ITEM C 3-Series User manual

item Industrietechnik GmbH Telephone: [phone]
Friedenstraße 107-109 Fax: [phone]
42699 Solingen E-mail: [e-mail]
Germany http://www.item24.com
Product Manual
item Servo Positioning Controller C 3-Series
designed for Functional Safety

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Translation of the original instructions
Copyrights
© 2016 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 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 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 3-Series“
File name: P-HB_item Steuerung_C3_5p0_EN_bearbeitet.docx
Version 5.0 November 2016

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TABLE OF CONTENTS:
1GENERAL .............................................................................................................15
1.1 Documentation..............................................................................................15
1.2 Scope of supply .............................................................................................16
2SAFETY NOTES FOR ELECTRICAL DRIVES AND CONTROLLERS .......................................17
2.1 Symbols.......................................................................................................17
2.2 General notes................................................................................................18
2.3 Hazards resulting from misuse...........................................................................20
2.4 Safety instructions..........................................................................................21
2.4.1 General safety instructions.................................................................21
2.4.2 Safety notes for assembly and maintenance...........................................23
2.4.3 Protection against contact with electrical parts .......................................25
2.4.4 Protection against electric shock by way of protective extra-low voltage (PELV)26
2.4.5 Protection against dangerous movements .............................................26
2.4.6 Protection against contact with hot parts...............................................27
2.4.7 Protection during the handling and installation of the devices .....................28
3PRODUCT DESCRIPTION..........................................................................................29
3.1 General .......................................................................................................29
3.2 Power supply ................................................................................................32
3.2.1 Three-phase AC power supply ............................................................32
3.2.1.1 Switch-on behaviour:....................................................................................32
3.2.2 DC bus circuit linking, DC supply .........................................................32
3.2.2.1 DC bus circuit linking....................................................................................32
3.2.2.2 DC supply..................................................................................................32
3.2.3 Mains fuse.....................................................................................32
3.3 Brake chopper ..............................................................................................33
3.4 Communication interfaces................................................................................33
3.4.1 Serial interface [X5] .........................................................................33
3.4.2 USB interface [X19] .........................................................................34
3.4.3 UDP interface [X18] .........................................................................34
3.4.4 CAN interface [X4]...........................................................................34

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3.4.5 Technology module: Profibus .............................................................35
3.4.6 Technology module: EtherCAT............................................................35
3.4.7 I/O functions and device control..........................................................35
4TECHNICAL DATA ..................................................................................................36
4.1 General technical data.....................................................................................36
4.2Control elements and display elements................................................................37
4.3 Power supply [X9] ..........................................................................................38
4.4 Motor connector [X6] ......................................................................................39
4.4.1 Current derating..............................................................................40
4.5 Angle encoder connector [X2A] and [X2B] ...........................................................44
4.5.1 Resolver connector [X2A]..................................................................45
4.5.2 Encoder connector [X2B] ..................................................................46
4.6 Communication interfaces................................................................................48
4.6.1 RS232 [X5] ...................................................................................48
4.6.2 USB [X19] .....................................................................................48
4.6.3 Ethernet [X18]................................................................................48
4.6.4 CAN bus [X4] .................................................................................48
4.6.5 SD/MMC card ................................................................................48
4.6.6 I/O interface [X1].............................................................................49
4.6.7 Incremental encoder input [X10].........................................................50
4.6.8 Incremental encoder output [X11] .......................................................51
5FUNCTION OVERVIEW.............................................................................................52
5.1 Motors ........................................................................................................52
5.1.1 Synchronous servomotors .................................................................52
5.1.2 Linear motors.................................................................................52
5.2 Functions of the item Servo Positioning Controller C 3-Series ....................................53
5.2.1 Compatibility ..................................................................................53
5.2.2 Pulse width modulation (PWM) ...........................................................53
5.2.3 Setpoint management ......................................................................54
5.2.4 Torque-controlled mode....................................................................54
5.2.5 Speed-controlled mode.....................................................................55
5.2.6 Torque-limited speed control..............................................................55

