Pilz PMCtendo SZ User manual

PMCtendo SZ
OperatingManual1002405EN03
Pilz Motion Control

Preface
Thisdocumentisatranslationoftheoriginaldocument.
AllrightstothisdocumentationarereservedbyPilzGmbH&Co.KG.Copiesmaybemade
forinternalpurposes.Suggestionsandcommentsforimprovingthisdocumentationwillbe
gratefullyreceived.
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

Operating Manual PMCtendo SZ
1002405-EN-03 3
Table of contents
Table of contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.1 Purpose of the manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2 Further support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3 Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 Notes on Safety . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 Warranty and liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Component part of the product . . . . . . . . . . . . . . . . . . . . . . . 7
2.3 Operation in accordance with its intended use . . . . . . . . . . . 7
2.4 Qualified personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.5 Working on the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.6 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.7 Directives and norms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.8 Presentation of notes on safety . . . . . . . . . . . . . . . . . . . . . . . 9
3 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.1 PMCtendo SZ servo motors. . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.1.1 Type label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.1.2 Order reference. . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.2 Drive controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.3 Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.4 Dynamic performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.5 Operating mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.6 Thermal winding protection . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.7 Cooling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.8 Holding brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.8.1 Motor holding brake . . . . . . . . . . . . . . . . . . . . . . . . 15
3.8.2 Brake test and grinding . . . . . . . . . . . . . . . . . . . . . . 16
3.9 Motor shaft and bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4 Transportation and storage. . . . . . . . . . . . . . . . . 17

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Table of contents
4.1 Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.2 Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.1 Installation Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.2 Install motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6 Electrical installation . . . . . . . . . . . . . . . . . . . . . . 21
6.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.1.1 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.1.2 Earthing, shielding and EMC. . . . . . . . . . . . . . . . . . 22
6.1.3 Selecting the cables . . . . . . . . . . . . . . . . . . . . . . . . 23
6.1.4 speedtec® and springtec® plug connector . . . . . . . 23
6.2 Servo motor and motor brake . . . . . . . . . . . . . . . . . . . . . . . . 26
6.2.1 Power cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.2.2 Assignment: Motor and power cable . . . . . . . . . . . . 28
6.3 Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6.4 External fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.5 Water cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7.1 Check installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7.2 Check connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7.3 Put into operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
8 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
8.1 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
8.2 In the event of disruptions . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
8.3 Replace motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
9 Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
9.1 Ambient conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
9.2 Device Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
9.3 Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
9.4 Cooling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

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Table of contents
9.4.1 Convection cooling . . . . . . . . . . . . . . . . . . . . . . . . . 40
9.4.2 External fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
9.4.3 Water cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
9.5 Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
9.6 Holding brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
9.7 Thermal winding protection . . . . . . . . . . . . . . . . . . . . . . . . . . 46
9.8 Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
9.8.1 Installation altitude . . . . . . . . . . . . . . . . . . . . . . . . . 47
9.8.2 Ambient temperature. . . . . . . . . . . . . . . . . . . . . . . . 48
9.9 Type-specific data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
9.9.1 Inertia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
9.9.2 Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
9.9.3 Permitted shaft load . . . . . . . . . . . . . . . . . . . . . . . . 64
9.9.4 Voltage limit curves . . . . . . . . . . . . . . . . . . . . . . . . . 70
9.9.5 Key safety-related indicators. . . . . . . . . . . . . . . . . . 79
10 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

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1 Introduction
1Introduction
1.1 Purpose of the manual
This operating manual describes the servo motors PMCtendo SZ. It includes information
about, transport, storage, installation, connection, commissioning, service and disposal.
Please also refer to the documentation for the servo amplifier.
1.2 Further support
If you have any queries that are not covered in this document, you can find more infor-
mation at www.pilz.com
1.3 Modifications
No. Version Date Change
1002504 01 0
7/2012
First edition
1002504 02 09/2012 Update: Feedback system
1002504 03 03/2014 • Additions:
Motor types SZ3x and SZ8x
Type keys
Directives and standards
springtec® plug connector 
Type-specific data
Characteristic safety values
• Updates:
Rating plate
Power cable
Feedback connection
External fan
Thermal winding protection
Electrical installation
Brake data, brake moment of inertia val-
ues
Number of motor poles
Formula symbols

