ITEM C 1-Series User manual

item Industrietechnik GmbH Phone: [phone]
Friedenstraße 107-109 Telefax: [phone]
42699 Solingen E-mail: [e-mail]
Germany http://www.item24.com
Product Manual
item Servo Positioning Controller C 1-Series
designed for Functional Safety

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Translation of the original instructions
Copyrights
© 2018 item Industrietechnik GmbH. 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 deficiencies 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 damages resulting from the combined use of its products
with other products or resulting from improper handling of machines or systems.
item Industrietechnik GmbH reserves the right to modify, amend, or improve the document or the product without prior
notification.
This document may, neither entirely nor in part, be reproduced, translated into any other natural or machine-readable
language nor transferred to electronic, mechanical, optical or any other kind of data media, without expressive authorisation by
the author.
Trademarks
Any product names in this document may be registered trademarks. The sole purpose of any trademarks in this document is
the identification of the corresponding products.
item Motion Soft® is a registered trademark of item Industrietechnik GmbH.

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Revision Information
Author: item Industrietechnik GmbH
Manual title: Product Manual „item Servo Positioning Controller C 1-Series“
File name: DOK_BEDA_Steuerung-C1-Serie_#SEN_#AQU_#V1.docx
Version 5.0 July 2018

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TABLE OF CONTENTS:
1GENERAL .............................................................................................................14
1.1 Documentation..............................................................................................14
1.2 Scope of supply .............................................................................................15
2SAFETY NOTES FOR ELECTRICAL DRIVES AND CONTROLLERS .......................................16
2.1 Used symbols................................................................................................16
2.2 General notes................................................................................................17
2.3 Danger resulting from misuse............................................................................19
2.4 Safety notes..................................................................................................20
2.4.1 General safety notes ........................................................................20
2.4.2 Safety notes for assembly and maintenance...........................................22
2.4.3 Protection against contact with electrical parts .......................................24
2.4.4 Protection against electrical shock by means of protective extra-low voltage
(PELV) ..........................................................................................24
2.4.5 Protection against dangerous movements .............................................25
2.4.6 Protection against contact with hot parts...............................................26
2.4.7 Protection during handling and assembly ..............................................27
3PRODUCT DESCRIPTION..........................................................................................28
3.1 General .......................................................................................................28
3.2 Power supply ................................................................................................31
3.2.1 Single-phase AC supply with active PFC ................................................31
3.2.1.1 Behaviour during switch-on............................................................................31
3.2.1.2 Behaviour during normal operation and control characteristics ..............................32
3.2.2 DC bus coupling, DC supply ...............................................................33
3.2.2.1 DC bus coupling..........................................................................................33
3.2.2.2 DC supply..................................................................................................33
3.2.3 Mains fuse.....................................................................................33
3.3 Brake chopper ..............................................................................................34
3.4 Communication interfaces................................................................................34
3.4.1 Serial interface [X5] .........................................................................35
3.4.2 USB interface [X19] .........................................................................35
3.4.3 UDP interface [X18] .........................................................................35

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3.4.4 CAN interface [X4]...........................................................................35
3.4.5 Technology module: PROFIBUS ..........................................................36
3.4.6 Technology module: EtherCAT............................................................36
3.4.7 I/O functions and device control..........................................................36
4TECHNICAL DATA ..................................................................................................37
4.1 General Technical data....................................................................................37
4.2 Operating and display elements.........................................................................39
4.3 Supply [X9]...................................................................................................40
4.4 Motor connection [X6].....................................................................................42
4.4.1 Current derating..............................................................................42
4.5 Motor feedback connection [X2A] ......................................................................47
4.5.1 Resolver connection [X2A].................................................................48
4.5.2 Encoder connection [X2B] .................................................................48
4.6 Communication interfaces................................................................................51
4.6.1 RS232 [X5] ...................................................................................51
4.6.2 USB [X19] .....................................................................................51
4.6.3 Ethernet [X18]................................................................................51
4.6.4 CAN bus [X4] .................................................................................51
4.6.5 SD/MMC card ................................................................................52
4.6.6 I/O interface [X1].............................................................................52
4.6.7 Incremental encoder input [X10].........................................................53
4.6.8 Incremental encoder output [X11] .......................................................54
5FUNCTION OVERVIEW.............................................................................................55
5.1 Motors ........................................................................................................55
5.1.1 Synchronous servo motors ................................................................55
5.1.2 Linear motors.................................................................................55
5.2 Functions of the item servo positioning controller C 1-Series.....................................56
5.2.1 Compatibility ..................................................................................56
5.2.2 Pulse width modulation (PWM) ...........................................................57
5.2.3 Setpoint management ......................................................................57
5.2.4 Torque-controlled mode....................................................................58
5.2.5 Speed-controlled mode.....................................................................58

