Pilz PMCprimo MC User manual

PMCprimo MC
Operating Manual-1003813-EN-03
}Control systems

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
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1 Introduction ............................................................................................................................ 6
1.1 Validity of documentation.......................................................................................................... 6
1.2 Retaining the documentation .................................................................................................... 6
1.3 Definition of symbols................................................................................................................. 6
2 Overview ................................................................................................................................. 8
2.1 Unit features ............................................................................................................................. 8
2.2 Front view ................................................................................................................................. 9
2.3 Type code ................................................................................................................................. 10
2.4 Type label ................................................................................................................................. 11
2.5 Scope........................................................................................................................................ 11
3 Safety ...................................................................................................................................... 12
3.1 Intended use ............................................................................................................................. 12
3.2 Safety regulations ..................................................................................................................... 12
3.2.1 Use of qualified personnel ........................................................................................................ 12
3.2.2 Warranty and liability ................................................................................................................ 13
3.2.3 Disposal .................................................................................................................................... 13
3.3 Standards ................................................................................................................................. 13
4 Function description ............................................................................................................. 14
4.1 Device properties...................................................................................................................... 14
4.1.1 Controller .................................................................................................................................. 14
4.1.1.1 Networking with servo amplifier ................................................................................................ 15
4.1.2 Connecting the supply voltage.................................................................................................. 17
4.1.3 Digital inputs ............................................................................................................................. 18
4.1.4 Digital outputs ........................................................................................................................... 19
4.1.5 Interfaces .................................................................................................................................. 19
4.1.5.1 Overview................................................................................................................................... 19
4.1.5.2 CANopen .................................................................................................................................. 20
4.1.5.3 PROFIBUS DP .........................................................................................................................21
4.1.5.4 Ethernet .................................................................................................................................... 21
4.1.5.5 EtherCAT .................................................................................................................................. 21
4.1.5.6 USB .......................................................................................................................................... 22
4.1.6 Encoder .................................................................................................................................... 22
4.1.7 Encoder emulation.................................................................................................................... 23
4.1.8 Reset button ............................................................................................................................. 24
4.2 Software.................................................................................................................................... 25
5 Installation .............................................................................................................................. 26
5.1 General requirements ............................................................................................................... 26
5.2 Dimensions ............................................................................................................................... 26
5.3 Installing the unit....................................................................................................................... 27
5.4 Installing the fieldbus junction box ............................................................................................ 28
6 Wiring ...................................................................................................................................... 29
6.1 Wiring guidelines ...................................................................................................................... 29
6.2 Supply voltage .......................................................................................................................... 29

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6.3 Digital inputs ............................................................................................................................. 31
6.4 Digital outputs ........................................................................................................................... 33
6.5 Interfaces .................................................................................................................................. 35
6.5.1 CANopen X42........................................................................................................................... 35
6.5.2 Ethernet X43............................................................................................................................. 35
6.5.3 EtherCAT X44........................................................................................................................... 36
6.5.4 CANopen, PROFIBUS X51 ...................................................................................................... 36
6.5.4.1 Wiring guidelines for the CANopen interfaces .......................................................................... 37
6.5.5 CANopen X52........................................................................................................................... 38
6.6 Encoder .................................................................................................................................... 39
6.6.1 Supply voltage .......................................................................................................................... 39
6.6.2 Incremental encoder with TTL signal........................................................................................ 40
6.6.3 Absolute encoder with SSI interface......................................................................................... 42
7 Commissioning ...................................................................................................................... 44
7.1 Safety guidelines ...................................................................................................................... 44
7.2 Commissioning the PMCprimo MC........................................................................................... 45
7.2.1 Preparing for commissioning .................................................................................................... 45
7.2.2 Establish communication between PMCprimo MC and PC...................................................... 47
7.2.3 Adapt basic configuration ......................................................................................................... 50
7.2.4 Configure servo amplifier.......................................................................................................... 51
7.2.5 Operate PMCprimo MC HW1 - Show Hardware ...................................................................... 52
7.2.6 Operate PMCprimo MC HW2 - Show hardware ....................................................................... 54
7.3 Install CODESYS...................................................................................................................... 54
8 Operation ................................................................................................................................ 55
8.1 Operating states and changes in operating status ................................................................... 55
8.1.1 Status graph ............................................................................................................................. 55
8.1.2 Operating states ....................................................................................................................... 56
8.1.2.1 "Power Off" operating status..................................................................................................... 56
8.1.2.2 "Startup" operating status ......................................................................................................... 56
8.1.2.3 "Boot Menu" operating status ................................................................................................... 56
8.1.2.4 "RUN" operating status............................................................................................................. 56
8.1.2.5 "STOP" operating status........................................................................................................... 57
8.1.2.6 "Fatal Error" operating status.................................................................................................... 57
8.1.3 Change in operating status....................................................................................................... 57
8.2 Reset, restart, start and stop options........................................................................................ 59
8.2.1 Overview................................................................................................................................... 59
8.2.2 Cold start, "Startup" .................................................................................................................. 60
8.2.3 Reset commands...................................................................................................................... 60
8.2.3.1 Warm reset ............................................................................................................................... 60
8.2.3.2 Cold reset .................................................................................................................................60
8.2.3.3 Original reset ............................................................................................................................61
8.3 Functions of the reset button .................................................................................................... 61
8.4 Messages ................................................................................................................................. 62
8.5 Display elements ...................................................................................................................... 63

