ITEM BL 1-04/C User manual

item Controller BL 1-04 /C – 0.0.698.50
Product manual

2
item Controller BL 1-04 /C ― Product manual
Original Product manual
Copyrights
© 2020 item. All rights reserved:
The information and data in this document have been composed to the best of our knowledge. However, deviations between
the document and the product cannot be excluded entirely. For the devices and the corresponding software in the version
handed out to the customer, item guarantees the contractual use in accordance with the user documentation. In the case
of serious deviations from the user documentation, item has the right and the obligation to repair, unless it would involve an
unreasonable effort. A possible liability does not include deciencies caused by deviations from the operating conditions
intended for the device and described in the user documentation.
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 damage resulting from the combined use of its products
with other products or resulting from improper handling of machines or systems.
item reserves the right to modify, amend or improve the document or the product without prior notication.
This document may, neither entirely nor in part, be reproduced, translated into any other natural or machine-readable lan-
guage nor transferred to electronic, mechanical, optical or any other kind of data media, without the express authorisation of
the author.
Trademarks
Any product names in this document may be registered trademarks. The sole purpose of any trademarks in this document is
the identication of the corresponding products.
item MotionSoft® is a registered trademark of item Industrietechnik GmbH.
Contact
item Industrietechnik GmbH
Friedenstrasse 107-109
42699 Solingen
Germany
Phone [phone]
Fax [phone]
[e-mail]
item24.com
Revision Information
Manual title Product manual "Controller BL 1-04 /C"
File name Product manual Controller BL 1-04-C EN
Version 1.0
Year 2020

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item Controller BL 1-04 /C ― Product manual
Table of Contents
1 1 About this Product manual..............................................................................................................................................................................5
1.1 1.1..Explanations and notation.................................................................................................................................................................5
1.1.1 Structure of the warning notes.....................................................................................................................................................5
1.1.2 Notation in this product manual...................................................................................................................................................5
1.2 Additional documents................................................................................................................................................................................6
1.3 Order numbers ...........................................................................................................................................................................................6
1.4 Applicable standards.................................................................................................................................................................................7
2 For your own safety...............................................................................................................................................................................................8
2.1 General information....................................................................................................................................................................................8
2.2 Intended use................................................................................................................................................................................................8
2.3 Traget group ................................................................................................................................................................................................9
2.4 General safety instructions ......................................................................................................................................................................9
2.5 Personal protective equipment ............................................................................................................................................................ 10
2.6 Safety notes for installation and maintenance................................................................................................................................. 10
2.7 Protection against contact with electrical parts................................................................................................................................11
2.8 Protection against electric shock by way of protective extra-low voltage (PELV)......................................................................12
2.9 Protection against dangerous movements.........................................................................................................................................12
2.10 Protection against contact with hot parts.........................................................................................................................................12
2.11 Protection during the handling and installation of the devices....................................................................................................13
3 Product description.............................................................................................................................................................................................13
3.1 Type 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 Certication/safety level.........................................................................................................................................................................17
4.3 Requirements for using the product ....................................................................................................................................................17
4.3.1 Qualication of the specialist personnel (personnel requirements)................................................................................ 18
4.3.2 Diagnostic coverage (DC)......................................................................................................................................................... 18
4.4 Purpose ..................................................................................................................................................................................................... 18
4.5 Principle of operation and use.............................................................................................................................................................. 18
4.5.1 Description of the STO safety function................................................................................................................................... 19
4.5.2 Overview of the [X3] interface .................................................................................................................................................20
4.5.3 Control inputs STOA, GNDA/STOB, GNDB [X3]...................................................................................................................20
4.5.4 Discrepancy time ........................................................................................................................................................................ 21
4.5.5 Test pulses.................................................................................................................................................................................... 21
4.5.6 Auxiliary supply [X3]................................................................................................................................................................... 21
4.5.7 Additional diagnostics functions ............................................................................................................................................. 21
4.6 Circuit examples.......................................................................................................................................................................................22
4.6.1 Safe torque off (STO)..................................................................................................................................................................23
4.6.2 Deceleration and safe torque switch off(SS1, "Safe Stop 1")........................................................................................... 24
4.7 Prior to commissioning ..........................................................................................................................................................................25
4.8 item MotionSoft® safety functions ...................................................................................................................................................... 25
4.8.1 Servo drive type indication and safety function................................................................................................................... 25
4.8.2 Status indication of the nite state machine ........................................................................................................................26
4.8.3 "Safety module (integrated)" window.....................................................................................................................................26
4.9 Functional test, validation...................................................................................................................................................................... 27
4.10 Operation................................................................................................................................................................................................. 27
4.11 Diagnostics and fault clearance......................................................................................................................................................... 27

