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
4
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

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item Controller BL 1-04 /C ― Product manual
Disconnect the electric equipment from the power supply via the main switch and secure it against reconnection. Wait until the
DC bus has discharged in the following cases:
▪ maintenance and repairs
▪ cleaning
▪ long downtimes
The standard motor holding brake that is included in the scope of supply or any other external motor holding brake that is
actuated by the servo drive is not suitable for the protection of the operators if used alone!
Be particularly careful during the installation process. During the installation and also later on during the operation of the
drive, ensure that no drilling chips, metal dust or installation parts (screws, nuts, cable sections) can fall into the servo drive.
Use suitable personal protective equipment during the installation.
Vertical axes must be additionally secured against falling down or lowering after the motor has been switched off, for example
by way of the following:
▪ mechanical locking of the vertical axis,
▪ external braking, catching or clamping devices, or
▪ su󹟠cient weight counterbalance of the axis
Perform the start-up process with idling motors. This is to avoid mechanical damage, e.g. due to an incorrect direction of
rotation.
2.7 Protection against contact with electrical parts
DANGER Dangerous electrical voltage!
In certain device constellations, the rapid discharge of the DC bus voltage of the servo drive may be rendered ineffective.
In these cases, the servo drives may still carry dangerous voltage levels up to 10 minutes 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 accidents, injuries and damage to property:
Follow the national accident prevention regulations (for Germany, this is DGUV regulation 3 (formerly BGV A3)).
Do not touch the electrical connections of the components when they are switched on.
Prior to accessing electrical parts carrying voltages above 50 V, disconnect the device from the mains power supply or voltage
source. Secure it against reconnection.
Install the respective covers and guards against accidental contact prior to switching the device/system on. Rack-mounted
devices must be protected against accidental contact by way of an enclosure, e.g. a switch cabinet.
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 (see section 9 Electrical installation on page 52) in a xed
manner (hardwiring) to the supply network or to the earthing system on site.
Comply with the minimum copper cross-section for the protective earth conductor (ground conductor) over its entire length
(see EN 61800-5-1). Otherwise, the housing may carry high voltages which can cause electric shock.
Due to the integrated line lters, the leakage current exceeds 3.5 mA. This is why two connection points must be hard-wired
The magnitude of the DC bus voltage must be taken into consideration during the installation process in order to ensure prop-
er insulation and protection. Ensure proper earthing (grounding), conductor rating and protection against short circuits.

item Controller BL 1-04 /C ― Product manual
12
2.8 Protection against electric shock by way of protective extra-low voltage (PELV)
DANGER Dangerous electrical voltage!
There is a risk of high electrical voltage due to incorrect electrical connections. Always follow the safety instructions stated
hereinbelow.
All of the connections and terminals with voltages up to 50 V of the servo drive have protective extra-low voltage. They are
protected against contact in accordance with IEC 61800-5-1 and EN 61800-5-1.
Only devices, electrical components and wires or cables with protective extra-low voltage (PELV) may be connected to connec-
tors and terminals with voltages from 0 to 50 V.
When connecting voltages and circuits, ensure that they are securely isolated from any dangerous voltages. This isolation can
be realised by way of isolation transformers, safe optocouplers or battery operation without mains power.
2.9 Protection against dangerous movements
WARNING Risk of injury due to dangerous movements
Always follow the safety instructions stated hereinbelow.
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 the superordinate control system.
These errors can occur directly after the activation of the device or after some time during the operation.
The monitoring systems in the drive components exclude any malfunction in the connected drives to the greatest possible
extent. However, in view of the protection of the operators, particularly in terms of the risk of injuries and damage to prop-
erty, relying solely on this measure is not recommended. Until the built-in monitoring systems become effective, faulty drive
movements should always be anticipated. The extent of these faulty drive movements depends on the type of control and on
the operating state.
For the reasons mentioned above, protection must be ensured by monitoring or by superordinate measures. This must be
implemented by the system manufacturer based on the specic system situation and on a hazard and fault analysis. This also
includes the safety rules and regulations that apply to the system. Random movements of the machine or other malfunctions
may be caused by deactivating, bypassing or failing to activate the safety devices.
2.10 Protection against contact with hot parts
WARNUNG 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.
DANGER

