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Faulhaber MC 5004 P STO, Installation Instructions Manual

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Faulhaber MC 5004 P STO Installation Instructions Manual Download Page 59

1st edition, 03-05-2018

7000.05063, 1st edition, 03-05-2018

7000.05063

Warranty

59

7

Warranty

Products of the company Dr. Fritz Faulhaber GmbH & Co. KG are produced using the most 
modern production methods and are subject to strict quality inspections. All sales and deliv-
eries are performed exclusively on the basis of our General Conditions of Sale and Delivery 
which can be viewed on the FAULHABER home page www.faulhaber.com/gtc and down-
loaded from it.

Summary of Contents for MC 5004 P STO

Page 1: ...WE CREATE MOTION Installation Instructions MC 5004 P STO Original Instructions EN ...

Page 2: ...aber GmbH Co KG cannot accept any liability for any errors in this document or for the consequences of such errors Equally no liability can be accepted for direct or consequential damages resulting from improper use of the equipment The relevant regulations regarding safety engineering and interference suppression as well as the requirements specified in this document are to be noted and followed ...

Page 3: ...roller PCBs 17 3 4 1 1 Standard PCB 17 3 4 1 2 EtherCAT PCB 18 3 4 1 3 State machine and start routine 20 3 4 2 Motherboard 23 4 Installation 25 4 1 Mounting 25 4 1 1 Mounting instructions 25 4 1 2 Installing the Motion Controller PCB on the motherboard 26 4 1 3 Installing the Motion Controller PCB in the top hat rail housing 27 4 2 Electrical connection 28 4 2 1 Notes on the electrical connection...

Page 4: ...ce and diagnostics 55 5 1 Maintenance tasks 55 5 2 Diagnostics 55 5 2 1 Standard PCB 55 5 2 2 EtherCAT PCB 56 5 2 3 Self test 57 5 3 Troubleshooting 57 6 Accessories 58 7 Warranty 59 8 Additional documents 60 8 1 Data sheet 60 8 2 Declaration of Incorporation 62 8 3 Declaration of Conformity 63 8 4 EC type examination certificate 66 ...

Page 5: ... download the documents please contact us see reverse of this docu ment You can find the data sheet for Motion Controller series MC 5004 P STO in chap 8 1 p 60 1 3 Using this document Read the document carefully before undertaking configuration in particular chapter Safety Retain the document throughout the entire working life of the product Keep the document accessible to the operating and if nec...

Page 6: ...High CLK Clock CS Command Specifier DC Direct Current DigIn Digital input DigOut Digital output DIP Dual In Line Package EMC Electromagnetic compatibility ESD Electrostatic discharge ET EtherCAT Ethernet for Control Automation Technology GND Ground I O Input Output LA Status LED EtherCAT MC Motion Controller Mot Motor n c not connected OSSD Output Signal Switching Device PWM Pulse Width Modulation...

Page 7: ...t avoided death or serious injury may result Measures for avoidance CAUTION CAUTION Danger with low level of risk if not avoided minor or moderate injury may result Measures for avoidance NOTICE NOTICE Risk of damage Measures for avoidance Pre requirement for a requested action 1 First step for a requested action Result of a step 2 Second step of a requested action Result of an action Request for ...

Page 8: ...e following fields of applica tion Robotics Toolbuilding Automation technology Industrial equipment and special machine building Medical technology Laboratory technology When using the Motion Controllers the following aspects should be observed The Motion Controller contains electronic components and should be handled in accordance with the ESD regulations Do not use the Motion Controller in envir...

Page 9: ...epairs to the Motion Controller Have loose or defective connections immediately replaced by an electrician After replacing a defective or damaged Motion Controller test and document the cor rect function of the entire safety circuit Electrostatic discharges can damage the electronics Store and transport the Motion Controller in suitable ESD packaging Handle the Motion Controller in compliance with...

Page 10: ... the electrical equipment observe the 5 safety rules a Disconnect from power b Secure against being switched on again c Check that no voltage is present d Ground and short circuit e Cover or block off adjacent parts that are under voltage 2 2 3 Heat development Active components may cause the Motion Controller to heat up If touched there is a risk of burn ing Protect the Motion Controller against ...

