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item Controller BL 1-04 /C

― Product manual

1 About this Product manual

The purpose of this Product manual is to ensure the safe use of the servo drives of the BL 1-04 /C series and of the item

MotionSoft

parameterisation software (abbreviated "iMS

").

The safety instructions and warnings in this Product manual must always be followed.

1.1 Explanations and notation

1.1.1 Structure of the warning notes

Warning notes have the following structure:

▪ Signal word "NOTE"

▪ Introductory phrase

▪ Explanations and special tips

Signal words

Indicates an imminent hazard. If the situation is not avoided, extremely serious and possibly fatal

injuries will result.

Indicates a potentially hazardous situation. If the situation is not avoided, extremely serious and

possibly fatal injuries may result.

Indicates a potentially hazardous situation. If the situation is not avoided, slight or minor injuries may

result.

Warns against damage to property.

Warning signs as per ISO 7010

Warning sign

Explanation

Warning against fatal electric voltage.

Warning against hot surfaces.

1.1.2 Notation in this product manual

Structure of notes

The notes in this Product manual have the following structure:

▪ Signal word "NOTE"

▪ Introductory phrase

▪ Explanations and special tips

Operating elements, menus

Operating elements, menus and menu paths are written in orange.
Example: Double-clicking the desired device or clicking the button Establish connection will establish an online connection.

DANGER

WARNING

CAUTION

NOTICE

Содержание 0.0.698.50

Страница 1: ...item Controller BL 1 04 C 0 0 698 50 Product manual...

Страница 2: ...s selected by the buyer item does not assume any liability for damage resulting from the combined use of its products with other products or resulting from improper handling of machines or systems ite...

Страница 3: ...ype designation 13 3 2 Device view 14 3 3 Features 15 4 STO safe torque off 16 4 1 Special safety instructions 17 4 2 Certification safety level 17 4 3 Requirements for using the product 17 4 3 1 Qual...

Страница 4: ...tion with a restart 50 8 12 MicroSD card 51 9 Electrical installation 52 9 1 Notes concerning the safe and EMC compliant installation 52 9 1 1 Explanations and terminology 52 9 1 2 General information...

Страница 5: ...esult Indicates a potentially hazardous situation If the situation is not avoided extremely serious and possibly fatal injuries may result Indicates a potentially hazardous situation If the situation...

Страница 6: ...04 C with a PROFINET control system You can find all of these documents on our homepage for download Certificates and declarations of conformity for the prod ucts described in this manual can also be...

Страница 7: ...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 62061 Safety of machinery Functional...

Страница 8: ...to prevent injuries and or damage to property The following safety instructions must be complied with at all times Do not attempt to install or start the servo drive without having read all of the saf...

Страница 9: ...tional or international rules and regulations must be complied with Safety critical applications of the servo drive are not allowed unless specifically approved by the manufacturer For information abo...

Страница 10: ...erforming any work on the connections Always measure the voltage with a suitable instrument WARNING Risk of burns due to hot surfaces The servo drive and in particular the external or internal braking...

Страница 11: ...utes after they have been switched off residual capacitor charge Wait 10 minutes prior to performing any work on the connections Always measure the voltage with a suitable instrument To prevent accide...

Страница 12: ...e or non EMC compliant components software errors in the superordinate control system These errors can occur directly after the activation of the device or after some time during the operation The mon...

Страница 13: ...pecified use special tools Use lifting equipment and tools in a proper manner Do not step under suspended loads Liquid spills on the floor must be removed immediately 3 Product description The servo d...

Страница 14: ...18 Ethernet interface 8 LED RUN SF MS 9 LED ERR BF MS 10 X21 Real time Ethernet interface 11 X4 CANopen interface 12 Safety Symbols as per ISO 7000 13 Warnings 2 1 13 12 3 4 5 6 7 8 9 10 11 Figure 2 F...

Страница 15: ...software Adjustment of all of the parameters via a PC and online representation of operating parameters and diagnostic messages User guided initial start up loading and saving of parameter sets as wel...

Страница 16: ...ycle times bandwidth in the current control circuit approx 2 kHz with ti 32 s in the speed control circuit approx 500 Hz with tn 64 s Parameterisable band stop filters for suppressing the natural freq...

Страница 17: ...ery Directive on page 74 The achievable safety level depends on the other components that are used to implement a safety function This has been certified by an independent testing authority 4 3 Requir...

