Metronix smartServo BL 4000-C Series User manual

Metronix Meßgeräte und Elektronik GmbH
Kocherstr. 3
38120 Braunschweig
Telefon: [phone]
Telefax: 0531 8668-555
Mounting Instructions
PRELIMINARY
Servo drives BL 4000-C

Original instructions
Copyrights
© 2017 Metronix Meßgeräte und Elektronik 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, Metronix guarantees the contractual
use in accordance with the user documentation. In the case of serious deviations from the user
documentation, Metronix 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.
Metronix 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. Metronix 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.
Metronix Meßgeräte und Elektronik 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.
ServoCommander® is a registered trademark of Metronix Meßgeräte und Elektronik GmbH.
Revision Information
Author: Metronix Meßgeräte und Elektronik GmbH
Manual title: Mounting Instructions “Servo drives BL 4000-C”
File name: MI_BL 4000-C_EN.docx
Version 0.1 December 2017

Page 3
Mounting Instructions „Servo drives BL 4000-C“ PRELIMINARY Version 0.1
Contents
1 General ........................................................................................................................... 4
1.1 Documentation .............................................................................................................................................. 4
2 Safety notes for electrical drives and controllers .............................................................. 5
2.1 Used symbols ................................................................................................................................................ 5
2.2 General notes ................................................................................................................................................ 5
2.3 Danger resulting from misuse ....................................................................................................................... 7
2.4 Safety notes .................................................................................................................................................. 7
2.4.1 General safety notes ............................................................................................................................. 7
2.4.2 Safety notes for assembly and maintenance ........................................................................................ 9
2.4.3 Protection against contact with electrical parts ................................................................................... 10
2.4.4 Protection against electrical shock by means of protective extra-low voltage (PELV) ........................ 11
2.4.5 Protection against dangerous movements .......................................................................................... 11
2.4.6 Protection against contact with hot parts ............................................................................................ 12
2.4.7 Protection during handling and assembly ........................................................................................... 13
3 Technical data ............................................................................................................... 14
4 Mechanical installation .................................................................................................. 18
4.1 Important notes ........................................................................................................................................... 18
4.2 Mounting ..................................................................................................................................................... 20
5 Electrical installation ...................................................................................................... 21
5.1 Pin assignment I/O communication [X1] ...................................................................................................... 22
5.2 Pin assignment Resolver [X2A] ................................................................................................................... 23
5.3 Pin assignment Encoder [X2B] .................................................................................................................... 24
5.4 Pin assignment CAN [X4] ............................................................................................................................ 28
5.5 Wiring diagram Motor [X6] and Power Supply [X9] ..................................................................................... 29
5.6 Ethernet communication [X18] .................................................................................................................... 32
5.7 USB communication [X19] .......................................................................................................................... 33
5.8 Pin assignment SAFE TORQUE OFF [X40] ................................................................................................ 34
5.9 MicroSD-Card slot ....................................................................................................................................... 34
6 Functional safety technology ......................................................................................... 35
6.1 General ....................................................................................................................................................... 35
6.2 Achievable safety level, Safety function according to EN ISO 13849-1 / EN 61800-5-2 ............................. 35
7 EMC-compliant cabling .................................................................................................. 36

General Page 4
Mounting Instructions „Servo drives BL 4000-C“ PRELIMINARY Version 0.1
1 General
1.1 Documentation
This installation information serves the purpose of a safe use of the BL 4000-C series servo drives. It
contains safety notes, which must be complied with.
Further information can be found in the following manuals of the BL 4000-C product range:
 Product Manual "Servo drives BL 4000-C”: Description of the technical data and the device
functionality plus notes concerning the installation and operation of the servo drives (German
version).
You can find all these documents on our homepage at the download area (http://www.metronix.de).
Certificates and declarations of conformity for the products described in this manual can be found at
http://www.metronix.de.

