Faulhaber MC 5004 P STO User manual

WE CREATE MOTION
Installation
Instructions
MC 5004 P STO
Original Instructions
EN

Imprint
2
Version:
1st edition, 03-05-2018
Copyright
by Dr. Fritz Faulhaber GmbH & Co. KG
Daimlerstr. 23 / 25 · 71101 Schönaich
All rights reserved, including those to the translation.
No part of this description may be duplicated, reproduced,
stored in an information system or processed or
transferred in any other form without prior express written
permission of Dr. Fritz Faulhaber GmbH & Co. KG.
This document has been prepared with care.
Dr. Fritz Faulhaber 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
when using the software.
Subject to change without notice.
The respective current version of this technical manual is
available on FAULHABER's internet site:
www.faulhaber.com
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Content
3
1 About this document ....................................................................................................... 5
1.1 Validity of this document ...................................................................................... 5
1.2 Associated documents ............................................................................................ 5
1.3 Using this document .............................................................................................. 5
1.4 List of abbreviations ............................................................................................... 6
1.5 Symbols and designations ...................................................................................... 7
2 Safety ................................................................................................................................ 8
2.1 Intended use ........................................................................................................... 8
2.2 Safety instructions .................................................................................................. 9
2.2.1 Dangers in the event of damages and changes.................................... 9
2.2.2 Correct installation and commissioning .............................................. 10
2.2.3 Heat development ................................................................................ 10
2.3 Environmental conditions .................................................................................... 10
2.4 Requirements on the higher-level control .......................................................... 11
2.5 EC directives on product safety ........................................................................... 12
3 Product description ........................................................................................................ 13
3.1 General product description ................................................................................ 13
3.2 Product information ............................................................................................. 15
3.3 Technical data ....................................................................................................... 16
3.4 Product variants .................................................................................................... 17
3.4.1 Controller 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 ...................................................... 28
4.2.2 Drive connections.................................................................................. 29
4.2.3 Screening ............................................................................................... 30
4.2.4 Connection of the power supply ......................................................... 31
4.2.4.1 Power supply.......................................................................... 31
4.2.5 Connector pin assignment.................................................................... 32
4.2.5.1 Pin assignment of the X100 connector strip of the
Motion Controller.................................................................. 32
4.2.5.2 Pin assignment of the motherboard (motor side) ............... 34
4.2.5.3 Pin assignment of the motherboard (supply side)............... 39
4.2.6 Motherboard: connection at the motor side ...................................... 41
4.2.7 I/O circuit diagrams ............................................................................... 44
4.2.7.1 Inputs...................................................................................... 44
4.2.7.2 Outputs................................................................................... 47
4.2.8 External circuit diagrams ...................................................................... 50

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4.3 Information on initial commissioning ................................................................. 54
5 Maintenance 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

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About this document
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1 About this document
1.1 Validity of this document
This document contains the information necessary for the intended use of the
MC 5004 P STO series.
This document is intended for use by trained experts authorised to perform installation and
electrical connection of the product.
All data in this document relate to the standard versions of the series listed above.
1.2 Associated documents
The following documents are part of these installation instructions. They can be down-
loaded in pdf format from the web page www.faulhaber.com/manuals.
If it is not possible to 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 necessary, maintenance person-
nel at all times.
Pass the document on to any subsequent owner or user of the product.
Document Description
Motion Manager 6 Operating instructions for FAULHABER Motion Manager PC software
Quick start guide Description of the first steps for commissioning and operation of FAULHABER
Motion Controllers
Drive functions Description of the operating modes and functions of the drive
Accessories manual Description of the accessories

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About this document
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1.4 List of abbreviations
Abbreviation Meaning
AC Alternating Current
AES Absolute encoder
AGND Analogue Ground
AnIn Analogue Input
CAN Controller Area Network
CAN_L CAN-Low
CAN_H CAN-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
RxD Receive data
SGND Signal Ground
STO Safe Torque Off
TxD Transmit data

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About this document
7
1.5 Symbols and designations
DANGER
DANGER
!
Danger with high level of risk: if not avoided, death or serious injury will result.
Measures for avoidance
WARNING
WARNING
!
Danger with medium level of risk: if not 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 a single-step action
Instructions for understanding or optimising the operational procedures

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Safety
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2 Safety
2.1 Intended use
The Motion Controllers with STO function described here are designed as slaves for control
and position tasks in which safe shutdown of the torque is required. When the STO (Safe
Torque Off – safe shutdown of the torque) safety function is requested, the outputs for the
connected drive are safely switched torque-free.
The Motion Controllers with STO function are suitable for actuating the following motors:
Linear DC-Servomotors
Brushless DC motors
The Motion Controller is suitable in particular for tasks in the 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 environments where it will come into contact with
water, chemicals and/or dust, nor in explosion hazard areas.
The Motion Controller is not suitable for use in combination with stepper and brushed
DC motors.
The Motion Controller should be operated only within the limits specified in these
installation instructions.
Please ask the manufacturer for information about use under individual special
environmental conditions.

