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Technology modules

Page 157

12.2

EtherCAT

12.2.1

Product description

The EtherCAT technology module enables the connection of the item servo positioning controller C Series to the EtherCAT
fieldbus system. The communication via the EtherCAT interface (IEEE-802.3u) is realised with the aid of standard EtherCAT
cabling.

In the case of the item servo positioning controller C Series, the CoE protocol (CANopen over EtherCAT) with
the FPGA ESC20 made by Beckhoff is supported.

The EtherCAT technology module is supported solely in the TECH 2 technology slot.
Additional technology modules will not be supported if the EtherCAT technology module is used.
If your specific requirements are more complex, please contact your sales partner in order to find a solution for
your particular application.

12.2.2

Characteristics of the EtherCAT technology module

The EtherCAT technology module has the following characteristics:



It can be fully mechanically integrated in the item servo positioning controller C Series



EtherCAT in accordance with IEEE-802.3u (100Base-TX) with 100 Mbps (full duplex)



Star and line topology



Connector: RJ45



Floating EtherCAT interface



Communication cycle : 1 ms



127 slaves max.



EtherCAT slave implementation based on FPGA ESC20 by Beckhoff



Support of the "Distributed Clocks" feature for synchronised set value transfer



LED display for indicating readiness and link-detect

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Summary of Contents for C 3-Series

Page 1: ... Telephone 49 0 212 6580 0 Friedenstraße 107 109 Fax 49 0 212 6580 310 42699 Solingen E mail info item24 com Germany http www item24 com Product Manual item Servo Positioning Controller C 3 Series designed for Functional Safety ...

Page 2: ...umentation item does not guarantee that the products meet the buyer s demands and purposes or that they work together with other products selected by the buyer item does not assume any liability for damages resulting from the combined use of its products with other products or resulting from improper handling of machines or systems item Industrietechnik GmbH reserves the right to modify amend or i...

Page 3: ...Revision Information Author item Industrietechnik GmbH Manual title Product Manual item Servo Positioning Controller C 3 Series File name P HB_item Steuerung_C3_5p0_EN_bearbeitet docx Version 5 0 November 2016 ...

Page 4: ... by way of protective extra low voltage PELV 26 2 4 5 Protection against dangerous movements 26 2 4 6 Protection against contact with hot parts 27 2 4 7 Protection during the handling and installation of the devices 28 3 PRODUCT DESCRIPTION 29 3 1 General 29 3 2 Power supply 32 3 2 1 Three phase AC power supply 32 3 2 1 1 Switch on behaviour 32 3 2 2 DC bus circuit linking DC supply 32 3 2 2 1 DC ...

Page 5: ...X2B 46 4 6 Communication interfaces 48 4 6 1 RS232 X5 48 4 6 2 USB X19 48 4 6 3 Ethernet X18 48 4 6 4 CAN bus X4 48 4 6 5 SD MMC card 48 4 6 6 I O interface X1 49 4 6 7 Incremental encoder input X10 50 4 6 8 Incremental encoder output X11 51 5 FUNCTION OVERVIEW 52 5 1 Motors 52 5 1 1 Synchronous servomotors 52 5 1 2 Linear motors 52 5 2 Functions of the item Servo Positioning Controller C 3 Series...

Page 6: ...equences 59 5 3 7 Optional stop input 60 5 3 8 Contouring control with linear interpolation 60 5 3 9 Time synchronised multi axis positioning 61 6 FUNCTIONAL SAFETY TECHNOLOGY 62 6 1 General 62 6 1 1 DIP switch 63 6 1 2 Assignment of the DIP switch 64 6 2 Integrated safety technology schematic representation 66 6 3 Module variants 67 6 3 1 FBA module 67 6 3 2 FSM 2 0 STO Safe Torque Off 68 7 MECHA...

Page 7: ...onnector X1 85 8 5 3 Pin assignment X1 86 8 5 4 Cable type and configuration X1 87 8 5 5 Connection notes X1 87 8 6 Connector resolver X2A 88 8 6 1 Configuration on the device X2A 88 8 6 2 Mating connector X2A 88 8 6 3 Pin assignment X2A 88 8 6 4 Cable type and configuration X2A 89 8 6 5 Connection notes X2A 89 8 7 Connector encoder X2B 90 8 7 1 Configuration on the device X2B 90 8 7 2 Mating conn...

Page 8: ...8 10 5 Connection notes X4 101 8 11 Connector RS232 COM X5 103 8 11 1 Configuration on the device X5 103 8 11 2 Mating connector X5 103 8 11 3 Pin assignment X5 103 8 11 4 Cable type and configuration X5 104 8 11 5 Connection notes X5 104 8 12 Connector USB X19 105 8 12 1 Configuration on the device X19 105 8 12 2 Mating connector X19 105 8 12 3 USB X19 105 8 12 4 Cable type and configuration X19 ...

Page 9: ... the motor 114 10 4 Connecting the item Servo Positioning Controller C 3 Series to the power supply 115 10 5 Connecting the PC serial interface 115 10 6 Connecting the PC USB interface alternative 115 10 7 Operability check 115 11 SERVICE FUNCTIONS AND ERROR MESSAGES 116 11 1 Protection and service functions 116 11 1 1 Overview 116 11 1 2 Phase and mains power failure detection 116 11 1 3 Overcurr...

Page 10: ... data 153 12 1 3 Pin assignment and cable specifications 155 12 1 3 1 Pin assignment 155 12 1 3 2 Mating connector 155 12 1 3 3 Cable type and configuration 155 12 1 4 Termination and bus terminating resistors 156 12 2 EtherCAT 157 12 2 1 Product description 157 12 2 2 Characteristics of the EtherCAT technology module 157 12 2 3 Technical data 158 12 2 4 Display elements 158 12 2 5 EtherCAT interf...

Page 11: ... motor and PC 76 Figure 15 Power supply X9 79 Figure 16 Motor connector X6 81 Figure 17 Connecting a holding brake with a high current demand 2 A to the device 82 Figure 18 Basic circuit diagram of connector X1 84 Figure 19 Pin assignment resolver connector X2A 89 Figure 20 Pin assignment analogue incremental encoder option X2B 94 Figure 21 Pin assignment incremental encoder with a serial interfac...

Page 12: ...Page 12 Figure 33 Servo positioning controller with an integrated technology module 160 ...

Page 13: ...nt temperature 40 C 40 Table 15 Controller C 3 05 rated current values for a rotating motor fel 20 Hz and for an ambient temperature 40 C 40 Table 16 Controller C 3 10 rated current values for a blocked or slow running motor fel 5 Hz and for an ambient temperature 40 C 42 Table 17 Controller C 3 10 rated current values for a rotating motor fel 20 Hz and for an ambient temperature 40 C 43 Table 18 ...

Page 14: ...ption X2B 93 Table 41 Pin assignment X10 incremental encoder input 96 Table 42 Pin assignment X11 incremental encoder output 98 Table 43 Pin assignment CAN bus X4 100 Table 44 Pin assignment RS232 interface X5 103 Table 45 Pin assignment USB interface X19 105 Table 46 Pin assignment SD card 107 Table 47 Pin assignment MMC card 107 Table 48 EMC requirements first and second environment 110 Table 49...