Страница 18: ...increasingly automated protecting persons against potentially hazardous movements is continuously gaining in importance Functional safety describes the necessary measures in the form of electrical or...

Страница 19: ...y supply to the drive is interrupted in a safe manner The drive can neither generate any torque nor any dangerous movements In the case of suspended loads or other external forces addi tional measures...

Страница 20: ...f safe semiconductor outputs electronic safety relays active safety sensors e g light grid with OSSD signals and of switching contacts safety relays with relay outputs passive safety sensors e g posit...

Страница 21: ...only with a considerable delay Consequently this state can only be signalled via the digital outputs or a fieldbus with a considerable delay The power output stage has already been switched off safel...

Страница 22: ...ty oriented The brake is actuated via the non safety oriented firmware of the servo drive If the application requires the safe actuation of the brake additional external measures must be implemented N...

Страница 23: ...tive gate a light grid or a safety relay The safety request is realised via two channels and via the switch S1 As a result the output stage will be switched off via two channels Notes concerning the c...

Страница 24: ...function A loss of the safety function can result in serious irreversible injuries e g due to uncontrolled movements of the connected actuators Use the integrated STO safety function only if all of th...

Страница 25: ...electrical installation connecting cables pin assignment see section 9 12 Connector STO X3 on page 70 3 Check whether all of the PE conductors are connected 4 8 item MotionSoft safety functions The w...

Страница 26: ...finite state machine that results from the evaluation of the driver supply voltages of the integrated STO safety function Regard less of the indication the power output stage may have already been swi...

Страница 27: ...he time intervals in the specified time period The check is to be conducted such that the correct operation of the safety system can be verified based on an interaction of all of the components Mainte...

Страница 28: ...es and warnings on page 80 2 Error elimination Eliminate the cause of the error in compliance with the safety instructions section 2 4 General safety instructions on page 9 3 Error acknowledgement Cle...

Страница 29: ...t will not be displayed and the application contin ues to run without being affected by the event Warning The event will be displayed briefly on the seven segment display of the servo drive Disable se...

Страница 30: ...13 Error buffer and Error messages windows INFO Error messages for the Application Engineering department If you want to forward an error to the Application Engineering department you should always s...

Страница 31: ...sonnel for the transport of the servo drive Transport the servo drive only in its original packaging Use only suitable transport equipment Use suitable personal protective equipment If you notice that...

Страница 32: ...afety rules and regulations concerning the installation Follow the safety instructions in section 2 6 Safety notes for installation and maintenance on page 10 Use only suitable tools If specified use...

Страница 33: ...ng may cause premature ageing and or damage 8 Technical data This chapter provides all of the relevant technical data of the BL 1 04 C servo drive with an integrated Safe Torque Off STO safety functio...

Страница 34: ...AC 10 50 60 Hz Supply network type TN TT Maximum mains current in continuous operation S1 1 6 Aeff DC bus voltage 325 VDC with Umains 230 VAC 24 V supply 24 VDC 20 0 35 A 2 1 with a supply voltage of...

Страница 35: ...12 Aeff Power loss efficiency 5 95 As a guide value for the control cabinet cooling system Current derating The BL 1 04 C series servo drives have a current derating during nominal operation The rate...

Страница 36: ...lue Cable length l 25 m See section 9 1 Notes concerning the safe and EMC compliant installation on page 52 Cable capacity C 160 pF m of one phase Motor temperature monitoring system Dangerous electri...

Страница 37: ...Nominal voltage 24 V Nominal current 2 A total of all digital outputs and of the holding brake 2 5 A max Voltage drop referred to the 24 V input with a load current of 2 A approx 1 5 V Overload protec...

Страница 38: ...Possibly not all encoders of a manufacturer are supported It is possible that not all encoders of a manufacturer are fully supported In individual cases it is therefore always recommend ed to test th...

Страница 39: ...w 2 V Hi 2 kW pull up Error input pin 6 TTL level 0 5 V Low 2 V Hi 2 kW pull up Track signal input impedance Differential input 120 Limit frequency 10 MHz Analogue incremental encoders with commutatio...

Страница 40: ...V Low 2 V Hi 2 k pull up Track signal input impedance Differential input 120 Limit frequency Up to 10 MHz depending on the encoder system Supported operating modes Storage of the parameter set in the...

Страница 41: ...3 1 EtherCAT CoE Can over EtherCAT The support of these fieldbus types is integrated in the servo drive Additional modules are not required The parameterisation is performed with the aid of item Motio...

