SEW-EURODRIVE MOVIDRIVE B Series Manual

SEW MOVIDRIVE ®  MDX60B/61B System Manual: Comprehensive Interpretation of Inverter Technology and Applications

In the field of modern industrial automation, as the core component of motor control, the performance and reliability of the frequency converter directly affect the efficiency and stability of the entire drive system. SEW-EURODRIVE, as a global leader in driving technology, has its MOVIDRIVE ®  The B-series (MDX60B/61B) frequency converter has become an ideal choice for many industrial applications due to its modular design, powerful control functions, and rich expansion options. This article is based on the official system manual (document number 27793230/EN, version 08/2022), and systematically reviews MOVIDRIVE ®  The system architecture, technical parameters, installation specifications, control modes, communication options, startup debugging, and fault diagnosis of MDX60B/61B provide a detailed technical reference for engineers and system integrators.

System Overview and Product Series

MOVIDRIVE ®  The B-series frequency converter covers three main sub series:

MOVIDRIVE ®  MDX60B: Suitable for asynchronous AC motors, without encoder feedback, and does not support option cards. The power range is 0.55 kW to 315 kW.

MOVIDRIVE ®  MDX61B: Suitable for asynchronous AC motors (with or without encoder feedback) and asynchronous/synchronous servo motors, supporting option card expansion. The power range is 0.55 kW to 315 kW.

MOVIDRIVE ®  MDR60A/61B: Regenerative power supply unit, used to feed back DC bus energy to the grid, suitable for 4Q operation, reducing brake resistance heating.

MDX61B adopts a modular concept and provides up to three option slots:

Encoder slot: used for connecting HIPERFACE ®、 Rotary transformer, SSI absolute value encoder or multi encoder card.

Fieldbus slot: used for bus interfaces such as PROFIBUS, INTERBUS, EtherCAT, PROFINET, DeviceNet, CANopen, etc.

Expansion slot: used for I/O expansion, synchronous operation card, safety module or MOVI-PLC ®  controller.

The equipment is divided into standard version (model suffix 00) and technical version (suffix 0T). The technical version provides additional electronic cam and internal synchronous operation functions, and supports MOVITOOLS ®  Application modules in MotionStudio.

Detailed explanation of control mode

MOVIDRIVE ®  B provides multiple control modes to meet different application requirements:

2.1 VFC Control Mode (Voltage Mode Flux Control)

Applicable motor: Asynchronous AC motor, with or without encoder feedback.

Features: When equipped with an encoder, it can achieve 150% torque in a stationary state; When there is no encoder, 150% torque can be achieved at 0.5 Hz. Suitable for conveyor belts, horizontal drives, and counterweight hoists.

2.2 CFC control mode (current mode flux control)

Applicable motors: Asynchronous servo motors (such as DRL series) must be equipped with encoder feedback.

Features: ≥ 160% torque in static state, excellent concentric operation characteristics, and response to load changes in just a few milliseconds. Suitable for high dynamic positioning and synchronization applications.

2.3 SERVO Control Mode

Applicable motors: Permanent magnet synchronous servo motors (such as CM, CMP series) with rotary transformers or HIPERFACE ®  encoder.

Features: High torque density, wide speed range, precise position control.

All control modes are based on a continuous calculation of the complete motor model, ensuring optimal magnetic field orientation control.

Technical data and selection points

3.1 Power and Overload Capacity

Voltage range: 400/500 V equipment (3 x AC 380-500 V) and 230 V equipment (3 x AC 200-240 V).

Overload capacity:

Size 0:200% I-N for at least 60 seconds.

Size 1-7:150% I-N lasts for at least 60 seconds.

All sizes: 125% I-N continuous operation (no overload, suitable for fans/pumps).

Environmental temperature: 0 ° C to+50 ° C (100% load), derating is required for temperatures exceeding 40 ° C (2.5%/° C to 50 ° C, 3%/° C to 60 ° C).

3.2 Dimensions and Installation

Sizes range from 0 to 7, covering 0.55 kW to 315 kW. Size 0 has a compact structure (45 mm wide), while Size 7 has the highest power (2500 type, AC 470 A). All dimensions must be installed vertically, with at least 100mm ventilation gap reserved at the top and bottom. Sizes 4, 5, and 6 should avoid installing thermal sensitive components within the top 300mm.

3.3 Built in functions

Sizes 0, 1, 2S, and 2 come standard with integrated circuit filters that meet the C2 class limit.

8 isolated digital inputs and 6 digital outputs (one of which is a relay output).

1 TF/TH/KTY input, used for motor thermal protection.

7-segment code display, used for operating status and fault indication.

Independent DC 24V input, capable of parameter setting and diagnosis in case of main power failure.

