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

Introduction
Operating Manual PMCtendo DD5
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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
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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