.12-3

152 ACOPOS User's Manual

 Wiring • Cables

6.1.4 Pin Assignments for 8CMxxx.12-5

Circular connector Pin Description Function

U U Motor Connection U
PE Protective Ground Conductor
W W Motor Connection W
V V Motor Connection V
1 T+ Temperature +
2 T- Temperature -
+ B+ Brake +
- B- Brake -

Table 84: Pin assignments for motor cables 8CMxxx.12-5

6.1.5 Cable Schematic for 8CMxxx.12-5

Chapter 5
Wiring

Figure 38: Cable schematic for motor cables 8CMxxx.12-5

ACOPOS User's Manual 153

 Wiring • Cables

6.2 EnDat Encoder Cables

6.2.1 EnDat Encoder Cable Construction

Pos. Amount Description Remark

1 1 Encoder cable 10 x 0.14 mm² + 2 x 0.50 mm²
2 1 Circular connector, 17 pin socket ASTA 035 FR 11 12 0005 000
3 1 DSUB housing 45°, metal plated, 15 pin plug
4 1 Shrink wrap

Table 85: EnDat encoder cable construction

6.2.2 Pin Assignments

Circular connector Pin Description Function Pin DSUB plug

15 A Channel A 1
10 COM (1, 3 - 9, 11, 13 - 15) Encoder supply 0 V 2
12 B Channel B 3
7 +5V out / 0.25A Encoder supply +5 V 4
14 D Data input 5
8 T Clock output 8
16 A\ Channel A inverted 9
4 Sense COM Sense input 0 V 10
13 B\ Channel B inverted 11
1 Sense +5V Sense input +5 V 12
17 D\ Data inverted 13
9 T\ Clock output inverted 15

Table 86: Pin assignments for EnDat encoder cables

154 ACOPOS User's Manual

 Wiring • Cables

6.2.3 Cable Schematic

Figure 39: Cable schematic for EnDat encoder cables

Chapter 5
Wiring

ACOPOS User's Manual 155

 Wiring • Cables

6.3 Resolver Cables

6.3.1 Resolver Cable Construction

Pos. Amount Description Remark

1 1 Encoder cable 3 x 2 x 24 AWG/19
2 1 Circular connector, 12 pin socket ASTA 021 FR 11 10 0005 000
3 1 DSUB housing 45°, metal plated, 9 pin plug
4 1 Kink protection

Table 87: Resolver cable construction

6.3.2 Pin Assignments

Circular connector Pin Description Function Pin DSUB plug

1 ---
2 ---
3 Cos Cosine input 3
4 Sin Sine input 4
5 Ref Reference Output 5
6 ---
7 Cos\ Cosine input inverted 7
8 Sin\ Sine input inverted 8
9 Ref \ Reference output inverted 9
10 ---
11 ---
12 ---

Table 88: Pin assignments for resolver cables

156 ACOPOS User's Manual

 Wiring • Cables

6.3.3 Cable Schematic

Figure 40: Cable schematic for resolver cables

Chapter 5
Wiring

ACOPOS User's Manual 157

 Wiring • Cables

158 ACOPOS User's Manual

 Getting Started • Preparation

CHAPTER 6 • GETTING STARTED

1. Preparation

1.1 Unpacking the ACOPOS Servo Drive

Remove the protective packaging from the ACOPOS servo drive. Check the ACOPOS servo
drive for obvious mechanical damage.

Danger!
Do not operate the ACOPOS servo drive if it is damaged. This can cause severe
personal injury or damage to property!

1.2 Installing and Connecting the ACOPOS Servo Drive

The guidelines and specifications for installing and wiring the respective ACOPOS servo drive
can be found in chapters 3 "Installation", 4 "Dimensioning" and 5 "Wiring".

1.3 Connecting the ACOPOS Servo Drive with a B&R PLC

Depending on the configuration, ACOPOS servo drives are equipped with a CAN (AC110) or
Ethernet Powerlink (AC112) interface which can be used to connect to a B&R PLC. The
connection is made using a a CAN cable (AC110) or an Ethernet cable 1) (AC112) (pin
assignments can be found in chapter 5 "Wiring" and in the User's Manual for the PLC). Getting Started
Chapter 6

1) Caution: In general, crossover Ethernet cables must be used for Ethernet Powerlink connections!

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2. Starting Up an ACOPOS Servo Drive

The goal of the following example is move the shaft of a motor connected to an ACOPOS servo
drive 5000 units. In order to emphasize the important points of starting up the hardware, this will
be done using an sample project contained in B&R Automation Studio™.

Danger!
Incorrect control of motors or mechanical parts connected to the motor shaft can
cause unwanted and dangerous movements!