Page 15: ...and operation of the FSM 2 0 STO PROFIBUS Manual item Servo Positioning Controller C Series Description of the implemented PROFIBUS DP protocol CANopen Manual item Servo Positioning Controller C Series Description of the implemented CANopen protocol as per DSP402 EtherCAT Manual item Servo Positioning Controller C Series Description of the implemented EtherCAT protocol CoE German version You can f...

Page 16: ...ections Power supply X9 Motor connection X6 Type Controller C 3 05 Controller C 3 10 item order number auf Anfrage erhältlich Table 3 Connector set DSUB connector 1x Connector set DSUB connector This connector set includes the mating connectors for the following connections I O interface X1 Angle encoder connection X2A Angle encoder connection X2B CAN fieldbus interface X4 Incremental encoder inpu...

Page 17: ...s and controllers 2 1 Symbols Information Important information and notes Caution Non compliance may result in severe damage to property DANGER Non compliance may result in damage to property and personal injuries Caution Hazardous voltage This safety note indicates a potential hazardous voltage ...

Page 18: ...rnings and precautions as per the instructions in this manual and who are sufficiently qualified in their field of expertise They have been trained instructed and authorised to perform the switching and earthing grounding of the devices systems in line with the applicable safety standards and to label them accordingly as per the job requirements They have been trained and instructed in line with t...

Page 19: ...fessional project planning is a prerequisite for the correct and trouble free operation of the servo positioning controller DANGER Improper handling of the servo positioning controller and non compliance with the warnings as well as improper manipulation of the safety devices may result in damage to property personal injuries electric shock or in extreme cases in death ...

Page 20: ...s personal injury from electric shock DANGER High electrical voltage caused by incorrect connections Danger to life or risk of personal injury from electric shock DANGER The surfaces of the device housing may be hot Risk of injury Risk of burns DANGER Dangerous movements Danger to life risk of serious personal injury or property damage due to unintentional movements of the motors ...

Page 21: ... diodes connected to the contactors and relays Compliance with the safety rules and regulations of the country in which the device will be operated must be ensured The ambient conditions that are specified in the product documentation must be maintained Safety critical applications are not allowed unless specifically approved by the manufacturer See chapter 8 14 Notes concerning the safe and EMC c...

Page 22: ...al power drive systems Part 5 1 Safety requirements Electrical thermal and energy EN 61800 5 2 Adjustable speed electrical power drive systems Part 5 2 Safety requirements Functional EN ISO 12100 Safety of machinery General principles for design Risk assessment and risk reduction EN ISO 13849 1 Safety of machinery Safety related parts of control systems Part 1 General principles for design EN ISO ...

Page 23: ...y by way of the main switch and secure it so that it cannot be reconnected Then wait until the DC bus circuit has discharged prior to any of the following maintenance and repairs cleaning long downtimes Prior to performing any maintenance tasks ensure that the power supply has been turned off and locked and that the DC bus circuit has been discharged The external or internal braking resistor carri...

Page 24: ...ies these safety features can be realised for example by way of an FSM 2 0 STO module Perform the commissioning with idle motors in order to avoid mechanical damage e g due to an incorrect direction of rotation Electronic devices are never fail safe It is the user s responsibility to ensure that the system is brought to a safe state if the electrical device fails The servo positioning controller a...

Page 25: ...um copper cross section for the protective earth conductor ground conductor over its entire length see EN 60800 5 1 for example Prior to start up and even for brief measurements or tests connect the protective earth conductor ground conductor of all of the electrical devices in accordance with the circuit diagram or connect it to the earthing system on site Otherwise the housing may carry high vol...

Page 26: ...without mains power 2 4 5 Protection against dangerous movements Dangerous movements can be caused by the faulty actuation of the connected motors Causes may be as follows improper or faulty wiring or cabling errors during the operation of the components errors of the sensors and transducers defective or non EMC compliant components software errors in superordinate control system These errors can ...

Page 27: ...stem Random movements of the machine or other malfunctions may be caused by deactivating bypassing or failing to activate the safety devices 2 4 6 Protection against contact with hot parts DANGER The surfaces of the device housing may be hot Risk of injury Risk of burns Do not touch the surfaces of the housing in the vicinity of heat sources Risk of burns Before accessing the devices let them cool...

Page 28: ...ral safety instructions apply Comply with the general set up and safety regulations concerning the handling and installation of the devices Use suitable installation and transport devices Prevent trapping and crushing by suitable protective measures Use suitable tools only If specified use special tools Use the lifting devices and tools in a proper manner If necessary use suitable protective equip...

Page 29: ...gh level of flexibility they can be adapted to numerous areas of application These servo positioning controllers are designed for the integration of so called FSM modules Functional Safety Modules Thanks to their integrated safety features external monitoring devices can be omitted for numerous applications The series includes types with single phase and three phase supply Type key item servo posi...

Page 30: ...ilters motor output filters filters for the 24 V supply and filters for the inputs and outputs into the device in order to ensure compliance with the EMC regulations during the operation 1 st environment with limited availability in accordance with EN 61800 3 Integrated braking resistor External resistors can be connected for higher levels of braking energy Automatic identification of externally c...

Page 31: ...m e g to a PLC via the I O level or fieldbus High resolution 16 bit analogue input Technology slots for extensions e g an I O extension module or Profibus interface Note Depending on the current consumption only one technology module with an additional fieldbus interface may be used STO option Safe Torque Off corresponds to EN 60204 Stop 0 SIL 3 in accordance with ISO EN 61800 5 2 PL e in accordan...

Page 32: ...ted After the DC bus circuit has been charged the relay responds and the DC bus circuit is coupled to the mains power supply without any resistors 3 2 2 DC bus circuit linking DC supply 3 2 2 1 DC bus circuit linking It is possible to link multiple item C 3 Series if their nominal DC bus circuit voltage is identical Caution Operation with DC bus coupling together with devices of the item C 1 Serie...

Page 33: ...egard to the mains voltage or negative DC bus circuit voltage Internal and external braking resistors cannot be used simultaneously The external resistors are not automatically protected against overload by the device 3 4 Communication interfaces The item C Series has several communication interfaces The basic device itself is equipped with many of these interfaces The following communication inte...

Page 34: ...rvo positioning controller C Series 3 4 3 UDP interface X18 The UDP communication enables the connection of the item servo positioning controller C Series to the Ethernet fieldbus system The communication via the UDP interface X18 is realised by way of standard cabling 3 4 4 CAN interface X4 The CANopen protocol as per DS301 with the DSP402 application profile is implemented ...

Page 35: ...hich the positioning targets can be stored and from where they can be retrieved at a later point of time At least four digital inputs are used for the target selection one input is used as a start input The limit switches are used to limit the range of movement for reasons of safety During homing one of the two limit switches can be used as a reference point for positioning control Two inputs are ...

Page 36: ...MSL Atmospheric humidity Relative humidity up to 90 non condensing Type of protection IP20 Protection class I Pollution degree 2 CE conformity Low voltage directive EMC directive 2006 95 EC as proved by the application of the harmonised standard EN 61800 5 1 2004 108 EC as proved by the application of the harmonised standard EN 61800 3 cULus certification Listed as per UL 508C C22 2 No 274 13 Tabl...

Page 37: ...tor temperature monitoring system Values Digital sensor N C contact Rcold 500 Ω Rhot 100 kΩ Analogue sensor Silicon temperature sensor e g KTY81 82 or similar R25 2000 Ω R100 3400 Ω 4 2 Control elements and display elements On its front panel the item Servo Positioning Controller C 3 Series has three LEDs and one seven segment display to indicate the operating status Table 9 Display elements and R...

