Kollmorgen Ksm55 User manual

Installation Manual

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Installation Manual

KSM55

EtherCAT

Installation Manual

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Installation manual for extension module KSM 55.

Note: The German version is the original version of the installation manual.

Status: 06/2013

Subject to change without prior notification

The contents of this documentation has been collated with greatest care and corresponds with our

present status of information. However, we would like to point out, that this document cannot always

be updated at the same time as the further development of the product. Information and specifications

can be changed at any time. Please keep yourself informed about the current version under

www.kollmorgen.com .

Devices of the

Kollmorgen Europe GmbH

Pempelfurtstraße 1

DE-40880 Ratingen

Installation Manual

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Contents

1IMPORTANT NOTES .......................................................................................... 4

1.1 Definitions ........................................................................................................................................... 4

1.2 Co-valid Documents............................................................................................................................. 4

1.3 Abbreviations Used ............................................................................................................................. 5

2SAFETY REGULATIONS.................................................................................... 6

2.1 Intended Use ....................................................................................................................................... 6

2.2 General Safety Regulations.................................................................................................................. 6

2.3 Operation and Service ......................................................................................................................... 7

2.4 Transport and Storage ......................................................................................................................... 7

2.5 Scope of Delivery ................................................................................................................................. 7

3DEVICE DESCRIPTION AND OPERATION ....................................................... 8

3.1 Characteristic Data .............................................................................................................................. 8

3.2 Device Settings .................................................................................................................................... 8

4SAFETY RELATED CHARACTERISTICS.......................................................... 9

5CONNECTION AND INSTALLAATION .............................................................. 9

5.1 General Notes on Installation ............................................................................................................ 10

5.2 Installation KSM-Module ................................................................................................................... 11

5.3 Assembly on Backplane Bus............................................................................................................... 11

5.4 Terminal Assignment ......................................................................................................................... 11

6START UP......................................................................................................... 12

6.1 Procedure .......................................................................................................................................... 12

6.2 Parameterization ............................................................................................................................... 12

6.2.1 Installation ESI-File............................................................................................................ 12

6.2.2 Settings SafePLC .............................................................................................................. 13

6.2.3 Integration KSM55 into TwinCAT ...................................................................................... 14

6.3 Diagnostic-LED................................................................................................................................... 21

6.4 Modification / Handling Changes to the Device ................................................................................. 21

7MAINTENANCE ................................................................................................ 22

7.1 Exchanging a Module......................................................................................................................... 22

8TECHNICAL DATA ........................................................................................... 22

8.1 Enviromental Conditions ................................................................................................................... 22

Installation Manual

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1 Important Notes

Definition of individual target groups

Project engineers for safe drive systems:

Engineers and technicians

Assembly, electric installation, maintenance and replacement of devices:

Maintenance electricians and service technicians

Commissioning, operation and configuration:

Technicians and engineers

1.1 Definitions

The designation KSM is used as generic term for all derivatives from the KSM product range.

Wherever this description refers to a certain derivative, the complete designation is used.

KSM55 is the short form of the communication device EtherCAT KSM55.

The term "safe" used in the following text in any case refers to the classification as a safe

function for application up to Pl e acc. to EN ISO 13849-1 or SIL3 acc. to EN 61508.

The system software "SafePLC" serves the purpose of configuring and programming KSM

modules.

1.2 Co-valid Documents

Description

Reference

General information about KSM

devices and their usage.

KSM Installation manual

KSM Programming manual

Description CAN data format.

TD-37350-810-51-xxF-EN Status

message data

Table 1: co-valid documents

Note:

Thoroughly read the manuals before you start the installation and the commissioning

of the KSM module.

Paying attention to the documentation is a prerequisite for trouble-free operation and

fulfillment of possible warranty claims.