Страница 42: ...e output Digital inputs Eigenschaft Value Nominal voltage 24 V as per DIN EN 61131 2 15 V 10 V low to 30 V high Current consumption 3 2 mA max The mode of operation of the digital outputs can be confi...

Страница 43: ...ut or open collector outputs If TTL encoders are used it must be taken into consideration that the hysteresis is negligible In addition the requirements concerning the signal shield must be fulfilled...

Страница 44: ...lso be generated as so called pulse packets depending on the covered rotational angle of the source This means that the interface for any downstream circuits must be suitable for incremental encoders...

Страница 45: ...sponds to ti 8 10 2 Time response of the digital outputs position controller cycle time tx internal event high low t t t t dig output DOUT high low output is set by the firmware tDOUT ON tHW ON tRISE...

Страница 46: ...ot tenc tRF tF tA tNoff tUZK Figure 17 Time diagram of the servo drive Parameter Min Typ Max Start of the firmware after power ON tboot 4 s Encoder start time tenc 0 7 s resolver 2 s Hiperface DSL DC...

Страница 47: ...ting of the STO function Comply with the following test intervals in order to reach the specified values For SIL 2 PL d category 3 1x per year For SIL 3 PL e category 3 every 3 months For SIL 3 PL e c...

Страница 48: ...functionality which is why the switching sequence of STOA STOB is interchangeable in all of the diagrams 8 11 2 1 Time response of the STO activation during operation with a restart The illustration...

Страница 49: ...issuing an error 100 ms tSTOA B OFF STOA B switching time from high to low See also section Response time until power output stage inactive and maximum OSSD test pulse duration on page 48 Maximum res...

Страница 50: ...safe torque switch off SS1 Safe Stop 1 on page 24 1 1 1 t t t t t t t t t k1_delay k1_out k1_in tSTOA B OFF tA tDRV tSTOA B ON tF tK1 tK1_delay tK1 tENAB HI on driver supply H is displayed holding br...

Страница 51: ...pulse duration on page 48 Maximum response time 5 ms tSTOA B ON STOA B switching time from high to low 0 6 ms typ 1 ms max tDRV Delay of the internal sequence control of the servo drive 10 ms max tENA...

Страница 52: ...echanical system Configuration and type of wiring Superordinate control system In order to increase interference immunity and to decrease interference emissions the servo drive has integrated filters...

Страница 53: ...r motor housing over a large contact area 9 1 4 Operation with long motor cables INFO Compliance with the EMC standard EN 61800 3 Compliance with the EMC standard EN 61800 3 is ensured only for a moto...

Страница 54: ...24V GND Mains phase Mains neutral conductor Pos DC bus voltage Neg DC bus voltage Connection of external brake resistor Connection ground conductor from mains 24V supply Reference ground for 24V suppl...

Страница 55: ...Supply voltage for the control module and holding brake 3 PE Connection of the protective earth ground conductor of the mains power supply 4 R_CH Braking resistor connection 5 R_EXT Braking resistor...

Страница 56: ...180 SN BK BX Pin assignment motor with a motor temperature sensor 1 2 3 4 5 6 7 8 9 back panel of control cabinet WEIDM LLER BLF 5 08HC 09 180 SN BK BX Pin assignment motor with a motor temperature se...

Страница 57: ...efer to cables made by Lapp However it is also possible to use comparable cables from other manufacturers for example L tze or Helukabel LAPP KABEL LFLEX SERVO 719 CY 4 G 1 5 2 x 2 x 0 75 For fixed in...

Страница 58: ...damaged if the connectors for the motor X6 and supply X9 are mixed up 9 5 Connector resolvers analogue Hall encoders X2A Two different encoder types can be connected to the 9 pin D Sub connector Reso...

Страница 59: ...of the angle encoder connector with the greatest possible surface area with low impedance Cable type and configuration X2A The cable names that are stated refer to cables made by Lapp However it is a...

Страница 60: ...X2B D SUB connector 15 pin type male Housing for a 15 pin D SUB connector with locking screws of type 4 40 UNC NOTICE Damage to property caused by an incorrect power supply If an incorrect power suppl...

Страница 61: ...ncremental encoder 6 SIN_Z1 C 14 COS_Z0 B COSINE track signal differential of the high resolution incremental encoder 7 COS_Z0 B 15 SIN_Z0 A SINE track signal differential of the high resolution incre...