STO (Safe Torque Off) complies with EN 61800-5-2 and can reach up to Cat.3 PL d.

Installation and EMC compliance

4.1 Mechanical Installation

Using original connectors, the power terminal torque is graded according to size (0.6 Nm for size 0/1/2S and 70 Nm for size 7).

Shielding clip is used for grounding the shielding layer of motor and braking resistor cables to ensure high frequency and low impedance.

For sizes 4-7, touch protection covers (such as DLB11B, DLB21B) need to be installed to achieve IP20 protection level.

4.2 EMC compliant installation (EN 61800-3)

Shielded cables: All signal cables must be shielded and grounded extensively at both ends. The motor cable can be shielded or an HD output choke can be used.

Line filter (NF series): used to meet C1 or C2 class limits, installed near the frequency converter, with a connection length of ≤ 400 mm.

Output choke (HD series): Only the U, V, and W phases pass through the magnetic core, and the PE line does not pass through. HD001- HD003 are suitable for different cable cross-sections.

Output filter (HF series): Sine filter, only used for VFC and V/f modes, not for elevator applications. Pay attention to voltage drop and PWM frequency limitation when using (12/16 kHz requires connection to DC bus terminal V5).

4.3 IT Systems

MOVIDRIVE ®  B is allowed to run on IT systems (ungrounded star points), but EMC limits do not apply. It is recommended to use an insulation monitoring instrument with pulse coding measurement to avoid false tripping caused by the grounding capacitance of the frequency converter.

Communication and Options

5.1 System Bus (SBus)

Based on CAN bus (ISO 11898), up to 64 stations. Cable requirements: twisted pair shielding, 0.25-0.75 mm ², characteristic impedance 120 Ω. Baud rate and bus length: 125 kBaud → 500 m, 1000 kBaud → 40 m. The terminal resistor S12=ON needs to be connected at the beginning and end stations.

5.2 RS485 interface

Used to connect up to 32 devices, with a fixed baud rate of 9.6 kBaud, a maximum length of 200 m, and built-in dynamic terminal resistors.

5.3 Fieldbus Options

PROFIBUS DFP21B: 12 Mbaud, DP-V1 support, GSD file SEW_6003.GSD.

INTERBUS DFI11B/DFI21B: 500 kBaud/2 MBaud, DFI21B supports fiber optics.

PROFINET IO DFE32B：100 Mbaud， Dual RJ45 switch, integrated with web server.

EtherNet/IP&Modbus TCP DFE33B: Supports DHCP, dual ports.

EtherCAT DFE 24B: 100 Mbaud, CoE, and VoE services.

DeviceNet DFD11B：125/250/500 kBaud， 5-pin Phoenix terminal.

CAN/CANopen DFC11B：125 kBaud–1 MBaud， 9-pin D-sub or terminal.

5.4 Encoder Options

DEH11B：HIPERFACE ®  Encoder card, supporting sin/cos, TTL, HIPERFACE ®。 X14 can be used as an external encoder input or incremental simulation output.

DER11B: Rotary transformer card, 2-pole, 7 V, 7 kHz. X14 simulation output fixed 1024 pulses per revolution.

DEU21B: Multi encoder card, supports incremental SSI、EnDat、HIPERFACE ®、 CANopen, providing 24V/12V encoder power supply.

DEH21B/DIP11B: SI absolute encoder interface, DIP11B also provides 8 additional digital I/O.

5.5 Safety Options

DFS11B/DFS12B：PROFIBUS DP-V1 with PROFIsafe， Integrated STO safety output (1 A, 24 V).

DFS21B/DFS22B：PROFINET IO with PROFIsafe， Also provide secure output.

DCS21B/22B/31B/32B：MOVISAFE ®  The safety module can achieve stop category 0, 1, 2 and speed/direction/position monitoring, with a maximum SIL of 3/PL e.

BST brake module: safety related brake control, supports AC 230/400/460 V brake coils, power ≤ 120 W.

5.6 Controller and I/O Expansion

DHP11B：MOVI-PLC ®  Basic controller, IEC 61131-3 programming, PROFIBUS slave, 2 SBus interfaces.

DHE/DHF/DHR21B/41b: High performance motion and logic controller, supporting Ethernet, PROFIBUS, PROFINET, etc.

DIO11B: I/O expansion board, with 8 digital inputs, 8 digital outputs, 2 analog inputs, and 2 analog outputs.

Startup and parameter debugging

6.1 Startup Tool

DBG60B keyboard: backlit text display, 21 keys, IP40。 Supports VFC/V/f mode startup, can copy parameter sets, and has parameter memory function.