2.1 General Information

The start-up procedure described here is based on the following configuration: 1)

Model Number Short Description

Servo Drives
8V1045.00-1 Servo drive 3 x 400-480V 4.4A 2kW, line filter and braking resistor integrated
Plug-in Modules
8AC110.60-1 ACOPOS plug-in module, CAN interface
8AC120.60-1 ACOPOS plug-in module, EnDat encoder interface
Motor
8MSA4L.E0-B4 Motor MSA4 series with EnDat encoder
Accessories
7AC911.9 Bus connector, CAN (2 pcs.)
8CE005.12-1 EnDat cable, length 5m, 10 x 0.14mm² + 2 x 0.5mm², EnDat connector 17 pin Intercontec
socket, servo connector 15 pin DSUB plug, can be used in cable drag chains, UL/CSA
listed
8CM005.12-1 Motor cable, length 5m, 4 x 1.5mm² + 2 x 2 x 0.75mm², motor connector 8 pin Intercontec
socket, can be used in cable drag chains, UL/CSA listed
0G0001.00-090 Cable PC <--> PLC/PW, RS232, Online cable
PLC CPU
7CP476.60-1 2003 CPU, 750 KB SRAM, 1.5 MB FlashPROM, 24 VDC, 12.5 W supply, 1 RS232
interface, 1 CAN interface, CAN: electrically isolated, network capable, 4 slots for screw-in
modules, system bus for expansion modules, max. 272 digital / 80 analog I/O points
B&R Automation Studio™
1A4000.Lx B&R AutomationSoftware™ CD, full version

Table 89: Configuration for the start-up example

1) The procedure can change slightly depending on the hardware configuration.

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The hardware configuration will be called the "target system" in the following sections. A PC with
B&R Automation Studio™ installed will also be needed.

2.1.1 Sample Project

Several sample projects are available in B&R Automation Studio™ which can be used to test
ACOPOS servo drives. They are found in the directory "...\BR_AS_xxx\SAMPLES\MOTION" in
the B&R Automation Studio™ installation directory (xxx is the Automation Studio™ version
number).
This start-up example is based on the sample project
"...\BR_AS_xxx\SAMPLES\MOTION\ENGLISH\C\ACP10.PGP\ACP10.GDM" starting with
ACOPOS operating system version V 0.47.2 (xxx is the Automation Studio™ version number).

Figure 41: Open sample project

Information:
During start-up, changes will be made to the sample project. We recommend that
you make a copy of the sample project (entire ACP10.PGP directory, see Diagram 41
"Open sample project") in a different project directory and use it for the start-up.

2.1.2 Preparing the Hardware for Sample Project acp10.gdm

• Check the wiring of the ACOPOS servo drive connections (also see chapter 5 "Wiring").
• Set node number 1 on the AC110 plug-in module (see chapter 2 "Technical Data").
• Connect the PC with the PLC using the online cable (see user's manual for the PLC for
information concerning the online cable connection to the PLC).
• Apply power to the PLC and the ACOPOS servo drive (24 VDC, 400 VAC). You can
Getting Started

make sure the ACOPOS servo drive boots correctly by watching the blink code (see
Chapter 6

chapter 2 "Technical Data").

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2.2 Start-up

2.2.1 Load Sample Project

Start B&R Automation Studio™:

Figure 42: B&R Automation Studio™ version is shown during the start procedure

Figure 43: B&R Automation Studio™ Start-up Screen

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Open the project (recommended: make a copy of sample project ACP10.GDM in the respective
project path):
• Click Open Project ... in the File menu.

Figure 44: Opening a project

• Select ...\ACP10.PGP\ACP10.GDM.
• Load the project by clicking on the Open button.

Figure 45: Selecting the project

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The selected project is then opened in the project window:

Figure 46: Project window with representation of the hardware and software configuration

The left part of the window contains the hardware configuration for the project and the right part
of the window contains the software configuration for the hardware component selected in the
left part of the window.

Information:
When loading the project, a connection is automatically established between the PC
and the PLC.
If the connection is active, the CPU type and "RUN" are shown to the right below the
status bar (see Diagram 46 "Project window with representation of the hardware and
software configuration").

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2.2.2 Preset Values for the Sample Project

A few preset values must be defined on the target system before downloading the project.

CPU

The sample project was originally created for a different PLC CPU (7CP474.60-1).
This must be changed to the CPU used on the target system (shown to the right under the status
bar):
• In the left part of the window, position the mouse pointer on the CPU (7CP474.60-1).

Figure 47: Select the CPU in the left part of the window
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• Open the shortcut menu with the right mouse button.

• Position the mouse pointer on Replace with 7CP476.60-1.
• Select this menu item with the left mouse button.

Figure 48: Select the command used to replace the CPU from the shortcut menu

• Acknowledge the change of the CPU by clicking on the OK button.

Figure 49: Acknowledge the change of the CPU

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User Memory

Before downloading the sample project, we recommend clearing the user memory on the PLC:
• In the Project menu, select Services and then Clear Memory ....

Figure 50: Clearing user memory on the PLC

• Activate the checkbox Erase USER ROM.

• Acknowledge the selection by clicking the OK button.

Figure 51: Selecting the user memory on the PLC

Getting Started
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• The user memory is erased.

