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

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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

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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
AC
Alternating voltage
IL
Instruction list
ELIA
Employer's liability insurance association
CLK
Clock (cycle)
CPU
Central Processing Unit
DC
Direct voltage
DI1..DI14
Digital Input
DIN
Deutsches Institut für Normung (German Institute for Standardization)
DO
Digital Output
EMU
Emergency Monitoring Unit
EMC
Electromagnetic compatibility
ELC
Emergency Limit Control
EN
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.