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Safety
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2.2 Safety instructions
In addition to the safety risks described in these installation instructions, machine-specific
dangers could arise that cannot be foreseen by the manufacturer of the Motion Controller
(e.g., risk of injury from driven components). The manufacturer of the machine in which the
Motion Controller is installed must perform a risk analysis in accordance with the regula-
tions applicable to the machine and inform the end user of the residual risks.
2.2.1 Dangers in the event of damages and changes
A defect or damage or change to the Motion Controller can impair its safety functions. If
safety functions are unavailable, the drive can start up unexpectedly or shutdown of the
torque may be ineffective. Depending on the use of the Motion Controller, this can lead to
severe or fatal injury.
Do not start up a machine with a defective or damaged Motion Controller.
Appropriately mark a defective or damaged Motion Controller.
Do not replace defective or damaged components of the Motion Controller.
Make no changes (modifications, repairs) 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 the ESD handling regulations (e.g.
wear an ESD wristband, earth surrounding components).
During installation, ensure that components in the surroundings cannot be electrostati-
cally discharged.
Soiling, foreign bodies, humidity and mechanical influences can damage the electronics.
Keep foreign bodies away from the electronics.
Install the Motion Controller in a housing that protects it from mechanical influences
and is adapted to the ambient conditions (protection class determination).
Installation and connection work whilst supply voltage is applied at the device can dam-
age the electronics.
Do not insert or withdraw connectors whilst supply voltage is applied at the Motion
Controller.
During all aspects of installation and connection work on the Motion Controller, switch
off the power supply.
Incorrect connection of the pins can damage the electronic components.
Connect the wires as shown in the connection assignment.

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Safety
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2.2.2 Correct installation and commissioning
Errors during the installation and commissioning of the Motion Controller could impair its
safety function. If safety functions are unavailable, the drive can start up unexpectedly or
shutdown of the torque may be ineffective. Depending on the use of the Motion Control-
ler, this can lead to severe or fatal injury.
Follow the instructions for installation and commissioning given in these installation
instructions exactly.
Only have work on electrical operating equipment performed by an electrician.
Do not bypass the safety circuit.
Do not bypass STO inputs with Performance Level d (PL d) or higher.
To avoid crosstalk on signal lines, lay the power supply cable separate from the signal
cable or take appropriate interference suppression measures.
During all work on 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 being touched and cool sufficiently.
If necessary, affix a suitable warning sign in the immediate vicinity of the controller.
Fig. 1: Suitable warning sign acc. to DIN EN ISO 7010
2.3 Environmental conditions
Select the installation location so that clean dry air is available for cooling the Motion
Controller.
Secure the Motion Controller against unauthorised access (e.g., install in a lockable
switch cabinet).
Select the installation location so that the air has unobstructed access to flow around
the drive.
When installed within housings and cabinets take particular care to ensure adequate
cooling of the Motion Controller.
Select a power supply that is within the defined tolerance range.

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Protect the Motion Controller against humidity and wet.
Protect the Motion Controller against chemical pollutants.
To store, protect the Motion Controller against dust, humidity and electrostatic charge
(e.g., pack in ESD foil).
Observe technical data (see chap. 3.3, p. 16 and chap. 8.1, p. 60).
2.4 Requirements on the higher-level control
When switching on the Motion Controller, a self-test is performed automatically. The
higher-level control must de-energise the Motion Controller and then switch it back on
again daily to force the self-test. The internal diagnostics of the Motion Controller monitor
the shutdown of the outputs during operation.
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 equalization cable
of the shielding of a shielded cable
Provide indication of a self-test error, e.g., for the following reasons:
Faulty wiring
defective cables (cable breakage, loss of contact at the connector, short-circuit,
hanging)
If the self-test reports errors, return the Motion Controller to the manufacturer with indica-
tion of the error messages.
The control of the Motion Controller and the executable functions are described in the
manuals for the Motion Manager 6 and the drive functions (see chap. 1.2, p. 5).

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Safety
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2.5 EC directives on product safety
The following EC directives and standards on product safety must be observed.
If the Motion Controller is being used outside the EU, international, national and
regional directives must be also observed.
Machinery Directive (2006/42/EC)
The products described in these installation instructions are electrical components with
integrated safety function according to the Machinery Directive. They are therefore to be
considered incomplete machines according to the Machinery Directive. Compliance is docu-
mented by the Declaration of Incorporation for the product and by the EC Declaration of
the Conformity for the safety function.
Low Voltage Directive (2014/35/EU)
The Low Voltage Directive applies for all electrical equipment with a nominal voltage of 75
to 1500 V DC and 50 to 1000 V AC. The products described in these installation instructions
do not fall within the scope of this directive, since they are intended for lower voltages.
EMC Directive (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 certain hazardous materials in electrical and electronic
devices. The products described in these installation instructions fall within the scope of this
directive. Conformity with the directive is documented in the EC Declaration of Conformity.
WEEE Directive (2012/19/EU)
The directive on the disposal of electrical and electronic devices prescribes the separate col-
lection of old electrical and electronic devices. The products described in these installation
instructions fall within the scope of this directive.
Applied standards
Various harmonised standards were applied to the products described in these installation
instructions; these standards are documented in the EC Declaration of Conformity.
You can find the Declaration of Incorporation for the product and the EC Declaration of
Conformity for the safety function in chap. 8.2, p. 62 and chap. 8.3, p. 63.