MOVITOOLS ®  MotionStudio: Engineering software that provides communication establishment, parameterization, startup wizard, oscilloscope (SCOPE), and IPOSplus ®  Programming. Supports multiple channels such as RS485, SBus, Ethernet, EtherCAT, PROFIBUS, etc.

6.2 Quick Start Process (Taking DBG60B as an Example)

Ensure that X13:1 (DI00 "/Controller inhibit") is a "0" signal.

Enter the context menu and select 'STARTUP'.

Select the parameter set (1 or 2) and choose the motor type (SEW or third-party).

Enter the motor nameplate data (rated voltage, frequency, current, power, cos φ, speed).

If using an encoder, select the encoder type and resolution.

Set closed-loop stiffness (default 1.0), input load inertia and minimum ramp time.

Perform calculations and save parameters.

After startup, it is recommended to activate the encoder monitoring (P504=ON).

6.3 Key parameter group (partial)

P0_: Display values (speed, current, temperature, fault memory, etc.).

P1_: Set value and ramp generator (analog input, fixed set value, motor potentiometer, ramp time).

P2_: Controller parameters (speed loop gain, integration time, acceleration feedforward).

P3_: Motor parameters (speed limit, current limiting, Boost, IxR, slip compensation, pre magnetization time).

P4_: Reference signal (speed/current threshold, window comparison).

P5_: Monitoring function (speed monitoring, encoder monitoring, synchronous operation monitoring).

P6_: Terminal allocation (programming of digital input/output functions).

P7_: Control functions (boost function, brake control, speed jump, master-slave).

P8_: Equipment functions (factory settings, parameter lock, serial communication, fault response, automatic reset).

P9_：IPOSplus ®  Parameters (reference operation, positioning, software limit, modulus function).

Fault diagnosis and maintenance

7.1 Fault Display and Storage

The 7-segment code displays a fault code (flashing), such as "F01" overcurrent. The fault memory P080-P084 stores the last 5 faults and their current operating data (I/O status, temperature, speed, current, DC bus voltage, operating hours, etc.).

7.2 Typical fault codes

Possible causes and countermeasures for fault code name response

01 Immediately disconnect the output short circuit, motor overload, and output stage damage due to overcurrent, eliminate the short circuit, replace the motor with a smaller one, and contact SEW

Immediately disconnect the 04 brake chopper. The regenerative power is too high, the brake resistor is open and the deceleration slope is prolonged. Check the resistance wiring

07 DC bus overvoltage immediately disconnected, deceleration too short, brake resistor fault extends slope, check resistance

Immediately disconnect the overload, phase loss, and encoder reverse connection for speed monitoring in 08. Check the load and encoder wiring

Immediately disconnect the 14 encoder, check for poor cable shielding, broken wires, and damaged encoder for shielding and wiring

31 TF/TH triggers programmable motor overheating, TF is not connected to cooling motor, check connection or short circuit

42 hysteresis error programmable encoder reverse connection, slope too short, position loop P too small. Check encoder polarity, extend slope, and increase P gain

84 motor protection emergency stop motor thermal model overload reduces load, extends slope

7.3 Reset Method

Power off and restart (main contactor disconnected for ≥ 10 seconds).

By programming the digital input as' Reset '.

MOVITOOLS ®  Manual reset (P840=YES).

Press the<E>key on DBG60B.

Automatic reset (P841=YES, up to 5 times, requires setting the restart time P842). Attention: Automatic reset is strictly prohibited for dangerous applications such as lifting.

Project planning and selection suggestions

8.1 Selection of driving characteristics

The SEW Workbench project planning software supports complete calculations from applications to gearboxes, motors, and frequency converters. Selection process:

Select control mode based on positioning accuracy: no encoder VFC (± 360 °), VFC with encoder (± 5 ° -45 °), CFC/SERVO (<± 1 °).

Determine the type of motor (asynchronous or synchronous servo).

Select the size of the frequency converter based on continuous current and peak current.

Calculate the regenerative power and select the braking resistor (considering the cycle period CDF and overload factor).

Select line filters, output chokes, or output filters according to EMC requirements.

8.2 Example of brake resistor selection

Peak braking power P_peak=V_DC_stink ²/R_BW, where V_DC_stink has a maximum of 970 V (400/500 V equipment) or 485 V (230 V equipment). Determine the resistance model based on continuous braking power and CDF overload factor. The manual provides a detailed allocation table for BW series (flat, wound, grid) resistors.

8.3 Motor cable length

The maximum length of shielded cable is affected by PWM frequency: it can reach 400 m (size 0-6) at 4 kHz, and drops to 50 m at 16 kHz. The use of HF output filters is not limited by this, but voltage drop needs to be considered.