Pilz PMCtendo DD5 User manual

Operating Manual — No. 1002236-EN-01
Servo amplifiers
Operating Manual PMCtendo DD5
Operating Manual PMCtendo DD5
PMCtendo DD5

This document is a translation of the original document.
All rights to this documentation are reserved by Pilz GmbH & Co. KG. Co ies may be made
for internal ur oses.
Suggestions and comments for im roving this documentation will be gratefully received.
Pilz®, PIT®, PMI®, PNOZ®, Primo®, PSEN®, PSS®, PVIS®, SafetyBUS ®, SafetyEYE®,
SafetyNET ®, the s irit of safety® are registered and rotected trademarks of
Pilz GmbH & Co. KG in some countries.
SD means Secure Digital.
Preface

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [email protected] 1
Contents
Contents
Contents Page
Chapter 1 Introduction
1.1 Validity of the documentation 1-1
1.1.1 Retaining the documentation 1-1
1.2 Overview of documentation 1-2
1.3 Definition of symbols 1-3
Chapter 2 Overview
2.1 Unit structure 2-1
2.1.1 Unit features 2-1
2.1.1.1 Power element 2-1
2.1.1.2 Control element 2-2
2.2 Front view 2-4
2.3 Plan view 2-5
2.4 Scope of supply 2-6
2.5 Type code 2-7
2.6 Type label 2-8
Chapter 3 Safety
3.1 Intended use 3-1
3.1.1 Hazard analysis 3-1
3.1.2 Electrical data 3-1
3.1.3 Environmental conditions 3-1
3.1.4 Guidelines for UL approval 3-2
3.1.5 Safety function STO 3-2
3.1.6 Use of qualified personnel 3-3
3.1.7 Warranty and liability 3-4
3.1.8 Disposal 3-4
3.2 Safety during operation 3-5
3.3 Standards 3-6
3.4 Stop and E-STOP functions 3-8
3.4.1 Stop functions 3-8
3.4.2 E-STOP functions 3-8
Chapter 4 Function description
4.1 Overview 4-1
4.2 Power element 4-3
4.2.1 Mains voltage 4-3
4.2.2 Motor connection 4-5
4.2.3 Motor holding brake 4-6
4.2.4 Brake resistor 4-8
4.2.5 Intermediate circuit 4-9
4.3 Control element 4-11
4.3.1 Supply voltage 24 VDC 4-11

Contents
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2
4.3.2 Digital inputs and outputs 4-11
4.3.2.1 Overview 4-11
4.3.2.2 Digital inputs 4-12
4.3.2.3 Digital outputs 4-13
4.3.3 Safety function STO 4-14
4.3.3.1 Safety information 4-14
4.3.3.2 Signal states 4-15
4.3.3.3 Connection example 4-16
4.3.4 Analogue inputs 4-17
4.3.5 Encoder systems 4-18
4.3.5.1 Overview 4-18
4.3.5.2 Resolver 4-21
4.3.5.3 SinCos encoder 4-22
4.3.5.4 Incremental encoder 4-24
4.3.5.5 Absolute encoder with SSI interface 4-25
4.3.6 Electronic gearing 4-26
4.3.6.1 Stepper motor control systems (pulse/di-
rection)
4-27
4.3.6.2 Master-Slave mode 4-27
4.3.7 Encoder emulation 4-28
4.3.8 Communication interfaces 4-31
4.3.8.1 RS232 interface 4-31
4.3.8.2 CANopen interface 4-31
4.3.9 Tools 4-32
4.4 Expansion cards 4-34
4.4.1 Expansion card I/O-14/08 4-34
4.4.2 Expansion card for PROFIBUS-DP inter-
face
4-36
4.4.3 Expansion card for SERCOS interface 4-36
4.4.4 Expansion card for DeviceNet 4-38
4.4.5 Fieldbus junction box 4-41
4.5 Switch on/switch off behaviour 4-43
4.5.1 Normal operation 4-44
4.5.2 Fault condition 4-45
4.6 Implementation of stop categories 4-47
4.6.1 Stop Category 0 4-47
4.6.2 Stop Category 1 4-49
4.6.3 Stop Category 2 4-51
Chapter 5 Installation
5.1 General requirements 5-1
5.2 Dimensions 5-2
5.3 Installing the servo amplifier 5-3
5.4 Installing the expansion cards 5-5
5.5 Installing the fieldbus junction box 5-6

