Pilz PMCprotego D.48 User manual

PMCprotego D.48, PMCprotego D.72
Operating Manual-1001735-EN-04
}Servo amplifiers

Preface
This document is the original document.
All rights to this documentation are reserved by Pilz GmbH & Co. KG. Copies may be made
for the user's internal purposes. Suggestions and comments for improving this documenta-
tion will be gratefully received.
Source code from third-party manufacturers or open source software has been used for
some components. The relevant licence information is available on the Internet on the Pilz
homepage.
Pilz®, PIT®, PMI®, PNOZ®, Primo®, PSEN®, PSS®, PVIS®, SafetyBUS p®,
SafetyEYE®, SafetyNET p®, the spirit of safety® are registered and protected trademarks
of Pilz GmbH & Co. KG in some countries.
SD means Secure Digital

Contents
Operating Manual PMCprotego D.48, PMCprotego D.72
1001735-EN-04 3
Section 1 Introduction 8
1.1 Validity of documentation 8
1.1.1 Retaining the documentation 8
1.2 Definition of symbols 8
Section 2 Overview 10
2.1 Unit structure 10
2.1.1 Unit features 10
2.1.1.1 Power element 10
2.1.1.2 Control element 11
2.2 Front view 14
2.3 Plan view 15
2.4 Scope of delivery 15
2.5 Type code 16
2.6 Type label 17
Section 3 Safety 19
3.1 Intended use 19
3.1.1 Hazard analysis 20
3.1.2 Electrical data 20
3.1.3 Ambient conditions 20
3.1.4 Guidelines for UL approval 20
3.1.5 Safety function STO 21
3.1.6 Use of qualified personnel 22
3.1.7 Warranty and liability 23
3.1.8 Disposal 23
3.2 Safety during operation 23
3.3 Standards 24
3.4 Stop, emergency stop and emergency switching off functions 25
3.4.1 Stop functions 26
3.4.2 E-STOP functions 26
3.4.3 Emergency stop functions 27
Section 4 Function Description 28
4.1 Overview 28
4.2 Power element 30
4.2.1 Mains voltage 30
4.2.2 Motor connection 33
4.2.3 Motor holding brake 33
4.2.4 Brake resistor 36
4.2.5 Intermediate circuit 37
4.2.6 Intermediate circuit topology 38
4.3 Control element 39
4.3.1 Supply voltage 24 VDC 39
4.3.2 Digital inputs and outputs 39
4.3.2.1 Overview 39
4.3.2.2 Digital inputs 40

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4.3.2.3 Digital outputs 43
4.3.3 Safety function STO 44
4.3.3.1 Safety information 44
4.3.3.2 Signal states 45
4.3.3.3 Safety function STO without a safety card 46
4.3.3.4 Safety function STO with safety card 48
4.3.3.5 Reaction time 48
4.3.3.6 Connection example for STO, single-channel 48
4.3.3.7 Connection example for STO, dual-channel 49
4.3.4 Analogue inputs 50
4.3.5 Encoder systems 51
4.3.5.1 Overview 51
4.3.5.2 Resolver 57
4.3.5.3 Encoder 57
4.3.5.4 Incremental encoders 59
4.3.5.5 Absolute encoder with SSI interface 61
4.3.5.6 Hall encoder 62
4.3.6 Electronic gearing, Master-Slave mode 62
4.3.6.1 Stepper motor control systems (pulse/direction) 63
4.3.6.2 Master-Slave mode 63
4.3.7 Encoder emulation 65
4.3.8 Communications interfaces 67
4.3.8.1 RS 232 interface 67
4.3.8.2 CANopen interface 68
4.3.8.3 Ethernet-based interface 68
4.3.9 SD card 69
4.3.10 Tools 69
4.4 Expansion cards 70
4.4.1 Expansion card PMCprotego S1-2, PMCprotego S2-2 70
4.4.2 Expansion card I/O-14/08 70
4.4.3 Expansion card PosI/O, PosI/O-AIO 73
4.4.3.1 Incremental encoder ROD (AquadB) 5 V, (X5, X1) 73
4.4.3.2 Absolute encoder with SSI interface (X5, X1) 74
4.4.3.3 SinCos encoder with SSI interface (X5, X1) 74
4.4.3.4 Electronic gearing, Master-Slave mode 74
4.4.3.5 Encoder emulation 75
4.4.3.6 Analogue inputs 78
4.4.3.7 Analogue outputs 78
4.4.4 Expansion card with PROFIBUS-DP interface 78
4.4.5 Expansion card PROFINET 79
4.4.6 Expansion card Fan Controller 79
4.5 Switch on/switch off behaviour 79
4.5.1 Normal mode 81
4.5.2 Fault condition 82
4.6 Implementation of stop categories 84
4.6.1 Stop Category 0 84
4.6.2 Stop Category 1 84
4.6.3 Stop Category 2 87