Safety notes for electrical drives and controllers Page 5
Mounting Instructions „Servo drives BL 4000-C“ PRELIMINARY Version 0.1
2 Safety notes for electrical drives and
controllers
2.1 Used symbols
INFORMATION
Important information and notes.
CAUTION!
Nonobservance may result in severe property damages.
DANGER!
Nonobservance may result in property damages and in personal injuries.
CAUTION! DANGEROUS VOLTAGE.
The safety note indicates a possible perilous voltage.
2.2 General notes
In case of damage resulting from non-compliance with the safety notes in this manual, Metronix
Meßgeräte und Elektronik GmbH will not assume any liability.
INFORMATION
Prior to the initial use you must read chapter 2 Safety notes for electrical drives and
controllers, starting on page 5 and chapter 7 EMC-compliant cabling, starting on
page 36.
If the documentation in the language at hand is not understood accurately, please contact and inform
your supplier.
Sound and safe operation of the servo drive requires proper and professional transportation, storage,
mechanical installation, and project planning – with a consideration of the risks as well as the protective
and emergency measures – plus the proper and professional electrical installation, operation, and
maintenance of the devices.
Only trained and qualified personnel is authorised to handle electrical devices and systems:

Page 6 Safety notes for electrical drives and controllers
Mounting Instructions „Servo drives BL 4000-C“ PRELIMINARY Version 0.1
TRAINED AND QUALIFIED PERSONNEL
in the sense of this product manual or the safety notes on the product itself are persons who are
sufficiently familiar with the project, the setup, assembly, commissioning and operation of the product as
well as all warnings and precautions as per the instructions in this manual and who are sufficiently
qualified in their field of expertise:
 Education and instruction concerning the standards and accident prevention regulations for the
application, or authorisation to switch devices/systems on and off and to ground them as per the
standards of safety engineering and to efficiently label them as per the job demands.
 Education and instruction as per the standards of safety engineering regarding the maintenance and
use of adequate safety equipment.
 First aid training.
The following notes must be read prior to the initial operation of the system to prevent personal injuries
and/or property damages:
INFORMATION
 These safety notes must be complied with at all times.
 Do not try to install or commission the servo drive before carefully reading all
safety notes for electrical drives and controllers contained in this document.
These safety instructions and all other user notes must be read prior to any work
with the servo drive.
 In case you do not have any user notes for the servo drive, please contact your
sales representative. Immediately demand these documents to be sent to the
person responsible for the safe operation of the servo drive.
 If you sell, rent and/or otherwise make this device available to others, these
safety notes must also be included.
 The user must not open the servo drive for safety and warranty reasons.
 Professional control process design is a prerequisite for sound functioning of the
servo drive!
DANGER!
Inappropriate handling of the servo drive and non-compliance with the warnings as
well as inappropriate intervention in the safety features may result in property
damage, personal injuries, electric shock or in extreme cases even death.

Safety notes for electrical drives and controllers Page 7
Mounting Instructions „Servo drives BL 4000-C“ PRELIMINARY Version 0.1
2.3 Danger resulting from misuse
DANGER!
High electrical voltages and high load currents!
Danger to life or serious personal injury from electrical shock!
DANGER!
High electrical voltage caused by wrong connections!
Danger to life or serious personal injury from electrical shock!
DANGER!
Surfaces of device housing may be hot!
Risk of injury! Risk of burning!
DANGER!
Danger to life, serious personal injury or property damage due to unintentional
movements of the motors!
2.4 Safety notes
2.4.1 General safety notes
The servo drive corresponds to IP20 degree of protection as well as pollution degree 2. Make sure
that the environment corresponds to this degree of protection and pollution degree.
Only use replacement parts and accessories approved by the manufacturer.
The devices must be connected to the mains supply as per EN regulations, so that they can be cut
off the mains supply by means of corresponding separation devices (for example main switch,
contactor, power switch).
The servo drive may be protected using an AC/DC sensitive 300 mA fault current protection
switch, type B (RCD = Residual Current protective Device).
Gold contacts or contacts with a high contact pressure should be used to switch the control
contacts.
Preventive interference rejection measures should be taken for control panels, such as connecting
contactors and relays using RC elements or diodes.
The safety rules and regulations of the country in which the device will be operated must be
complied with.
The environment conditions defined in the product documentation must be kept. Safety-critical
applications are not allowed, unless specifically approved by the manufacturer.