item Controller BL 1-04 /C ― Product manual
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5 Fault messages.................................................................................................................................................................................................... 27
5.1 Error management ..................................................................................................................................................................................28
5.2 Error buffer................................................................................................................................................................................................30
6 Storage/transport............................................................................................................................................................................................... 31
7 Installation ...........................................................................................................................................................................................................32
8 Technical data...................................................................................................................................................................................................... 33
8.1 General technical data............................................................................................................................................................................33
8.2 BL 1-04 /C: Power supply [X9] ............................................................................................................................................................34
8.3 BL 1-04 /C: Motor connector [X6] ......................................................................................................................................................35
8.4 Resolver connector [X2A] .....................................................................................................................................................................38
8.5 Encoder connector [X2B]......................................................................................................................................................................38
8.6 USB [X19]...................................................................................................................................................................................................41
8.7 Standard-Ethernet [X18].........................................................................................................................................................................41
8.8 Real-time-Ethernet [X21] ........................................................................................................................................................................41
8.9 CAN bus [X4]............................................................................................................................................................................................42
8.10 I/O Interface [X1]...................................................................................................................................................................................42
8.10.1 Time response of the digital inputs.......................................................................................................................................44
8.10.2 Time response of the digital outputs....................................................................................................................................45
8.10.3 Time response during power ON...........................................................................................................................................46
8.11 STO [X3]................................................................................................................................................................................................... 47
8.11.1 Electrical data of the STO function........................................................................................................................................ 47
8.11.2 Time response............................................................................................................................................................................48
8.11.2.1 Time response of the STO activation during operation with a restart........................................................48
8.11.2.2 Time response of the SS1 activation during operation 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 about electromagnetic compatibility................................................................................................. 52
9.1.3 Proper wiring.................................................................................................................................................................................52
9.1.4 Operation with long motor cables............................................................................................................................................ 53
9.1.5 ESD protection..............................................................................................................................................................................53
9.2 Additional requirements for the UL approval....................................................................................................................................54
9.3 BL 1-04 /C: Connector: power supply [X9]......................................................................................................................................54
9.4 BL 4300-C: Connector: power supply [X9], [X9A], [X9B].............................................................................................................. 56
9.5 BL 1-04 /C: Connector: motor [X6]....................................................................................................................................................58
9.6 BL 4300-C: Connector: motor [X6], [X6A] .......................................................................................................................................59
9.7 Connector: USB [X19]............................................................................................................................................................................ 63
9.8 Connector: standard Ethernet [X18] ..................................................................................................................................................64
9.9 Connector: real-time Ethernet [X21]................................................................................................................................................... 65
9.10 Connector: CAN bus [X4].....................................................................................................................................................................66
9.11 Connector: I/O interface [X1].............................................................................................................................................................. 67
9.12 Connector: STO [X3]............................................................................................................................................................................. 70
10 Maintenance, cleaning, repair and disposal............................................................................................................................................ 71
11 Appendix ...........................................................................................................................................................................................................73
11.1 CE conformity (EMC, RoHS, Low Voltage Directive)....................................................................................................................... 73
11.2 CE conformity (Machinery Directive)..................................................................................................................................................74
11.3 cULus certication ................................................................................................................................................................................ 75
11.4 Safety technology glossary.................................................................................................................................................................. 78
11.6 Error messages and warnings............................................................................................................................................................. 80

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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