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Telephone: [phone], Telefax: [phone], E-Mail: [email protected] 3
Contents
Chapter 6 Wiring
6.1 Connector description 6-1
6.2 Block diagram 6-2
6.3 Wiring guidelines 6-4
6.3.1 Protection against contact 6-5
6.3.1.1 Leakage current 6-5
6.3.1.2 Residual current devices FI 6-6
6.3.1.3 Isolating transformer 6-7
6.3.2 Connection cables 6-7
6.4 Wiring procedure 6-9
6.5 EMC-compliant wiring 6-10
6.5.1 Earthing 6-10
6.5.2 Shielding 6-10
6.5.2.1 Shield connection on the front plate 6-11
6.5.2.2 Motor connection 6-12
6.5.3 Filters 6-12
6.5.4 Chokes 6-13
6.6 Power element 6-14
6.6.1 Mains voltage 6-14
6.6.2 Motor with brake 6-15
6.6.3 External brake resistor 6-17
6.6.4 Intermediate circuit 6-17
6.7 Control element 6-20
6.7.1 Supply voltage 24 VDC 6-20
6.7.2 Digital inputs 6-21
6.7.3 Digital outputs 6-22
6.7.4 Analogue inputs 6-23
6.7.5 Encoder systems 6-24
6.7.5.1 Resolver 6-24
6.7.5.2 SinCos encoder with HIPERFACE inter-
face
6-25
6.7.5.3 SinCos encoder with EnDat 2.1 interface 6-27
6.7.5.4 SinCos encoder with EnDat 2.2 interface 6-28
6.7.5.5 SinCos encoder with BISS interface, ana-
logue
6-30
6.7.5.6 SinCos encoder with BISS interface, digital 6-31
6.7.5.7 SinCos encoder with SSI interface 6-33
6.7.5.8 SinCos encoder without data track 6-34
6.7.5.9 Incremental encoder ROD (AquadB) 5 V,
350 kHz
6-36
6.7.5.10 Incremental encoder ROD (AquadB) 5 V,
1.5 MHz
6-38
6.7.5.11 Absolute encoder with SSI interface 6-41
6.7.5.12 Electronic gearing, Master-Slave mode 6-43
6.7.5.13 Encoder emulation 6-46

Contents
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6.7.6 Communication interfaces 6-48
6.7.6.1 RS232 interface 6-48
6.7.6.2 CANopen interface 6-49
6.8 Expansion cards 6-52
6.8.1 Expansion card I/O-14/08 6-52
6.8.2 Expansion card for PROFIBUS-DP inter-
face
6-54
6.8.3 Expansion card for SERCOS interface 6-54
6.8.4 Expansion card for DeviceNet 6-55
6.8.5 Fieldbus junction box 6-57
Chapter 7 Commissioning
7.1 Safety information 7-1
7.2 Commissioning the servo amplifier 7-3
7.2.1 Gather the project data 7-3
7.2.2 Wire components 7-3
7.2.3 Preparing for commissioning 7-5
7.2.4 Connect 24 VDC supply voltage 7-5
7.2.5 Establish communication PMCtendo DD5
<-> PC
7-5
7.2.6 Set parameters for the servo amplifier 7-6
7.2.7 Perform the first test run 7-8
7.3 LEDs and keys 7-9
7.3.1 Key functions 7-9
7.3.2 Standard menu 7-9
7.3.3 Advanced menu 7-10
7.4 Messages/errors 7-12
7.4.1 Status messages 7-12
7.4.2 Error messages 7-12
7.4.3 Warning messages 7-13
Chapter 8 Technical details
8.1 PMCtendo DD5.03/230V 8-1
8.2 PMCtendo DD5.06/230V 8-4
8.3 PMCtendo DD5.10/230V 8-5
8.4 PMCtendo DD5.01/480V 8-6
8.5 PMCtendo DD5.03/480V 8-7
8.6 PMCtendo DD5.06/480V 8-8
Chapter 9 Appendix
9.1 Glossary 9-1
9.2 Abbreviations 9-2
9.3 Index 9-4