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9 Technical details .................................................................................................................... 65
10 Order reference ...................................................................................................................... 69
10.1 Product ..................................................................................................................................... 69
10.2 Accessories .............................................................................................................................. 69

Introduction
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1 Introduction
1.1 Validity of documentation
This operating manual explains the function and operation, describes the installation and
provides guidelines on how to connect the product.
This documentation is valid for the product PMCprimo MC. It is valid until new documenta-
tion is published.
Please also refer to the following documents from the motion control range:
}The online help for the PASmotion commissioning software describes how to set the
parameters for the servo amplifiers from the PMC product area.
}Guidelines regarding installation and environmental conditions can be found in the oper-
ating manual for the servo amplifier PMCprotegoD.
}The configuration and programming software for motion control devices (e.g. CODESYS,
PASmotion) can be found on the Internet at www.pilz.com.
You will need to be conversant with the information in these documents in order to fully un-
derstand this operating manual.
1.2 Retaining the documentation
This documentation is intended for instruction and should be retained for future reference.
1.3 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
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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
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2 Overview
2.1 Unit features
PMCprimo MC is a motion controller used to automate multi-axis motion sequences. The
device contains a PLC with the functionality of a logic and motion controller.
}Logic controller universally programmable in accordance with IEC61131-3
}Motion controller
– Speed axes
– Positioning axes
– Synchronisation axes (electrical cam disk)
– Path axes (interpolation)
– Technology functions
}Digital inputs and outputs
– 16 digital inputs, 6 of which are inputs, which can be used as reference inputs
– 16 single-pole digital outputs
}2/3 Mini-I/O sockets for encoder or 1 Mini-I/O socket (X41) for encoder emulation
– Incremental encoder with TTL signal
– Absolute encoder with SSI interface
}Supply voltages for
– Device plus digital outputs
– Encoder
}Memory for
– Applications
– Non-volatile data (non-volatile ST memory)
}USB interface for data exchange
}Reset button
– For switching between operating states
– For a hardware reset (cold start)
– For importing project data when devices are exchanged
}LED display for device's operating status
}Interfaces
– 1 Ethernet TCP/IP on RJ45 socket
– 1 EtherCAT on RJ45 socket
– 2 CANopen on RJ45 socket
– 1 CANopen on 9-pin female D-Sub connector
}1 CANopen or 1 PROFIBUS DP interface on 9-pin male D-Sub connector, selectable with
software

Overview
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2.2 Front view
X46
USB
CAN1
X45
X43
X44
ECat
RESET
ETH
FUNC
X41
ENC1
STAT
CAN2
X56
ENC2
X55
ENC3
X52
CAN3
X51
CAN4
X50c
X50b
X50a
PB
X40a
X40b
X42
[1]
[5]
[3]
[4]
[2]
[6]
[7]
[8]
[9]
[10]
[11]
[17]
[16]
[15]
[14]
[13]
[12]
Legend
[1] Type label, on the side of the housing
[2] Reset button and LEDs to display operating states
[3] X46, USB interface
[4] X45, unused
[5] X44, EtherCAT interface
[6] X43, Ethernet TCP/IP interface
[7] X42, CANopen interfaces
[8] X41, Connection for encoder 1 or in emulation mode: Output encoder
[9] X40b, Digital inputs and outputs
[10] X40a, supply voltages for device and encoder on the right-hand side of the device
[11],
[12]
X50a, X50b, Supply voltages for device and encoder on the left-hand side of the
device
[13] X50c, Digital inputs/outputs
[14] X51, CANopen/PROFIBUS DP interface