Figure 52: Erasing the user memory

After clearing the user memory, the project window will be shown again.

Operating System Download

The first time an ACOPOS servo drive is started up, the ACOPOS operating system ACP10SYS
must also be transferred to the target system. In the sample project, transferring ACP10SYS is
deactivated (shown in gray in the right part of the window). Transferring ACP10SYS must be
activated separately in the sample project:
• Position the mouse pointer on ACP10SYS in the right part of the window.

Figure 53: Place mouse pointer on ACOPOS operating system ACP10SYS

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• Open the shortcut menu with the right mouse button.

• Position the mouse pointer on Disable.
• Click on Disable with the left mouse button to cancel deactivation.

Figure 54: Enable transferring the ACOPOS operating system

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ACP10SYS is now enabled (shown in black instead of gray) and is also transferred the next time
the project is downloaded.

Figure 55: The operating system is also transferred the next time the project is downloaded

Information:
After successfully downloading the operating system the first time, "Disable" can
be set again which shortens the download time for projects.

2.2.3 Preset Values Concerning Wiring

The further procedure depends on the wiring of the digital servo drive control inputs.

End Switch and Quickstop are Wired

If the hardware end switches (normally closed) are wired to X1 / End+ and X1 / End- and a
quickstop switch (normally closed) is wired to X1 / Quickstop/Trigger2 according to chapter 5
"Wiring", Section 2 "Connections ACOPOS 1022, 1045, 1090", then start-up can be continued
with Section 2.2.4 "Downloading the Project".

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End Switch and Quickstop are not Wired

If the hardware end switches and quickstop are not wired, it is possible to change the parameters
so that the motor shaft can still be moved.

Danger!
When moving the motor shaft without the hardware end switches connected,
movements of mechanical parts mounted on the motor shaft must be considered.
Otherwise severe personal injury or damage to property can occur!

• Position the cursor on the initial parameter module AX1_PAR.

• Open the object by double-clicking with the left mouse button.

Figure 56: Open initial parameter module AX1_PAR

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Chapter 6

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• Position the mouse pointer on "dig_in".

Figure 57: Place the mouse pointer on "dig_in"

• Expand the view by clicking on "+".

Figure 58: Expand the view

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• Position the mouse pointer on "level". The parameters are now shown in the right part of
the window.

Figure 59: Displaying the level parameters

To allow movement of the motor shaft, the following parameters must be changed to the value
"ncACTIV_HI":
• pos_hw_end
• neg_hw_end
• trigger2 (quickstop)
"ncACTIV_HI" means that the inputs for both hardware end switches and the quickstop are
activated (logical "1"). This allows the motor shaft to be moved without wiring the hardware end
switches and a quickstop.
The procedure is shown here in an example for pos_hw_end:
• In the right part of the window, position the mouse pointer on level "ncACTIV_LO" for the
shaft parameter pos_hw_end.
Getting Started
Chapter 6

Figure 60: Place mouse pointer on level "ncACTIV_LO"

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• Open the selection list by clicking with the left mouse button.
• Select "ncACTIV_HI" by clicking with the left mouse button.

Figure 61: Change the level for the positive hardware end switch

• Acknowledge the selection by pressing the ENTER key.

Figure 62: Acknowledge level change

Use the same procedure for the other two parameters, neg_hw_end and trigger2 (quickstop).
When all changes are made, the value list looks like this:

Figure 63: Levels after all changes are made

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Now the object window can be closed.

• In the File menu, click on Close.

Figure 64: Closing the object window

• Acknowledge the changes by clicking the Yes button.

Figure 65: Acknowledge level changes

The project window will be shown again.

Getting Started
Chapter 6

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2.2.4 Downloading the Project

After making the preparations, the project can now be transferred to the target system:
• In the Project menu, click on Transfer To Target.

Figure 66: Click on the command to transfer the project to the target system

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If an operating system has already been transferred to the PLC, a version conflict could occur.
In this case, the operating system on the PLC is to be applied to the operating system in the
sample project:
• Select option Apply the current version ....

Figure 67: Operating system version conflict

• Acknowledge by clicking the Continue button.

Figure 68: Acknowledge selection of conflict resolution

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• A message will be displayed by B&R Automation Studio™. Acknowledge this message

by clicking Yes.

Figure 69: Acknowledge message from B&R Automation Studio™ with Yes

• The project is transferred.

Figure 70: The project is transferred

• The following message is given after the project has been successfully transferred:

Figure 71: The project was transferred successfully

• Acknowledge the message by clicking the OK button.

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2.2.5 Test Function

Now control of the motor shaft can be taken over using the test function (ACP10 - real axis):
• Position the cursor on the initial parameter module AX1_PAR.

Figure 72: Select initial parameter module AX1_PAR

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• In the Open menu, click on Test.

