Pilz PMCtendo DD5 User manual

PMCtendo DD5
Operating Manual-1002236-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 PMCtendo DD5
1002236-EN-04 3
Section 1 Introduction 8
1.1 Validity of the 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 13
2.3 Plan view 14
2.4 Scope of supply 14
2.5 Type code 15
2.6 Type label 15
Section 3 Safety 17
3.1 Intended use 17
3.1.1 Hazard analysis 18
3.1.2 Electrical data 18
3.1.3 Environmental conditions 18
3.1.4 Guidelines for UL approval 18
3.1.5 Safety function STO 19
3.1.6 Use of qualified personnel 20
3.1.7 Warranty and liability 20
3.1.8 Disposal 20
3.2 Safety during operation 21
3.3 Standards 22
3.4 Stop and E-STOP functions 24
3.4.1 Stop functions 24
3.4.2 E-STOP functions 24
3.4.3 Emergency stop functions 25
Section 4 Function description 26
4.1 Overview 26
4.2 Power element 28
4.2.1 Mains voltage 28
4.2.2 Motor connection 31
4.2.3 Motor holding brake 31
4.2.4 Brake resistor 33
4.2.5 Intermediate circuit 34
4.3 Control element 34
4.3.1 Supply voltage 24 VDC 35
4.3.2 Digital inputs and outputs 35
4.3.2.1 Overview 35
4.3.2.2 Digital inputs 36
4.3.2.3 Digital outputs 37

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4.3.3 Safety function STO 37
4.3.3.1 Safety information 37
4.3.3.2 Signal states 38
4.3.3.3 Connection example 39
4.3.4 Analogue inputs 40
4.3.5 Encoder systems 41
4.3.5.1 Overview 41
4.3.5.2 Resolver 46
4.3.5.3 Encoder 46
4.3.5.4 Incremental encoder 48
4.3.5.5 Absolute encoder with SSI interface 51
4.3.5.6 Hall encoder 52
4.3.6 Electronic gearing 52
4.3.6.1 Stepper motor control systems (pulse/direction) 53
4.3.6.2 Master-Slave mode 53
4.3.7 Encoder emulation 54
4.3.8 Communication interfaces 57
4.3.8.1 RS232 interface 57
4.3.8.2 CANopen interface 57
4.3.9 Tools 57
4.4 Expansion cards 58
4.4.1 Expansion card I/O-14/08 58
4.4.2 PROFIBUS DP interface expansion card 60
4.4.3 Fieldbus junction box 61
4.4.4 PROFINET expansion card 62
4.4.5 Expansion card Fan Controller 62
4.4.6 EtherCAT expansion card 63
4.5 Switch on/switch off behaviour 63
4.5.1 Normal operation 65
4.5.2 Fault condition 66
4.6 Implementation of stop categories 68
4.6.1 Stop Category 0 68
4.6.2 Stop Category 1 68
4.6.3 Stop Category 2 70
Section 5 Installation 73
5.1 General requirements 73
5.2 Dimensions 74
5.3 Installing the servo amplifier 74
5.4 Installing the expansion cards 76
5.5 Installing the fieldbus junction box 77
Section 6 Wiring 78
6.1 Connector description 78
6.2 Block diagram 79
6.3 Wiring guidelines 81
6.3.1 Protection against contact 82