Overview
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[15] X52, CANopen interface
[16] X55, Connection for encoder 2
[17] X56, Connection for encoder 3
2.3 Type code
Type
PMCprimo MC. _ / _ _ _ _ _ _ / _
CPU 1.3 GHz
16DIDO
Software option
Without
Path interpolation
Dynamic curve calculation
IEC 61131 - 3 programming
2 3 4 5
Hardware
C
6 7
Fig.: PMCprimo MC type code
Explanation of type code
}CPU
Clock frequency of processor
}Hardware
– Diverse interfaces, see section entitled Interfaces [ 19] plus an optional
PROFIBUS DP Slave interface via software switching.
}Software
–2: Software options not enabled
–3, 5, 7: Dynamic curve calculation enabled
The dynamic curve calculation is a calculation program for allocation tables.
–4-7: IEC 61231-3 programming enabled
The PLC functionality is programmed with CODESYS.
–6, 7: Path interpolation enabled
PLC functionality and path interpolation

Overview
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2.4 Type label
The type label is positioned on the side of the motion controller.
[1] [2] [3] [4]
[5]
[6]
[7]
Fig.: Type label PMCprimo MC
Legend
[1] Order number
[2] Serial number
[3] Hardware version
[4] Firmware version
[5] Type code
[6] Supply voltage, voltage tolerance
[7] Year of manufacture
2.5 Scope
Order reference Description Order number
PMCprimo MC Motion controller (for function range
see "Type code")
See "Type
code"

Safety
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3 Safety
3.1 Intended use
The motion controller is suitable for use in logic and motion control applications.
Examples of typical application areas for the product are
}Clocked production machinery
}Continuous manufacturing processes (winding, flying saw, cross cutter)
}Machine tools
}Packaging machines
}Pick and place applications
The following is deemed improper use in particular
}Any component, technical or electrical modification to the product,
}Use of the product outside the areas described in this manual,
}Use of the product outside the technical details (see Technical details).
NOTICE
EMC-compliant electrical installation
The product is designed for use in an industrial environment. The product
may cause interference if installed in other environments. If installed in other
environments, measures should be taken to comply with the applicable
standards and directives for the respective installation site with regard to in-
terference.
3.2 Safety regulations
3.2.1 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 prevention,
}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 specific
application.

Safety
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3.2.2 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.).
3.2.3 Disposal
}When decommissioning, please comply with local regulations regarding the disposal of
electronic devices (e.g. Electrical and Electronic Equipment Act).
3.3 Standards
To use the device correctly you will need to have a good knowledge of the relevant stand-
ards and directives. The following standards are relevant:
}EN 61131-1: Programmable controllers – Part 1: General information
}EN 61131-2: Programmable controllers – Part 2: Equipment requirements and tests
}EN 61131-3: Programmable controllers – Part 3: Programming languages
Please note this is not an exhaustive list of safety standards and directives.
Where standards are undated, the 2015-05 latest editions shall apply.

Function description
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4 Function description
4.1 Device properties
4.1.1 Controller
The PMCprimo MC is a programmable logic controller with motion control functionalities.
The controller has volatile and non-volatile memory for the operating system, the data and
the device project with the user program.
It can be used for logic and motion control of intelligent drives.
User programs can be programmed in the main IEC61131-3 languages. The software
CODESYS is used to program the PLC functionality.
The motion controller has 16 digital inputs and 16 single-pole digital outputs. The inputs
and outputs are read cyclically. The cycle time is ≤1ms. It can also access inputs and out-
puts on networked servo amplifiers from the PMC product area.
The motion controller has fieldbus interfaces for communication with the periphery.
3 encoders can be connected (incremental encoder with TTL signal or absolute encoder
with SSI interface).
Two LEDs provide information on the operating states of the controller and indicate any er-
rors.
X51 X52
X40b
X50c
1 ... 16
X41 X55 X56
(1...4, 9...12)
(5...8, 13...16)
(1...4, 9...12)
(5...8, 13...16)
1 ... 16
X40a
X50a/b
X46
USB
Logic
Motion Control
FUNC
USB
X50a X50b
X40a
EtherCAT
Fig.: Block diagram PMCprimo MC