Page 38: ...C Alternative DC supply 60 700 VDC 24 V supply 24 VDC 20 1 A plus the current consumption of a holding brake and I Os if included Table 11 Technical data internal braking resistor X9 Type Controller C 3 05 Controller C 3 10 Braking resistor 68 Ω Peak power 8 5 kW Continuous power 110 W Response threshold 760 V Overvoltage detection 800 V Table 12 Technical data external braking resistor X9 Type Co...

Page 39: ...nt for 0 5 s 20 0 ARMS fel 20 Hz 40 0 ARMS fel 20 Hz Current derating from 12 5 kHz 5 kHz Clock frequency 4 16 kHz programmable via the software Holding brake 24 V Signal level depending on the switching state high side low side switch 2 A max Motor temperature sensor Normally closed contact normally open contact PTC KTY 3 3 V 5 mA Power loss efficiency with regard to the nominal power Typically 8...

Page 40: ...n the case of rotational frequencies between these two values interpolation is required This leads to two tables the first one applies to motors at a standstill or to slow running motors electrical rotational frequency 5 Hz and the second one applies to fast running motors electrical rotational frequency 20 Hz Note The heat sink turn off temperature is 70 C The servo positioning controller will be...

Page 41: ...eter Values Nominal current ARMS 5 Max output current ARMS 10 15 20 Max permissible time s 5 2 0 5 Power output stage clock frequency kHz 16 Nominal current ARMS 2 5 Max output current ARMS 5 7 5 10 Max permissible time s 5 2 0 5 ...

Page 42: ...e clock frequency kHz 5 Nominal current ARMS 10 Max output current ARMS 20 30 40 Max permissible time s 5 0 1 0 07 Power output stage clock frequency kHz 10 Nominal current ARMS 7 Max output current ARMS 14 21 28 Max permissible time s 5 0 1 0 06 Power output stage clock frequency kHz 16 Nominal current ARMS 3 45 Max output current ARMS 6 9 10 35 13 8 Max permissible time s 5 0 2 0 15 ...

Page 43: ...clock frequency kHz 5 Nominal current ARMS 10 Max output current ARMS 20 30 40 Max permissible time s 5 2 0 5 Power output stage clock frequency kHz 10 Nominal current ARMS 7 Max output current ARMS 14 21 28 Max permissible time s 5 2 0 5 Power output stage clock frequency kHz 16 Nominal current ARMS 3 45 Max output current ARMS 6 9 10 35 13 8 Max permissible time s 5 2 0 5 ...

Page 44: ... signals SinCos encoders single turn multi turn with HIPERFACE Multi turn absolute encoders with EnDat The encoder type can be defined via the item Motion Soft parameterisation software The feedback signal is made available to any subsequent drives via the incremental encoder output X11 It is possible to evaluate two shaft encoder systems in parallel Typically the resolver for the current control ...

Page 45: ...0resolver Incorrect combinations e g P0resolver 2 and P0motor 5 will result in an error message during the motor identification process The resolver offset angle which is automatically determined during the identification process is a read write value for service purposes Table 18 Technical data resolver X2A Parameter Value Transformation ratio 0 5 Carrier frequency 5 to 10 kHz Excitation voltage ...

Page 46: ...n interface EnDat Heidenhain and HIPERFACE Sick Stegmann Supply output 5 V or 12 V 300 mA max current limited Control via sensor lines Setpoint programmable via SW Standard incremental encoders without commutation signals This type of encoder is used for low cost linear motor applications in order to save the costs for the provision of the commutation signals Hall sensor With this type of encoder ...

Page 47: ... be connected and evaluated Absolute non contact length measuring system L230 and TTK70 HIPERFACE Digital incremental encoder CDD 50 SinCoder encoders like SNS 50 or SNS 60 are no longer supported Heidenhain encoders Incremental and absolute encoders by Heidenhain can be evaluated The following encoder models can be connected Analogue incremental encoders ROD 400 ERO 1200 1300 1400 ERN 100 400 110...

Page 48: ...d Connector type USB B no current consumption from the bus integrated power supply Protocol item specific generic device 4 6 3 Ethernet X18 Table 23 Technical data Ethernet X18 Communication interface Values Function Ethernet 10 100 MBaud automatic selection Connector type RJ45 4 6 4 CAN bus X4 Table 24 Technical data CAN bus X4 Communication interface Values CANopen controller ISO DIS 11898 full ...

Page 49: ...it 3 msb most significant bit DIN 4 Control input for power stage enable at high signal DIN 5 Controller enable at high signal error acknowledgement with falling edge DIN 6 Limit switch input 0 DIN 7 Limit switch input 1 DIN 8 Control signal for positioning start DIN 9 Homing switch for homing or saving of positions Logic outputs general Electrically isolated 24 V 8 V 30 V active high DOUT 0 Ready...

Page 50: ... bit resolution flimit 1 kHz 4 6 7 Incremental encoder input X10 The input supports all standard incremental encoders For example encoders in accordance with the industry standard ROD426 by Heidenhain or encoders with single ended TTL outputs as well as open collector outputs As an alternative the A and B track signals of the device are interpreted as pulse direction signals by the device so that ...

Page 51: ...ion this index pulse turns high for the programmed number of lines for of a signal period as long as the track signals A and B are high Table 29 Technical data incremental encoder output X11 Parameter Value Number of lines Programmable 1 2 13 and 2 14 lines revolution Connection level Differential RS422 specification Track signals A B N In accordance with the RS422 specification Special feature N ...

Page 52: ...rd servomotors The motor specifications are determined and parameterised by an automatic motor identification system 5 1 2 Linear motors In addition to rotary applications item Servo Positioning Controller C 3 Series are also suitable for linear drives In this case too permanent magnet synchronous linear motors are supported Due to the high signal processing quality the item C 3 Series is particul...

Page 53: ...h of them PI controllers However to provide a better overview the id controller is not included in Figure 2 The basic operating modes are torque control speed control and positioning Other functions such as synchronisation flying saw etc are variants of these basic operating modes Furthermore individual functions of these operating modes can be combined e g torque control with speed limitation 5 2...

Page 54: ...ntal encoder input X10 If no setpoint source is activated the setpoint is zero The setpoint management system has a ramp generator with a preceding adder Via the corresponding selectors any of the above mentioned setpoint sources can be selected and run through the ramp generator Additional sources can be selected as setpoints by way of two additional selectors These however cannot be run through ...

Page 55: ...er is then fed back e g via the external incremental encoder input The speed setpoint can be set internally or it can be derived from the data of an external encoder system speed synchronisation via X10 for the speed controller 5 2 6 Torque limited speed control The item Servo Positioning Controller C 3 Series support torque limited speed controlled operation with the following features Fast updat...

Page 56: ...determine the current position and or speed of the master via the incremental encoder input X10 It is also possible to derive this information needed for the slave via an external encoder X2B The synchronisation can be activated or deactivated via the communication interfaces or via digital inputs The item Servo Positioning Controller C 3 Series can calculate the speed forward control independentl...

Page 57: ...cludes entries for the parameterisation of a target via a communication interface and also target positions that can be retrieved via the digital inputs For each entry the positioning method motion profile acceleration and deceleration times and maximum speed can be defined All of the targets can be pre parameterised All that the user has to do for performing the positioning is to select the desir...

