LMC20 & LXM05 Upgrade

LMC20A1309 -> LMC078

LXM05AD22N4 -> LXM32S

Due to the Schneider LMC20 controller and LXM05 servo drives being obsolete, OMS was tasked with replacing this hardware with new electrical components for a gapping belt system. The controller was replaced with the Modicon LMC078 motion controller, and the LXM 05 servo drives were replaced with the LXM 32 Servo Drive. The Lexium Drive features the sercos communication option which allows for fast, reliable communication between all three servo drives and the motion controller unlike the older CAN communication protocol. The motors previously installed with the older controller and drives were the Schneider BSH servo motors which did not require being upgraded. Instead, only a new encoder cable was required drastically reducing the cost since new motors were not necessary. Apart from the replacement of the Lexium Motion Controller and Lexium servo drives being replaced, there was a unique challenge presented to the OMS team to maintain current communication options with the Allen Bradley Control Logix master PLC. On the DeviceNet network was the LMC controller, and multiple VFDs that were not apart of the upgrade. Because of this OMS needed to maintain the DeviceNet communication with limited changes to the Allen Bradley PLC. Since there is no native DeviceNet module with the Modicon controller, OMS engineers had to think outside the box and research some alternative methods. They eventually came across the HMS Anybus Convertor which could take the Ethernet IP data from the LMC078 controller and export it to the Allen Bradley PLC via DeviceNet. This allowed the end user to maintain the DeviceNet communication without drastically changing the control logix software. Despite maintaining the antiquated communication, the Schneider Modicon controller included an Ethernet IP module so upgrading the Control Logix PLC and VFDs can be done easily with limited changes in hardware.

Below are a few of the actions taken by OMS:

• Replace LMC20 controller with Modicon LMC078 Motion Controller
• Replace LXM05 servo drives with LXM32S servo drives
• Replace BSH – LXM32 encoder cables
• Installed HMS Anybus convertor
• Installed HMI to display diagnostic information
• Developed new SoMachine program for LMC078
• Maintained DeviceNet communication to Control Logix PLC
• Provided training documentation for new hardware
• Provided updated schematics for new system