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5.2.6 Torque-limited speed control..............................................................58
5.2.7 Synchronization to the external clock signal ...........................................58
5.2.8 Load torque compensation for vertical axes ...........................................59
5.2.9 Positioning and position control ..........................................................59
5.2.10 Synchronisation, electronic gearing .....................................................59
5.2.11 Brake management .........................................................................59
5.3 Positioning control..........................................................................................60
5.3.1 Overview.......................................................................................60
5.3.2 Relative positioning..........................................................................61
5.3.3 Absolute positioning.........................................................................61
5.3.4 Driving profile generator....................................................................61
5.3.5 Homing.........................................................................................62
5.3.6 Positioning sequences......................................................................63
5.3.7 Optional stop input...........................................................................63
5.3.8 Contouring control with linear interpolation............................................63
5.3.9 Time-synchronized multi-axis positioning ...............................................64
6FUNCTIONAL SAFETY TECHNOLOGY ..........................................................................65
6.1 General .......................................................................................................65
6.1.1 DIP switch .....................................................................................66
6.1.2 Assignment of the DIP switch .............................................................67
6.2 Integrated safety technology (schematic representation)..........................................69
6.3 Module variants .............................................................................................70
6.3.1 FBA module ...................................................................................70
6.3.2 FSM 2.0 – STO (Safe Torque Off) ........................................................71
7MECHANICAL INSTALLATION ...................................................................................72
7.1 Important notes .............................................................................................72
7.2 View of the device ..........................................................................................74
7.3 Mounting .....................................................................................................76
8ELECTRICAL INSTALLATION.....................................................................................77
8.1 Connector configuration ..................................................................................77
8.2 item C 1-Series complete system .......................................................................78

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8.3 Connection: Power supply [X9]..........................................................................80
8.3.1 Device side [X9]..............................................................................80
8.3.2 Counterplug [X9].............................................................................80
8.3.3 Pin assignment [X9].........................................................................81
8.3.4 Cable type and design [X9] ................................................................81
8.3.5 Connection notes [X9] ......................................................................82
8.4 Connection: Motor [X6]....................................................................................83
8.4.1 Device side [X6]..............................................................................83
8.4.2 Counterplug [X6].............................................................................83
8.4.3 Pin assignment [X6].........................................................................84
8.4.4 Cable type and design [X6] ................................................................84
8.4.5 Connection notes [X6] ......................................................................85
8.5 Connection: I/O communication [X1]...................................................................87
8.5.1 Device side [X1]..............................................................................89
8.5.2 Counterplug [X1].............................................................................89
8.5.3 Pin assignment [X1].........................................................................90
8.5.4 Cable type and design [X1] ................................................................91
8.5.5 Connection notes [X1] ......................................................................91
8.6 Connection: Resolver [X2A] ..............................................................................92
8.6.1 Device side [X2A] ............................................................................92
8.6.2 Counterplug [X2A]...........................................................................92
8.6.3 Pin assignment [X2A] .......................................................................92
8.6.4 Cable type and design [X2A] ..............................................................93
8.6.5 Connection notes [X2A] ....................................................................93
8.7 Connection: CAN-Bus [X4]................................................................................94
8.7.1 Device side [X4]..............................................................................94
8.7.2 Counterplug [X4].............................................................................94
8.7.3 Pin assignment [X4].........................................................................94
8.7.4 Cable type and design [X4] ................................................................95
8.7.5 Connection notes [X4] ......................................................................95
8.8 Connection: RS232/COM [X5] ..........................................................................97
8.8.1 Device side [X5]..............................................................................97
8.8.2 Counterplug [X5].............................................................................97