Page 58: ...profile generator In terms of the motion profiles time optimal and jerk limited positioning can be distinguished In the case of time optimal positioning the maximum set acceleration is used for starting and braking The drive approaches the target in the shortest time possible the velocity profile is trapezoidal and the acceleration profile is block shaped In the case of jerk limited positioning th...

Page 59: ...ds on the method and type of communication If a homing process is activated via the fieldbus there will be no follow up positioning to the zero position This can be done optionally during the start process via controller enable or RS232 A follow up positioning run is always possible as an option The default setting is no follow up positioning run It is possible to parameterise ramps and speed valu...

Page 60: ...tion setpoints are specified by a superordinate control system in a fixed time pattern synchronisation interval If this interval exceeds a position controller cycle the controller autonomously interpolates the data values between two set position values as shown in the following illustration The servo positioning controller also calculates a corresponding speed feedforward y t t synchronisation in...

Page 61: ...ng Controller C 3 Series i e the entire controller cascade will be synchronised with the external clock signal As a result any pending positioning values in the case of multiple axes will be taken over and executed simultaneously without jitter The sync message of a CAN bus system or the EtherCAT DC Distributed Clock for example can be used as a clock signal As a result several axes with different...

Page 62: ...ed safety technology In their delivery state the item servo positioning controller C Series are not equipped with any integrated functions for safety related motion monitoring and motion control However they have an extension slot for a safety module As a standard the item servo positioning controller C Series come supplied with the module FSM 2 0 FBA Fieldbus Activation Module integrated in the e...

Page 63: ...he module are set to zero factory setting the fieldbus communication parameters of the parameter data set of the basic device will be used The position of the DIP switch is read in only once after a reset Modifications of the switch positions during the operation therefore do not affect the current operation Table 31 Overview of the DIP switch functionality Technology module type Functionality of ...

Page 64: ...meterisation of the technology modules that are listed in Table 32 Switch position 0 The activation of the communication baud rate and fieldbus address will be taken from the parameter data set or depending on the parameterisation optionally also by an addition of digital inputs Switch position 0 The configuration of the communication parameters via the DIP switch takes precedence over the corresp...

Page 65: ...y the addresses will be added as an offset of a predefined base address of the corresponding bus system The base address can be predefined in the item Motion Soft and can then be saved in the parameter set of the item C Series The activation of a fieldbus via the DIP switch takes precedence over the activation of the fieldbus based on the parameter data set In order to be nonetheless able to chang...

Page 66: ...bus circuit Inverter Synchronus machine Shaft encoder Angle Motor speed Current DC bus circuit voltage Control signals Circuit breaker Signal processing control Control module Communication Fieldbus I Os digital analogue Parameterisation Diagnostics Set values actual values Communication Figure 6 Schematic representation of the integrated safety technology ...

Page 67: ...nfigured with the aid of this DIP switch Depending on the fieldbus that is used it is possible for example to adjust the fieldbus node number baud rate etc This means for example that a servo positioning controller that is supplied in its original state i e without a parameterisation or fieldbus data settings can be installed and used in a system In addition the FBA module is required for enabling...

Page 68: ...Functional safety technology Page 68 6 3 2 FSM 2 0 STO Safe Torque Off Please refer to the original instructions FSM 2 0 STO for further information ...

Page 69: ...al wiring of the motor cable and angle encoder cable under the device an installation clearance of 150 mm is recommended item Servo Positioning Controller C 3 Series may be installed directly next to one another on a heat dissipating back plate provided that they are installed properly and used as intended Please note that excessive heat may cause premature ageing of and or damage to the device In...

Page 70: ...Mechanical installation Page 70 Figure 8 item Servo Positioning Controller C 3 Series installation space ...

Page 71: ...Mechanical installation Page 71 7 2 Device view Figure 9 item Servo Positioning Controller C 3 10 front view ...

Page 72: ...ground conductor from mains 24V 24VDC GND24V GND 24VDC Figure 10 item Servo Positioning Controller C 3 05 view from above X6 Motor Connection BR holding brake BR holding brake PE connection for inner shield holding brake temperature sensor MT motor sensor MT motor sensor PE protective earth ground conductor W motor phase 3 V motor phase 2 U motor phase 1 X2A Connection for the resolver X2B Connect...

Page 73: ...e best possible heat transfer to the control cabinet plate must be ensured Recommended tightening torque for an M5 screw of property class 5 6 2 8 Nm Please use M5 screws for the mounting of the item Servo Positioning Controller C 3 05 and Controller C 3 10 R5 R2 6 R2 6 M4 flush head stud M4 flush head stud R2 5 5mm 24 mm 31 75 mm 39 5 mm 58 5 mm 63 5 mm 69 mm 9 mm 12 mm 15 mm 21 mm 28 9 mm 320 8 ...

Page 74: ...oltage BR INT Connector for internal braking resistor BR CH Brake chopper connector for internal external braking resistor PE Protective earth ground conductor 24V Supply for control part 1A and holding brake 2A GND24V Reference potential supply Mains phase 2 L 3 Motor X6 U Motor phase 2 W Motor phase 3 PE Protective earth ground conductor of motor MT Motor temperature sensor normally closed conta...

Page 75: ...ts PE connector As a first step the item Servo Positioning Controller C 3 Series must be completely wired It is only then that the operating voltages for the DC bus circuit and the electronic supply may be switched on In the case of reverse connection of the operating voltage connectors excessive operating voltage or accidental interchanging of the operating voltage and motor connectors the item S...

Page 76: ...Electrical installation Page 76 Figure 14 Complete set up of the item C 3 Series with a motor and PC ...

Page 77: ...c control system via connector X9 The mains power supply is a three phase system As an alternative to AC power supply or for the purpose of DC bus circuit linking a direct DC supply for the DC bus circuit is possible 8 3 1 Configuration on the device X9 PHOENIX Power COMBICON PC 4 11 G 7 62 BK 8 3 2 Mating connector X9 PHOENIX Power COMBICON PC5 11 ST1 7 62 BK ...

Page 78: ...nternal braking resistor bridge to BR CH when using the internal resistor 9 PE PE Connection of the protective earth ground conductor of the mains power supply 10 24 V 24 VDC 20 1 A Supply voltage for the control module and holding brake 11 GND24V GND 0 VDC Supply voltage reference potential plus the current consumption of a holding brake and I Os if included 8 3 4 Cable type and configuration X9 ...

Page 79: ...nector Table 34 Pin and socket connector X9 external braking resistor Pin no Name Value Specification 6 BR EXT 800 VDC Connection of the external braking resistor 7 BR CH 800 VDC Brake chopper connection for the internal braking resistor against BR INT and for the external braking resistor against BR EXT 8 BR INT 800 VDC Connection of the internal braking resistor bridge to BR CH when using the in...

Page 80: ...shield connection holding brake temperature sensor 4 MT GND Motor temperature sensor 1 normally closed contact normally open contact PTC NTC KTY 5 MT 3 3 V 5 mA 6 PE PE Protective earth ground conductor of the motor 7 W 0 360 VRMS 0 5 ARMS 0 10 ARMS 0 1000 Hz C 3 05 C 3 10 Connection of the three motor phases 8 V 9 U 1 Please refer to chapter 9 Additional requirements to be fulfilled by the servo ...