Страница 62: ...ignal differential of the high resolution incremental encoder 7 COS_Z0 B 15 SIN_Z0 A SINE track signal differential of the high resolution incremental encoder 8 SIN_Z0 A INFO Avoiding EMC interference...

Страница 63: ...emental encoder 8 B a2 INFO Avoiding EMC interferences The outer cable shield must be connected to the housing of the angle encoder connector with the greatest possible surface area with low impedance...

Страница 64: ...dapter Configuration on the device X19 USB connector female type B Mating connector X19 USB connector male type B Pin assignment USB X19 Interface cable for the USB interface 4 cores shielded and twis...

Страница 65: ...Reception signal Blue 7 8 9 9 Connector real time Ethernet X21 The connection to an EtherCAT or PROFINET network must be realised via two female RJ45 connectors Details can be found in the Fieldbus ma...

Страница 66: ...ith exactly two twisted pairs must be used for cabling Use one twisted pair to connect CAN H and CAN L The cores of the other pair are used jointly for CAN GND The shield of the cable is led to the CA...

Страница 67: ...AIN are connected to the control system via twisted cables twisted pair type Alternatively it is also possible to use a shielded cable If the control system is equipped with single ended outputs the...

Страница 68: ...nputs can be activated directly via switches The digital outputs are designed as so called high side switches This means that only these 24 V are supplied to the output in the active state In the pass...

Страница 69: ...r signal DIR 5 N Incremental encoder index pulse N 18 N Incremental encoder index pulse N 6 GND24 Reference potential for I Os at X1 19 DIN0 Digital input 0 target 0 7 DIN1 Digital input 1 target 1 20...

Страница 70: ...n to the associated connector Configuration on the device X3 SC 3 81 08 90F 3 2SN BK BX Mating connector BCF 3 81 08 180F SN BK BX Pin assignment X3 1 8 Figure 32 STO connector X3 Pin Name Description...

Страница 71: ...e final safety wiring is performed 10 Maintenance cleaning repair and disposal The following requirements must be fulfilled for the maintenance cleaning repair and disposal of the servo drive Maintena...

Страница 72: ...tch the power supply completely off Disconnect the mains power connectors Lock the system so that it cannot be reactivated Check whether the device is really voltage free measure the voltage at the ma...

Страница 73: ...73 item Controller BL 1 04 C Product manual 11 Appendix 11 1 CE conformity EMC RoHS Low Voltage Directive...

Страница 74: ...item Controller BL 1 04 C Product manual 74 11 2 CE conformity Machinery Directive...

Страница 75: ...models Have been investigated by UL in accordance with the component requirements in the Standard s indicated on this Certificate UL Recognized components are incomplete in certain constructional fea...

Страница 76: ...ul com aboutul locations Page 2 of 2 This is to certify that representative samples of the product as specified on this certificate were tested according to the current UL requirements Power conversio...

Страница 77: ...switching device output signals with 24 V level cycle rates for error detection PFD Probability of failure on demand in accordance with IEC 61508 PFH Probability of dangerous failures per hour in acco...

Страница 78: ...d risk been reduced as far as practically possible Yes No 4 Can it be guaranteed that the implemented measures will not pose new hazards Yes No 5 Have the users been adequately informed and warned abo...

Страница 79: ...been connected to X3 Yes No Has the safety relay been certified and wired in accordance with the requirements of the application Yes No c Functional tests Actuation of the emergency cut out switch of...

Страница 80: ...ve has been switched on Entry in the perma nent event memory No measures required 0 9 Servo drive safety parame ters changed Logging of the parameterisation of the FSM 2 0 MOV Entry in the permanent e...

Страница 81: ...rive from the entire periphery and check whether the er ror is still present after a reset If the error is still present replace the servo drive 5 1 Failure of internal voltage 2 5 2 Driver supply fai...

Страница 82: ...Angle encoder communication error 8 7 Master frequency input Incorrect signal amplitude incremental track 8 8 Internal angle encoder error The internal monitoring system of the angle encoder at X2B h...

Страница 83: ...5 Homing I t following error Unsuitable parameterisation of the acceleration ramps The stop has been reached e g because no reference switch has been installed 11 6 Homing end of search distance reach...

Страница 84: ...ot be performed with the current angle encoder settings Check the angle encoder configuration Please contact the Technical Support team 14 5 Index pulse not found The index pulse could not be found af...