Figure 73: Command to open the test window

The test window is shown:

Figure 74: Test window for ACOPOS servo drives

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2.2.6 Starting the Motor Movement

Danger!
The traverse path must be adjusted for the conditions present (installed mechanical
parts, etc.).
Incorrect control of motors or mechanical parts connected to the motor shaft can
cause unwanted and dangerous movements. This can cause severe personal injury
or damage to property!

If mechanical parts are mounted on the motor, the number of encoder units per motor revolution
must be adjusted to the mechanical characteristics (possible traverse path, etc.).
The number of encoder units per motor revolution (units, rev_motor) can be set as follows:
• Position the mouse pointer on "encoder_if"
• Expand the view by clicking on "+"
• Position the mouse pointer on "parameter"
• Expand the view by clicking on "+"
• Position the mouse pointer on "scaling"
• Expand the view by clicking on "+"
• Position the mouse pointer on "load"
The parameters are now shown in the right part of the window:

Figure 75: Setting the encoder resolution

Now the values can be adjusted to the mechanical parts used and acknowledged by pressing
the ENTER key.
Getting Started
Chapter 6

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For additional safety, the traverse path can be limited using software end switches (pos_sw_end,
neg_sw_end).
The software end switches can be defined as follows:
• Position the mouse pointer on "limit"
• Expand the view by clicking on "+"
• Position the mouse pointer on "parameter"
The parameters are now shown in the right part of the window:

Figure 76: Defining the software end switches

Now the values can be adjusted to the mechanical parts used and acknowledged by pressing
the ENTER key.

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Entering the Traverse Path

• Position the mouse pointer on the action "ncSTART" for the subject "ncREL_MOVE" in
the action window.

Figure 77: Place mouse pointer on the action "ncSTART"

• Enter the value (e.g. 5000) for s (target position or relative traverse path) in the
parameter object , value column.

Danger!
The traverse path must be adjusted for the conditions present (installed mechanical
parts, etc.).
Incorrect control of motors or mechanical parts connected to the motor shaft can
cause unwanted and dangerous movements! This could result in death, severe
injury or material damage.

• Acknowledge by pressing the ENTER key.

Getting Started

The new value is sent to the PLC.

Chapter 6

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Enabling the Trace Function

• Position the mouse pointer on the Trace enabled checkbox in the action window.
• Activate the checkbox by clicking on it with the left mouse button.

Figure 78: Enable trace function

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Start the Motor Movement

• Position the mouse pointer on the action "ncSTART" for the subject "ncREL_MOVE" in
the action window.

Figure 79: Place mouse pointer on the action "ncSTART"

• Click on the button on the toolbar:

The motor shaft now moves according to the traverse path (s) defined and the Trace
function starts.

Getting Started
Chapter 6

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Display and Evaluation of the Trace Function

Figure 80: During the movement of the shaft, the traverse path already completed is shown in the Watch
window

Figure 81: The defined traverse path was completed and the Trace data is loaded

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Figure 82: The data recorded is shown in the Trace window

The current position of the motor shaft is shown in the Watch window:

Display of the current position of the motor shaft

Before the shaft movement During the shaft movement After the shaft movement

Table 90: Display of the current position of the motor shaft in the Watch window
Getting Started
Chapter 6

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The following data concerning shaft movement is displayed in the Trace window:

Set Speed

The acceleration phase, the constant speed phase and the braking phase of the shaft movement can be evaluated here.
Lag Error

In the acceleration phase for the motor shaft → increasing lag error
At constant speed → constant lag error
In the braking phase → decreasing lag error
Actual stator current quadrature component

The various movement phases are represented here:

Acceleration of the motor shaft → current increases
Constant speed → current decreases
Braking phase → current becomes negative

Table 91: Output of the recorded data in the Trace window

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 Standards and Certifications

Standards and
Certifications
Chapter 7
CHAPTER 7 • STANDARDS AND
CERTIFICATIONS

1. Valid European Guidelines for ACOPOS Servo Drives

• EMC guidelines 89/336/EWG

• Low-voltage guidelines 73/23/EWG
• Machine guidelines 98/37/EG

2. Valid Standards for ACOPOS Servo Drives

Standard Description
IEC/EN 61800-2 Adjustable speed electrical power drive systems:
Part 2: General requirements - Rating specifications for low voltage adjustable frequency a.c. power drive
systems
IEC/EN 61800-3 Adjustable speed electrical power drive systems:
Part 3: EMC product standard including specific test methods
IEC 61800-5 (draft) Adjustable speed electrical power drive systems:
Part 5: Safety requirements - Electrical and thermal
IEC/EN 61131-2 Programmable controllers:
Part 2: Equipment requirements and tests
IEC 60204-1 Safety of machinery - Electrical equipment of machines:
Part 1: General requirements
EN 1037 Safety of machinery - prevention of unexpected start-up
IEC 61508 Functional safety of electrical / electronic / programmable electronic safety-related systems
IEC 954-1 Safety of machinery - safety-related parts of control systems
Part 1: General principles of design
TÜV: Sample test for secure restart prevention according to category 3 planned
UL 508 C Power Conversion Equipment

Table 92: Valid Standards for ACOPOS Servo Drives

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 Standards and Certifications

3. Electrical Limit Values for Immunity Tests according to

IEC 61800-3

These immunity tests are valid for industry (2nd environment).