Page 8 Safety notes for electrical drives and controllers
Mounting Instructions „Servo drives BL 4000-C“ PRELIMINARY Version 0.1
For notes on installation corresponding to EMC, please refer to chapter 7 EMC-compliant cabling,
starting on page 36. The compliance with the limits required by national regulations is the
responsibility of the manufacturer of the machine or system.
The technical data and the connection and installation conditions for the servo drive are to be
found in this product manual and must be met.
DANGER!
The general setup and safety regulations for work on power installations (for example
DIN, VDE, EN, IEC or other national and international regulations) must be complied
with.
Non-compliance may result in death, personal injury or serious property damages.
Without claiming completeness, the following regulations and others apply:
VDE 0100 Erection of power installations with nominal voltages up to 1000 V
EN 1037 Safety of machinery - Prevention of unexpected start-up
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 specific 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 ISO 12100 Safety of machinery - General principles for design - Risk assessment and
risk reduction
EN ISO 13849-1 Safety of machinery - Safety-related parts of control systems
Part 1: General principles for design
EN ISO 13849-2 Safety of machinery - Safety-related parts of control systems
Part 2: Validation
More standards to be respected by the user:
EN 574 Safety of machinery - Two-hand control devices
EN 1088 Safety of machinery - Interlocking devices associated with guards
EN ISO 13850 Safety of machinery - Emergency stop

Safety notes for electrical drives and controllers Page 9
Mounting Instructions „Servo drives BL 4000-C“ PRELIMINARY Version 0.1
2.4.2 Safety notes for assembly and maintenance
The appropriate DIN, VDE, EN and IEC regulations as well as all national and local safety regulations and
rules for the prevention of accidents apply for the assembly and maintenance of the system. The plant
engineer or the operator is responsible for compliance with these regulations:
The servo drive must only be operated, maintained and/or repaired by personnel trained and
qualified for working on or with electrical devices.
Prevention of accidents, injuries and/or damages:
Additionally secure vertical axes against falling down or lowering after the motor has been
switched off, for example by means of:
 Mechanical locking of the vertical axle,
 External braking, catching or clamping devices or
 Sufficient balancing of the axle
The motor holding brake supplied by default or an external motor holding brake driven by the servo
drive alone is not suitable for personal protection!
Keep the electrical equipment voltage-free using the main switch and protect it from being
switched on again until the DC bus circuit is discharged, in the case of:
 Maintenance and repair work
 Cleaning
 long machine shutdowns
Prior to carrying out maintenance work make sure that the power supply has been turned off,
locked and the DC bus circuit is discharged.
The external or internal brake resistor carries dangerous DC bus voltages during operation of the
servo drive and up to 5 minutes thereafter. Contact may result in death or serious personal injury.
Wait for this time prior to performing any work on the affected connections. Measure the voltages
for your own protection. Contact with these high DC bus circuit voltages may result in death or
serious personal injury.
Be careful during the assembly. During the assembly and also later during operation of the drive,
make sure to prevent drill chips, metal dust or assembly parts (screws, nuts, cable sections) from
falling into the servo drive.
Also make sure that the external power supply of the servo drive (24 V) is switched off.
The DC bus circuit or the mains supply must always be switched off prior to switching off the 24 V
servo drive supply.