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Telephone: [phone], Telefax: [phone], E-Mail: [email protected] 1-1
1.1 Validity of the documentation
1 Introduction
11000Introduc tionIntroduc tion1-1.1Validity of th e documenta tion1100Validity of th e documenta tion1-BA_Einfuehrung_1
This documentation is valid for the product PMCtendo DD5. It is valid
until new documentation is published.
This operating manual explains the function and operation, describes
the installation and provides guidelines on how to connect the product
PMCtendo DD5.
][Einfhrun g_Dokumen te_beach ten
Please also refer to the following documents from the motion control
range:
The online help for the PDrive 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 CAN-
open devices.
All these manuals can be found on the supplied CD-ROM: "Motion Con-
trol Documentation".
You will need to be conversant with the information in these documents
in order to fully understand this manual.
BA_Einfuehrung_DD5
This operating manual is valid for the following products:
PMCtendo DD5 from Version 1.1
1.1.1 Retaining the documentation
Retaining the documentation1-Einf Aufbewahren
This documentation is intended for instruction and should be retained
for future reference.

1.2 Overview of documentation
1 Introduction
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Telephone: [phone], Telefax: [phone], E-Mail: [email protected]
1-2
1.2Overview of documentation1200Overview of documentation1-][Einfuehrung_Uebersicht_1
1 Introduction
The introduction is designed to familiarise you with the contents, struc-
ture and specific order of this manual.
2 Overview
This chapter provides information on the product's most important fea-
tures.
3 Safety
This chapter must be read as it contains important information on in-
tended use.
4 Function Description
This chapter describes the product's individual components.
5 Installation
This chapter explains how to install the product.
6 Wiring
This chapter describes the product's wiring.
7 Commissioning
This chapter describes how to commission the product.
8 Technical Details
9 Appendix
This chapter contains a glossary, a list of the abbreviations used and the
index.

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1.3 Definition of symbols
1 Introduction
1.3Definition of symbols1300Definition of symbols1-Einfhrung Zeichen
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 preven-
tive 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.
NOTICE
This describes a situation in which the unit(s) could be damaged
and also provides information on preventive measures that can
be taken. It also highlights areas within the text that are of partic-
ular importance.
INFORMATION
This gives advice on applications and provides information on
special features.

1 Introduction
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Telephone: [phone], Telefax: [phone], E-Mail: [email protected]
1-4

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
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2.1 Unit structure
2 Overview
22000OverviewOverview2-2.1Unit structure2100Unit structure2-
2.1.1 Unit features
Unit features2-][Ueber_Geraeteaufbau_DD5
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
Power element2-Ueber_Merkmale_Leistungsteil_DD5
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, connection to other networks only with isolating transformer
B6 rectifier bridge integrated directly on the three-phase, earthed net-
work, 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 intermediate circuit
Internal brake resistor is standard, external brake resistor available on
request
Inverted rectifier with isolated current measurement and IGBT transis-
tors
Connection of synchronous servo motors, linear motors, asynchro-
nous motors
Fan installed on the following device types:
– 230 V series: 6 A, 10 A
– 480 V series: 3 A, 6 A
][Ueber_Merkmale_Entstoerfilter Integrated noise suppression filters in accordance with EN 61800-3

