Pilz PMCenergy SD User manual

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Operating Manual PMCenergy SD
1004547-EN-01
Table of contents
Deutsch
3
1 Introduction
1.1 Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Environmental protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 Working with this Operating Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3.1 Target group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3.2 Basic information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3.3 Abbreviations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3.4 Symbols used in the text . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3.5 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 Description of the device
2.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.2 Applied guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.3 Type designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.4 Overview diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.5 Type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.6 Labels on the housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.7 Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.8 Electrical supply data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.9 Dimensions and weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.10 Noise emission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3 Basic safety instructions
3.1 Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.2 The device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4 Transport / Storage / Installation
4.1 Checking the delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.2 Transporting the Dynamic Energy Storage Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.3 Storing the Dynamic Energy Storage Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.4 Unpacking the Dynamic Energy Storage Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.5 Installing the Dynamic Energy Storage Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.6 Earthing the Dynamic Energy Storage Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5 Commissioning
5.1 Connecting the Dynamic Energy Storage Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.2 Connecting two or more Dynamic Energy Storage Units in parallel . . . . . . . . . . . . . . . . . . . . 21
5.3 Connecting two or more servo amplifiers with a DC link system
to a Dynamic Energy Storage Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.4 Connecting the RS422 communication interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.5 Disconnecting the Dynamic Energy Storage Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.6 Conditioning the Dynamic Energy Storage Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6 Other tasks
6.1 Cleaning the Dynamic Energy Storage Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.2 Maintenance of the Dynamic Energy Storage Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.3 Repairing Dynamic Energy Storage Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.4 Disposing of an Dynamic Energy Storage Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Operating Manual PMCenergy SD
1004547-EN-01
Table of contents
Deutsch
4
7 Extension module (option)
7.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.2 Transport / Storage / Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.3 Connecting an extension module to the Dynamic Energy Storage Unit . . . . . . . . . . . . . . . . . 27
7.4 Connecting an additional extension module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7.5 Disconnecting an extension module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
7.6 Other tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
8 Ordering data

Operating Manual PMCenergy SD
1004547-EN-01
Introduction
English
5
1I NTRODUCTION
1.1 Foreword
We would like to thank you for the confidence you have placed in us by choosing our
pioneering energy technology.
We thank you for your trust in us.
As a system provider, we set reliable standards in energy technology with our inno-
vative products.
1.2 Environmental protection
Packaging We use environmentally friendly materials for our packaging which can be disposed
of via the local waste disposal system.
Equipment The manufacturer will take back faulty equipment or equipment which is no longer in
use.
1.3 Working with this Operating Manual
1.3.1 Target group
This Operating Manual is aimed at qualified electricians who are to work with the Dy-
namic Energy Storage Unit
in all phases of its service life.
1.3.2 Basic information
This Operating Manual is divided into chapters.
Please note the following:
• Before using the Dynamic Energy Storage Unit, read through this Operating Man-
ual carefully and thoroughly. It is too late when the equipment is in use.
• Make an effort to understand it. Only then will you be able to operate the Dynamic
Energy Storage Unit safely and as intended.
• Always follow the instructions given in the Operating Manual.
• Keep this Operating Manual close to the device.
Operators must know where it is kept.

Operating Manual PMCenergy SD
1004547-EN-01
Introduction
English
6
1.3.3 Abbreviations
1.3.4 Symbols used in the text
Reference A reference to other pages in this Operating Manual starts with the double arrow
symbol "
 ".
Action and reaction The "
⌧ " symbol indicates an action taken by the operator, while the "  " symbol
shows the resulting reaction of the device.
For example:
⌧ Switch on the main switch.
 The lamp illuminates.
Image items and
relationship between
text and image
Important details are marked with numbers (e.g.
 ) in diagrams.
This is referred to in the text by this number after the associated detail.
BGV Occupational health and safety regulations
EEPROM Electrical erasable programmable read only memory
Electrical erasable programmable read only memory (integrated circuit)
EM Extension module
EN European standard
EU European Union
IT Isolated Terra (no connection to earth)
LED Light-emitting diode
PLC Programmable logic control

Operating Manual PMCenergy SD
1004547-EN-01
Introduction
English
7
1.3.5 Definitions
Person-Related
Warning Instructions
A personnel warning consists of several parts:
• a pictogram,
• a signal word that characterises the degree of danger,
• a note about the type of danger and
• one (or several) instruction(s) to prevent the danger, introduced by a "
⌧ " symbol.
Example of a personnel warning:
Property damage Dangers with possible property damage are identified as follows:
Information Additional information is identified as follows:
Application Application" stands for "drive unit with frequency converter" or "servo drive" in this
Operating Manual.
Pictogram Signal word Danger
Danger Danger with a high level of risk which can cause
death or serious injury if it is not prevented.
Warning Danger with a medium level of risk which can
cause death or serious injury if it is not prevented.
Caution Danger with a low level of risk which can cause mi-
nor or moderate injury if it is not prevented.
W ARNING !
There is a risk of injury!
Touching hot surfaces may result in burns.
⌧ Switch off the device at least 30 minutes before cleaning it.
Pictogram Instruction about
Property damage.
Pictogram Instruction about
Additional assistance or other useful information.