item Controller BL 1-04 /C ― Product manual
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1.2 Additional documents
Further information can be found in the following manuals:
▪ EtherCAT and CANopen manual Servo Positioning Controller C-Series:This manual describes the commissioning procedure
for the servo drives C-Series or BL 1-04 /C with a CANopen or EtherCAT control system.
▪ PROFIBUS/PROFINET manual Servo Positioning Controller C-Series / BL 1-04 /C: This manual describes the commission-
ing procedure for the servo drives C-Series or BL 1-04 /C with a PROFINET control system.
You can nd all of these documents on our homepage for download. Certicates and declarations of conformity for the prod-
ucts described in this manual can also be found at our homepage: https://www.item24.com
1.3 Order numbers
Order number Description
0.0.698.50 Controller BL 1-04 /C
0.0.688.62 I/O Transfer Module C-Series
0.0.689.27 I/O Cable C-Series
0.0.703.51 Power Cable BL SC1 04/5
0.0.704.65 Power Cable BL SC1 04/10
0.0.704.66 Power Cable BL SC1 04/15
0.0.704.71 Data Cable BL RSC/5
0.0.704.72 Data Cable BL RSC/10
0.0.704.73 Data Cable BL RSC/15
0.0.704.75 Data Cable BL AKSC/5
0.0.704.76 Data Cable BL AKSC/10
0.0.704.77 Data Cable BL AKSC/15

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item Controller BL 1-04 /C ― Product manual
1.4 Applicable standards
Standard Description
EN 13849-1:2015 Safety of machinery - Safety-related parts of control systems - Part 1: General principles for
design
EN 50581 Technical documentation for the assessment of electrical and electronic products with respect
to the restriction of hazardous substances
EN 60204-1 Safety of machinery - Electrical equipment of machines - Part 1: General requirements
EN 61800-3 Adjustable speed electrical power drive systems - Part 3: EMC requirements and specic test
methods
EN 61800-5-1 Adjustable speed electrical 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 62061 Safety of machinery - Functional safety of safety-related electrical, electronic and programmable
electronic control systems
EN ISO 12100 Safety of machinery - General principles for design - Risk assessment and risk reduction
IEC 61508 Teil 1-7 Functional safety of electrical/electronic/programmable electronic safety-related systems
IEC 82079-1 Preparation of instructions for use - Structuring, content and presentation - Part 1: General
principles and detailed requirements
UL 61800-5-1 Standard for Adjustable Speed Electrical Power Drive Systems - Part 5-1: Safety Requirements -
Electrical, Thermal and Energy
CSA C22.2 No. 274 Adjustable speed drives

item Controller BL 1-04 /C ― Product manual
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2 For your own safety
2.1 General information
Servo drives of the BL 1-04 /C series can only be used safely if you read and comply with this document.
The servo drive has a safe design. However, certain hazards exist in the context of certain activities. These hazards can be
avoided by following the correct procedures. The correct procedures for avoiding these hazards are described in this docu-
ment.
In addition to the instructions described in this document, there may be additional health and safety instructions as well as
general safety instructions that you must comply with. Keep informed about all of these aspects.
Professional project planning is a prerequisite for the correct and trouble-free operation of the servo drive.
The following requirements must be fullled to ensure the trouble-free and safe operation of the servo drive.
▪ Proper and correct transport
▪ Proper storage
▪ Proper installation
▪ Proper project planning taking in consideration all of the potential risks, necessary protective and emergency measures
and the installation
▪ Careful operation and proper maintenance.
Only trained and qualied personnel in accordance with section 2.3 Target group on page 9 are authorised to work with or on
the electrical systems.The following instructions must be read and understood prior to the initial operation of the system in
order 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 safety instructions in this document concern-
ing the electrical drives and controllers. These safety instructions and all other user notes must be read prior to performing
any work with the servo drive.
▪ If the servo drive is sold, rented out or otherwise distributed to third parties, these safety instructions must be included.
▪ The user must not open the servo drive for safety and warranty reasons.
2.2 Intended use
The electronic drive control unit (servo drive) is intended for operation in combination with electric motors in an industrial
environment. The handling of the servo drive requires qualied personnel that have been trained in terms of general and, in
particular, electrical safety. The intended use also includes compliance with the information and instructions in this manual.
Any use going beyond or deviating from the intended use will be considered as misuse.
WARNING Hazards caused by misuse
Misuse of the servo drive will lead to dangerous situations.
▪ Use the servo drive only under the ambient conditions that are specied in section 8.
▪ Do not use the servo drive outdoors or in explosive atmospheres.
▪ Use suitable and qualied specialist personnel for any type of work on the servo drive.
▪ Always comply with the voltage ranges that are specied in section 8 Technical data on page 33.
▪ Follow all of the instructions in this manual concerning the safe use of the servo drive.