2.1 Unit structure
2 Overview
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2-2
2.1.1.2 Control element
Control element2-Ueber_Allgemein_Steuerteil
The servo amplifier's control element has the following features:
][Ueber_Merkmale_Versorg_24_VDC_D D5
Supply voltage
24 VDC supply voltage for control element, digital outputs and motor
holding brake
][Ueber_Merkmale_Entstoerfilter Integrated noise suppression filters in accordance with EN 61800-3
Ueber_Merkmale_Geber
Encoder systems
Integrated evaluation of the following encoder systems
Resolver
Incremental encoder
SinCos encoder
– with HIPERFACE® interface
– with EnDat interface 2.1 and 2.2
– with BISS interface
– with SSI interface
Ueber_Merkmale_Ein_Aus_DD5
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
][Ueber_Merkmale_dig_Regelung_protego_D
Digital control
Digital control loop
Digital speed regulator
Digital position controller
Pulse/direction interface for connecting a servo motor to a stepper
motor controller
][Ueber_Merkmale_Parametrierung
Parameter setting
Via the serial interface, using the PDrive commissioning software
Via the CAN interface, using the motion control system PMCprimo C
together with the commissioning software PDrive and CoDeSys (de-
velopment environment in accordance with IEC 61131-3)
][Ueber_Merkmale_Bedienung_protego _D
Operation and display
Servo amplifier operated via two keys
Three-digit LED display for status and messages
Ueber_Merkmale_integrierte_Sicherhei t_DD5

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2.1 Unit structure
2 Overview
Integrated safety
Device safety
– Safe electrical isolation between mains voltage/motor connection
and control element, 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
Ueber_Merkmale_Erweiterungen_D D5
Expansion cards
1 slot for expansion cards:
–I/O
– PROFIBUS
–SERCOS II
– DeviceNet
Fieldbus junction box
CAN Adapter: Splits the combined RS232/CANopen interface on the
PMCtendo DD5 into one RS232 interface and two CANopen interfac-
es wired in parallel

2.2 Front view
2 Overview
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2-4
2.2Front view2200Front view2-Uebersicht_Front
Front view of the PMCtendo DD5
Key:
1: LED display for messages
2: Buttons
3: External brake resistor, intermediate circuit
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 function STO
9: Inputs and outputs, ENABLE, operational readiness
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
ENAB E 12
Digital-Out1 13
Digital-Out2 14
+24 V 1
+24 V 2
DGND 3
DGND 4
5
STO-ENAB E
n.c.
xt
nt
2
1
3
4
5
6
7
9
8

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2.3 Plan view
2 Overview
2.3Plan view2300Plan view2-Uebersicht_Drauf
Plan view of the PMCtendo DD5
Key:
10: Expansion cards
11: Connection for incremental encoder, sine/cosine en-
coder, pulse/direction 24 V
12: Connection for resolver
13: Connection for encoder emulation, Master-Slave
mode, stepper motor control system
14: RS232 interface for commissioning and parameter set-
ting or CANopen controller
X1X2X5X6
10
11
12
13
14

2.4 Scope of supply
2 Overview
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2-6
2.4Scope of supply2400Scope of supply2-Uebersicht_Lie ferumfan g
This is what you receive when you order a servo amplifier from the series
PMCtendo DD5:
Servo amplifier PMCtendo DD5
Mating connectors X0, X3, X4, X8
Operating manual on CD-ROM
Software manual PDrive on CD-ROM
Software tools "PMCprimo Motion Control Tools" on CD-ROM
INFORMATION
The D-Sub mating connectors and the motor connector are not
supplied with the unit! They are available as accessories.