Page 11: ...tion To achieve the required safety level SIL 3 acc to IEC 61800 5 2 EN 62061 the higher level control must perform the following diagnostics and tests Evaluate and display the error status message STO status message Monitor the STO signals for short circuit to ground or power supply shunt line breakage hanging signal state Interruption at the power supply return line of the functional potential e...

Page 12: ... 2014 30 EU The directive concerning electromagnetic compatibility EMC applies to all electrical and electronic devices installations and systems sold to an end user In addition CE marking can be undertaken for built in components according to the EMC Directive Conformity with the directive is documented in the Declaration of Conformity RoHS Directive 2011 65 EU The directive restricts the use of ...

Page 13: ... Motion Manager the controller can also be operated without any communi cations interface In drive applications it is often necessary to safely isolate a motor in response to an exter nal event if e g a protective door is opened or a light curtain is interrupted This safe shutdown is realized via the standardized integrated STO Safe Torque Off safety circuit Isolation is achieved here via two redu...

Page 14: ...ted output stage with optimised current measurement BL and LM motors from the FAULHABER product line from 12 to 32 mm can be controlled The following connections are available on the connector strip Communications interfaces Common or separate power supplies between motor and controller When using the motherboard only shared power supply possible Various inputs and outputs Motor phases Feedback co...

Page 15: ... 8 digit Calendar week 2 and year 2 of manufacture sequential number 4 3 Firmware version FW XXY Example 44170001 Manufactured during calendar week 44 of year 2017 with sequential number 1 RS RS232 Serial interface CO CANopen interface ET EtherCAT interface P PCB version with pin terminals STO Safe Torque Off 50 Max power supply 50 V MC Motion Controller 04 Max continuous output current 4 A 50 04 ...

Page 16: ...n degree 2 acc to DIN EN 61010 Dimensions and mass Dimensioned drawing See chap 8 1 p 60 Ground Safety Safety integrity level SIL 3 acc to IEC 61800 5 2 EN 62061 Performance level PL e with separate switching of the STO inputs acc to EN 13849 Outage rate a PFHD 4 57 10 10 a Assumed as the basis of the calculation of the outage rates was a demand rate of 1 per 8 hours Maximum time between the reque...

Page 17: ...r catalog number MC 5004 P STO RS CO 6500 01717 MC 5004 P STO ET 6500 01718 Status LED STO Status LED USB X1 Power LED No Error LED Designation Function USB X1 Connection of the USB communication Designation Function State LED Green continuous light Device active Green flashing Device active However the state machine has not yet reached the Operation Enabled state Red continuously flashing The dri...

Page 18: ...iew No Error LED STO status LED For states of the STO state machine a a see chap 3 4 1 3 p 20 Motor state Off Off Powerdown Motor is inactive Off Yellow Error Motor is inactive Green Yellow STO On Motor is inactive Green Off STO Off Motor is active USB X1 LA Run LED Error LED OUT IN STO Status LED No Error LED Status LED Power LED Designation Function IN OUT Connection of the EtherCAT communicatio...

Page 19: ...ible range RUN LED EtherCAT Green continuous Connection available Device is ready for operation Green flashing Device is in the Pre Operational state Green single flash Device is in the Safe Operational state Off Device is in the Initialisation state ERR LED EtherCAT Red flashing Defective configuration Red single flash Local error Red double flash Watchdog timeout Off No connection error LA LED E...

Page 20: ...ff No torque at motor STO On STO shutdown is active Outputs are switched off No torque at motor STO Off STO shutdown is inactive Outputs are switched on Torque possible at motor STO Reset Pulse START Powerdown Motor inactive No Error STO status Error Motor inactive No Error LED STO status LED No Error LED STO status LED No Error LED STO status LED STO On Motor inactive STO Off Motor active Undervo...

Page 21: ...e must be appropriately evaluated via the two STO outputs After an error it is only possible to switch back to the operating state after triggering an STO reset pulse The fault state remains stored until the STO reset pulse is triggered The switch on sequence must be executed daily see chap 2 4 p 11 During this process the state machine executes the sequence shown in Fig 8 No Error STO IN 1 STO IN...

Page 22: ...switching on again it is mandatory that the following sequence be exe cuted 1 Powerdown for at least 1000 ms Error state 2 STO IN 1 low 3 STO IN 2 low STO reset pulse is triggered via the Motion Controller STO On state is reached 4 STO IN 1 high 5 STO IN 2 high STO Off state is reached Drive can be activated ...