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item Controller BL 1-04 /C ― Product manual
2.3 Target group
Over its entire service life, work on the servo drive, with the exception of its operation, may only be performed by specialist per-
sonnel and/or instructed persons who have been trained for the required tasks. The servo drive is to be operated by the user.
Trained and qualied personnel
Qualied personnel in the sense of this product manual are persons who are su󹟠ciently familiar with the project, set-up,
installation, commissioning and operation of the servo drive as well as with all of the warnings and precautions and who are
su󹟠ciently qualied in their eld of expertise:
▪ They have been trained, instructed and authorised to perform the switching and earthing (grounding) of the devices/sys-
tems in line with the applicable safety standards and to label them accordingly as per the job requirements.
▪ The service and maintenance personnel have undergone special training in the context of ESD protection measures.
▪ They have been trained and instructed in line with the applicable safety standards in terms of the maintenance and use of
adequate safety equipment.
▪ They have completed rst aid training.
2.4 General safety instructions
DANGER Danger to life due to electric shock!
Non-compliance with the safety instructions will lead to a potentially fatal electric shock.
The general set-up and safety rules and regulations concerning the work on power installations (e.g. DIN, VDE, EN, IEC or any
other national or international rules and regulations) must be complied with.
▪ Safety-critical applications of the servo drive are not allowed unless specically approved by the manufacturer.
▪ For information about the EMC-compliant installation, see section 9.1 Notes concerning the safe and EMC-compliant instal-
lation on page 52. The manufacturer of the machine or system is responsible for ensuring compliance with the limits that
are specied by the applicable national rules and regulations.
▪ The ambient conditions that are specied in the product manual must be strictly observed.
▪ The technical data as well as the connection and installation conditions of the servo drive are stated in this document and
must be complied with at all times.
▪ The servo drive has an IP20 protection rating and a pollution degree rating of 2. Ensure that the environment corresponds
to this protection rating and pollution degree rating.
▪ Use only original accessories and original spare parts that have been approved by the manufacturer.
▪ The servo drives must be connected to the mains power supply in accordance with the country-specic regulations (EN
standards, VDE rules) so that they can be disconnected from the mains power supply by way of suitable disconnectors (e.g.
main switches, contactors, circuit breakers).
▪ Use gold contacts or contacts with a high contact pressure for switching the control contacts.
▪ You can protect the servo drive with an AC/DC-sensitive residual-current device (RCD) with 300 mA minimum.
▪ Preventive interference suppression measures should be taken for the switchgear. This can be done, for example, by
connecting RC circuits or diodes to the contactors and relays.
DANGER

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2.5 Personal protective equipment
Always use personal protective equipment during the transport, installation, start-up, cleaning, maintenance and removal of
the servo drive, for example:
▪Protective gloves
To prevent supercial hand injuries.
▪ESD safety shoes
To prevent foot injuries caused by falling parts. To prevent electrostatic charging.
▪Protective work clothes
To prevent supercial injuries and soiling.
▪Protective goggles
To prevent eye injuries caused by dust or shards/splinters.
▪Light respiratory protection
To prevent the inhalation of harmful substances.
2.6 Safety notes for installation and maintenance
DANGER Dangerous electrical voltage!
Prior to performing any maintenance tasks, you need to ensure that the power supply and the external power supply of the
servo drive have been disconnected and secured against reconnection and that the DC bus has discharged.
During the operation of the servo drive and up to 10 minutes thereafter, the corresponding connections and an external brak-
ing resistor carry dangerous DC bus voltages. Contact with these voltages may result in serious or even fatal injuries.
Wait 10 minutes prior to performing 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 resistor may become hot during operation. Always wait a
su󹟠cient amount of time prior to touching these parts.
Always use suitable personal protective equipment to avoid severe burns.
CAUTION Risk of injury for unqualied personnel!
Only personnel who are trained and qualied for working on or with electrical devices are authorised to install, maintain and
repair the servo drive.
To prevent accidents, injuries and damage to property:
Perform a risk assessment and follow all of the statutory and local safety instructions and accident prevention regulations
when installing or maintaining the system.
Ensure that the AC or DC power supplies are switched off and locked prior to performing any work in the area of the machine.
The deactivation of the output stages or servo drive enable signals is not a suitable means of locking. In the case of a malfunc-
tion, the drive may accidentally be put into action. This does not apply to drives with the special "Safe Torque Off" feature in
accordance with EN 61800-5-2.
Electronic devices are never completely fail-safe. It is the user’s responsibility to ensure that the system is brought to a safe
state if the electrical device fails.
DANGER