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item Controller BL 1-04 /C ― Product manual
2.11 Protection during the handling and installation of the devices
CAUTION Risk of injury caused by crushing, shearing, cutting or impacts
Improper handling and installation of certain parts will cause injuries. Always follow the safety instructions stated hereinbelow.
▪ When installing the servo drive, ensure that it can be installed, operated and removed without any danger.
▪ Appropriate installation clearances must also be dened.
▪ Comply with the intended use of the servo drive.
▪ When transporting the servo drive, pay particular attention to the edges and corners of housings and other components.
Use suitable personal protective equipment.
▪ If you install the components of the system on a wall or on the oor, dust may be created by drilling. Use suitable personal
protective equipment.
▪ Use only suitable installation and transport equipment.
▪ Prevent trapping and crushing by suitable protective measures.
▪ Use only suitable tools. If specied, use special tools.
▪ Use lifting equipment and tools in a proper manner.
▪ Do not step under suspended loads.
▪ Liquid spills on the oor must be removed immediately.
3 Product description
The servo drives of the smartServo BL 4000-C series are smart AC servo drives for controlling three-phase synchronous mo-
tors, torque motors and linear motors. The servo drives can be used in a universal manner, since they can be combined with a
wide range of encoder systems and motors. Due to their extensive parameterisation options, they can be adapted to a variety
of different applications. Servo drives of the BL 4000-C series are intended for use as devices installed in control cabinets.
The connection to a superordinate control system can be realised by way of the integrated EtherCAT/Pronet or CAN inter-
face.
Parameter sets that have been created for the Servo Positioning Controller C-Series series can be used for the BL 1-04 /C and
vice versa.
3.1 Type designation
Type key using the example of a BL 4104-C.
1 Type designation: Basic Line
2 Power line connection: single-phase
3 Nominal current in [A eff]
4 Cabinet (control cabinet device)
Figure 1: Nomenclature
BL
1
04
3
C
4
1
2
/-

item Controller BL 1-04 /C ― Product manual
14
3.2 Device view
Front view
1 Product name
2 Earthing screw
3 Status indicator LED (READY, ERROR, ENABLE)
4 Seven-segment status indicator
5 [X3] STO interface (STOA, STOB), Limit switch (DIN6, DIN7),
Dig. output (DOUT0)
6 [X19] USB interface
7 [X18] 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: Front view of a BL 1-04 /C
Top view / Bottom view
14 [X9] Power supply
15 [X6] Motor connection
16 [X2B] Multi-encoder
17 [X2A] Resolver/ analogue Hall sensors
18 Slot for microSD cards
19 [X1] I/O communication
19
14
18
17
16
15
Figure 3: Top view (left) / Bottom view (right) of a BL 1-04 /C

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item Controller BL 1-04 /C ― Product manual
3.3 Features
All of the servo drives of this series have the following features
Integrated eldbus interfaces
▪ CANopen interface for the integration in automation systems
▪ EtherCAT interface (CoE)
▪ ProNet interface (Item standard telegrams, based on PROFIdrive)
Integrated universal shaft encoder evaluation for the following encoder types:
▪ Resolvers
▪ Analogue and digital incremental encoders with and without commutation signals
▪ High-resolution Stegmann incremental encoders with HIPERFACE®
▪ High-resolution Sick incremental encoders with HIPERFACE DSL (single-cable variant)
▪ High-resolution Heidenhain incremental encoders with EnDat 2.2 (ENDAT22)
▪ Master frequency input/output and pulse direction interface
Suitable motors
▪ Permanent-magnet synchronous machines with sinusoidal EMF
▪ Torque motors
▪ Linear motors
▪ Air-core and iron-core linear motors with a low motor inductance (0.5 … 4 mH)
▪ Automatic determination of the motor parameters
User-friendly parameterisation with the item MotionSoft®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 well as o󹟡ine parameterisation are possible
▪ Oscilloscope function for optimising the drive and for analysing the PLC I/O coupling
▪ Supported languages: German, English, French, Spanish, Italian, Polish
▪ Automatic motor identication and procedures for the automatic determination of the commutation position in the case of
encoders without a commutation track
▪ Automatic adjustment of the control circuits for current, speed and position control
Integrierte Funktionale Sicherheit
▪ "Safe Torque Off (STO)" safety function integrated in the device
▪ SS1 functionality possible
Homing and positioning
▪ Integrated positioning control with a wide range of functions as per "CAN in Automation (CiA) DSP402" plus numerous
additional application-specic functions.
▪ Jerk-free or time-optimal positioning, relative or absolute with regard to a reference point. Point-to-point positioning with
and without smooth position transitions.
▪ High-speed sample inputs for triggering the storage of position marks
▪ Numerous homing methods
▪ Rotor and position triggers