Page 81: ...pplications C 3 10 LAPP KABEL ÖLFLEX SERVO FD 755 P 4 G 2 5 2 x 2 x 0 75 CP 15 1 mm with tinned CU overall shielding for highly flexible use in drag chains 8 4 5 Connection notes X6 PHOENIX COMBICON at X6 PE optional Motor phase U or 1 resp Motor phase V or 2 resp Motor phase W or 3 resp BR BR MT MT Motor connector PE motor 1 4 7 9 2 5 8 3 6 Connector housing Motor housing Shield terminal SK14 Fig...

Page 82: ...ntroller Please note the maximum output current that is provided by the item Servo Positioning Controller C 3 Series It may be necessary to connect a relay between the device and the holding brake as shown in Figure 17 item C 3 Series BR BR 1 2 Power supply unit 24 V Power supply unit GND Resistor and capacitor for spark suppression Motor with holding brake Holding brake 24 V Holding brake GND Fly...

Page 83: ... two potential ranges Analogue inputs and outputs All of the analogue inputs and outputs refer to AGND AGND is internally connected to GND the reference potential for the control module with µC and AD converters in the servo positioning controller This potential range is electrically isolated from the 24 V range and from the DC bus circuit 24 V inputs and outputs These signals refer to the 24 V su...

Page 84: ...VREF AMON 0 AIN 1 AIN 0 Pin Nr X1 AMON 1 AIN 2 AIN 0 AGND AGND DOUT x GND24 24 VDC 24 VDC GND GND24 PE PE 100 mA max 100 mA max Connector housing VREF AIN 0 AIN 0 AGND AIN 1 AIN 2 AGND 15 V AGND AGND AMON x AGND GND AGND DIN x GND24 GND Control system item C 3 Series Figure 18 Basic circuit diagram of connector X1 ...

Page 85: ...erence potential of the control system This is necessary in order to prevent the differential input of the item Servo Positioning Controller C 3 Series from being overridden by high common mode interference There are two analogue monitor outputs with output voltages in the range of 10 V and one output for a reference voltage of 10 V These outputs can be led to the superordinate control system the ...

Page 86: ...mA Auxiliary voltage for I Os at X1 6 GND24 Ref GND Reference potential for digital I Os 19 DIN 0 POS Bit 0 Target selection positioning bit 0 7 DIN 1 POS Bit 1 Target selection positioning bit 1 20 DIN 2 POS Bit 2 Target selection positioning bit 2 8 DIN 3 POS Bit 3 Target selection positioning bit 3 21 DIN 4 FG_E Power output stage enable 9 DIN 5 FG_R Controller enable input 22 DIN 6 END 0 Limit...

Page 87: ... signals and lead to common mode interferences which may lead to deviations of the analogue values In the case of a limited cable length l 2 m wiring inside the control cabinet the outer dual sided PE shield is sufficient for guaranteeing a trouble free operation For optimal interference suppression of the analogue signals the cores for the analogue signals must be shielded together and separate f...

Page 88: ...VRMS 5 10 kHz Ri 5 kΩ SINE track signal differential 6 S4 2 S1 3 5 VRMS 5 10 kHz Ri 5 kΩ COSINE track signal differential 7 S3 3 AGND 0 V Shield for signal pairs inner shield 8 MT GND Temperature sensor reference potential 4 R1 7 VRMS 5 10 kHz Iout 150 mARMS Carrier signal for the resolver 9 R2 GND 5 MT 3 3 V Ri 2 kΩ Motor temperature sensor normally closed contact PTC KTY In addition the outer ca...

Page 89: ...or highly flexible applications LAPP KABEL ÖLFLEX SERVO FD 770 CP 3 x 2 x 0 14 D12Y 2 x 0 5 D12Y CP 8 3 mm with tinned CU overall shielding error during the angle measurement up to approx 1 5 with a cable length of 50 m Use 2 x 0 5 D12Y for the resolver carrier 8 6 5 Connection notes X2A 2 3 4 5 6 7 8 1 9 Connector housing 1 5 9 6 Cable shield optional S3 COS S1 COS S2 SIN AGND TEMP R1 carrier R2 ...

Page 90: ... 8 7 Connector encoder X2B 8 7 1 Configuration on the device X2B D SUB connector 15 pin type female 8 7 2 Mating connector X2B D SUB connector 15 pin type male Housing for a 15 pin D SUB connector with locking screws of type 4 40 UNC ...

Page 91: ... Ω COSINE commutation signal differential of the high resolution incremental encoder 5 COS_Z1 2 13 SIN_Z1 2 1 Vpp 10 RI 120 Ω SINE commutation signal differential of the high resolution incremental encoder 6 SIN_Z1 2 14 COS_Z0 2 1 Vpp 10 RI 120 Ω COSINE track signal differential of the high resolution incremental encoder 7 COS_Z0 2 15 SIN_Z0 2 1 Vpp 10 RI 120 Ω SINE track signal differential of th...

Page 92: ...directional RS485 data line differential EnDat HIPERFACE 5 DATA 13 SCLK 5 Vpp RI 120 Ω Clock output RS485 differential EnDat 6 SCLK 14 COS_Z0 2 1 Vpp 10 RI 120 Ω COSINE track signal differential of the high resolution incremental encoder 7 COS_Z0 2 15 SIN_Z0 2 1 Vpp 10 RI 120 Ω SINE track signal differential of the high resolution incremental encoder 8 SIN_Z0 2 1 Please refer to chapter 9 Addition...

Page 93: ...tal incremental encoder 7 A 15 B 2 Vpp 5 Vpp RI 120 Ω B track signal RS422 differential of the digital incremental encoder 8 B 1 Please refer to chapter 9 Additional requirements to be fulfilled by the servo positioning controllers for UL approval page 113 In addition the outer cable shield of the angle encoder cable must be connected to the mounting plate of the controller over a large contact ar...

Page 94: ... SUB connector at X2B U_SENS U_SENS TEMP TEMP Figure 20 Pin assignment analogue incremental encoder option X2B 2 3 4 5 9 10 11 1 12 Cable shield optional Connector housing 6 7 8 13 14 15 Connector housing 1 9 8 15 Male COS_Z0 COS_Z0 SCLK SIN_Z0 SCLK DATA DATA SIN_Z0 GND US Output of the incremental encoder with serial communication interface at the motor D SUB connector at X2B U_SENS U_SENS TEMP T...

Page 95: ...er at the motor D SUB connector at X2B Cable shield optional Connector housing Connector housing 2 3 4 5 9 10 11 1 12 6 7 8 13 14 15 1 9 8 15 B B GND A VCC N N SENSE A SENSE HALL_U HALL_V HALL_W TEMP TEMP Male Figure 22 Pin assignment digital incremental encoder option X2B ...

Page 96: ... motor signal CLK pos polarity as per RS422 6 A CLK 5 V RI 120 Ω Incremental encoder signal A stepper motor signal CLK neg polarity as per RS422 2 B DIR 5 V RI 120 Ω Incremental encoder signal B stepper motor signal DIR pos polarity as per RS422 7 B DIR 5 V RI 120 Ω Incremental encoder signal B stepper motor signal DIR neg polarity as per RS422 3 N 5 V RI 120 Ω Incremental encoder index pulse N po...