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1.3 Abbreviations Used

Abbreviation

Meaning

Alternating voltage

Instruction list

ELIA

Employer's liability insurance association

CLK

Clock (cycle)

CPU

Central Processing Unit

Direct voltage

DI1..DI14

Digital Input

DIN

Deutsches Institut für Normung (German Institute for Standardization)

Digital Output

EMU

Emergency Monitoring Unit

EMC

Electromagnetic compatibility

ELC

Emergency Limit Control

European Standard

HISIDE

Output with 24VDC nominal level switching to plus

IP20

Degree of protection for housing

ISO

International Organisation for Standardisation

LED

Light Emitting Diode

LOSIDE

Output switching to reference potential

OLC

Operational Limit Control

PIA

Process image of outputs

PII

Process image of inputs

PESSRAL

Programmable electronic system in safety related applications for

elevators

P1,P2

Pulse outputs

PLC

Programmable Logic Controller

POR

Power on Reset

PSC

Position Supervision Control

SELV

Safety Extra Low Voltage

SSI

Synchronous Serial Interface

VDE

Verband der Elektrotechnik, Elektronik und Informationstechnik e. V.

(association for el. engineering, electronics and information technology)

Table 2: Abbreviations

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2 Safety Regulations

2.1 Intended Use

The communication device EtherCAT KSM55 is an extension for the devices of the

KSM11/12 series for non safe data exchange over EtherCAT protocol.

2.2 General Safety Regulations

Safety Note:

In order to avoid damage to persons and property only qualified personnel is entitled to

work on the device. The term qualified personnel refers to persons who have successfully

completed electro technical training and are fully familiar with the applicable rules and

standards of electrical engineering.

The qualified person must become familiar with the operating instructions (see IEC364,

DIN VDE0100).

The qualified must have profound knowledge of the national accident prevention

regulations

The use of the device must be strictly limited to the intended use as specified in the

following list. The values of data listed under section "3.2 Characteristic device data"

must also be observed.

The contents of this installation manual is restricted to the basic function of the device or

its installation. The "Programming instructions KSM11/12" contains a more detailed

description of the programming and re-parameterization of the devices. Exact knowledge

and understanding of these instructions is mandatory for a new installation or

modification of device functions or device parameters.

Commissioning (i.e. starting up the intended operation) is only permitted in strict

compliance with the EMC-directive. The EMC-testing regulations EN55011:2007 +

A2:2007 and EN 61000-6-2:2005 are used as basis.

Compliance with the conditions acc. to EN 60068-2-6 related to the values specified

under "Technical characteristics" is mandatory for storage and transport.

The wiring and connecting instructions in chapter "Installation" must be strictly followed.

The applicable VDE-regulations and other special safety regulations of relevance for the

application must be strictly followed.

Evidence of the configured monitoring functions as well as their parameters and links

must be issued by means of a validation report.

The implementation of the module must be coordinated with the demands of the

responsible acceptance testing authority (e.g. TÜV or ELIA).

Do not install or operate damaged products. Report damages immediately to the

responsible forwarding agent.

Never open the housing and/or make unauthorized conversions.

Inputs and outputs for standard functions or digital and analog data transmitted via

communication modules must not be used for safety relevant applications.

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WARNING:

Using our devices contrary to the rules and conditions specified hereunder can lead

to injuries or fatalities as well as damage to connected devices and machines!

This will also cause the loss of all warranty and compensation claims against

Kollmorgen.

2.3 Operation and Service

The module must always be de-energized before installation and removal, or before

disconnecting signal lines. For this purpose all live supply lines to the device must be

checked for safe isolation from supply

When installing or removing the module appropriate measures must be applied to prevent

electrostatic discharge to the externally arranged terminal and plug connections. Contact with

such terminals should be reduced to a minimum and earthing should by means of e.g. an

earthing strap should take place before and during these procedures.

2.4 Transport and Storage

Information concerning transport, storage and proper handling must be strictly followed.

The climate related specifications in chapter "Technical data" must be complied with.

2.5 Scope of Delivery

The scope of delivery contains

Extension device EtherCAT KSM55

ESI-file

Installation manual

Backplane bus plug

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3 Device Description and Operation

Together with the KSM basic device this device works as a gateway from back plane CAN

bus to EtherCAT. The user has the possibility to send the status message data to EtherCAT.

Max. user data from 8 CAN messages can be send.

Till 32 byte user data can be received from EtherCAT and send to the KSM device. This 32

byte data will be transmitted with 4 CAN messages to 4 basic devices.

Device has to be configured as a EtherCAT slave device.

Ethernet data rate will be 100Mbit/s in full duplex mode. Size of output data is 64 byte, input

data is 32 Byte.