Page 10 Safety notes for electrical drives and controllers
Mounting Instructions „Servo drives BL 4000-C“ PRELIMINARY Version 0.1
Carry out work in the machine area only, if AC and/or DC supplies are switched off. Switched off
output stages or servo drive enablings are no suitable means of locking. In the case of a
malfunction the drive may accidentally be put into action.
This does not apply to drives with the special “Safe Stop” feature in accordance with EN 954-1
CAT 3 or with the “Safe Torque Off” feature in accordance with EN 61800-5-2.
Initial operation must be carried out with idle motors, to prevent mechanical damages for example
due to the wrong direction of rotation.
Electronic devices are never fail-safe. It is the user’s responsibility, in the case an electrical device
fails, to make sure the system is transferred into a secure state.
The servo drive and in particular the brake resistor, externally or internally, can assume high
temperatures, which may cause serious burns.
2.4.3 Protection against contact with electrical parts
This section only concerns devices and drive components carrying voltages exceeding 50 V. Contact with
parts carrying voltages of more than 50 V can be dangerous for people and may cause electrical shock.
During operation of electrical devices some parts of these devices will inevitably carry dangerous
voltages.
DANGER!
High electrical voltage!
Danger to life, danger due to electrical shock or serious personal injury!
The appropriate DIN, VDE, EN and IEC regulations as well as all national and local safety regulations and
rules for the prevention of accidents apply for the assembly and maintenance of the system. The plant
engineer or the operator is responsible for compliance with these regulations:
Before switching on the device, install the appropriate covers and protections against accidental
contact. Rack-mounted devices must be protected against accidental contact by means of a
housing, for example a switch cabinet. The national regulations for safety/accident prevention must
be complied with!
Always connect the ground conductor of the electrical equipment and devices securely to the
mains supply. Due to the integrated line filter the leakage current exceeds 3.5 mA!
Comply with the minimum copper cross-section for the ground conductor over its entire length (see
for example EN 60800-5-1).
Prior to the initial operation, even for short measuring or testing purposes, always connect the
ground conductor of all electrical devices as per the terminal diagram or connect it to the ground
wire. Otherwise the housing may carry high voltages which can cause electrical shock.
Do not touch electrical connections of the components when switched on.
Prior to accessing electrical parts carrying voltages exceeding 50 Volts, disconnect the device from
the mains or power supply. Protect it from being switched on again.

Safety notes for electrical drives and controllers Page 11
Mounting Instructions „Servo drives BL 4000-C“ PRELIMINARY Version 0.1
For the installation the amount of DC bus voltage must be considered, particularly regarding
insulation and protective measures. Ensure proper grounding, wire dimensioning and
corresponding short-circuit protection.
The device comprises a rapid discharge circuit for the DC bus as per EN 60204-1. In certain
device constellations, however, mostly in the case of parallel connection of several servo drives in
the DC bus or in the case of an unconnected brake resistor, this rapid discharge may be rendered
ineffective. The servo drives can carry voltage until up to 5 minutes after being switched off
(residual capacitor charge).
2.4.4 Protection against electrical shock by means of protective extra-low
voltage (PELV)
All connections and terminals with voltages of up to 50 Volts at the servo drive are protective extra-low
voltage, which are designed safe from contact in correspondence with the following standards:
 International: IEC 60364-4-41
 European countries within the EU: EN 61800-5-1
DANGER!
High electrical voltages due to wrong connections!
Danger to life, risk of injury due to electrical shock!
Only devices and electrical components and wires with a protective extra low voltage (PELV) may be
connected to connectors and terminals with voltages between 0 to 50 Volts.
Only connect voltages and circuits with protection against dangerous voltages. Such protection may be
achieved by means of isolation transformers, safe optocouplers or battery operation.
2.4.5 Protection against dangerous movements
Dangerous movements can be caused by faulty control of connected motors, for different reasons:
 Improper or faulty wiring or cabling
 Error in handling of components
 Error in sensor or transducer
 Defective or non-EMC-compliant components
 Software error in superordinated control system
These errors can occur directly after switching on the device or after an indeterminate time of operation.
The monitors in the drive components for the most part rule out malfunctions in the connected drives. In
view of personal protection, particularly the danger of personal injury and/or property damage, this may
not be relied on exclusively.