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8.8.3 Pin assignment [X5].........................................................................97
8.8.4 Cable type and design [X5] ................................................................98
8.8.5 Connection notes [X5] ......................................................................98
8.9 Connection: USB [X19]....................................................................................99
8.9.1 Device side [X19] ............................................................................99
8.9.2 Counterplug [X19]...........................................................................99
8.9.3 Pin assignment [X19] .......................................................................99
8.9.4 Cable type and design [X19] ..............................................................99
8.10 SD/MMC card .............................................................................................100
8.10.1 Supported card types .....................................................................100
8.10.2 Supported functions.......................................................................100
8.10.3 Supported file systems ...................................................................100
8.10.4 File names...................................................................................100
8.10.5 Pin assignment SD/MMC card..........................................................101
8.10.6 BOOT-DIP-Switch...........................................................................102
8.11 Notes on safe and EMC-compliant installation .....................................................103
8.11.1 Definitions and terms .....................................................................103
8.11.2 General information on EMC.............................................................103
8.11.3 EMC areas: first and second environment............................................104
8.11.4 EMC-compliant cabling ...................................................................104
8.11.5 Operation with long motor cables ......................................................105
8.11.6 ESD protection .............................................................................106
9ADDITIONAL REQUIREMENTS FOR THE SERVO DRIVES CONCERNING THE UL APPROVAL...107
9.1 Circuit protection .........................................................................................107
9.2 Wiring and environment regards ......................................................................107
9.3 Motor temperature sensor..............................................................................107
10 INITIAL OPERATION..............................................................................................108
10.1 General notes on connection...........................................................................108
10.2 Tools / material ...........................................................................................108
10.3 Connecting the motor....................................................................................108
10.4 Connecting the item servo positioning controller C 1-Series to the power supply ..........109

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10.5 Connecting the PC (serial interface) ..................................................................109
10.6 Connecting the PC (USB interface, alternative) ....................................................109
10.7 Checking operability .....................................................................................109
11 SERVICE FUNCTIONS AND ERROR MESSAGES...........................................................110
11.1 Protection and service functions ......................................................................110
11.1.1 Overview .....................................................................................110
11.1.2 Overcurrent and short-circuit monitoring .............................................110
11.1.3 Overvoltage monitoring for the DC bus................................................111
11.1.4 Temperature monitoring of the heat sink .............................................111
11.1.5 Monitoring of the motor ..................................................................111
11.1.6 I²t monitoring ...............................................................................111
11.1.7 Power monitoring for the brake chopper .............................................112
11.1.8 I²t monitoring for the PFC stage ........................................................112
11.1.9 Initial operation status ....................................................................112
11.1.10 Rapid discharge of the DC bus..........................................................112
11.1.11 Operating hours counter .................................................................112
11.2 Display of operating mode and error messages ...................................................113
11.2.1 Operating mode and error display......................................................113
11.2.2 Error messages ............................................................................114
12 TECHNOLOGY MODULES.......................................................................................147
12.1 PROFIBUS-DP interface .................................................................................147
12.1.1 Product description........................................................................147
12.1.2 Technical data..............................................................................147
12.1.3 Pin assignments and cable specifications ............................................149
12.1.3.1 Pin assignment .........................................................................................149
12.1.3.2 Counterplug .............................................................................................149
12.1.3.3 Cable type and configuration........................................................................149
12.1.4 Termination and bus terminating resistors ...........................................150
12.2 EtherCAT ...................................................................................................151
12.2.1 Product description........................................................................151
12.2.2 Characteristics of the EtherCAT technology module ...............................151
12.2.3 Technical data..............................................................................152

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12.2.4 Display elements...........................................................................152
12.2.5 EtherCAT interface ........................................................................153
12.3 General installation notes for technology modules................................................154