Page 23: ... description 23 3 4 2 Motherboard Fig 10 Side view top top view middle and isometric view bottom of the mother board dimensions in mm On delivery there are rubber pads in the outer and centre holes of the motherboard These holes are marked in blue in Fig 10 100 72 max 24 5 33 ...

Page 24: ...driver Alternatively an absolute encoder can be connected with or without line driver M1_1 motor sensor Combi connection for motor phases and Hall sensors X2 RS232 RS232 interface connection X2_1 CAN CANopen interface connection X3 I O Inputs or outputs for external circuits X5 power supply Voltage supply for motor and controller X6 STO Voltage supply and inputs and outputs for Safe Torque Off RS2...

Page 25: ...be ineffective Depending on the use of the Motion Controller this can lead to severe or fatal injury Observe the safety information in the chap 2 2 1 p 9 Use suitable fastening material see chap 4 1 3 p 27 Visual inspection After unpacking the Motion Controller perform and document a visual inspection Motion Controller is undamaged Sticker with serial number is present Pin contacts are OK not oxid...

Page 26: ...board Fig 12 Installing the Motion Controller PCB on the motherboard NOTICE NOTICE Incorrect installation can damage the Motion Controller Note orientation of the Motion Controller PCB acc to Fig 12 Mounting Guide the Motion Controller board 1 into the side guide rails 2 and connect to the motherboard 4 using plug connection X100 3 3 4 1 2 ...

Page 27: ...PCB installed in a top hat rail housing Fig 13 Example for installation in a top hat rail housing 1 Motion Controller PCB 2 Motherboard 3 Top hat rail housing The following components from Phoenix Contact could for example be used as a suitable top hat rail housing Quan tity Component designation Manufacturer number 1 UMK BE 45 2970015 1 UMK BE 22 5 2970028 1 UMK BE 11 25 2971535 2 UMK SE 11 25 29...

Page 28: ...ICE Destruction of the controller if voltage is too high When connecting the controller observe the maximum permissible voltage for the inputs and outputs Do not plug in or unplug the controller while under voltage NOTICE NOTICE A short term voltage peak during braking can damage the power supply or other con nected devices For applications with high load inertia the FAULHABER Braking Chopper of t...

Page 29: ...um length of the cable between the Motion Controller and motor depends on the sensor system used and the electrical and magnetic fields in the environment Tab 9 Guide values for the cable length Longer cables are generally permissible but must be validated for the target installation Optimisation of the behaviour in respect of transient emission and interference resistance may require additional E...

Page 30: ...best screening effect is achieved if the braiding is laid flat for instance on a screen terminal If the installation ensures potential equalisation the braid can also be attached to an earthed surface on the motor Alternatively equalisation currents can also be suppressed by connected the cable screen at the motor end via a capacitor approx 1μF 2μF 50 V Cable Shield Motor A Phase A Sensor C Hall S...

Page 31: ...ply Connect the Motion Controller to a sufficiently well dimensioned power supply unit During acceleration procedures current peaks with values up to the peak current limit setting of the motor can occur for multiples of 10 ms During braking procedures energy can be regenerated and fed back into the DC power supply network If this energy cannot be taken up by other drives the voltage in the DC pow...

Page 32: ...tion Meaning 1 Phase A Motor phase A 2 Phase A Motor phase A 3 Phase B Motor phase B 4 Phase B Motor phase B 5 Phase C Motor phase C 6 Phase C Motor phase C 7 Umot Power supply of the motor 8 Umot Power supply of the motor 9 GND Ground connection 10 GND Ground connection 11 Up Power supply of the electronics 12 GND Ground connection Up 13 n c 14 Sens A Hall sensor A 15 Sens B Hall sensor B 16 Sens...

Page 33: ...ut 36 STO GND 2 Ground connection for STO input 2 37 STO IN 2 Signal STO 2 38 STO IN 1 Signal STO 1 39 STO GND 1 Ground connection for STO input 1 40 AGND Analogue ground connection 41 AnIn 1 Analogue input 42 AnIn 2 Analogue input 43 STO Out 1 Status STO status message active inactive 44 STO 24V In Supply of the status outputs 45 STO Out 2 No Error STO error message ok nok 46 CAN H CAN High inter...