Tests according to IEC 61000-4-2 Electrostatic Discharge

IEC 61800-3
Contact discharge to powder-coated and bare metal 4 kV, criteria B
housing parts
Discharge through the air to plastic housing parts 8 kV, criteria B

Tests according to IEC 61000-4-3 Electromagnetic Fields

IEC 61800-3
Housing, completely wired 80 MHz - 1 GHz, 10 V/m,
80 % amplitude modulation with 1 kHz, criteria A

Tests according to IEC 61000-4-4 Burst

IEC 61800-3
Power lines 2 kV, 1 min, criteria B, direct coupling
Lines for measurement and control functions in the 2 kV, 1 min, criteria B
process environment
Signal interfaces, other lines 1 kV, 1 min, criteria B

Tests according to IEC 61000-4-5 Surge

IEC 61800-3
Power lines 1 kV (2 Ω), DM, symmetrical, criteria B
2 kV (12 Ω), CM, unsymmetrical, criteria B

Tests according to IEC 61000-4-6 HF Coupling

IEC 61800-3
Power lines
Lines for measurement and control functions in the 0.15 - 80 MHz, 10 V,
process environment 80 % amplitude modulation with 1 kHz, criteria A
Signal interfaces, other lines

Table 93: Electrical Limit Values for Immunity Tests according to IEC61800-3

Performance Criteria (simplified)

Criteria A: Test object not influenced during test.

Criteria B: Test object only temporarily influenced during test.
Criteria C: The system does not reboot automatically (reset required).

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4. Electrical Limit Values for Emission Tests according to

Standards and
Certifications
IEC 61800-3

Chapter 7
These emission tests are valid for industry (2nd environment).

Tests according to IEC 55011 (conducted emissions)

Continuous Current on Motor Frequency Range [MHz] Quasi-peak Value Average
0,15 ≤ f < 0.5 100 dB (µV) 90 dB (µV)
I ≤ 100 A 0,5 ≤ f < 5 86 dB (µV) 76 dB (µV)
5 ≤ f < 30 90 dB (µV) 80 dB (µV)
0,15 ≤ f < 0.5 130 dB (µV) 120 dB (µV)
100 A < I 0,5 ≤ f < 5 125 dB (µV) 115 dB (µV)
5 ≤ f < 30 115 dB (µV) 105 dB (µV)

Tests according to IEC 55011 (radiated emissions)

Frequency Range [MHz] Quasi-peak Value
30 ≤ f ≤ 230 40 dB (µV/m), measured at distance of 30 m
230 < f ≤ 1000 50 dB (µV/m), measured at distance of 30 m

Table 94: Electrical limit values for emission tests according to IEC 61800-3

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 Standards and Certifications

5. Environmental Limit Values according to IEC 61800-2

Operational Conditions
IEC 61800-2
Environmental Temperature during Operation 5 to 40 °C
Relative Humidity during Operation 5 -85 %, non-condensing
Power Reduction in Relation to Installation Altitude 1) 10 % per 1000 m installation altitude
Max. 2,000 m above sea level
Degree of Pollution according to IEC 60664-1 2 (non-conductive material)
Overvoltage Category according to II
IEC 60364-4-443:1999
Protection according to IEC 60529 IP20
Vibration
2 ≤ f < 9 Hz 0.3 mm amplitude
9 ≤ f < 200 Hz 1 m/s² acceleration

Storage and Transport Conditions

Storage Temperature -25 to +55 °C
Relative Humidity for Storage 5 - 95 %, non-condensing
Transport Temperature -25 to +70 °C
Relative Humidity for Transport 95 % at 40 °C, non-condensing
Vibration during Transport
2 ≤ f < 8 Hz 3.5 mm amplitude
8 ≤ f < 200 Hz 10 m/s² acceleration
200 ≤ f < 500 Hz 15 m/s² acceleration

Table 95: Environmental Limit Values according to IEC 61800-2

1) Unusual operating conditions must be arranged with B&R.

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6. International Certifications

Standards and
Certifications
Chapter 7
B&R products and services comply with the applicable standards. These are international
standards from organizations such as ISO, IEC and CENELEC, as well as national standards of
organizations such as UL, CSA, FCC, VDE, ÖVE, etc. We give special consideration to the
reliability of our products in an industrial environment.

Certifications

USA and Canada All important B&R products are tested and listed by Underwriters Laboratories and are
checked quarterly by a UL inspector.
This mark is valid for the USA and Canada and eases certification of your machines and
systems in these areas.

Europe All harmonized EN standards for the valid guidelines are met.

Russian Federation A GOST-R certification is planned for the export of ACOPOS servo drives in the Russian
Federation.