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5.2.7 Synchronisation with external clock signals............................................55
5.2.8 Load torque compensation in the case of vertical axes..............................55
5.2.9 Positioning and position control ..........................................................55
5.2.10 Synchronisation, electronic gear unit....................................................56
5.2.11 Brake management .........................................................................56
5.3 Positioning control..........................................................................................57
5.3.1 Overview.......................................................................................57
5.3.2 Relative positioning..........................................................................58
5.3.3 Absolute positioning.........................................................................58
5.3.4 Motion profile generator....................................................................58
5.3.5 Homing.........................................................................................58
5.3.6 Positioning sequences......................................................................59
5.3.7 Optional stop input...........................................................................60
5.3.8 Contouring control with linear interpolation............................................60
5.3.9 Time-synchronised multi-axis positioning ...............................................61
6FUNCTIONAL SAFETY TECHNOLOGY ..........................................................................62
6.1 General .......................................................................................................62
6.1.1 DIP switch .....................................................................................63
6.1.2 Assignment of the DIP switch .............................................................64
6.2 Integrated safety technology (schematic representation)..........................................66
6.3 Module variants .............................................................................................67
6.3.1 FBA module ...................................................................................67
6.3.2 FSM 2.0 – STO (Safe Torque Off) ........................................................68
7MECHANICAL INSTALLATION ...................................................................................69
7.1 Important notes .............................................................................................69
7.2 Device view ..................................................................................................71
7.3 Installation....................................................................................................73
8ELECTRICAL INSTALLATION.....................................................................................74
8.1 Connector configuration ..................................................................................74
8.2 item C 3-Series – complete system.....................................................................75
8.3 Connector: power supply [X9] ...........................................................................77

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8.3.1 Configuration on the device [X9]..........................................................77
8.3.2 Mating connector [X9] ......................................................................77
8.3.3 Pin assignment [X9].........................................................................78
8.3.4 Cable type and configuration [X9]........................................................78
8.3.5 Connection notes [X9] ......................................................................79
8.4 Connector: motor [X6].....................................................................................80
8.4.1 Configuration on the device [X6]..........................................................80
8.4.2 Mating connector [X6] ......................................................................80
8.4.3 Pin assignment [X6].........................................................................80
8.4.4 Cable type and configuration [X6]........................................................81
8.4.5 Connection notes [X6] ......................................................................81
8.5 Connector: I/O communication [X1]....................................................................83
8.5.1 Configuration on the device [X1]..........................................................85
8.5.2 Mating connector [X1] ......................................................................85
8.5.3 Pin assignment [X1].........................................................................86
8.5.4 Cable type and configuration [X1]........................................................87
8.5.5 Connection notes [X1] ......................................................................87
8.6 Connector: resolver [X2A] ................................................................................88
8.6.1 Configuration on the device [X2A]........................................................88
8.6.2 Mating connector [X2A] ....................................................................88
8.6.3 Pin assignment [X2A] .......................................................................88
8.6.4 Cable type and configuration [X2A] ......................................................89
8.6.5 Connection notes [X2A] ....................................................................89
8.7 Connector: encoder [X2B] ................................................................................90
8.7.1 Configuration on the device [X2B]........................................................90
8.7.2 Mating connector [X2B] ....................................................................90
8.7.3 Pin assignment [X2B] .......................................................................91
8.7.4 Cable type and configuration [X2B] ......................................................93
8.7.5 Connection notes [X2B] ....................................................................94
8.8 Connector: incremental encoder input [X10].........................................................96
8.8.1 Configuration on the device [X10]........................................................96
8.8.2 Mating connector [X10] ....................................................................96
8.8.3 Pin assignment [X10] .......................................................................96