Page 97: ...e control boards for stepper motors The input amplifier at the signal input is designed to process differential signals in accordance with the RS422 interface standard Processing of other signals and levels e g 5 V single ended or 24 VHTL of a PLC may also be possible Please contact your sales partner 2 3 4 5 6 7 8 1 9 Connector housing 1 5 9 6 Cable shield optional B DIR B DIR N A CLK N GND VCC A...

Page 98: ...oder output Pin no Name Value Specification 1 A 5 V Rout 66 Ω Incremental encoder signal A 6 A 5 V Rout 66 Ω Incremental encoder signal A 2 B 5 V Rout 66 Ω Incremental encoder signal B 7 B 5 V Rout 66 Ω Incremental encoder signal B 3 N 5 V Rout 66 Ω Incremental encoder index pulse N 8 N 5 V Rout 66 Ω Incremental encoder index pulse N 4 GND Reference GND for the encoder 9 GND Shield for the connect...

Page 99: ...onnector housing 1 5 9 6 Cable shield optional B B N A N GND VCC A Incremental encoder input e g item Servo Positioning Controller C Series X10 D SUB connector at X11 Incremental encoder output Male Connector housing Figure 24 Pin assignment X11 incremental encoder output The output driver at the signal output provides differential signals 5 V as per the RS422 interface standard Up to 32 additiona...

Page 100: ...ecification 1 Not used 6 GND 0 V CAN GND electrically coupled to GND in the controller 2 CANL CAN low signal line 7 CANH CAN high signal line 3 GND 0 V See pin no 6 8 Not used 4 Not used 9 Not used 5 Shield PE Connector for the cable shield An external terminating resistor of 120 Ω is required on both ends of the bus If the bus ends are not formed by item Servo Positioning Controller C 3 Series wi...

Page 101: ... 22 7 6 mm with CU overall shielding For highly flexible applications LAPP KABEL UNITRONIC BUS CAN FD P 2 x 2 x 0 25 8 4 mm with CU overall shielding 8 10 5 Connection notes X4 Caution When cabling the servo positioning controllers via the CAN bus comply with the following information and notes in order to ensure a stable and interference free system Improper cabling may cause the CAN bus to malfu...

Page 102: ...e is connected to the CAN shield connectors for all nodes For information about suitable and item recommended cables refer to chapter 8 10 4 Cable type and configuration X4 We advise against the use of plug adaptors for cabling the CAN bus However if this is necessary use metal connector housings for connecting the cable shield In order to keep interferences as low as possible ensure that the moto...

Page 103: ...ng screws of type 4 40 UNC 8 11 3 Pin assignment X5 Table 44 Pin assignment RS232 interface X5 Pin no Name Value Specification 1 Not used 6 Not used 2 RxD 10 V RI 2 kΩ Reception line RS232 specification 7 Not used 3 TxD 10 V Rout 2 kΩ Transmission line RS232 specification 8 Not used 4 RS485 Reserved for optional RS485 use 9 RS485 Reserved for optional RS485 use 5 GND 0 V Interface GND electrically...

Page 104: ...n X5 Interface cable for the serial interface null modem 3 cores 8 11 5 Connection notes X5 D SUB connector at X5 PC 2 3 4 5 6 7 8 1 9 Connector housing 1 5 9 6 Connector housing 2 3 4 5 6 7 8 1 9 1 5 9 6 Female Female Figure 27 Pin assignment RS232 null modem cable X5 ...

Page 105: ...e Specification 1 VCC 5 VDC 2 D Data 3 D Data 4 GND GND Figure 28 Pin assignment USB interface X19 front view 8 12 4 Cable type and configuration X19 Interface cable for the USB interface 4 cores shielded and twisted In order to set up a USB connection it is mandatory to use a twisted and shielded 4 core cable since otherwise the transmission may be subject to interferences In addition it must be ...

Page 106: ...ware file 8 13 3 Supported file systems FAT12 FAT16 FAT32 8 13 4 File names Only file and directory names in accordance with the 8 3 standard are supported 8 3 file and directory names have a maximum of eight characters letters or numbers followed by a full stop period and an extension with a maximum of three characters In addition only upper case letters and numbers are permissible in the file an...

Page 107: ...Supply voltage earth ground 7 DAT0 DO Data line 0 bit 0 Card to host data and status 8 DAT1 Data line 1 bit 1 Reserved 9 DAT2 Data line 2 bit 2 Reserved Table 47 Pin assignment MMC card Pin no Name SD mode SPI mode 1 RES CS Not connected or always 1 Chip select 2 CMD DI Command response Host to card commands and data 3 Vss1 Supply voltage earth ground Supply voltage earth ground 4 Vcc Supply volta...

Page 108: ...irmware download requested BOOT DIP switch in position OFF firmware download not requested If there is no SD MMC card in the card slot of the servo positioning controller and the BOOT DIP switch is in the position ON firmware download requested the error 29 0 will be issued after a restart reset This error stops any further executions This means that communication via the serial interface RS232 or...

Page 109: ...nfiguration and type of wiring Superordinate control system In order to increase interference immunity and to decrease interference emissions the item Servo Positioning Controller C 3 Series has integrated output chokes and line filters so that it can be used without additional shielding and filtering devices in most applications The item Servo Positioning Controller C 3 Series are certified as pe...

Page 110: ... The motor cable and angle encoder cable must be shielded The shield of the motor cable must be connected to the housing of the item Servo Positioning Controller C 3 Series shield connection terminals The cable shield must also be connected to the associated servo positioning controller so that the leakage currents can flow back into the controller causing the leakage The mains end PE connector mu...

Page 111: ...bles and or in the case of unsuitable motor cables with a non permissible high cable capacity the filters may be thermally overloaded To avoid these problems we strongly recommend the following procedure for applications requiring long motor cables In the case of a cable length of more than 50 m use only cables with less than 150 pF m capacitance per unit length between the motor phase and shield ...

Page 112: ...uppliers e g Spoerle The item Servo Positioning Controller C 3 Series has been designed to provide high interference immunity For this reason some function blocks are electrically isolated Inside the device the signals are transmitted via optocouplers The following isolated areas are distinguished Power output stage with a DC bus circuit and mains input Electronic control system for the processing...

Page 113: ...nts and environmental conditions Use 60 75 or 75 C copper CU wires only Tightening torque for the connectors 0 22 0 25 Nm To be used solely in an environment of pollution degree 2 9 3 Motor temperature sensor The servo positioning controller is not equipped with an integrated motor overtemperature sensor system in accordance with UL If a UL certification is required the servo positioning controlle...

Page 114: ...able Power supply cable Controller enabling cable Connector set if required power and D Sub connector 10 3 Connecting the motor Plug the connector of the motor cable into the corresponding socket of the motor and tighten the connection Plug the PHOENIX connector into the X6 socket of the servo positioning controller Connect the PE line of the motor to the PE earthing grounding socket Plug the conn...

Page 115: ... the PC USB interface alternative Plug the plug A of the USB interface cable into the socket for the USB interface of the PC Plug the plug A of the USB interface cable into the X19 USB socket of the item Servo Positioning Controller C 3 Series Check all of the connections 10 7 Operability check 1 Ensure that the controller enable switch is turned off 2 Switch on the power supply of all of the devi...

Page 116: ...o exist Operational safety is ensured by an extensive sensor system and numerous monitoring functions Measurement of the motor temperature Measurement of the power unit temperature Detection of earth ground faults PE Detection of connections between two motor phases Detection of mains power phase failure Detection of overvoltage in the DC bus circuit Detection of errors concerning the internal vol...