Contents
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6.3.1.1 Leakage current 82
6.3.1.2 Residual current devices FI 83
6.3.1.3 Isolating transformer 84
6.3.2 Connection cables 84
6.4 Wiring procedure 85
6.5 EMC-compliant wiring 85
6.5.1 Earthing 86
6.5.2 Shielding 86
6.5.2.1 Shield connection on the front plate 87
6.5.2.2 Motor connection 87
6.5.3 Filters 88
6.5.4 Chokes 89
6.6 Power element 89
6.6.1 Mains voltage 89
6.6.2 Motor with brake 91
6.6.3 External brake resistor 92
6.6.4 Intermediate circuit 95
6.6.5 Energy store PMCenergy SD 96
6.7 Control element 99
6.7.1 Supply voltage 24 VDC 99
6.7.2 Digital inputs 100
6.7.3 Digital outputs 101
6.7.4 Analogue inputs 102
6.7.5 Encoder systems 103
6.7.5.1 HIPERFACE DSL, one-cable connection 103
6.7.5.2 SFD3, one-cable connection 105
6.7.5.3 Resolver 105
6.7.5.4 SinCos encoder with HIPERFACE interface 107
6.7.5.5 SinCos encoder with EnDat 2.1 interface 109
6.7.5.6 Encoder with EnDat 2.2 interface 111
6.7.5.7 SinCos encoder with BISS interface, analogue 113
6.7.5.8 Encoder with BISS interface, digital 115
6.7.5.9 SinCos encoder with SSI interface 117
6.7.5.10 SinCos encoder without data track 119
6.7.5.11 SinCos encoder with Hall encoder 121
6.7.5.12 Incremental encoder ROD (AquadB) 5V, 350 kHz 123
6.7.5.13 Incremental encoder ROD (AquadB) 5V, 1.5 MHz 125
6.7.5.14 Incremental encoder ROD (AquadB) 5 V, with zero pulse, with Hall en-
coder
129
6.7.5.15 Incremental encoder ROD (AquadB) 5 V, with zero pulse, with Hall en-
coder (X1/X5)
131
6.7.5.16 Incremental encoder ROD (AquadB) 24 V, without zero pulse 133
6.7.5.17 Incremental encoder ROD (AquadB) 24 V, without zero pulse, with Hall en-
coder
134
6.7.5.18 Absolute encoder with SSI interface 137
6.7.5.19 Hall encoder 139
6.7.5.20 Electronic gearing, Master-Slave mode 140
6.7.5.21 Encoder emulation 144

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6.7.6 Communication interfaces 145
6.7.6.1 RS232 interface 145
6.7.6.2 CANopen interface 147
6.8 Expansion cards 148
6.8.1 Expansion card I/O-14/08 148
6.8.2 PROFIBUS DP interface expansion card 151
6.8.3 Fieldbus junction box 151
6.8.4 PROFINET interface expansion card 151
Section 7 Commissioning 152
7.1 Safety information 152
7.2 Commissioning the servo amplifier 153
7.3 LEDs and keys 159
7.3.1 Key functions 159
7.3.2 Status indicator 160
7.3.3 Standard menu 161
7.3.4 Advanced menu 162
7.4 Messages/errors 162
7.4.1 Status messages 162
7.4.2 Error messages 163
7.4.3 Warning messages 164
7.5 Expansion cards 165
7.5.1 PROFINET interface expansion card 165
7.5.2 PROFIBUS DP interface expansion card 165
Section 8 Technical details PMCtendo DD5.01/480V 166
Section 9 Technical details PMCtendo DD5.03/230V 170
Section 10 Technical details PMCtendo DD5.03/480V 174
Section 11 Technical details PMCtendo DD5.06/230V 178
Section 12 Technical details PMCtendo DD5.06/480V 182
Section 13 Technical details PMCtendo DD5.10/230V 186
Section 14 Safety characteristic data 190
Section 15 Order reference 191
15.1 Order reference for device 191
15.2 Order reference for accessories 191
15.2.1 Interface cable, interface adapter 191
15.2.2 Expansion cards 191
15.2.3 Spare connector set 191
15.2.4 Y connector 192
15.2.5 Energy store 192

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Operating Manual PMCtendo DD5
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15.2.6 Connection cable to the motor series "PMCtendo SZ" 192
Section 16 Appendix 193
16.1 Abbreviations 193
Section Glossary 195

Introduction
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1002236-EN-04 8
1 Introduction
1.1 Validity of the documentation
This documentation is valid for the product PMCtendoDD5. It is valid until new documenta-
tion is published.
This operating manual explains the function and operation, describes the installation and
provides guidelines on how to connect the product PMCtendoDD5.
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:
}PMCtendo DD5 from Version1.4
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.
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.

Introduction
Operating Manual PMCtendo DD5
1002236-EN-04 9
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 PMCtendo DD5
1002236-EN-04 10
2 Overview
2.1 Unit structure
2.1.1 Unit features
The compact servo amplifier PMCtendoDD5 consists 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:
}Units with various mains voltages and output currents
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 and continuous output
current:
– 230V series: 1 x 110V - 3 x 230V (3A, 6A, 10A)
– 480V series: 3 x 208V – 3 x 480V (1.5A, 3A, 6A)
}TN network and TT network with earthed star point, symmetrical rated current, connec-
tion to other networks only with isolating transformer
}B6 rectifier bridge integrated directly on the three-phase, earthed network, mains filter
and start-up circuit
}Single-phase supply possible (e.g. for commissioning or set-up mode)
}Fuse protection (e.g. blow-out fuse) through user
}All shield connections directly on the servo amplifier
}Max. intermediate circuit voltage in generator mode:
– 230V series: 135 – 450VDC
– 480V series: 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 [ 96]).
}Internal brake resistor is standard, external brake resistor available on request.
}Inverted rectifier with isolated current measurement and IGBT transistors
}Connection of synchronous servo motors, linear motors, asynchronous motors