item Controller BL 1-04 /C ― Product manual
16
Brake control and automatic brake
▪ Direct control of a holding brake in the motor with high current. As a result, an external relay is not necessary. In addition,
variable delays can be used.
▪ "Automatic brake" for deactivating the power section during longer breaks to save energy
Electrical characteristics
▪ Wide-range supply input (AC)
▪ "Soft switch-on" features for the soft precharging and quick charging of the DC bus
▪ DC bus coupling between devices with the same mains power supply for buffering the brake energy
▪ Improved monitoring and analysis of the mains power supply by a direct measurement of the mains voltage
Applications
▪ Speed- and angle-synchronous operation with an electronic gear unit via the incremental encoder input or eldbus. Exten-
sive modes of operation for synchronisation, e.g. "ying saw"
▪ Jog mode, teach-in mode, motion programs, torque-limited set control and much more
Special control features
▪ High control quality due to high-quality sensors, far superior to conventional market standards, and above-average proces-
sor resources
▪ Short cycle times, bandwidth in the current control circuit approx. 2 kHz (with ti= 32 µs), in the speed control circuit approx.
500 Hz (with tn= 64 µs)
▪ Parameterisable band-stop lters for suppressing the natural frequency of the controlled system
▪ Load torque compensation for vertical axes
▪ Synchronisable internal clock system for the synchronisation with external clock sources for CANopen and EtherCAT
eldbus systems by way of an internal PLL
Certication and qualication
▪ Compliance with the current CE and EN standards without any additional external measures
▪ UL certication
▪ Completely closed, EMC-optimised housing for mounting on conventional switch cabinet mounting plates. The devices
have an IP20 degree of protection.
▪ Integration of all of the required lters, e.g. line lters, lters for the 24 V supply and lters for the inputs and outputs, into
the device in order to ensure compliance with the EMC regulations during operation (industrial environment)
4 STO (safe torque off)
The purpose of this chapter is to ensure the safe use of the STO (safe torque off) safety function that is integrated
in the servo drive.
This documentation refers to the following versions:
▪ Controller BL 1-04 /C with the STO function, revision 1.0 or higher
▪ item MotionSoft parameterisation program version 3.0 or higher.

17
item Controller BL 1-04 /C ― Product manual
4.1 Special safety instructions
DANGER Dangerous electrical voltage!
Always follow the safety instructions for electric drives and control systems in section 2. For your own safety on page 8.
WARNING Hazards due to the loss of the safety function
If you do not comply with the specied ambient and connection conditions, the safety function will be lost. This may lead to
injuries in the worst case.
Always comply with the specied ambient and connection conditions. This applies particularly to the input voltage tolerances.
See section 8.11 STO [X3] on page 47.
4.2 Certication/safety level
A servo drive of the BL 1-04 /C series with an integrated safety function is a safety device in accordance with the EC Machin-
ery Directive 2006/42/EC and it bears the CE mark.
Information about the product-relevant EC Directives can be found in the declaration of conformity in section 11.2 CE conform-
ity (Machinery Directive) on page 74.
The achievable safety level depends on the other components that are used to implement a safety function. This has been
certied by an independent testing authority.
4.3 Requirements for using the product
Make this documentation available to the design engineer, installation technician and personnel responsible for commission-
ing the machine or system in which this product is used.
Ensure that the specications of the documentation are always complied with. Also take into account the documentation for
the other components (e.g. safety relays, cables, etc.).
Take into consideration the legal regulations applicable at the installation site as well as:
▪ regulations and standards
▪ regulations of the testing organisations and insurers
▪ national specications
▪ all of the safety instructions in section 2 For your own safety on page 8
▪ the special safety instructions in section 4.1 Special safety instructions on page 17
For emergency stop applications, protection against automatic restarting must be provided in accordance with the required
safety category. This can be realised, for example, by way of an external safety relay.