Page 117: ...s the following protective functions to monitor the motor and the connected shaft encoder Monitoring of the shaft encoder An error of the shaft encoder leads to the shut down of the power output stage In the case of a resolver the track signal is monitored for example In the case of incremental encoders the commutation signals are checked Other intelligent encoders have other error detection featu...

Page 118: ...tus and requests the user to parameterise the servo positioning controller At the same time the device displays an A on the seven segment display to indicate that it is ready but not parameterised 11 1 10Rapid discharge of the DC bus circuit If the system detects a failure of the mains power supply the DC bus circuit will be rapidly discharged within the safety period in accordance with EN 60204 1...

Page 119: ...seven segment display A In the torque control mode the two segments on the left are active seven segment display I P xxx Positioning xxx stands for the position number The numbers are successively displayed PH x Homing x stands for the currently active phase of the homing run 0 Search phase 1 Crawling phase 2 Positioning to zero position The numbers are successively displayed E xxy Error message w...

Page 120: ...ex y for example E 0 1 0 Warnings have the same code numbers as error messages As a distinguishing feature warnings have centre segment before and after the number e g 1 7 0 Table 50 Error messages provides an overview of the various messages and corresponding measures Error messages with the main index 00 are no runtime errors They include information In general no measures by the user are requir...

Page 121: ...nge Information Only for connected service module An exchangeable error buffer has been plugged into another device No measures required 7 Log add on Permanent event memory and FSM module Information Entry in permanent event memory An additional record was found No measures required 8 Servo drive switched on Information Entry in permanent event memory No measures required 9 Servo drive safety para...

Page 122: ...ation of wire break detection system threshold value 3 Motor overtemperature analogue short circuit Check the connecting cables of the temperature sensor short circuit Check the parameterisation of the short circuit monitoring system threshold value 04 0 Power module overtemperature Plausible temperature indication Check the installation conditions Fan filter mats dirty Device fan defective 1 DC b...

Page 123: ...Check whether the resistance value is too small Check the brake chopper output of the device 07 0 Overvoltage in the DC bus circuit Check the connection to the braking resistor internal external External braking resistor overloaded Check the rating 08 0 Resolver angle encoder error See items 08 2 08 8 1 Sense of rotation of the serial and incremental position evaluation systems not identical A and...

Page 124: ...ucture in encoder parameter set If necessary re determine the data and save it in the encoder again 4 EEPROM data faulty customer specific configuration Motor repaired Perform a homing run and save the data in the angle encoder Then save to the basic device Motor replaced Parameterise the basic device perform a homing run save the data in the angle encoder and then save to the basic device 5 Read ...

Page 125: ...hed 7 Homing Encoder difference control The deviation fluctuates e g due to gear slackness If necessary increase the shut down threshold Check actual value encoder connection 12 0 CAN two nodes with the same ID Check the configuration of the devices that are connected to the CAN bus 1 CAN communication error bus OFF Check the cabling compliance with the cable specification cable break maximum cabl...

Page 126: ... output stage could not be enabled The power output stage has not been enabled Check the connection of DIN 4 3 Power output stage prematurely disabled The power output stage has been disabled during a running identification process e g via DIN 4 4 Selected resolver type not supported by the identification system The identification cannot be performed with the present angle encoder settings Check t...

Page 127: ...le encoder not connected or defective The deviation fluctuates e g due to gear slackness If necessary increase the shut down threshold 2 Current jerk control Please contact the Technical Support 18 0 Analogue motor temperature warning threshold Motor too hot Check the parameterisation current controller current limits Suitable sensor Sensor defective Check the parameterisation of the sensor or the...

Page 128: ...upported 2 HW revision not supported Check the firmware version If necessary request an update from the Technical Support 3 Device functionality restricted Please return the device to our sales partner 4 Invalid power module type Check the firmware version If necessary request an update from the Technical Support 5 Incompatibility firmware hardware The firmware is not suitable for the device Check...

Page 129: ...on error 2 SD card data error 3 SD card write error 4 SD card firmware download error 30 0 Internal conversion error Please contact the Technical Support 31 0 Motor I t Motor blocked Check the power rating of the drive 1 Servo positioning controller I t Check the power rating of the drive package 2 PFC I t Check the power rating of the drive Select operation without PFC 3 Braking resistor I t Brak...

Page 130: ...us synchronisation error Failure of synchronization messages from master Insufficient synchronisation interval 35 0 Overspeed protection of the linear motor The encoder signals are disturbed Check the installation for compliance with EMC recommendations 5 Error during the determination of the commutation position The selected method is not suitable for the motor Please contact the Technical Suppor...

Page 131: ... Check the speed and acceleration parameters 43 0 Limit switches negative setpoint blocked The drive has left the intended motion range Technical defect in the system Check the limit switches 1 Limit switches positive setpoint blocked 2 Limit switches positioning suppressed 44 0 Error in the cam disc tables Check whether the index has been assigned correctly Check whether there are cam discs prese...

Page 132: ...module replacement Module type not yet configured Accept currently integrated safety or fieldbus activation module 3 FSM different module version Cause Type or revision of the module is not supported Action Install safety or fieldbus activation module appropriate for the firmware and hardware If only a module with a more recent version is available Load firmware that is appropriate for the module ...

Page 133: ...1 Safety function Discrepancy time overrun Cause Control ports STO A and STO B are not actuated simultaneously Action Check discrepancy time Cause Control ports STO A and STO B are not wired in the same way Action Check circuitry of the inputs Cause Upper and lower switch supply voltage not simultaneously activated discrepancy time exceeded Error in control external circuitry of safety module Erro...

Page 134: ...iolated Cause Violation of monitored speed limits of the SSF0 in operation when USF0 SSF0 requested Action Check when the violation of the safety condition occurs a During dynamic braking to safe rotational speed b After the drive has reached the safe speed With a Check of braking ramp record measuring data can the drive follow the ramp Change parameters for the slowdown ramp or start time delay t...

Page 135: ...on Violated Cause Brake should engage no feedback received within the expected time Action Check how the feedback signal is configured was the correct input selected for the feedback signal Does the feedback signal have the correct polarity Check whether the feedback signal is actually switching Is the parameterised time delay for the analysis of the feedback signal appropriate to the brake used m...

Page 136: ...e after reaching the zero speed or remains at idle and stable increase monitoring tolerance time if necessary With b If the actual speed value is very noisy at rest Check and if necessary adjust expert parameters for speed recording and detection of idling 3 SOS Safety Condition Violated Cause Angle encoder analysis reports Motor running actual speed exceeds limit Drive has rotated out of its posi...

Page 137: ...p With b Check whether the drive continues to oscillate after reaching the zero speed or remains at idle and stable increase monitoring tolerance time if necessary With b If the actual speed value is very noisy when at rest Check and if necessary adjust expert parameters for speed recording and detection of standstill 5 STO Safety Condition Violated Cause Internal hardware error voltage error of t...

Page 138: ...itched on energised Only if brake control takes place via DOUT4x and an external brake controller Deactivate 24 hr monitoring in the SBC parameters if the external brake controller allows this 7 SOS SOS requested 24 hrs Cause If SOS is requested for more than 24 hours the error is triggered Action Terminate SOS and move axle at least once during this time 55 0 No actual rotational speed position v...