Table 96: International Certifications

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 Standards and Certifications

7. Standards, Definitions for Safety Techniques

Stop Functions according to IEC 60204-1/11.98 (electrical equipment for machines,

part 1: general requirements)

The following three stop function categories exist:

Category Description
0 Stop by immediately switching off the power to the machine drive elements (i.e. uncontrolled stop).
1 A controlled stop, the power to the machine drive elements remains on until the stop procedure is completed. The power is
switched off after the stop is complete.
2 A controlled stop, the power to the machine drive elements is not switched off.

Table 97: Overview of stop function categories

The necessary stop functions must be determined based on a risk evaluation for the machine.
Stop functions in category 0 and category 1 must be able to function regardless of the operating
mode. A category 0 stop must have priority. Stop functions must have priority over assigned start
functions. Resetting the stop function is not allowed to cause a dangerous state.

Emergency stops according to IEC 60204-1/11.98 (electrical equipment for machines,

part 1: general requirements)

The following requirements are valid for emergency stops in addition to the requirements for the
stop functions:
• It must have priority over all other functions and operations in all operating modes.
• The power to the machine drive elements which can cause a dangerous state must be
switched off as quickly as possible without creating other dangers.
• Resetting is not allowed to cause a restart.
Emergency stops must be category 0 or category 1 stop functions. The necessary stop function
must be determined based on a risk evaluation for the machine.
For emergency stop function in stop category 0, only hard wired, electromechanical equipment
can be used. Additionally, the function is not allowed to depend on electronic switching logic
(hardware or software) or the transfer of commands via a communication network or data
connection. 1)

1) In accordance to the national foreword for the valid German version of EN 602041-1/11.98, it is determined that electronic equipment
(and also especially for emergency stop systems) can be used regardless of the stop category, if e.g. it provides the same safety using
the standards EN 954-1 and/or IEC 61508 as required by IEC 60204-1.

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When using a category 1 stop function for the emergency stop function, it must be guaranteed

Standards and
that the power to the machine drive elements is completely switched off. These elements must

Certifications
Chapter 7
be switched off using electromechanical equipment 1) .

Safety category according to EN 954-1/03.97 (safety of machines - safety related parts of

control systems, part 1: general design principles) 2)

The safety related parts of control systems must meet one or more of the requirements for five
defined safety categories. The safety categories define the required behavior of safety related
controller parts regarding their resistance to errors.

Safety Category Safety Integrity Short Description System Behavior

(according to EN 954- Level - SIL (according
1) to IEC 61508-2)
B --- Safety related parts must be designed and Warning!
built so that they can meet the expected
An error can cause the safety function to
operational requirements.
fail.
(No specific safety measures are
implemented.)
1 1 Safety related parts must be designed and Warning!
built so that only reliable components and
An error can cause the safety function to
safety principles are used.
fail.
(e.g. preventing short circuits by using
sufficient distances, reducing the probability
of errors by over-dimensioning components,
defining the failure route - closed-circuit
current principle, etc.)
2 1 Safety related parts must be designed so Warning!
that their safety functions are checked in
An error between checks can cause the
suitable intervals by the machine controller.
safety function to fail. If the safety
function fails, it will be recognized during
(e.g. automatic or manual check during start-
the check.
up)
3 2 Safety related parts must be designed so Warning!
that individual errors do not cause the safety
The safety function remains active when
function to fail. Individual errors should - if
an error occurs. Some, but not all errors
possible - be recognized the next time (or
are recognized. A buildup of errors can
before) the safety function is required.
cause the safety function to fail.
4 3 Safety related parts must be designed so Information:
that individual errors do not cause the safety
The safety function remains active when
function to fail. Individual errors must be
an error occurs. Errors are recognized in
recognized the next time (or before) the
time to prevent the safety function from
safety function is required. If this type of
failing.
recognition is not possible, a buildup of
errors is not allowed to cause the safety
function to fail.

Table 98: Safety category overview

1) In accordance to the national foreword for the valid German version of EN 602041-1/11.98, it is determined that electronic equipment
(and also especially for emergency stop systems) can be used regardless of the stop category, if e.g. it provides the same safety using
the standards EN 954-1 and/or IEC 61508 as required by IEC 60204-1.
2) To prevent confusing EN 951-1 categories with IEC 60204-1 stop categories, the term "safety categories" was used in the text shown
above for EN 954-1 categories.

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Selecting the suitable safety category must be done separately for each ACOPOS servo drive
(or for each shaft) based on a risk evaluation. This risk evaluation is a part of the total risk
evaluation for the machine.
The following risk graph (according to EN 954-1, Appendix B) provides a simplified procedure
for risk evaluation:

Figure 83: Risk graph according to EN 954-1, Appendix B

196 ACOPOS User's Manual

 Standards and Certifications

Begin at the starting point shown and follow the parameters S, F and P to the safety category to

Standards and
be used.