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8.8.4 Cable type and configuration [X10] ......................................................97
8.8.5 Connection notes [X10] ....................................................................97
8.9 Connector: incremental encoder output [X11] .......................................................98
8.9.1 Configuration on the device [X11]........................................................98
8.9.2 Mating connector [X11] ....................................................................98
8.9.3 Pin assignment [X11] .......................................................................98
8.9.4 Cable type and configuration [X11] ......................................................99
8.9.5 Connection notes [X11] ....................................................................99
8.10 Connector: CAN bus [X4] ...............................................................................100
8.10.1 Configuration on the device [X4]........................................................100
8.10.2 Mating connector [X4] ....................................................................100
8.10.3 Pin assignment [X4].......................................................................100
8.10.4 Cable type and configuration [X4]......................................................101
8.10.5 Connection notes [X4] ....................................................................101
8.11 Connector: RS232/COM [X5]..........................................................................103
8.11.1 Configuration on the device [X5]........................................................103
8.11.2 Mating connector [X5] ....................................................................103
8.11.3 Pin assignment [X5].......................................................................103
8.11.4 Cable type and configuration [X5]......................................................104
8.11.5 Connection notes [X5] ....................................................................104
8.12 Connector: USB [X19] ...................................................................................105
8.12.1 Configuration on the device [X19]......................................................105
8.12.2 Mating connector [X19] ..................................................................105
8.12.3 USB [X19] ...................................................................................105
8.12.4 Cable type and configuration [X19] ....................................................105
8.13 SD/MMC card .............................................................................................106
8.13.1 Supported card types .....................................................................106
8.13.2 Supported functions.......................................................................106
8.13.3 Supported file systems ...................................................................106
8.13.4 File names...................................................................................106
8.13.5 Pin assignment SD/MMC card..........................................................107
8.13.6 BOOT-DIP switch...........................................................................108
8.14 Notes concerning the safe and EMC-compliant installation......................................109

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8.14.1 Definitions and terms .....................................................................109
8.14.2 General information on EMC.............................................................109
8.14.3 EMC areas: first and second environment............................................109
8.14.4 EMC-compliant cabling ...................................................................110
8.14.5 Operation with long motor cables ......................................................111
8.14.6 ESD protection .............................................................................112
9ADDITIONAL REQUIREMENTS TO BE FULFILLED BY THE SERVO POSITIONING CONTROLLERS
FOR UL APPROVAL...............................................................................................113
9.1 Mains fuse..................................................................................................113
9.2 Wiring requirements and environmental conditions...............................................113
9.3 Motor temperature sensor..............................................................................113
10 START-UP...........................................................................................................114
10.1 General connection notes...............................................................................114
10.2 Tools/material.............................................................................................114
10.3 Connecting the motor....................................................................................114
10.4 Connecting the item Servo Positioning Controller C 3-Series to the power supply .........115
10.5 Connecting the PC (serial interface) ..................................................................115
10.6 Connecting the PC (USB interface, alternative).....................................................115
10.7 Operability check .........................................................................................115
11 SERVICE FUNCTIONS AND ERROR MESSAGES...........................................................116
11.1 Protection and service functions ......................................................................116
11.1.1 Overview .....................................................................................116
11.1.2 Phase and mains power failure detection.............................................116
11.1.3 Overcurrent and short-circuit monitoring .............................................117
11.1.4 Overvoltage monitoring of the DC bus circuit ........................................117
11.1.5 Temperature monitoring of the heat sink .............................................117
11.1.6 Monitoring of the motor ..................................................................117
11.1.7 I²t monitoring ...............................................................................117
11.1.8 Power monitoring of the brake chopper ..............................................118
11.1.9 Start-up status ..............................................................................118
11.1.10 Rapid discharge of the DC bus circuit .................................................118

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11.1.11 Operating hours counter .................................................................118
11.2 Operating mode and error messages ................................................................119
11.2.1 Operating mode and error indication ..................................................119
11.2.2 Error messages ............................................................................120
12 TECHNOLOGY MODULES.......................................................................................153
12.1 PROFIBUS-DP interface .................................................................................153
12.1.1 Product description........................................................................153
12.1.2 Technical data..............................................................................153
12.1.3 Pin assignment and cable specifications..............................................155
12.1.3.1 Pin assignment .........................................................................................155
12.1.3.2 Mating connector ......................................................................................155
12.1.3.3 Cable type and configuration........................................................................155
12.1.4 Termination and bus terminating resistors ...........................................156
12.2 EtherCAT ...................................................................................................157
12.2.1 Product description........................................................................157
12.2.2 Characteristics of the EtherCAT technology module ...............................157
12.2.3 Technical data..............................................................................158
12.2.4 Display elements...........................................................................158
12.2.5 EtherCAT interface ........................................................................159
12.3 General installation notes for technology modules ................................................160