Page 12 Safety notes for electrical drives and controllers
Mounting Instructions „Servo drives BL 4000-C“ PRELIMINARY Version 0.1
Until the built-in monitors come into effect, faulty drive movements must be taken into account; their
magnitude depends on the type of control and on the operating state.
DANGER!
Dangerous movements!
Danger to life, risk of injury, serious personal injuries or property damage!
For the reasons mentioned above, personal protection must be ensured by means of monitoring or
superordinated measures on the device. These are installed in accordance with the specific data of the
system and a danger and error analysis by the manufacturer. The safety regulations applying to the
system are also taken into consideration. Random movements or other malfunctions may be caused by
switching the safety installations off, by bypassing them or by not activating them.
2.4.6 Protection against contact with hot parts
DANGER!
Housing surfaces may be hot!
Risk of injury! Risk of burning!
Do not touch housing surfaces in the vicinity of heat sources! Danger of burning!
Before accessing devices let them cool down for 10 minutes after switching them off.
Touching hot parts of the equipment such as the housing, which contain heat sinks and resistors,
may cause burns!

Safety notes for electrical drives and controllers Page 13
Mounting Instructions „Servo drives BL 4000-C“ PRELIMINARY Version 0.1
2.4.7 Protection during handling and assembly
Handling and assembly of certain parts and components in an unsuitable manner may under adverse
conditions cause injuries.
DANGER!
Risk of injury due to improper handling!
Personal injury due to pinching, shearing, cutting, crushing!
The following general safety notes apply:
Comply with the general setup and safety regulations on handling and assembly.
Use suitable assembly and transportation devices.
Prevent incarcerations and contusions by means of suitable protective measures.
Use suitable tools only. If specified, use special tools.
Use lifting devices and tools appropriately.
If necessary, use suitable protective equipment (for example goggles, protective footwear,
protective gloves).
Do not stand underneath hanging loads.
Remove leaking liquids on the floor immediately to prevent slipping.

Page 14 Technical data
Mounting Instructions „Servo drives BL 4000-C“ PRELIMINARY Version 0.1
3 Technical data
Ambient conditions and qualification
Feature Value
Admissible temperature ranges Storage
temperature:
-25°C to +70°C
Operating
temperature:
0°C to +40°C
+40°C to +50°C at reduced power 4%/K
Admissible installation height Mounting height maximum 2000 m above msl, above 1000 m
above msl with power reduction 1% per 100 m
Humidity Relative humidity up to 90%, no bedewing
Protection degree IP20
Protection class I
Pollution degree 2
Dimensions and weight
Feature Value
Dimensions including the mounting
plate (H*W*D)
245 mm*50 mm*163 mm
Housing dimensions (H*W*D) 200 mm*50 mm*163 mm
Weight approx. 1,5 kg
Performance data [X9]
Feature Value
Supply voltage 1 x 240 VAC [± 10%], 50…60 Hz
24V supply 24 VDC [± 20%]
Intermediate circuit voltage
for a supply voltage of 230 VAC
325 VDC
Internal brake resistor [X9]
Feature Value
Brake resistance 75 
Pulse power 2 kW
Continuous power 8 W

Technical data Page 15
Mounting Instructions „Servo drives BL 4000-C“ PRELIMINARY Version 0.1
External brake resistor [X9]
Feature Value
Brake resistance external 75 
Continuous power max. 2000 W
Motor connection specifications [X6]
Feature Value
Specifications for operation with 1x 230 VAC [± 10%], 50 Hz
Output power 800 VA
Max. output power for 3 s 2,0 kVA
Output current 4 ARMS
Max. output current for 3 s 8 ARMS
Max. output current for 0,5 s 12 ARMS
Max. PWM frequency 20 kHz (software programmable)
Brake output (BR+) 2A (max. 3A altogether incl. DOUTx outputs)
Maximum motor cable length
for interference emission according to EN 61800
-
3 for PWM

10 kHz
Feature Value
Category C2 l  25 m
Category C3 l  25 m
Cable capacity of a phase against shield or
between two lines
C‘  200 pF/m
Derating of the cable length
Feature Value
fPWM = 12 kHz l  21 m
fPWM = 16 kHz l  15 m
fPWM = 20 kHz l  12 m