Certifications
Chapter 7
Parameter S ... Seriousness of injury
S1 Light (usually reversible) injury.
S2 Serious (usually irreversible) injury.
Parameter F ... Frequency and/or duration of the danger exposure
F1 Seldom to slightly more frequent and/or short exposure duration.
F2 Frequent to continuous and/or long exposure duration.
Parameter P ... Possibility to prevent danger
P1 Possible under some conditions.
P2 Nearly impossible.

Table 99: Parameters S, F and P lead you to the safety category to be used

Restart inhibit according to IEC 1037/04.96 (Safety of machinery - prevention of

unexpected start-up)

Keeping a machine in an idle state when people are working in the danger zone is one of the
most important requirements for safe operation of machines.
Starting refers to the transition of a machine or its parts from an idle state to moving state. Any
start is unexpected if it is caused by:
• A start command sent because of a controller failure or because of external influences on
the controller.
• A start command sent because of incorrect operation of a start element or another part
of the machine.
• Restoration of power supply after an interruption.
• External/internal influences on parts of the machine.
To prevent unexpected starting of machines or parts of machines, power should be removed and
dissipated. If this is not practical (e.g. frequent, short work in danger zone), other measures must
be taken:
• Measures to prevent random start commands.
• Measures to prevent that random start commands cause unexpected starting.
• Measures to automatically stop dangerous parts of the machine before a dangerous
situation can be caused by unexpected starting.

ACOPOS User's Manual 197

 Standards and Certifications

198 ACOPOS User's Manual

 Index

Numerics 8PM003.00-1 .............................................. 71

8PR001.00-1 .............................................. 74
8AC110.60-2...............................................41 8V1022.00-2 ............................................... 34
8AC112.60-1...............................................43 8V1045.00-2 ............................................... 34
8AC120.60-1...............................................48 8V1090.00-2 ............................................... 34
8AC122.60-1...............................................51 8V1180.00-2 ............................................... 36
8AC123.60-1...............................................53 8V128M.00-2 .............................................. 38
8AC130.60-1...............................................56 8V1320.00-2 ............................................... 36
8CE005.12-1...............................................66 8V1640.00-2 ............................................... 38
8CE007.12-1...............................................66
8CE010.12-1...............................................66
A

Index
8CE015.12-1...............................................66
8CE020.12-1...............................................66 AC110.................................................41, 144
8CE025.12-1...............................................66 AC112.................................................43, 145
8CM005.12-1 ..............................................61 AC120.................................................47, 146
8CM005.12-3 ..............................................61 AC122.................................................50, 147
8CM005.12-5 ..............................................62 AC123.................................................53, 148
8CM005.12-8 ..............................................62 AC130.................................................56, 149
8CM007.12-1 ..............................................61 ACOPOS
8CM007.12-3 ..............................................61 1022 ................................................34, 130
8CM007.12-5 ..............................................62 1045 ................................................34, 130
8CM007.12-8 ..............................................62 1090 ................................................34, 130
8CM010.12-1 ..............................................61 1180 ................................................36, 134
8CM010.12-3 ..............................................61 128M ...............................................38, 139
8CM010.12-5 ..............................................62 1320 ................................................36, 134
8CM010.12-8 ..............................................62 1640 ................................................38, 139
8CM015.12-1 ..............................................61 See Servo Drives
8CM015.12-3 ..............................................61
8CM015.12-5 ..............................................62
8CM015.12-8 ..............................................62 B
8CM020.12-1 ..............................................61
Braking Resistor ....................................... 104
8CM020.12-3 ..............................................61
8CM020.12-5 ..............................................62
8CM020.12-8 ..............................................62 C
8CM025.12-1 ..............................................61
8CM025.12-3 ..............................................61 Cables
8CM025.12-5 ..............................................62 Encoder Cables
8CM025.12-8 ..............................................62 EnDat...........................................66, 154
8CR005.12-1 ..............................................68 Resolver.......................................68, 156
8CR007.12-1 ..............................................68 General Information ................................ 60
8CR010.12-1 ..............................................68 Motor Cables...................................61, 151
8CR015.12-1 ..............................................68 Cam Editor.................................................. 19
8CR020.12-1 ..............................................68 CAN Bus Interface AC110..................41, 144
8CR025.12-1 ..............................................68 Certifications............................................. 193
8PE001.00-1...............................................74 Configurations
8PM001.00-1 ..............................................71 CAN......................................................... 20
8PM002.00-1 ..............................................71 Powerlink................................................. 22