Страница 85: ...ent measurement U Please contact the Technical Support team 21 1 Error 1 current measurement V 21 2 Error 2 current measurement U 21 3 Error 2 current measurement V Group 22 PROFIBUS 22 0 PROFIBUS inc...

Страница 86: ...the Technical Support team 25 5 Incompatibility Firmware Hardware The customer specific firmware is not compatible with the servo drive Please contact the Technical Support team Group 26 Flash 26 0 N...

Страница 87: ...ownload error Group 30 Internal calculations 30 0 Internal calculation error Please contact the Technical Support team Group 31 I t 31 0 I t motor Is the motor blocked Check the power rating of the dr...

Страница 88: ...ion interval Group 35 Linear motor 35 0 Overspeed protection of linear motor The encoder signals are disturbed Check the installation for compliance with the EMC recommendations 35 5 Error during the...

Страница 89: ...r 38 4 Sercos S 0 0127 impermis sible IDNs in AT or MDT Check the configuration for the cyclic data transfer 38 5 Sercos S 0 0128 invalid data in S 0 0022 Check the scaling settings Check the operatin...

Страница 90: ...parameterisation of the position sets 42 1 Positioning reversal of rota tion not permissible stop 42 2 Positioning reversal of rotation after stop not permissible 42 3 Positioning start rejected wron...

Страница 91: ...up mode 47 0 Set up mode timeout The speed has not fallen below the speed required for the set up mode in time Check the processing of the request by the PLC Check the speed threshold Check the timeo...

Страница 92: ...fieldbus activation module 51 3 FSM unequal module version Cause Type or revision of the module is not supported Measure Install safety or fieldbus activation module appropriate for the firmware and h...

Страница 93: ...of the FSM 2 0 MOV in view of the application since the modules have been replaced Group 52 FSM 2 0 STO 52 1 FSM Diskrepanzzeit abgelaufen Cause Control ports STO A and STO B are not actuated simulta...

Страница 94: ...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 the speed can the drive foll...

Страница 95: ...amp record the speed can the drive follow the ramp Change parameters for the slowdown ramp or start time delay times for monitoring With a If the option Activate quick stop ramp in base device is acti...

Страница 96: ...ible replace with another module Cause Error in driver circuit section in the servo drive Measure Servo drive presumably defective If possible replace with another servo drive Cause No feedback receiv...

Страница 97: ...put signals of the SinCos encoder have not changed by a minimum amount for 24 hours when safety function is requested Measure Terminate SS2 or SOS and move axle at least once during this time 55 3 FSM...

Страница 98: ...ue 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 servo drive acknowledge error once Group 56 FSM...

Страница 99: ...ted 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 replacing the module 57 1 FSM dig...

Страница 100: ...has thus termin ated the parameterisation session The error message is saved in the permanent event memory Measure Terminate parameterisation session within 8 hrs If necessary start a new para meteri...

Страница 101: ...is is an internal error in the module that should not occur during operation Check the operating conditions temperature air humidity condensation Check the EMC wiring as specified and shield design ar...

Страница 102: ...e corrupted e g by extreme malfunctions Measure Check whether the error recurs after a reset If it does parameterise the module again and validate the parameter set again If error persists safety modu...

Страница 103: ...uted Clocks feature Please contact the Technical Support team 63 4 EtherCAT Missing SYNC message in IPO cycle Check the cycle times of the servo drive and PLC 63 5 EtherCAT wrong firmware found Please...

Страница 104: ...hort Check the configuration of the master 67 4 Modbus message length too long Check the configuration of the master Group 68 Ethernet IP 68 0 Ethernet IP general error Replace the module Please conta...

Страница 105: ...OFINET different module configuration Master Slave Check whether the telegram lengths set in the PROFINET telegram editor match the setting in the master 72 8 PROFINET failure in cyclic data Check wir...

Страница 106: ...le Contact the Technical Support team 83 1 Technology module not supported Load the most recent firmware 83 2 Technology module HW revision not supported Load the most recent firmware 83 3 Service mod...

Страница 107: ...SW initialisation 91 0 Internal initialisation error Please contact the Technical Support team 91 1 Memory error copy 91 2 Reading of the controller po wer output stage type failed 91 3 Internal soft...

Страница 108: ...0 701 34 item Industrietechnik GmbH Made in Germany 03 2021 item Industrietechnik GmbH Friedenstrasse 107 109 42699 Solingen Germany Phone 49 212 6580 0 Fax 49 212 6580 310 info item24 com item24 com...

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