Page 16 Technical data
Mounting Instructions „Servo drives BL 4000-C“ PRELIMINARY Version 0.1
Resolver [X2A]
Feature Value
Resolution 14 Bit
Delay time signal detection < 200 µs
Speed resolution approx. 10 min-1
Absolute accuracy of angle detection < 0,1°
Max. rotational speed 16.000 min-1
Digital inputs and outputs [X1]
Feature Value
Signal level 24V (8V...30V) active high, conforming with EN 61131-2
DOUT0 24 V
max. 1 A,
max. 3A altogether incl. Brake output
DOUT1
DOUT2
Analogue input [X1]
Feature Value
Analogue input AIN0 10 V input range, 12 Bit, differentially
Incremental encoder input [X1]
Feature Value
Parameterisable number of encoder
lines
1 – 228 lines/rev
Trace signals: A, #A, B, #B, N, #N As per RS422 specification
Max. input frequency 1000 kHz
Pulse direction interface: CLK, #CLK,
DIR, #DIR, RESET, #RESET
As per RS422 specification
Output supply 5 V, max. 200 mA
Incremental encoder output [X1]
Feature Value
Number of lines Programmable 1 – 213 and 214 lines/revolution
Connection level Differential / RS422 specification
Encoder signals A, B, N As per RS422 specification
Output impedance Ra,diff = 66 
Limit frequency fLimit > 1,8 MHz (lines/s)
Edge triggering (min. pulse width) Can be limited by parameters

Technical data Page 17
Mounting Instructions „Servo drives BL 4000-C“ PRELIMINARY Version 0.1
Communication interfaces
Feature Value
Ethernet [X18] RJ 45, 10/100 MBaud, UDP communication
USB [X19]: According to USB 2.0, USB-B, slave-client
MicroSD-Card File systems FAT16, FAT32

Page 18 Mechanical installation
Mounting Instructions „Servo drives BL 4000-C“ PRELIMINARY Version 0.1
4 Mechanical installation
4.1 Important notes
 Only use the servo drive BL 4000-C as a built-in device for switch cabinets
 Mounting position vertical with supply lines [X9] on top
 Mount to control cabinet plate using a fastening strap
 Installation free spaces:
Keep a minimum distance of 100 mm to other components each above and underneath the device to
ensure sufficient venting.
For optimal wiring of the motor cable and angle encoder cable on the bottom of the device an
installation free space of 150mm is recommended!
 Mounting distance:
The servo drive BL 4000-C may be installed adjacently in one switch cabinet without a gap, proper
usage and installation on a heat-dissipating rear panel provided. Please note that excessive heat may
cause premature aging and/or damaging of the device. In case the servo drives BL 4000-C are
subject to high thermal stress, a mounting distance of 59 mm is recommended!

Mechanical installation Page 19
Mounting Instructions „Servo drives BL 4000-C“ PRELIMINARY Version 0.1
100 mm free space for
sufficient ventilation
100 mm free space for
sufficient ventilation
LED Ready / Error
7SEG 7-Segment display
X3 STO
X19 USB
X18 Ethernet
LED RUN | SF
LED ERR | BF
X21 Realtime-Ethernet
X22
X4 CAN
Figure 1:Servo drive: Front view – Installation free space and mounting distance
X9: Power Supply
X1: DIN, DOUT, AIN,
INK IN/OUT
SD: microSD-Slot
X9: Motor,
Brake,
Motor-Temp.
X2B: Multi-Encoder
X2A: Resolver
Figure 2: Servo drive: Top view Figure 3: Servo drive: Bottom view
1
1

Page 20 Mechanical installation
Mounting Instructions „Servo drives BL 4000-C“ PRELIMINARY Version 0.1
4.2 Mounting
The servo drive BL 4000-C has attachment lugs on the top and the bottom of the device. These lugs are
used to mount the servo drive vertically to a control cabinet plate.
The lugs are part of the cooling body profile. This is why the best possible heat transfer to the control
cabinet plate has to be ensured.
Please use M5 screws for the mounting of the servo drives.
Recommended tightening torque for an M5 screw of property class 5.6: 2.8 Nm.
Figure 4: Servo drive BL 4000-C: Mounting plate