Contents
Operating Manual PMCprotego D.48, PMCprotego D.72
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Section 5 Installation 90
5.1 General requirements 90
5.2 Dimensions 91
5.3 Installing the servo amplifier 91
5.4 Installing the shielding plate 93
5.5 Installing the expansion cards 94
5.5.1 Expansion cards for slot 1 94
5.5.2 Expansion cards for slot 2 95
5.5.3 Expansion cards for slot 3 96
Section 6 Wiring 97
6.1 Connector description 97
6.2 Block diagram 98
6.3 Notes on wiring 100
6.3.1 Contact protection 101
6.3.1.1 Leakage current 101
6.3.1.2 Residual current devices FI 102
6.3.1.3 Isolating transformer 103
6.3.2 Connection cables 103
6.4 Wiring procedure 104
6.5 EMC-compliant wiring 105
6.5.1 Earthing 105
6.5.2 Shielding 106
6.5.2.1 Shield connection on the front plate 107
6.5.3 Filters 107
6.5.4 Chokes 108
6.6 Power element 108
6.6.1 Mains voltage 108
6.6.2 Motor 110
6.6.3 Motor holding brake 111
6.6.4 External brake resistor 112
6.6.5 Intermediate circuit 114
6.6.6 Energy store PMCenergy SD 115
6.7 Control element 119
6.7.1 Supply voltage 24 VDC 119
6.7.2 Digital inputs 120
6.7.3 Digital outputs 124
6.7.4 Analogue inputs 125
6.7.5 Encoder systems 126
6.7.5.1 HIPERFACE DSL, one-cable connection 126
6.7.5.2 SFD3 one-cable connection 128
6.7.5.3 Resolver 129
6.7.5.4 SinCos encoder with HIPERFACE interface 130
6.7.5.5 SinCos encoder with EnDat 2.1 interface 132
6.7.5.6 Encoder with EnDat 2.2 interface 134
6.7.5.7 SinCos encoder with BISS interface, analogue 136
6.7.5.8 Encoder with BISS interface, digital 138