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2 Notes on Safety
2 Notes on Safety
2.1 Warranty and liability
The devices can represent a source of danger. Therefore observe
• the safety guidelines, technical rules and regulations given in the following sections
•andpoints.
Warranty and liability claims will be void if
• the product has not been used for its intended purpose,
• the damage is attributable to a failure to observe the operation instruction,
• the operating personnel has not been properly trained, or
• modifications of any kind have been made.
2.2 Component part of the product
The technical documentation is a component part of a product.
• Since the technical documentation contains important information, always keep it
handy in the vicinity of the device until the machine is disposed of.
• If the product is sold, disposed of, or rented out, always include the technical docu-
mentation with the product.
2.3 Operation in accordance with its intended use
The servo motors are intended for installation in machines or systems or for assembly
with other components in a machine They must be operated in conjunction with suitable
and correctly configured servo amplifiers (e.g. PMCtendo DD4, PMCtendo DD5 or
PMCprotego D).
The thermal motor protection integrated in the motor winding must be monitored and
evaluated.
The following is deemed improper use:
• direct connection to the mains power supply,
• any component, technical or electrical modification,
• use outside the areas described in this manual,
• use outside the documented technical details.

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2 Notes on Safety
2.4 Qualified personnel
Devices may cause residual risks. For this reason, all work on the devices as well as op-
eration and disposal must only be performed by qualified personnel who are aware of the
possible dangers.
Qualified personnel are persons who have acquired the authorisation to perform these
activities by
• Training from specialists and/or
• Instruction from specialists
In addition, they must have
• read,
• understood and
• observed the applicable regulations, legal provisions, rules and standards and exist-
ing technical documentation including the safety information contained in it.
2.5 Working on the machine
Apply the 5 safety rules in the order stated before working on the machine:
1. Activate. Make sure the auxiliary circuits are activated.
2. Secure against unintentional restart.
3. Make sure no voltage is present.
4. Ground and short-circuit.
5. Cover or enclose adjacent live parts.
2.6 Disposal
Please comply with the latest national and regional regulations! Dispose of the individual
parts separately depending on their nature and currently valid regulations such as, for
example:
• Electronic scrap (PCBs)
• Plastic
• Sheet metal
• Copper
•Aluminum
2.7 Directives and norms
The servo motors meet the following guidelines and norms
• Directive 2006/95/EC (Low Voltage Directive)
• Directive 2004/108/EC (Directive on Electromagnetic Compatibility)
• DIN EN 60204-1 version 2007
• DIN EN 60034-1 version 2011

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2 Notes on Safety
• DIN EN 60034-5 version 2007
• DIN EN 60034-6 version 1996
• DIN EN 60034-9 version 2008
• DIN EN 60034-14 version 2008
• UL and CSA approval 
All motors are supplied with certifications as "Recognized Component Class 155 (F)
motor insulation system". 
UL approval is registered with Underwriters Laboratories USA under UL File Number
E182088 (N), Classes OBJY2 and OBJY8, Component-Systems, Electrical Insula-
tion. UL certification is needed mainly for the use of motors and geared motors on
the US market. But, also in many countries UL approval is considered a special mark
of quality.
2.8 Presentation of notes on safety
IMPORTANT
IMPORTANT
This means that material damage may occur
if the safety precautions stated are not observed.
NOTICE!
CAUTION
This means that a minor injury may occur.
if the safety precautions stated are not observed.
WARNING!
Warning
means that there may be a serious danger of death
if the stated precautionary measures are not taken.

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2 Notes on Safety
DANGER!
Danger
means that serious danger of death exists
if the stated precautionary measures are not taken.
INFO
refers to important information about the product or serves to emphasize a
section in the documentation to which the reader should pay special atten-
tion.