Page 34: ...t the sensor connection M2 Tab 14 Electrical data for the sensor connection M2 Pin Designation Meaning 1 Motor A Connection to motor phase A 2 Motor B Connection to motor phase B 3 Motor C Connection to motor phase C Designation Value Motor power supply 0 Umot Max 4 12 A 100 kHz Pin Designation Meaning 1 UDD Power supply for the sensor 2 GND Ground 3 Sens A Hall sensor A 4 Sens B Hall sensor B 5 S...

Page 35: ...ne driver M3 Pin Designation Meaning 1 UDD Power supply for the incremental encoder 2 GND Ground 3 Channel A Encoder channel A logically inverted sig nal 4 Channel A Encoder channel A 5 Channel B Encoder channel B logically inverted sig nal 6 Channel B Encoder channel B 7 Index Encoder index logically inverted signal 8 Index Encoder index Designation Value Power supply for incremental encoder 5 V ...

Page 36: ... 1 UDD Power supply for absolute encoder 2 GND Ground 3 CS Command Specifier for absolute encoder logically inverted signal 4 CS Command Specifier for absolute encoder 5 Data Data for absolute encoder logically inverted signal 6 Data Data for absolute encoder 7 CLK Clock for absolute encoder logically inverted signal 8 CLK Clock for absolute encoder Designation Value Absolute encoder power supply ...

Page 37: ...olute encoder power supply 5 V 100 mA Command Specifier connection port 5 V Connection port for data 5 V 5 kΩ Connection port for clock 5 V 1 MHz Pin Designation Meaning 1 Motor C Connection of motor phase C 2 Motor B Connection of motor phase B 3 Motor A Connection of motor phase A 4 GND Ground connection 5 UDD Power supply for sensors 6 Sens C Hall sensor C 7 Sens B Hall sensor B 8 Sens A Hall s...

Page 38: ...istinction is made between the following types of communication RS232 CANopen Tab 25 Pin assignment of the COM port X2 for RS232 Tab 26 Pin assignment of CAN X2_1 with CANopen Pin Designation Meaning 1 TxD RS232 interface transmit direction 2 RxD RS232 interface receive direction 3 GND Ground Pin Designation Meaning 1 CAN H CAN High interface 2 CAN L CAN Low interface 3 GND Ground ...

Page 39: ...n 3 DigOut 1 Digital output open collector 4 DigOut 2 Digital output open collector 5 GND Ground connection 6 DigIn 1 Digital input 7 DigIn 2 Digital input 8 DigIn 3 Digital input 9 DigIn 4 Digital input 10 AnIn 1 Analogue input 11 AnIn 2 Analogue input 12 AGND Ground connection for analogue inputs Designation Value Power supply for external consumer load 5 V 100 mA DigOut low GND high high resist...

Page 40: ...message ok nok 2 STO Out 1 Status STO status message active inactive 3 STO GND Ground connection for STO output 4 STO 24V In Supply of the STO outputs 5 STO GND 2 Ground connection for STO input 2 6 STO In 2 Signal STO 2 7 STO GND 1 Ground connection for STO input 1 8 STO In 1 Signal STO 1 Designation Value STO 24V In 24 V max 50 mA STO Out1 Status low 7 V high 11 5 V STO Out2 Error STO GND 1 STO ...

Page 41: ...9 BL LM motor with Hall sensors Connection M1_1 can be used as an alternative to the combination of connections M1 and M2 1 2 3 1 2 3 4 5 PIN M1 1 2 3 BL Motor Motor A M2 3 4 2 1 5 Sens A Hall Sensor A Motor B Motor C GND GND Sens B Hall Sensor B Sens C Hall Sensor C 5 V Power Supply DD U Motor Phase A Motor Phase B Motor Phase C M1_1 ...

Page 42: ...3 4 2 1 5 Sens A Hall Sensor A Motor B Motor C GND GND Sens B Hall Sensor B Sens C Hall Sensor C 5 V Power Supply DD U Motor Phase A Motor Phase B Motor Phase C 1 2 3 4 5 6 7 8 M3 1 3 5 7 2 4 6 8 Index Encoder Index Index Encoder Index Channel B Encoder Channel B Channel B Encoder Channel B Channel A Encoder Channel A Channel A Encoder Channel A Encoder U 5 V Encoder Supply DD GND GND M1_1 ...