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6.7.5.9 SinCos encoder with SSI interface 140
6.7.5.10 SinCos encoder without data track 142
6.7.5.11 SinCos encoder with Hall encoder 144
6.7.5.12 Incremental encoder ROD (AquadB) 5V, 350 kHz 146
6.7.5.13 Incremental encoder ROD (AquadB) 5V, 1.5 MHz 148
6.7.5.14 Incremental encoder ROD (AquadB) 5 V, with zero pulse and Hall encoder 150
6.7.5.15 Incremental encoder ROD (AquadB) 24 V, without zero pulse 152
6.7.5.16 Incremental encoder ROD (AquadB) 24 V, without zero pulse, with Hall en-
coder
153
6.7.5.17 Absolute encoder with SSI interface 155
6.7.5.18 Hall encoder 157
6.7.5.19 Electronic gearing, Master-Slave mode 159
6.7.5.20 Encoder emulation 161
6.7.6 Communications interfaces 162
6.7.6.1 RS 232 interface 162
6.7.6.2 CANopen interface 164
6.7.6.3 Ethernet-based interface 165
6.8 Expansion cards 166
6.8.1 Expansion card PMCprotego S1, PMCprotego S2 166
6.8.2 Expansion card I/O-14/08 167
6.8.3 Expansion card PosI/O, PosI/O-AIO 169
6.8.3.1 Electronic gearing 169
6.8.3.2 Encoder emulation 171
6.8.3.3 Analogue inputs and outputs 173
6.8.3.4 Incremental encoder ROD (AquadB) 5 V 174
6.8.3.5 Absolute encoder with SSI interface 178
6.8.3.6 SinCos encoder with SSI interface 179
6.8.4 Expansion card with PROFIBUS-DP interface 182
6.8.5 PROFINET interface expansion card 183
Section 7 Commissioning 184
7.1 Safety guidelines 184
7.2 Commissioning the servo amplifier 185
7.3 Download firmware from SD card to servo amplifier 191
7.4 LEDs and keys 192
7.4.1 Key functions 192
7.4.2 Status indicator 193
7.4.3 Standard menu 194
7.4.4 Advanced menu 195
7.5 Messages/errors 195
7.5.1 Status messages 195
7.5.2 Error messages 196
7.5.3 Warnings 197
7.6 Safety checks 198
7.7 Expansion cards 199
7.7.1 PROFIBUS DP interface expansion card 199
7.7.2 PROFINET interface expansion card 199

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Operating Manual PMCprotego D.48, PMCprotego D.72
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Section 8 Technical details PMCprotego D.48 200
Section 9 Technical details PMCprotego D.72 204
Section 10 Safety characteristic data 208
Section 11 Order reference 209
11.1 Order reference for device 209
11.2 Order reference for accessories 209
11.2.1 Safety cards to retrofit or as spare part 209
11.2.2 Expansion cards to retrofit or as spare part 209
11.2.3 Interface cable, interface adapter, SD card 209
11.2.4 Connector for cable assembly, motor power cable 210
11.2.5 Connector set as spare part 210
11.2.6 Energy store 210
11.2.7 Connection cable to the motor series "PMCtendo SZ" 210
Section 12 Appendix 211
12.1 Abbreviations 211
Section Glossary 213

Introduction
Operating Manual PMCprotego D.48, PMCprotego D.72
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1 Introduction
1.1 Validity of documentation
This documentation is valid for the products PMCprotego D.48 and PMCprotego D.72. It is
valid until new documentation is published.
This operating manual explains the product's function and operation, describes the installa-
tion and provides guidelines on how to connect the PMCprotegoD.
Please also refer to the following documents from the motion control range:
}The online help for the commissioning software describes how to set the parameters for
the servo amplifier.
}The "PMCprimo CAN Networking" manual contains guidelines for networking multiple
PMCprimo control systems and additional CANopen devices.
All these manuals can be found on the supplied CD-ROM: "Motion Control Documentation".
You will need to be conversant with the information in these documents in order to fully un-
derstand this manual.
This operating manual is valid for the following products:
}PMCprotego D.48 from Version1.6
}PMCprotego D.72 from Version1.6
1.1.1 Retaining the documentation
This documentation is intended for instruction and should be retained for future reference.
1.2 Definition of symbols
Information that is particularly important is identified as follows:
DANGER!
This warning must be heeded! It warns of a hazardous situation that poses
an immediate threat of serious injury and death and indicates preventive
measures that can be taken.
WARNING!
This warning must be heeded! It warns of a hazardous situation that could
lead to serious injury and death and indicates preventive measures that can
be taken.

Introduction
Operating Manual PMCprotego D.48, PMCprotego D.72
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CAUTION!
This refers to a hazard that can lead to a less serious or minor injury plus
material damage, and also provides information on preventive measures
that can be taken.
NOTICE
This describes a situation in which the product or devices could be dam-
aged and also provides information on preventive measures that can be
taken. It also highlights areas within the text that are of particular import-
ance.
INFORMATION
This gives advice on applications and provides information on special fea-
tures.