item Controller BL 1-04 /C ― Product manual
18
4.3.1 Qualication of the specialist personnel (personnel requirements)
The device may only be set into operation by a qualied electrical technician who is familiar with:
▪ the installation and operation of electrical control systems
▪ the applicable regulations for operating safety-oriented systems
▪ the applicable regulations for accident protection and industrial safety
▪ the documentation for the product.
4.3.2 Diagnostic coverage (DC)
The diagnostic coverage depends on the integration of the safety functions, which are integrated in the servo drive, into the
overall system and on the implemented diagnostic measures.
If a malfunction is detected during the diagnosis process, appropriate measures must be taken to maintain the safety level.
INFO Cross-circuit detection
Check whether your application requires a cross-circuit detection of the input circuit and of the connecting wiring.
If necessary, use a safety relay with cross-circuit detection for actuating the safety function
4.4 Purpose
As processes become 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 electronic devices for
the reduction or elimination of hazards caused by malfunctions. Under normal operating conditions, protective devices and
guards prevent human access to danger areas. However, in certain operating modes, e.g. during set-up, persons are required
to be present in these danger areas. In these situations, the machine operator must be protected by way of drive- and con-
trol-system-related measures.
The integrated functional safety technology provides the control-system- and drive- specic conditions for the optimal realisa-
tion of protective functions. As a result, planning and installation become less labour-intensive. The use of integrated functional
safety technology leads to an enhanced machine functionality and availability compared to the levels achieved by conventional
safety technology.
4.5 Principle of operation and use
The STO function includes the feature "Realisation of the "Safe Torque Off" (STO) function".
The "Safe Stop 1" (SS1) function can be realised with a suitable external safety relay and by suitable wiring of the servo drive.

19
item Controller BL 1-04 /C ― Product manual
4.5.1 Description of the STO safety function
Use the "Safe Torque Off" (STO) function if you need to disconnect the motor safely from the energy supply for your applica-
tion. The "Safe Torque Off" function switches off the driver supply for the power semiconductors. This prevents the power
output stage from providing the voltage that is required by the motor. As a result, the motor cannot start unexpectedly. See the
following illustration.
DC
DC
DC
DC
ZK+
ZK-
U / V / W
STOA
STOB
GNDA
GNDB
+5V_OS
+5V_US
Figure 4: "Safe Torque Off" - principle of operation
When the "Safe Torque Off" (STO) function is active, the energy 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 must be taken in order to prevent the load from sagging (e.g. mechanical holding brakes). In the "Safe Torque
Off" (STO) state, the standstill position will not be monitored.
NOTICE Risk of a jerky movement of the drive in the case of multiple errors
If the output stage of the servo drive fails while in the STO state (simultaneous short circuit of 2 power semiconductors in dif-
ferent phases), a limited dwell movement of the rotor may result. The angle of rotation/distance corresponds to one pole pitch.
Examples:
▪ Rotary axis, synchronous machine, 8 poles
→ movement < 45° of the motor shaft.
▪ Linear motor, pole pitch 20 mm
→ movement < 20 mm of the moved part.

item Controller BL 1-04 /C ― Product manual
20
4.5.2 Overview of the [X3] interface
Figure 5: Position of connector X3
At its front, the servo drive has an 8-pin connector [X3] for
▪ the STO control inputs,
▪ the digital output DOUT0, and
▪ the digital inputs DIN 6 and DIN
The STO safety function is requested exclusively via the two digital control inputs STOA and STOB. The safety-oriented integra-
tion of additional interfaces is not necessary/intended.
The servo drive does not monitor the input circuit for cross-circuit faults.
The [X3] interface enables the direct connection of active and passive sensors as DOUT0/GND provide a short-circuit-proof 24
V supply voltage (see section 9.12 Connector: STO [X3] on page 70).
4.5.3 Control inputs STOA, GNDA/STOB, GNDB [X3]
The control inputs STOA and STOB are used for requesting the STO safety function ("Safe Torque Off") via two channels. They
enable the direct connection of 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. positively driven position
switches). See, for example, section 9.12 Connector: STO [X3] on page 70.
To request the STO safety function ("Safe Torque Off"), the 24 V control voltage is switched off at both control inputs STOA and
STOB (0 V). If both control inputs are switched off simultaneously or within a predened discrepancy time, the STO function
becomes active.
The table in section 8.11.1 Electrical data of the STO function on page 47 includes the technical data of the control inputs for
the specied operating range of logic voltages.
Certain tolerance ranges have been dened for the input voltage range of the control inputs STOA and STOB. The amount of
energy that is stored in the components of the STO circuit (e.g. capacitors) depends on this input voltage. During switching
processes, this energy must be charged or discharged. This results in specic values for the switch-off time for the transition