Page 43: ...coders 1 2 3 1 2 3 4 5 PIN M1 1 2 3 BL Motor Motor A M2 3 4 2 1 5 Sens A Hall Sensor A Motor B Motor C GND GND Sens B Hall Sensor B Sens C Hall Sensor C 5 V Power Supply DD U Motor Phase A Motor Phase B Motor Phase C 1 2 3 4 5 6 7 8 M3 1 3 5 7 2 4 6 8 CLK CLK CLK CLK Data Data Data Data CS CS CS CS U 5 V Power Supply DD GND GND M1_1 ...

Page 44: ...d or position Use as a free measurement input queried via the interface Digital input Fig 23 Digital input circuit diagram internal The digital inputs are switchable from the input level PLC TTL The digital inputs can be configured for the following purposes see the Drive Functions Digital input for reference and limit switches Connection of an external encoder PWM Pulse Width Modulation set value...

Page 45: ...nexpected startup of the drive or shutdown of the torque Because there is no redundancy when the circuit of the two STO inputs is bridged there is a risk of serious injury or death Bridged circuit see Fig 24 is only to be used for applications up to Performance Level c PL a PL b PL c For applications with Performance Level d or higher PL d PL e that use redundant cir cuitry see Fig 25 Fig 24 Circu...

Page 46: ...ically isolated from each other and from other circuits Isolation voltage Max 110 V DC Typical standby current per channel 3 mA Delay when changing from low to high and from high to low 5 ms typically 1 ms Evaluation of the input signals Static evaluation A change has immediate effect Design for test pulses OSSD test pulses with a maximum test pulse duration of 400 μs and a maximum test pulse cycl...

Page 47: ...iagram internal The digital output has the following properties Open collector switch to ground Monitored output current switch opens in the event of an error A digital output can be assigned to an error output It can be configured for the following purposes Pulse output Digital output freely programmable I mA 1 2 3 4 0 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 U V DC DigOut 33k UP DigOut ...

Page 48: ... not necessary Power supply Common voltage supply with 24 V via the STO 24V In connection The supply line of the outputs must be protected against overcurrent The provided plug connectors must be taken into account for the dimensioning Isolation voltage The outputs are designed according to overvoltage category III for an isolation voltage of 800 V Output current The output current for both channe...

Page 49: ...3 05 2018 7000 05063 1st edition 03 05 20187000 05063 Installation 49 Fig 29 Output characteristic curve for STO Out Status I mA 2 4 0 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 U V DC 6 8 10 12 14 16 18 20 22 24 26 ...

Page 50: ...polar analogue set value specification via potentiometer Analogue set value specification via potentiometer with internally set offset and scaling Fig 31 Analogue set value specification via potentiometer with internally set offset and scaling 20 V 10k 4 7k 1k Motion Controller AnIn AGND Interface Ref UP GND GND UP 10 V 10k Motion Controller AnIn AGND Interface Ref UP GND GND UP UDD ...

Page 51: ...on the type of switch it may be necessary to use additional pull up resistors No internal pull up resistors are incorporated in the Motion Controller Depending on the type of encoder it may be necessary to use additional pull up resis tors No internal pull up resistors are incorporated in the Motion Controller 1k 1k Interface Limit Switch Motion Controller DigIn X DigIn Y GND GND GND UP UP 2 7k In...

Page 52: ...ontrol Systems in RS232 network operation Fig 35 Wiring with several Motion Control Systems in RS232 network operation Depending on the number of networked controllers a smaller value may be necessary for the pull down resistor PC or High Level Control Node 1 TxD RxD RxD TxD GND GND D Sub9 Pin 2 D Sub9 Pin 3 D Sub9 Pin 5 PC or High Level Control 4 7k Node 1 Node n TxD TxD RxD RxD RxD TxD GND GND G...

Page 53: ...id in a straight line it may be necessary to individually opti mise the amount and location of the terminating resistors For instance in a star net work a central 60 Ohm terminating resistor may be more suitable When the optimum arrangement of terminating resistors is fitted no accumulation of error frames should be evident Node 1 CAN Bus Line Node n GND CAN_H CAN_L 120 120 Safety Control Node 1 N...