Overview
Operating Manual PMCprotego D.48, PMCprotego D.72
1001735-EN-04 10
2 Overview
2.1 Unit structure
2.1.1 Unit features
The PMCprotego D is a compact servo amplifier consisting of
}A power element
}A control element with
– Inputs and outputs
– Sequence control
– Control loops for current, speed and position
– Interfaces for communication with the periphery
Unit types:
}Continuous output currents:
– PMCprotegoD.48: 48A
– PMCprotegoD.72: 72A
}C type
– Devices with coated PCB boards, see Typenschlüssel
2.1.1.1 Power element
The servo amplifier's power element has the following features:
}Connection to earthed three-phase supplies, rated voltage range 208V – 480V
}TN network and TT network with earthed star point, max. 42 kA symmetrical rated cur-
rent, connection to other networks only with isolating transformer
}B6 rectifier bridge integrated directly on the three-phase, earthed network, mains filter
and start-up circuit
}Fuse protection (e.g. blow-out fuse) through user
}All shield connections directly on the servo amplifier
}Max. intermediate circuit voltage in generator mode: 260 – 900VDC, can be connected
in parallel
}Brake chopper, brake power distributed over several amplifiers on the same intermedi-
ate circuit
}Optionally, an energy store can be connected to the intermediate circuit (see Energy
store PMCenergy SD [ 115]).
}No internal brake resistor, external brake resistor available if required.
}Inverted rectifier with isolated current measurement and IGBT transistors
}Connection of synchronous servo motors, linear motors, asynchronous motors
}Integrated noise suppression filters in accordance with EN61800-3

Overview
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2.1.1.2 Control element
The servo amplifier's control element has the following features:
Supply voltage
}Supply voltage 24 VDC
}Controller supply isolated from fan and brake, fused internally
}Separate supply voltage for control element, external motor holding brake and digital
outputs
}Integrated noise suppression filters in accordance with EN61800-3
Encoder systems
Integrated evaluation of the following encoder systems
}Resolver
}Incremental encoder
}Absolute encoder
– with or without SinCos tracks
– with various interfaces
Inputs and outputs
}2 analogue voltage inputs
– Differential input
– Signal range: ±10 V, referenced to earth
– Resolution (with sign bit): 16 Bit
}4 digital inputs
– 2 of these digital inputs are suitable for fast signals
}2 digital inputs or outputs (switchable signal direction)
}Pulse/direction 24V
}All digital signals are free to be linked
Digital control
}Digital control loop
}Digital speed regulator
}Digital position controller
}Pulse/direction interface for connecting a servo motor to a stepper motor controller
Setting the parameters
}With the commissioning software, via the serial interface
}With the motion control system PMCprimoC, via the CAN interface in conjunction with
the commissioning software and CoDeSys (development environment in accordance
with IEC61131-3)
}Via the PROFINET-/ETHERNET parameter channel (PASmotion)
(Requirement: The expansion card PROFINET is inserted)
Operation and display
}Servo amplifier operated via two keys

Overview
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}Three-digit LED display for status and messages
Integrated safety
}Device safety
– Safe electrical isolation between mains voltage/motor connection and control ele-
ment, in accordance with EN61800-5-1
– Soft start, overvoltage detection, short circuit protection, phase failure monitoring
– Temperature monitoring of servo amplifier and motor (when using Pilz motors with
ready-made cables)
}Protection of personnel and plant
– Safety function STO – Safe Torque Off
Single-channel without feedback: Up to PL d (Cat. 2) of ENISO13849-1 and
SILCL2 of EN/IEC62061
Dual-channel with feedback: Up to PL e (Cat. 4) of ENISO13849-1 and SILCL3 of
EN/IEC62061
– Slot for safety card: Safety functions for safe operation of drive axes in accordance
with DINIEC61800-5-2, up to PL e (Cat. 4) of ENISO13849-1 and SILCL3 of
EN/IEC62061
Communication interfaces
}CANopen interface for
– Connection to CAN bus systems
– Parameters for several drives can be set via a servo amplifier's serial interface
}RS232 interface for parameter setting with the commissioning software
}Ethernet-based interface
– EtherCAT
Card slot for SD card
}Card slot for SD card, for reading and writing parameters and firmware
Expansion cards
3 slots for expansion cards
}Expansion cards for slot 1:
– I/O-14/08
– PROFIBUS DP
– PROFINET
}Expansion cards for slot 2:
– PMC expansion card PosI/O
– PMC expansion card PosI/O-AIO
– Fan controller, available only on request