Overview
Operating Manual PMCtendo DD5
1002236-EN-04 11
}Fan installed on the following device types:
– 230 V series: 6 A, 10 A
– 480 V series: 3 A, 6 A
}Integrated noise suppression filters in accordance with EN61800-3
2.1.1.2 Control element
The servo amplifier's control element has the following features:
Supply voltage
}24VDC supply voltage for control element, digital outputs and motor holding brake
}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
}4 digital inputs
}2 digital outputs
}1 volt-free relay contact to display operational readiness
}1 input for safety functions STO
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
}Three-digit LED display for status and messages

Overview
Operating Manual PMCtendo DD5
1002236-EN-04 12
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
Expansion cards
}1 slot for expansion cards:
– I/O
– PROFIBUS
– PROFINET
– EtherCAT (cannot be retrofitted)
– Fan controller, available only on request
Fieldbus junction box
}CAN Adapter: Splits the combined RS232/CANopen interface on the PMCtendoDD5
into one RS232 interface and two CANopen interfaces wired in parallel

Overview
Operating Manual PMCtendo DD5
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2.2 Front view
BR
BR
BTB/RTO 1
BTB/RTO 2
Analog-In1+ 3
Analog-In1- 4
Analog-In2+ 5
Analog-In2- 6
AGND 7
Digital-In1 8
Digital-In2 9
Digital-In3 10
Digital-In4 11
ENABLE 12
Digital-Out1 13
Digital-Out2 14
+24 V 1
+24 V 2
DGND 3
DGND 4
5
STO-ENABLE
n.c.
xt
nt
2
1
3
4
5
6
7
9
8
Legend:
1: LED display for messages
2: Keys
3: External brake resistor, intermediate cir-
cuit, optionally energy storage
4: Mains voltage, power element
5: Connection for earth conductor PE
6: Connection for motor
7: Connection for motor brake
8: Supply voltage 24VDC and safety func-
tion STO
9: Inputs and outputs, ENABLE, operational
readiness
Plan view of the PMCtendo DD5

Overview
Operating Manual PMCtendo DD5
1002236-EN-04 14
2.3 Plan view
X1X2X5X6
10
11
12
13
14
Legend:
10: Expansion cards
11: Connection for incremental encoder,
sine/cosine encoder, hall encoder, pulse/dir-
ection 24V
12: Connection for resolver
13: Connection for encoder emulation, Mas-
ter-Slave mode, stepper motor control sys-
tem
14: RS232 interface for commissioning and
parameter setting or CANopen controller
Plan view of the PMCtendo DD5
2.4 Scope of supply
This is what you receive when you order a servo amplifier from the PMCtendo series:
}Servo amplifier PMCtendo DD5
}Mating connectors X0, X3, X4, X8
}Operating manual on CD-ROM
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 PMCtendo DD5
1002236-EN-04 15
2.5 Type code
PMCtendo DD5._ _ / _ _ _ / 0 / 0 / 0 / _ _ _ _ _ VAC
230V
480V
3 A 03
6 A 06
10 A 10
1,5 A 01
3 A 03
6 A 06
Hardware-Option
PROFINET
I/O-14/08
PROFIBUS
000 100 200 A00
230V
480V
110...230 VAC
208...480 VAC
0
1
2
A
5
500
EtherCAT
Type Supply voltage
Series Series
Series
Series
Without
Current Size
Current Size
Fig.: Type code
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.