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2.5 Type code
2 Overview
2.5Type code2500Type code2-Typenschlüssel
Fig. 2-1: Type code
Always state when ordering Type Supply voltage
Order number PMCtendo DD5. / / 0 / 0 / 0 / VAC
3 A 03
Current
Hardware options
None
I/O-14/08
SERCOS II
PROFIBUS
DeviceNet
000 100 200 300
Size230V series
6 A
10 A
06
10
1.5 A 01
Current Size480V series
3 A
6 A
03
06
230V series
480V series
110...230 VAC
208...480 VAC
400

2.6 Type label
2 Overview
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2-8
2.6Type label2600Type label2-Typ enschild
The type label is situated on the side of the servo amplifier.
Fig. 2-2: Type label
Key:
Type: Type code
Ident. No.: Order number
Ser. No.: Serial number
Prod.version: Product version
Firmware: Firmware version
Mains Voltage: Mains voltage
Power: Power
Inorm: Continuous output current
YOM: Year of manufacture
Firmware: Firmware version
Prot. type: Protection type
Ambient temp: Ambient temperature

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3.1 Intended use
3 Safety
33000SafetySafety3-3.1Intended use31 00Intended use3-Sicherheit_Bestimmung_DD5
The servo amplifiers PMCtendo DD5 are designed to drive suitable
brushless, synchronous servo motors and asynchronous motors with
speed, torque and/or position control.
][Sicherheit_Bestimmung_Ausschluss
The following is deemed improper use:
Any component, technical or electrical modification to the servo am-
plifier
Use of the servo amplifier outside the areas described in this manual
Use of the servo amplifier outside the documented technical details
(see chapter entitled “Technical Details”)
Intended use includes making the installation and wiring EMC-compli-
ant. Please refer to the guidelines stated in this manual.
3.1.1 Hazard analysis
Hazard analysis3-][Sicherheit_Bestimmung_Gefahrenanalyse
The machine manufacturer must produce a hazard analysis for the ma-
chine. He must take appropriate measures to ensure that unexpected
movements do not lead to hazardous situations for either people or
equipment.
3.1.2 Electrical data
Electrical data3-][Sicherheit_Bestimmung_elektrisch_protego_D
Please note the electrical requirements stated in the chapters entitled
“Technical Details”, “Wiring” and “Function Description”.
3.1.3 Environmental conditions
Environmental conditions3-][Sicherheit_Bestimmung_Umgebung
Please note the following conditions for using the servo amplifier:
Operation of the servo amplifier is forbidden in the following condi-
tions:
– Potentially explosive areas
– Environments containing corrosive and/or conductive acids, alka-
line 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 “Wir-
ing”, section on “Mains voltage”.
–On ships and offshore installations

3.1 Intended use
3 Safety
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3-2
The servo amplifier may only be operated in an enclosed control cab-
inet in compliance with the ambient conditions defined under “Tech-
nical details”. Ventilation or cooling may be required to maintain the
control cabinet temperature below 40 °C.
][EMV_Wohnumgebung
3.1.4 Guidelines for UL approval
Guidelines for UL approval3-Sicherheit_Bestimmung_UL_DD5
Please note the following guidelines for UL approval:
Only use copper wiring that can withstand temperatures of 60°/75°C.
Only use Class 1 wiring or comparable.
Clamping torque for power connection terminals:
X0, X8, X9: 0.5 - 0.6 Nm
Only use the servo amplifier in max. pollution degree 2 environments.
The servo amplifier can be used on supply networks that are able to
provide no more than 42 kA symmetrical at a maximum voltage of 480
VAC.
3.1.5 Safety function STO
Safety function STO3-][Sicherheit_Bestimmung_STO_DD5
The safety function "safe torque off" (Safe Torque Off, STO) activates
the pulse disabler on the servo amplifier 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.
The safety function STO may not be used when the drive is to be
stopped for the following reasons:
Cleaning, maintenance and repair work, or long interruptions in oper-
ation: Remove the voltage and secure the entire plant (main switch).
E-STOP: Switch off the mains contactor (E-STOP pushbutton).
][Sicherheit_Bestimmung_Gefahr
WARNING!
In a residential environment this product may cause high-fre-
quency noise, so that suppression measures may be required.