Overview
Operating Manual PMCprotego D.48, PMCprotego D.72
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INFORMATION
An expansion card in slot 1 can be used in conjunction with a fan controller
expansion card in slot 2. Other than that, only expansion cards can occupy
slot 1 or slot 2 (for combinations see Type code).
}Expansion cards for slot 3:
– PMCprotego S1, PMCprotegoS1-2
– PMCprotego S2, PMCprotegoS2-2
– PMC expansion card PosI/O
– PMC expansion card PosI/O-AIO
– Fan controller, available only on request

Overview
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2.2 Front view
1
2
3
4
5
67
9
8
10
11
12
13
14
15
16
Legend:
1: Mains voltage, power element
2: External brake resistor, connec-
tion for motor, intermediate circuit,
optional energy store
3: Connection for earth conductor
PE
4: Connection for motor holding
brake
5: Supply voltage for motor holding
brake
6: Supply voltage 24VDC and
safety function STO
7: Expansion cards slot 3
8: Enable signal, 4 digital inputs, 2
digital inputs or outputs (parameters
can be set)
9: 2 analogue inputs, relay output
for operational readiness
10: Expansion cards slot 2
11: Connection for incremental en-
coder, sine/cosine encoder, pulse/
direction 24V
12: Connection for resolver
13: EtherCAT interface
14: Expansion cards slot 1
15: Keys
16: LED display for messages
Front view of the PMCprotego D

Overview
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1001735-EN-04 15
2.3 Plan view
18
17
Legend:
17: RS232 interface for commissioning
and parameter setting or CANopen con-
troller
18: Card slot for SD card
Plan view of the PMCprotego D
2.4 Scope of delivery
This is what you receive when you order a servo amplifier from the PMCprotego series:
}Servo amplifier PMCprotego D
}Mating connectors X3A, X3B, X4, X9A, X9B
}Documentation CD
}Commissioning software (PASmotion) on the Internet
INFORMATION
The D-Sub mating connectors, the motor connector and the fieldbus junc-
tion box are not supplied with the device! They are available as accessories.

Overview
Operating Manual PMCprotego D.48, PMCprotego D.72
1001735-EN-04 16
2.5 Type code
PMCprotego D._ _ /_ _ _ / 0 / _ / 2 / _ _ _ _ _ _
Option
Standard 0
000 100 200 A00 101 201 202 A0210C 20C A0C10D 20DA0D 001 002 00C 00D 010 01C01D 020
72 A
48 A
72
48
Hardware-Option
0
0
2
A
1I/O 14/08
PROFIBUS
PROFINET
A01 102
PosI/O 3)
PosI/O AIO 4)
1 2
0
PosI/O 3)
PosI/O AIO 4)
1
2
PMCprotego S1-2
PMCprotego S2-2
C
D
208...480 VAC
480V-Series 7)
coated 6)
PMCprotego S1-2-C 6)
E FPMCprotego S2-2-C 6)
02D
02C
00E 00F
C
Mains voltageType
Slot 1 Slot 3 Slot 2
4) Expansion card with analogue inputs/outputs
6) Coated circuit boards
7) Series 480 V with UL Listing
Fieldbus Standard CANopen/EtherCAT
Current Size Value
3) Expansion card without analogue inputs/outputs
Without Without Without
Fig.: Type code