Function description
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4.1.1.1 Networking with servo amplifier
PMCprimoMC has the following options for networking with servo amplifiers:
Networking of PMCprimoMC(1) with the servo amplifierPMCprotegoD(3)
}Via the communication protocol CANopen
}Via the interface X52 (9-pin D-Sub).
To create a connection, a fieldbus distributor PMCprotego D.CAN-Adapter (2) is required
with the servo amplifier PMCprotego D.
X40a
X50a/b
PMCprotego D.CAN-Adapter (2)
X43
X52
CAN1 CAN2
CANopen 1
PMCprimo MC (1)
PMCprotego D (3)
Ethernet
Fig.: Motion controller with servo amplifier, networking via CANopen
Networking of PMCprimoMC(1) with the servo amplifierPMCprotegoD(3)
}Via the communication protocol CANopen
}Via the interface X42 (RJ45).

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To create a connection, a fieldbus distributor PMCprimo DriveP.CAN-CAN-Adapter (2) is
required with the servo amplifier PMCprotego D.
X40a
PMCprimo DriveP.CAN-CAN-Adapter (2)
X43
CAN1 CAN2
CAN1 CAN2
PMCprimo MC (1)
PMCprotego D (3)
Ethernet X42
Fig.: Motion controller with servo amplifier, networking via CANopen
Networking of PMCprimoMC(1) with the servo amplifierPMCprotegoD(3)
}Via the communication protocol EtherCAT
}Via the interface X44 (RJ45).
There is not adapter required.
X40a
X50a/b
X43
PMCprimo MC (1)
PMCprotego D (2)
Ethernet
X7A
X7B EtherCAT
X44
Fig.: Motion controller with servo amplifier, networking via EtherCAT
INFORMATION
Networking with PROFIBUS between servo amplifier and motion controller
is not possible because both devices operate as slaves.

Function description
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4.1.2 Connecting the supply voltage
Connect the following supply voltages to the device:
Supply voltage for the device, the digital outputs and interfaces
}X40a/Pin 1 and Pin 3
Supply voltage for the device, the digital outputs X40b (24VDC), the interfaces X42 to
X45 and the interfaces X51 and X52
}X50a/Pin 1 and Pin 3 and X50b/Pin 1 and Pin 3
Supply voltage for the digital outputs X50c (24VDC).
The following terminals are linked internally:
– X50a/Pin 1 and X50b/Pin 1 (24V)
– X50a/Pin 3 and X50b/Pin 3 (0V)
– X50a/Pin 2 and X50b/Pin 2
– X50a/Pin 4 and X50b/Pin 4
X46
USB
SNet
CAN1
X45
Out
X43
In
X44
SNet
RESET
ETH
FUNC
X41
ENC1
STAT
CAN2
X56
ENC2
X55
ENC3
X52
CAN3
X51
CAN4
X50c
X50b
X50a
PB
X40a
X40b
X42
X40a
X40a
X50ab
X40b
X50c
Fig.: Connecting the supply voltage for device, digital outputs and interfaces
Connect the following supply voltages for the encoders:
}X40a/Pin 2 and Pin 4
Supply voltage for the encoder X41 (5V, 10-30VDC).
The voltage is wired directly to the Mini-I/O socket X41/Pin1 and Pin2.
}X50a/Pin 1 and Pin 3 and X50b/Pin 1 and Pin 3
Supply voltage for the two encoders X55 and X56 (5V, 10-30VDC).
The following terminals are linked internally:
- X50a/Pin 1 and X50b/Pin 1 (24V)
- X50a/Pin 3 and X50b/Pin 3 (0V)