ACOPOS User's Manual 199

 Index

Connections EnDat Encoder Interface.................48, 146

ACOPOS Servo Drives .........................130 Incremental/SSI Encoder IF ............53, 148
Cable and Plug ......................................151 Resolver interface ...........................51, 147
Plug-in Modules.....................................144 EnDat Cable
Connector Cable Schematic ................................... 155
Encoder Connector Order Data .............................................. 66
EnDat .......................................... 74, 154 Pin Assignments ................................... 154
Resolver...................................... 74, 156 Specifications .......................................... 66
General Information.................................70 EnDat Cables
Motor Connector....................................152 Construction .......................................... 154
Motor Connectors ....................................71 EnDat Connector
Correctly installing cooling aggregates .......87 Order Data .............................................. 74
Cross Sections..........................................129 Pin Assignments ................................... 154
Specifications .......................................... 75
EnDat Encoder Interface AC120 ........48, 146
D
Ethernet Powerlink Interface AC112 ..43, 145
Danger Warning..........................................24
DC Bus .......................................................99 F
Digital Mixed Module AC130 ............. 56, 149
Dimensioning Formula Variables .................................... 111
Braking Resistor ....................................104 Function Test......................................17, 186
Current Requirements of Plug-in Modules .
110
G
DC Bus ....................................................99
Formula Variables .................................111 Getting Started ......................................... 159
Motor Connection ..................................102 Guidelines................................................. 189
Power Mains Connection ........................91
Dimensions .................................................79
Drive Oscilloscope ......................................18 I
Drives Incremental/SSI Encoder IF AC123 ...53, 148
See Servo Drives Installation ................................... 25, 77, 113
Installation Dimensions............................... 79
E
Electromagnetic Compatibility of the Installati- L
on..............................................................113 Limit Values .............................................. 190
Embedded Parameter Chip ........................13
Encoder ......................................................74
Encoder Cables M
EnDat ............................................. 66, 154
Modular Servo Drive Concept .................... 29
Resolver ......................................... 68, 156
Motor Cable
Encoder Connector
Cable Schematic ...........................152, 153
EnDat ............................................. 74, 154
Order Data .............................................. 61
Resolver ......................................... 74, 156
Pin Assignments ...........................152, 153
Encoder Resolution ..................................181
Specifications .......................................... 63
Encoder Systems
Motor Cables

200 ACOPOS User's Manual

 Index

Construction ..........................................151 Specifications .......................................... 76

Motor Connection .....................................102 Resolver Interface AC122 ..................51, 147
Motor Connector Restart Inhibit ...................................117, 194
Order Data...............................................71 Risk Evaluation......................................... 196
Pin Assignments........................... 152, 153
Specifications ..........................................72
S
Motors
Configurations .........................................20 Safety Categories ..................................... 195
Embedded Parameter Chip .....................13 Safety Guidelines ....................................... 24
General Information.................................13 Sample Project ......................................... 160
Secure Restart Inhibit .......................117, 194

Index
N Security.................................................13, 14
Service........................................................ 15
NC Objects .................................................16 Servo Drives
ACOPOS 1022, 1045, etc. ..............34, 130
Cables
P See Cables
Plug-in Modules Cam Editor .............................................. 19
AC110 ............................................ 41, 144 Concept................................................... 29
AC112 ............................................ 43, 145 Configurations
AC120 ............................................ 47, 146 CAN ..................................................... 20
AC122 ............................................ 50, 147 Powerlink ............................................. 22
AC123 ............................................ 53, 148 Connections .......................................... 130
AC130 ............................................ 56, 149 Connector
Current Requirements ...........................110 See Connectors
General Information.......................... 15, 40 Danger Warning ...................................... 24
Installation and Removal .........................83 Dimensioning .......................................... 91
Overview .................................................40 Dimensions ............................................. 79
Power Mains Connection............................91 Drive Oscilloscope .................................. 18
Powerlink Interface AC112 ................ 43, 145 Function Test ..................................17, 186
Programming ..............................................15 General Information ..........................13, 29
Protective Ground Connection (PE) . 92, 133, Installation ................................ 25, 77, 113
138 Installation Dimensions ........................... 79
NC Objects.............................................. 16
Order Data .............................................. 34
R Plug-in Modules ........ 15, 40, 83, 110, 144
Resolver Cable Programming........................................... 15
Cable Schematic ...................................157 Safety Guidelines .................................... 24
Order Data...............................................68 Sample Project...................................... 160
Pin Assignments....................................156 Service .................................................... 15
Specifications ..........................................69 Software .................................................. 15
Resolver Cables Start-up ................................................. 159
Construction ..........................................156 Status LEDs ............................................ 31
Resolver Connector Storage.................................................... 25
Order Data...............................................74 Technical Data ........................................ 34
Pin Assignments....................................156 Trace ...............................................17, 186
Transport................................................. 25

ACOPOS User's Manual 201

 Index

Trigger .....................................................18 T
Wiring ....................................................113
Shield Connection.....................................115 Terminal Cross Sections .......................... 129
Software......................................................15 Trace ..................................................17, 186
Software End Switches.............................182 Transport .................................................... 25
Standards .................................................189 Trigger ........................................................ 18
Start-up .....................................................159
Status LEDs W
AC112 .....................................................45
ACOPOS .................................................31 Wiring ....................................................... 113
Storage .......................................................25

202 ACOPOS User's Manual

 Index

Index

ACOPOS User's Manual 203

 Index

204 ACOPOS User's Manual

ACOPOS Anwenderhandbuch