Overview
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2.6 Type label
The type label is situated on the side of the servo amplifier.
The type label consists of:
}Type label modified device
}Type label standard device
INFORMATION
Type label
Always state the full details on the "Type label modified device" (configura-
tion) in new orders or spare parts orders.
Fig.: Type label modified device
Legend
new type Modified type key
Ident. No. Order number
Ser. No. Serial number
Firmware Firmware version

Overview
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Fig.: Type label standard device
Legend
Type Type key
Ident. No. Order number
Prod. version Product version
Firmware Firmware version
Mains Voltage Mains voltage
Power Power
Inom Continuous output current
YOM Year of manufacture
Prot. type Protection type
Ambient temp Ambient temperature

Safety
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3 Safety
3.1 Intended use
The servo amplifiers PMCprotego D are designed to drive suitable brushless, synchronous
servo motors and asynchronous motors with closed loop speed, torque and/or position con-
trol.
The following is deemed improper use:
}Any component, technical or electrical modification to the servo amplifier
}Use of the servo amplifier outside the areas described in this manual
}Use of the servo amplifier outside the documented technical details (see chapter en-
titled “Technical Details”)
Intended use includes making the installation and wiring EMC-compliant. Please refer to
the guidelines stated in this manual.
The servo amplifier is not classified under Annex 1 (Category 3, AL-3A225) of the EC Dual-
Use Regulation No. 428/2009, when the commutation frequency for sensorless operation of
asynchronous motors (motor type MTYPE=3) is limited to less than 600 Hz. The cutoff fre-
quency was set to 599 Hz.
Conversion of commutation frequency into the speed:
Speed (rpm)= commutation frequency ∙ 60 / number of pole pairs of the motor
Example: 12-pole asynchronous motor, commutation frequency = 599 Hz
Speed (rpm)= 599 Hz ∙ 60 / (6 pole pairs) = 5990 rpm
From the following product and firmware version, the devices follow the export regulations
of the EC Dual-Use Regulation:
}PMCprotego D.XX
– Product version: 1.4
– Firmware version: 5.71
Please refer to the type label of the device for product and firmware versions. A query is
possible with the terminal:
→ VER
V5.71 ND0
}"ND0": not export-restricted device, firmware with limited commutation frequency in
sensorless operation
Servo amplifiers with higher commutation frequencies are available only on request.
INFORMATION
On servo amplifiers from firmware version 5.71, no firmware version prior to
Version 5.71 can be loaded. It is possible to downgrade from Version 5.73
to 5.71, for example.

Safety
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3.1.1 Hazard analysis
The machine manufacturer must produce a hazard analysis for the machine. He must take
appropriate measures to ensure that unexpected movements do not lead to hazardous situ-
ations for either people or equipment.
3.1.2 Electrical data
Please note the electrical requirements stated in the chapters entitled "Technical Details",
"Wiring" and "Function Description".
INFORMATION
A 3L line choke with uk = 2% must be used in the event of a mains voltage
imbalance of > 3%. Install the line choke on the mounting plate in a way that
is EMC-compliant.
3.1.3 Ambient conditions
Please note the following conditions for using the servo amplifier:
}Operation of the servo amplifier is forbidden in the following conditions:
– Potentially explosive areas
– Environments containing corrosive and/or conductive acids, alkaline solutions, oils,
fumes or dusts
– Where there is a direct connection to unearthed or asymmetrically earthed mains
supplies with UN>240V. See chapter entitled "Wiring", under "Mains voltage".
– On ships and offshore installations
}The servo amplifier may only be operated in an enclosed control cabinet in compliance
with the ambient conditions defined under “Technical details”. Ventilation or cooling
may be required to maintain the control cabinet temperature below 40°C.
WARNING!
In a residential environment this product may cause high-frequency noise,
so that suppression measures may be required.
3.1.4 Guidelines for UL approval
The devices are certified to UL 508C and UL 840.
}UL 508C describes the fulfilment by design of minimum requirements for electrically op-
erated power converters, such as frequency converters and servo amplifiers.
}UL 840 describes the fulfilment by design of clearance and creepage distances on elec-
trical equipment and printed circuit boards.