3.1 Characteristic Data

Device KSM55

Response time

Cycle Time 10 ms

Number of CAN objects

1 to 8

Data size CAN telegram

8 Byte

CAN ID

Standard (11 bBit)

Table 3: Characteristic Data

3.2 Device Settings

Image 1: Front

No settings on the device needed.

Diagnostic-LED’s

(see chapter “Diagnostic LED”)

EtherCAT-plug

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4 Safety Related Characteristics

KSM55 can only be used as a non safe communication with EtherCAT protocol.

5 Connection and Installation

KSM55 has to be connected to a basic device (KSM11, KSM12 ) with a back plan.

Example: KSM 55 together with KSM12:

Image 2: Device Connection

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5.1 General Notes on Installation

Strictly follow the safety regulations when installing!

Degree of protection IP20

Route all signal lines for the interfacing of digital inputs and contact monitoring separately.

You should in any case disconnect 230VAC voltages from low voltage power lines, if these

voltages are used in connection with the application.

The cable lengths for digital inputs and outputs must normally not exceed 30 m.

If the cable lengths exceeds 30 m you must apply appropriate measures for fault exclusion

concerning impermissible overvoltage. Appropriate measures include e.g. lightning protection

for outdoor lines, overvoltage protection of the indoor system, protected routing of cables.

Measures concerning the electromagnetic compatibility (EMC)

The KSM module is intended for use in the drive environment and meets the EMC-

requirements mentioned above.

It is also assumed that the electromagnetic compatibility of the overall system is ensured by

application of appropriate measures.

Safety Notes:

Electric power supply lines of the KSM and "discontinuous-action lines" of the power

converter must be isolated from each other.

Signal lines and power lines of the power converter must be routed through separate cable

ducts. The distance between the cable ducts should be minimum 10 mm.

Only shielded cables must be used to connect the position and speed sensors. The signal

transmission cable must be RS-485-standard compliant (lines twisted in pairs).

Care must be taken to ensure that the shielding is correctly connected in the 9-pin SUB-D

plugs of the position and speed sensors. Only metal or metal coated plugs are permitted.

The shielding on the sensor side must comply with appropriate methods.

EMC-compliant installation of the power converter technology in the environment of the KSM

module must be assured. Special attention must be paid to the routing of cables, the

shielding of motor cables and the connection of the braking resistor. Strict compliance with

the installation instructions of the power converter manufacturer is mandatory.

All contactors in the environment of the power converter must be equipped with appropriate

suppressor circuits.

Suitable measures to protect against overvoltages must be applied.

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5.2 Installation KSM-Module

The module is solely to be installed in control cabinets with a degree of protection of at least

IP54.

The modules must be vertically fastened on a top hat rail.

The ventilation slots must be kept unobstructed, to ensure adequate air circulation inside the

module.

5.3 Assembly on Backplane Bus

Image 3: Assembly

For more information see “Installation Manual KSM”.

5.4 Terminal Assignment

Image 4: Assignment RJ45

Pins

1 … 8

RJ45

Name

Description

Color

TX+

Tranceive Data +

White-Orange

TX-

Tranceive Data -

Orange

RX+

Receive Data +

White-Green

nc.

Not used

Blue

nc.

Not usedt

White-blue

RX-

Receive Data -

Green

nc.

Not used

White-Brown

nc.

Not usedt

Brown

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6 Start Up

6.1 Procedure

Start-up must only be performed by qualified personnel!

Strictly follow the safety regulations when commissioning!

6.2 Parameterization

Usage of program TwinCAT from Beckhoff.

6.2.1 Installation ESI-File

Copy ESI-File into ESI-Folder of TwinCAT program.

TwinCAT program has to be closed for this step.

After starting TwinCAT the ESI cache will be reinitialized.

Image 5: TwinCAT root for ESI-File

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6.2.2 Settings SafePLC

CAN-IDs for the status message data can be configured in the connection settings SafePLC.

Image 6: Connection settings SafePLC

Note: The 4 CAN messages with input bytes for KSM55 are sent with the backplane bus

with CAN ID’s - 0x9D bis 0xA0 –and can’t be use for other points.

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Following table shows the defined CAN ID’s for input and output bytes for EtherCAT.

Bytes

CAN-ID

Direction

0 bis 7

0xA1