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3 Description
3 Description
3.1 PMCtendo SZ servo motors
The PMCtendo SZ synchronous servo motors have a very short design achieved thanks
to an optimized winding technology. This feature makes it possible to manufacture the
stator windings with the highest possible copper fill factor. With this technology and fur-
ther optimizations in the mechanical parts it has been possible to shorten the length of
the motor by almost half without reducing the power output.

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3 Description
3.1.1 Type label
Description Value in example Meaning
Year of 
Manufacturing
YOM 2014 Year of manufacturing 2014
Type PMCtendo SZ.31/0/1/2/7/K/H/60/00 Order references
SN 7008874/001/000/010/00 Serial number
Ident.No. xxxxxxx Identification number
M00,95 Nm Standstill torque: Constant standstill torque for 
250 min-1 ± 5 %
MN0,89 Nm Rated torque; highest constant torque of the motor for
a rated speed nN± 5 %
I0eff 2,02 A Standstill current: I0eff is the current flowing at M0
IN1,93 A Rated current: Constant current at MN± 5 % and 
nN± 5 %
KEM40 V/1000 rpm EMC voltage stability: Peak value of the chained, in-
duced voltage for an operating voltage (∆T = 100 K)
when idle running as generator
KM,N 1,35 Nm/A Torque constant: Constant in the entire functional
range of a motor
n 6000 rpm Rated speed nN
Insul.-class F Thermal class acc. to EN 60034/VDE 0530
IP 56 Protection class
th.prot. PTC thermistor 145 °C Thermal winding protection by PTC drilling
encoder ECI 1118-G2 EnDat 2.2 ST Feedback system

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3 Description
3.1.2 Order reference
1 2 3 4 5 6 7 8 9 10
Product name Size Brake Feedback Design Connection Cooling Voltage Speed Option
1 Product name 5 Design Code
PMCtendo SZ B5, smooth shaft 2
2 Size Code 6 Connection Code
PMCtendo SZ3x 3x Feedback 7
PMCtendo SZ4x 4x
PMCtendo SZ5x 5x 7 Cooling Code
PMCtendo SZ7x 7x Convection K
PMCtendo SZ8x 8x External fan (not applicable for SZ.3x) F
Water cooling (not applicable for SZ.3x) W
3 Brake and dynamic design Code
Without brake and dynamic design 0 8 Voltage Code
With brake and dynamic design 1 400 V (UZK = 540 V) H
Without brake, with increased mass moment 2
of inertia 9 Speed a) Code
(not applicable for SZ.3x, SZ.51, SZ.71) 2000 min-1 20
With brake, with increased mass moment 3 3000 min-1 30
of inertia 4500 min-1 45
(not applicable for SZ.3x, SZ.51, SZ.71) 6000 min-1 60
4 Feedback Code 10 Option Code
Single-turn EnDat® 2.2 ECI1118-G2 1 Standard 00
inductive
Multi-turn EnDat® 2.2 EQN1135 optical 2
a) See section Type-specific data

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3 Description
3.2 Drive controller
The servo motors must be operated in conjunction with a servo amplifier with speed,
torque or position control, e.g. PMCtendo DD4, PMCtendo DD5 or PMCprotego D.
Servo motors, cables and servo amplifiers should always be regarded as one cohesive
system. The most important selection criteria are:
• Constant standstill torque M0[Nm]
• Constant standstill current I0eff [A]
• Rated speed nN[min-1]
• Mass moment of inertia of motor and load J [kgcm2]
• Effective torque (calculated) Meff [Nm]
• Regenerative energy in braking mode
• Overload capacity
•EMC
When selecting the servo amplifier, please consider both the static and the dynamic load
(acceleration/ braking).
3.3 Feedback
PMCtendo SZ motors may be fitted with the following feedback systems:
• Single-turn EnDat ®2.2 ECI1118-G2 inductive,
• Multi-turn EnDat ®2.2 EQN1135 optical.
Single-turn feedback systems provide an absolute position within one revolution while
multi-turn feedback systems specify an absolute position over a number of revolutions.
3.4 Dynamic performance
The PMCtendo SZ motors are designed as standard for applications with high dynamic
performance, i.e. they have the lowest possible mass moment of inertia. As an option the
servo motors can be supplied with an increased mass moment of inertia in order to opti-
mize the inertia ratio between motor and load.
3.5 Operating mode
The servo motors are designed for continuous operation. This corresponds to operating
mode S1 (in accordance with DIN EN 60 034-1).