Page 54: ...t all safety relevant components If necessary take additional safety measures to protect persons from danger during the initial commissioning which could arise from incorrect function of the safety circuit When started the Motion Controller performs an automatic self test An error message is output if the self test fails When starting the Motion Controller pay attention for error and STO status me...

Page 55: ... left and front view right of the standard PCB Tab 33 Device status LEDs Designation Function Status LED Green continuous Device active Green flashing Device active However the state machine has not yet reached the Operation Enabled state Red continuously flashing The drive has switched to a fault state The output stage will be switched off or has already been switched off Red Error code Boot proc...

Page 56: ...ED Error LED LA LA Designation Interface Function Status LED all Green continuous Device active Green flashing Device active However the state machine has not yet reached the Operation Enabled state Red continuously flashing The drive has switched to a fault state The output stage will be switched off or has already been switched off Red Error code Boot procedure failed Please contact FAULHABER Su...

Page 57: ...shing Faulty configuration Red single flash Local error Red double flash Watchdog timeout Off No connection error LA LED EtherCAT Green continuous light No data transfer Connection to another participant established Green flashing Data transfer active Off No data transfer No connection to another participant No Error LED STO status LED For states of the STO state machine a a see chap 3 4 1 3 p 20 ...

Page 58: ...5 20187000 05063 Accessories 58 6 Accessories Details of the following accessory parts can be found in the Accessories Manual Connection cables Connectors Connector sets Additional equipment Permissible motors see page 2 of the data sheet chap 8 1 p 60 ...

Page 59: ...Faulhaber GmbH Co KG are produced using the most modern production methods and are subject to strict quality inspections All sales and deliv eries are performed exclusively on the basis of our General Conditions of Sale and Delivery which can be viewed on the FAULHABER home page www faulhaber com gtc and down loaded from it ...

Page 60: ...pecification via fieldbus quadrature signal pulse and direction or analog inputs ႑ Optional stand alone operation via application programs in all interface versions ႑ Safe deactivation of torque via standardized integrated safe torque off circuit Use up to security level SIL 3 according to IEC 61800 5 2 und PL e according to EN ISO 13849 1 ႑ Failure value PFHD 4 57 10 10 at a request rate of 1 per...

Page 61: ...O Interface connector DIN for use in combination with flat cables see chapter accessories EtherCAT IN OUT Product combination Brushless DC Motors Linear DC Servomotors 1218 B LM 0830 01 1226 B LM 1247 11 1628 B LM 1483 11 1660 BHT LM 2070 11 2036 B 2057 B 2057 BHS 2232 BX4 2250 BX4 2250 BX4 S 2444 B 3056 B 3242 BX4 3268 BX4 Cables Accessories An extensive range of accessories is available for the ...

Page 62: ...1st edition 03 05 2018 7000 05063 1st edition 03 05 20187000 05063 Additional documents 62 8 2 Declaration of Incorporation ...

Page 63: ...1st edition 03 05 2018 7000 05063 1st edition 03 05 20187000 05063 Additional documents 63 8 3 Declaration of Conformity ...

Page 64: ...1st edition 03 05 2018 7000 05063 1st edition 03 05 20187000 05063 Additional documents 64 ...

Page 65: ...1st edition 03 05 2018 7000 05063 1st edition 03 05 20187000 05063 Additional documents 65 ...

Page 66: ...1st edition 03 05 2018 7000 05063 1st edition 03 05 20187000 05063 Additional documents 66 8 4 EC type examination certificate ...

Page 67: ...1st edition 03 05 2018 7000 05063 1st edition 03 05 20187000 05063 Additional documents 67 ...

Page 68: ...1st edition 03 05 2018 7000 05063 1st edition 03 05 20187000 05063 Additional documents 68 ...

Page 69: ...edition 03 05 2018 Dr Fritz Faulhaber GmbH Co KG DR FRITZ FAULHABER GMBH CO KG Antriebssysteme Daimlerstraße 23 25 71101 Schönaich Germany Tel 49 0 7031 638 0 Fax 49 0 7031 638 100 info faulhaber de www faulhaber com ...

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