Function description
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X46
USB
SNet
CAN1
X45
Out
X43
In
X44
SNet
RESET
ETH
FUNC
X41
ENC1
STAT
CAN2
X56
ENC2
X55
ENC3
X52
CAN3
X51
CAN4
X50c
X50b
X50a
PB
X40a
X40b
X42
X56
2
X55
3
X41
ENC1
X50a
X50b X40a
X56
X55
X41
Fig.: Connecting the supply voltage for encoder
CAUTION!
Risk of material damage by applying the supply voltage
Do not connect the supply voltage for the encoder when the encoder input
is used in emulation mode (as an output).
Further information on the emulation mode is available at: Encoder emulation [ 23].
4.1.3 Digital inputs
The device has 16 digital inputs (X40b: Pin1…4 and Pin9…12, X50c: Pin1…4 and
Pin9 …12).
The inputs are compatible with EN61131-2, Type 1.
The time behaviour of the digital inputs depends on the method of use:
}With normal use, the inputs have a filter time of ≤ 600 μs.
}If the inputs are used as reference inputs, the reaction time to 0/1 or 1/0 pulse edges is <
5μs.
}The inputs can be used as reference inputs, to poll the position of the encoder for ex-
ample.

Function description
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4.1.4 Digital outputs
The device has 16 single-pole digital outputs (X40b: Pin5…8 and Pin13…16, X50c:
Pin5…8 and Pin13…16).
Signals at the output
}"0" signal (0 V) at the output:
– Output is high impedance
– No current to the load
}"1" signal (+24 V) at the output:
– Output is low impedance
– Current is supplied to the load
– The maximum current strength per output is 0.5 A.
All digital outputs are protected against short circuit and overload.
The outputs can be used to connect relays, valves or inputs from another controller, for ex-
ample.
4.1.5 Interfaces
4.1.5.1 Overview
The motion controller PMCprimoMC has various fieldbuses for communication with the
periphery. These are available on RJ45 sockets on the front of the device or 9-pin D-Sub
connections. The interfaces are suitable for the following applications:
}CANopen
– Real-time capable networking between CAN devices and the motion controller
– Suitable for applications
– with ≤ 49 subscribers
– with cycle time of ≥1ms
– in existing networks (e.g. with PMCtendoDD5).
– Connection to the servo amplifier PMCprotegoD via the fieldbus junction box PMC-
protegoD.CAN-CANbus Adapter (fieldbus junction box, can be ordered as an option)
}PROFIBUS DP Slave
– Hardware switching via software command, from CANopen to PROFIBUS DP.
– Networking between the motion controller and a PROFIBUS Master.
– Suitable for data exchange with a third party controller.
}Ethernet
–Ethernet TCP/IP
– Communication between the programming device and the motion controller
– Suitable for configuration, programming, commissioning
–Modbus TCP/IP
– Communications protocol based on Industrial Ethernet (TCP/IP over Ethernet).

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– Suitable for networking between the motion controller and a visualisation device or
a PSS4000, for example.
}EtherCAT as a drive bus
– EtherCAT is an Ethernet-based master bus system suitable for industrial use. It is
suitable for real-time capable networking between the motion controller PMCprimo
MC and the servo amplifier PMCprotegoD.
– The PMCprimo MC acts as Master
– Suitable for applications
– with ≤ 32 subscribers
– with cycle time of1ms
}USB
– For data exchange, see section entitled USB [ 22]
4.1.5.2 CANopen
The CAN network is designed as a linear structure. The CANopen communication protocol
is based on CAN.
}CAN networking with the motion controller is suitable for applications with a maximum
subscriber number of ≤ 49 and a cycle time ≥ 1ms.
}Only CAN devices that are known to the controller or support a corresponding device pro-
file can be operated in the motion controller's CAN network.
}CAN devices detected by the motion controller are ready for operation immediately after
the initial network run-up. No complex configuration of the CAN devices is required.
}The overall line length and the length of the stub lines depend on the transmission rate,
see section entitled Wiring guidelines for the CANopen interfaces [ 37].
}Process data objects (PDO) are defined for each CAN device type and cannot be cus-
tomised by the user.
}For servo amplifiers, the "FS" command can be used to set which process data is to be
exchanged between the motion controller and the servo amplifier (see "PMCprimo Pro-
gramming Manual").
}The signal lines must be terminated with resistors (120 Ohm) on the first and last sub-
scriber.
–Interface X42 (RJ45)
For a PMCprimoMC, a terminating resistor can be activated in the fieldbus junction
box PMCprotegoD.CAN-CANbus Adapter or PMCprotegoD.CAN-PROFIBUS Ad-
apter. The resistors are generally integrated within the connected devices and must
not be activated there.
–Interface X51, X52 (9-pin D-Sub connector)
A terminating resistor is permanently installed between Pin 2 and Pin 7. The resistors
are generally integrated within the connected devices and must not be activated
there.