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3 Description
3.6 Thermal winding protection
The servo motors have a thermal winding protection, which protects the stator winding
from damage in the case of constant overload.
The PMCtendo SZ motors are fitted with PTC drilling as standard. If the motor tempera-
ture reaches a critical level, the ohmic resistance of the PTC resistors increases abruptly
and this indicates motor overload.
3.7 Cooling
As standard the servo motors are dimensioned for convection cooling.
In order to increase the continuous torque output or continuous power output, the servo
motors can be fitted as an option with external fan systems (IP44). External fan systems
can be retrofitted.
In applications requiring a higher protection class than IP44 or a lower noise level, the
servo motors can be water-cooled in the A-side flange.
3.8 Holding brake
WARNING!
Danger to life!
The motor brake is not a safety brake!
Check whether additional safety measures must be taken, e. g. when remaining un-
der suspended loads.
3.8.1 Motor holding brake
The servo motors may be supplied with a built-in permanent magnet brake for backlash-
free holding of the motor shaft. This blocks the rotor when the supply voltage is switched
off. The brake has electromechanical ventilation: The applied voltage generates a mag-
netic field that counteracts the permanent magnetic field and neutralises its influence.
INFO
Each thermal winding protection must be monitored and evaluated by the
servo amplifier or an external triggering device.

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3 Description
As the servo motors can be quickly and actively braked by appropriate setpoint settings
at the servo amplifier, the built-in brakes function as a holding brake. Additional brakes
must be provided for braking when the motor is turning, e.g. for an emergency stop.
3.8.2 Brake test and grinding
If a brake does not perform any friction work over an extended period of time, its friction
factor may change due to accumulations of flash rust or vapors resulting from high motor
temperatures. It is also possible that a slight material distortion may be noted as the re-
sult of major temperature fluctuations.
To ensure the functional safety of brakes, including the case of gravity-loaded vertical ax-
es, the brakes must be subjected to brake tests at regular intervals.
Testing brakes
Load the brake with 1.3 times the load torque. Make certain that the suspended load of
a vertical axis is already exerting torque on the motor when it is at a standstill.
Regrind the brake
If the tested braking torque differs from the required value, a brake can be reground.
To do this, run the motor at maximum 20 rpm.
Release and close the brake once per second so that the motor is required to work
against the closed brake for about 0.7 seconds.
Repeat these steps in the reverse direction of rotation after about 20 cycles. If the nom-
inal holding torque of the brake is still not correct after this regrinding, repeat the entire
process. If the nominal holding torque of the brake has still not been reestablished after
grinding five times, check for other factors that could be responsible for the deviating
nominal holding torque of the brake, for example if the wear limit has been reached.
Depending on the relevant servo inverter types, the grinding routine can also be auto-
mated. For further details see the corresponding documentation.
3.9 Motor shaft and bearings
The servo motors have a smooth shaft end (DIN 6885) on the drive side. With a friction
connection, torque transfer must be achieved through surface pressure. This guarantees
a safe, backlash-free force transfer.
The bearings are designed as ball bearings with permanent lubrication and non-contact
seals.