Page 139: ...requested Action Terminate SS2 or SOS and move axle at least once during this time 3 Resolver X2A Signal error Cause Vector length sin cos is outside the permissible range The amplitude of one of the two signals is outside the permissible range Input signal is static same values to right and left of maximum Action Check the resolver Check the connection wiring broken wire short between two signals...

Page 140: ...ltage for the ENDAT encoder Check the motor cable screening on motor and drive side EMC malfunctions may trigger the error 8 Impermissible acceleration detected Cause Error in connected position encoder EMC malfunctions affecting the position encoder Impermissibly high acceleration rates in the movement profiles Acceleration limit parameterised too low Angle jump after reference movement in the po...

Page 141: ...was parameterised correctly the limit value P06 07 should be at least 30 50 above the maximum acceleration actually occurring In case of an angle jump in the position data transmitted from the basic device Acknowledge error once 56 8 Rotational speed angle difference encoder 1 2 Cause Rotational speed difference between encoder 1 and 2 of one µC outside the permissible range for longer than the al...

Page 142: ...in capture times for the position encoders Action Timing disrupted If the error occurs again after a reset the safety module is presumably faulty 57 0 Error I O self test internal external Cause Internal error of digital inputs DIN40 DIN43 detected via internal test signals Error at brake output at X6 signalling detected by test pulses Internal error of brake output detected via internal test sign...

Page 143: ...es if 1 The brake output X6 was configured for the brake this is the case with factory settings and 2 A motor without a holding brake is used and the brake connection lines in the motor cable are terminated at X6 In this case Disconnect the brake connection lines at X6 If there is no error in the connection wiring there may be an internal error in the module check by swapping the module 1 Digital ...

Page 144: ... the assignment correct output selected configured for test pulse 6 Electronics temperature too high Cause The safety module s temperature monitor has been triggered the temperature of µC1 or µC2 was below 20 or above 75 C Action Check the operating conditions ambient temperature control cabinet temperature installation situation in the control cabinet If the servo drive is experiencing high therm...

Page 145: ...data error incorrect sequence packet counter in data transmission between the basic device and safety module Too much data traffic new requests are being sent to safety module before old ones have been responded to Action Check communication interfaces wiring screening etc Check whether other devices have read access to the servo drive and safety module during a parameterisation session this may o...

Page 146: ...o data or cross comparison faulty data for µC1 and µC2 are different Error in cross comparison for digital I O Error in cross comparison for analogue input Error in cross comparison for internal operating voltage measurement 5 V 3 3 V 24 V and reference voltage 2 5 V Error in cross comparison for SIN COS angle encoder analogue values Error in cross comparison for programme sequence monitoring Erro...

Page 147: ...for the servo drive or a new version of the safety module is available from the manufacturer 59 1 FSM Fail safe mode supply safe pulse inhibitor Cause Internal error in module in failsafe supply circuit section or in the driver supply for the upper and lower switches Action Module faulty replace 2 FSM Logic failure intermediate circuit Cause Reference voltage 2 5 V outside tolerance Logic supply o...

Page 148: ...act the Technical Support 6 FSM Parameter set save error Please contact the Technical Support 7 FSM Flash checksum error Cause Voltage interruption power off while parameters were being saved Flash memory in safety module corrupted e g by extreme malfunctions Action Check whether the error recurs after a reset If it does Parameterise the module again and validate the parameter set again If error p...

Page 149: ...O configuration of the servo positioning controller and of the control system 4 EtherCAT invalid TPDO length 5 EtherCAT faulty cyclic data transfer Check the EtherCAT wiring Check the configuration of the master 63 0 EtherCAT defective module Technology module defective Replace the technology module 1 EtherCAT invalid data Check the protocol Check the EtherCAT wiring 2 EtherCAT TPDO data has not b...

Page 150: ...the Profinet module 1 Profinet Bus error No communication possible e g because the bus cable is disconnected Check the cabling and restart the Profinet communication 3 Profinet Invalid IP configuration IP address subnet mask or gateway address are not valid or not permissible Change IP configuration 4 Profinet Invalid device name According to the Profinet standard the Profinet device name is not p...

Page 151: ...e correct firmware Check the slot If necessary contact the Technical Support 1 Technology module not supported Load the correct firmware If necessary contact the Technical Support 2 Technology module HW revision not supported 3 Service memory module write error Please contact the Technical Support 84 0 State change of the sequence control Detailed information concerning internal processes No measu...

Page 152: ...eters checksum error 9 DEBUG Firmware loaded 91 0 Internal initialisation error Please contact the Technical Support 1 Memory error 2 Controller power stage code read error 3 Internal software initialization error 92 0 Error during firmware download Incorrect firmware Load the correct firmware If necessary contact the Technical Support 1 Error during Bootloader Update Please contact the Technical ...

Page 153: ...x please contact your sales partner in order to find a solution for your particular application As a special feature S7 function blocks have been developed for the servo positioning controllers Using these function blocks the servo positioning controllers can be controlled directly by the PLC program and the users can integrate their systems easily and clearly into the Simatic S7 environment 12 1 ...

Page 154: ...nterface Floating D SUB 9 pin integrated bus terminating resistors can be activated by DIP switches Special functions Support of diagnosis data RTS signal led out fail safe mode sync freeze The following elements can be found on the front plate of the PROFIBUS DP interface see Figure 30 a green LED to indicate that the bus is ready for operation a 9 pin female DSUB connector two DIP switches for a...

Page 155: ... optional It is used for directional control in the case of an external optical waveguide module 12 1 3 2 Mating connector 9 pin DSUB connector for example Erbic MAX PROFIBUS IDC switch made by ERNI 12 1 3 3 Cable type and configuration The cable names that are stated refer to cables made by Lapp They have proved to be reliable and are successfully used in many applications However it is also poss...

Page 156: ...ut integrated terminating resistors the PROFIBUS DP interface has its own terminating resistors They can be activated with the help of the two DIP switches on the module switch set to ON To ensure safe operation of the network only one bus termination may be used at a time The external connection can also be set up discretely see Figure 31 The 5 V power supply that is required for the externally c...

Page 157: ...ot be supported if the EtherCAT technology module is used If your specific requirements are more complex please contact your sales partner in order to find a solution for your particular application 12 2 2 Characteristics of the EtherCAT technology module The EtherCAT technology module has the following characteristics It can be fully mechanically integrated in the item servo positioning controlle...

Page 158: ...nge 25 C to 75 C Operating temperature range 0 C to 50 C Atmospheric humidity 0 90 non condensing Installation altitude up to 2000 m above MSL External dimensions L x W x H approx 92 x 65 x 19 mm Weight approx 55 g Slot Technology slot TECH 2 12 2 4 Display elements The front panel of the EtherCAT technology module is equipped with two LEDs for indicating the operating states Table 55 Display elem...

Page 159: ...colour LED green red Run green link activity EtherCAT port 1 red EtherCAT active yellow LED 2 red Link activity EtherCAT port 2 12 2 5 EtherCAT interface Table 56 Signal level and differential voltage Signal level 0 2 5 VDC Differential voltage 1 9 2 1 VDC ...

Page 160: ... protection measures are applied when handling technology modules To insert a technology module into the item Servo Positioning Controller C 3 Series please proceed as follows 1 Remove the front plate of the technology slot TECH 1 or TECH 2 of the servo positioning controller with a suitable Phillips screwdriver 2 Push the technology module into the open technology slot so that the lateral guides ...

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