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Product description
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3 Product description
3.1 General product description
The products MC 5004 P STO are variants of the FAULHABER Motion Controllers without
housing and control either LM or BL motors. The Motion Controllers are configured here
via the FAULHABER Motion Manager software (version 6.3 and higher).
The drives can be incorporated into the network by means of the CANopen or EtherCAT
field bus interfaces. In smaller installations networking can be performed using the RS232
interface. The Motion Controller operates within the network principally as a slave. Master
functionality for controlling other axes is not provided. Alternatively, after initial commis-
sioning by the 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 redundant inputs which interrupt the motor
supply and switch off the output stage if the enabling voltage is lost.
Fig. 2: Functional principle
The connected motor is not actively braked in this situation, but is rather switched to a
torqueless state. By means of LEDs and status and error message outputs, the current device
state is signalled locally and reported to the higher-level control. The state of the inputs is
not signalled.
STO IN1
STO IN2
24V
GND
STO Device
LED
LED No-Error STO
LED Status STO
24V
24V
Status
No-Error
1
2
3
4
1
2
3
41
2
3
4
1
2
3
4

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Fig. 3: Torque shutdown
The products of the MC 5004 P STO series may only be used in combination with brushless
DC motors. Unlike brushed DC motors, these always require actuation. If the control signals
are interrupted via the safety circuit, they are thereby safely shut off.
The controllers can be plugged into a motherboard via the 50-pin connector strip.
FAULHABER offers an appropriately approved motherboard as accessory for this purpose.
With the integrated 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 components such as:
Digital/analogue Hall sensors
Incremental encoders with or without line drivers.
Motion Controllers with RS232, CANopen or EtherCAT interfaces can also be operated
independently of the communications interface if a pre-programmed function or
sequence program has been programmed without digital command controls.
STO activation
n
t

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3.2 Product information
Designation key
Fig. 4: Designation key
Type plate
Fig. 5: Type plate
1 Identification number 6500.01717 or 6500.01718
2 Serial number (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 P …STOMC
6500.10000
FW 03I
SNR 12340002
1
2
3

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3.3 Technical data
Dimensioning limits
Power supply of the electronics
See chap. 8.1, p. 60
Motor power supply (not if using
the motherboard)
PWM switching frequency
Electronics efficiency
Maximum continuous output cur-
rent
Maximum peak output current
Standby current of the electronics
Operating and storage conditions
Ambient temperature range See chap. 8.1, p. 60
Relative air humidity 5…93 % (non-condensing)
Maximum operating altitude 2000 m above sea level
Pollution 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
request of the safe state and the
shutdown of the output signals
5ms
Overvoltage category III, acc. to DIN EN 60664-1
Decisive voltage class DVC A, acc. to DIN EN 61800-5-1
Adjacent circuits require functional insulation (DVC A), basic insulation
(DVC B) or electrical separation (DVC C)
Protection class Housings must be suitable for use in the intended environment.

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3.4 Product variants
The following product variants are possible:
The Motion Controller PCBs can be mounted on a motherboard. The FAULHABER mother-
board offers space for a Motion Controller PCB.
3.4.1 Controller PCBs
3.4.1.1 Standard PCB
Fig. 6: Isometric (left) and front view (right) of the standard PCB
Tab. 1: Connector overview
Tab. 2: Device status LEDs
Product variant Identification number (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 drive has switched to a fault state. The output stage will be
switched off or has already been switched off.
Red (error code): Booting has failed. Please contact FAULHABER Support.
Power LED Green: Power supply within the permissible range.
Off: Power supply out of the permissible range.

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Tab. 3: No-Error LED and STO status LED
3.4.1.2 EtherCAT PCB
Fig. 7: Isometric (left) and front view (right) of the plugged-in EtherCAT PCB
Tab. 4: Connector overview
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 communication
USB (X1) Connection of the USB communication

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Tab. 5: Device LEDs
Tab. 6: No-Error LED and STO status LED
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 Support.
Power LED all Green: Power supply within the permissible range.
Off: Power supply not within the permissible 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 EtherCAT Green (continuous): No data transfer. Connection to another participant has
been 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
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

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3.4.1.3 State machine and start routine
Fig. 8: States of the STO state machine
Tab. 7: Description of the states
State Description
Powerdown Voltage supply is switched off
Outputs are switched off
No torque at motor
Error Fault state
Internal diagnostics of the STO circuit detected an error
Outputs are switched off
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
Undervoltage/
overvoltage
Undervoltage/
overvoltage
STO IN 1 = low
STO IN 2 = low
yes
yes
yes
yes
yes
no
nono
no
no
yesno Undervoltage/
overvoltage
yesno Undervoltage/
overvoltage
AND
STO IN 1 = high
STO IN 2 = high
AND