Overview
Operating Manual PMCtendo DD5
1002236-EN-04 16
Fig.: Type label modified device
Legend
new type Modified type key
Ident. No. Order number
Ser. No. Serial number
Firmware Firmware version
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
Operating Manual PMCtendo DD5
1002236-EN-04 17
3 Safety
3.1 Intended use
The servo amplifiers PMCtendoDD5 are designedto drive suitable brushless, synchronous
servo motors and asynchronous motors with speed, torque and/or position control.
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:
}PMCtendo DD5
– Product version: 1.2
– 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
Operating Manual PMCtendo DD5
1002236-EN-04 18
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".
3.1.3 Environmental 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.
UL Markings
}Use 60°C or 75°C copper wire only for every model of this section.
}Use Class 1 wire only.
}Tightening torque for field wiring terminals X0, X8, X9: 0.5 - 0.6Nm (4.43 to 5.31 lbf in)
}Use in a pollution degree 2 environment.
}These devices provide solid state motor overload protection at 130% of full load cur-
rent.

Safety
Operating Manual PMCtendo DD5
1002236-EN-04 19
}Integral solid state short circuit protection does not provide branch circuit protection.
Branch circuit protection must be provided in accordance with the National Electrical
Code and any additional local codes.
}These devices are not provided with motor over-temperature sensing.
}Suitable for use on a circuit capable of delivering not more than 42kA rms symmetrical
amperes for a max. voltage of 480 Vac.
}The drives may be connected together via the “common bus” (DC bus link) based on
the instructions on p. 61ff. The devices may also be grouped from the AC input side
based on the max. input fuse (e.g. 3 pcs. S346 with one common 6A fuse in line).
3.1.5 Safety function STO
The safety function "Safe torque off" (STO) activates the pulse disabler on the servo ampli-
fier and removes the power to the motor. It meets the requirements in accordance with
EN61800-5-2.
The input STO-ENABLE meets the requirements of EN ISO 13849-1: PL d (Cat. 2) and EN/
IEC 62061: SIL CL 2.
The safety function "safe torque off" corresponds to a category0 stop (uncontrolled stop) in
accordance with EN60204-1.
Improper use STO
The safety function STO may not be used when the drive is to be stopped for the following
reasons:
}Cleaning, maintenance and repair work, long interruptions in operation
Remove the voltage from the entire plant and secure it (main switch).
}Switching off the energy supply of the servo amplifier
(see standard EN60204, emergency switching stop).
Before carrying out any work on the machine, you must comply with the five safety rules in
the order stated:
– Enable (switch off the voltage.)
Also disconnect the auxiliary circuits.
– Secure against reconnection
– Verify that the system is dead
– Carry out earthing and short circuiting
– Provide protection from adjacent live parts.
DANGER!
Risk from rotating motor after STO has been triggered!
The safety function STO switches the motor to torque-free. On motors
without a safe holding brake, moving parts present a threat to life.
Use an additional mechanical measure to block the drives safely (e.g. with
the motor holding brake), particularly with suspended loads.

Safety
Operating Manual PMCtendo DD5
1002236-EN-04 20
DANGER!
Risk from non-safety-related activation of the motor holding brake!
Activation of a holding brake via output BR+/BR- of the servo amplifier is not
safety-related. Depending on the application, hazardous motor movements
may cause serious injury or death.
A motor holding brake activated by the servo amplifier alone is not suitable
for personal protection.
Block the drive through an additional mechanical holding brake, which is ac-
tivated safely.
3.1.6 Use of qualified personnel
The products may only be assembled, installed, programmed, commissioned, operated,
maintained and decommissioned by competent persons.
A competent person is a qualified and knowledgeable person who, because of their train-
ing, experience and current professional activity, has the specialist knowledge required. To
be able to inspect, assess and operate devices, systems and machines, the person has to
be informed of the state of the art and the applicable national, European and international
laws, directives and standards.
It is the company’s responsibility only to employ personnel who
}Are familiar with the basic regulations concerning health and safety / accident preven-
tion,
}Have read and understood the information provided in the section entitled Safety
}Have a good knowledge of the generic and specialist standards applicable to the spe-
cific application.
3.1.7 Warranty and liability
All claims to warranty and liability will be rendered invalid if
}The product was used contrary to the purpose for which it is intended,
}Damage can be attributed to not having followed the guidelines in the manual,
}Operating personnel are not suitably qualified,
}Any type of modification has been made (e.g. exchanging components on the PCB
boards, soldering work etc.).
3.1.8 Disposal
}In safety-related applications, please comply with the mission time TM in the safety-re-
lated characteristic data.
}When decommissioning, please comply with local regulations regarding the disposal of
electronic devices (e.g. Electrical and Electronic Equipment Act).