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4 Transportation and storage
4 Transportation and storage
4.1 Transportation
Secure the shafts and bearings of the servo motor against impact when transporting. Use
eye bolts (if provided) and suitable slings when transporting the servo motor. Only lift the
servo motor at the eye bolts without additional attachments. Never transport the servo
motor on the fan guards or the angular flange sockets.
4.2 Storage
Store the servo motors in enclosed, dry spaces. Storage on the fan guards is not permit-
ted.
If the servo motors are protected from all harmful environmental influences, brief storage
in open-air spaces with roofing is permitted.
Make sure that no condensation forms during storage, e.g. because of extreme tempera-
ture fluctuations with a high level of humidity.
Protect the motor shaft from corrosion when storing over an extended period. Note that
the insulation resistance of the winding must be checked after storing over an extended
period.

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5 Installation
5Installation
WARNING!
Electric shock hazard!
Risk of serious injury from contact with live parts!
Observe the 5 safety rules (see chapter 2.5 Working on the machine).
Disconnect the motor from the power supply before carrying out work!
Ensure that the motor shaft is at a standstill before carrying out work! A rotating rotor
can generate high voltages at the terminals.
Switch off the power supplies to all connected devices and devices to be connected.
Note that dangerously high voltages can still occur at the servo amplifier even 10
minutes after switching off the power supply due to the residual charge of the DC link
capacitors.
Cover all open electrical connections, e.g with protective caps.
Cordon off the installation area according to the safety regulations, e.g. with barriers,
warning signs.
WARNING!
Burns!
The surface temperature of the servo motor can exceed 65 °C during operation!
Safety measures should be put in place to protect against contact during operation,
whether accidental or intentional.
5.1 Installation Location
The following preconditions apply for the installation location:
• The installation location must be free from aggressive substances and electrically
conductive atmospheres.
• The substructure must be level, vibration-free and torsionally rigid.
• Ensure adequate heat dissipation. Ensure compliance with the admissible ambient
temperature. If necessary, cool the servo motor additionally, e.g. using an external
fan.
• Observe the minimum clearance to the air intake of an external fan.

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5 Installation
The following installation positions are admissible:
Particularly in installation position IM V3, ensure that no liquids from attachments can run
into the motor bearings.
5.2 Install motor
IMPORTANT
Material damage!
Impact and other forces can cause damage to the bearings, feedback system and motor
shaft.
Do not hit the motor shaft or motor housing with a hammer or other tools.
Do not apply any pressure, impact or high acceleration to the motor.
Use backlash-free, frictionally engaged chucks or clutches.
Always use the tightening thread provided in the motor shaft to fit or remove clutches,
gears or belt pulleys. Use suitable tools!
Motor External fan Minimum distance xFmin [mm]
SZ.4x FL4 20
SZ.5x FL5 20
SZ.7x FL7 30
SZ.8x FL8 30
Admissible installation positions
IM B5 IM V1 IM V3

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5 Installation
IMPORTANT
Material damage!
Solvent damages the sealing lips of the shaft seal rings.
Make sure that solvent can not come into contact with the sealing lips of the shaft
seal rings.
Prepare the motor for installation
• Check the motor for transport damage. Never install a servo motor that shows clear
signs of damage!
• Check the insulation resistance of the winding of the motor after storage.
• Thoroughly remove anti-corrosion agents and/or contamination on the motor shaft.
This can be done using a standard solvent. Make sure that the solvent can not come
into contact with the sealing lips of the shaft seal rings, otherwise materials may be
damaged.
• If possible, warm up the drive elements, e.g. belt pulley
• Make sure that the paintwork of the servo motors is not damaged.
Install motor
• Align the clutch correctly. Misalignment can cause undue vibration and can damage
the ball bearings and clutch!
• Mechanical overdefinition of the motor shaft bearing should be avoided. A rigid clutch
and/or an external additional bearing (e.g. in the gear unit) can cause excess me-
chanical stress on the motor shaft.
• Prevent temperature-sensitive components coming into contact with the motor.
During operation, the surface temperature of the servo motor can exceed 65 °C!
• When removing the eye bolts after installation, permanently close the threaded hole
according to the protection class of the motor.