Operating Manual PMCenergy SD
1004547-EN-01
Description of the device
English
8
2D ESCRIPTION OF THE DEVICE
2.1 Intended use
Dynamic Energy
Storage Unit
The Energy Storage Unit is used to store braking energy from applications (drives
with frequency converters or servo drives). The Dynamic Energy Storage Unit does
not need its own power supply. It is possible to operate several Dynamic Energy
Storage Unit units in parallel, to increase the maximum power. Optional extension
modules (EMs) can also be used to increase the amount of energy stored.
The Dynamic Energy Storage Unit is supplied according to customer specifications
and may only be operated when these specifications are met.
Expansion Module
(EM)
Expansion modules (EM) are connected to the Dynamic Energy Storage Unit to
increase its energy storage capacity.
If several Dynamic Energy Storage Units are connected in parallel, they must be
distributed symmetrically.
Protective devices Protective devices (e.g. covers) may not be removed.
Place of installation The Dynamic Energy Storage Unit is to be used within electrical cabinets in the
industrial area. Operation in areas at risk of explosion is prohibited.
Modifications Unauthorised modifications are prohibited.
Unauthorised modifications will invalidate all claims under warranty and liability.
Repairs Repairs may only be undertaken by the manufacturer.
2.2 Applied guidelines
The Dynamic Energy Storage Unit meets the basic requirements of the 2014/35/EU
directive (Low Voltage Directive) and the 2014/30/EU directive (EMC directive).

Operating Manual PMCenergy SD
1004547-EN-01
Description of the device
English
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2.3 Type designation
Fig. 1: Type designation
Description of the expansion module, (  Chapter 7, page 27).

Operating Manual PMCenergy SD
1004547-EN-01
Description of the device
English
10
2.4 Overview diagram
Fig. 2: OverviewDynamic Energy Storage Unit
1 Mounting holes (4x), dia. 6.5
2 Connecting terminals for extension
module (X1)
3 Indicator LED
4 Label showing installation location
5 Type plate
6 Warnings
7 RS422 communication interface
(X4 plug)
8 Connecting terminal for DC link and
brake chopper
9 Earth connection






Operating Manual PMCenergy SD
1004547-EN-01
Description of the device
English
11
2.5 Type plate
Fig. 3: Type plate
1 Type designation
2 Serial number
3 Year of manufacture
4 Technical data





Operating Manual PMCenergy SD
1004547-EN-01
Description of the device
English
12
2.6 Labels on the housing
Symbol Words on label / Meaning
Words on label:
"Caution! After switching off the DC link, if the capacitor dis-
charge time > 5 minutes, please read the operator's manual."
Meaning:
The converter must be switched off. The energy store must be
discharged. Check the state of charge via the LED on the top.
While discharging, the lamp should flash more slowly. If in
doubt, measure the voltage between the "DC link" connecting
terminals "-DC" and "+DC" at the bottom of the Dynamic Energy
Storage Unit.
You may only force the discharge with a suitable resistor.
The effective discharge resistance of the entire system must be
>22ohms.
Words on label:
"Warning! Hot surface."
Words on label:
"Danger! Risk of electric shock. After the power supply is
switched off there is a dangerous supply voltage, please read
the operator's manual."
Meaning:
The high DC voltage on the live parts will fall slowly.

Operating Manual PMCenergy SD
1004547-EN-01
Description of the device
English
13
2.7 Ambient conditions
2.8 Electrical supply data
2.9 Dimensions and weight
2.10 Noise emission
The Dynamic Energy Storage Unit does not emit any significant amount of noise
(< 70 dB(A)).
Ambient temperature -10° C to +85° C (transport, storage)
0° C to +40° C (operation)
Relative humidity ≤95% (transport, storage)
≤85% (operation)
Type of cooling Air cooling (convection)
Degree of protection for housing IP20
Degree of contamination at place of in-
stallation
2
Max. continuous voltage on DC link 800 VDC
Maximum power 18 kW
Standby power dissipation < 10 W
Usable storage capacity approx. 1.6 kWs
Built-in discharge resistor PTC, 1750 ohms/35 W at 25° C
Overvoltage category III (installed at altitudes up to 2000 m
above sea level)
II (installed at altitudes over 2000 m
above sea level)
Immunity to interference Industrial area
to EN 6100-6-2-2005 and
EN 6100-6-4-2007
Width 100 mm
Depth 201 mm
Height 300 mm
Weight approx. 6.9 kg

Operating Manual PMCenergy SD
1004547-EN-01
Basic safety instructions
English
14
3B ASIC SAFETY INSTRUCTIONS
3.1 Personnel
Minimum age Not specified.
Duty of care and
attention
Personnel must:
• be qualified electricians.
• have read and understood the Operating Manual.
• have been instructed in how the Dynamic Energy Storage Unit works.
• know how to do the individual jobs.
What to do in an
emergency
Please note the following points:
• The locations of first-aid stations must be known.
• The personnel must be informed about what to do in an emergency.
• Their correct behaviour must be regularly checked monitored and
corresponding records must be kept.
The following must be done in an emergency:
• Provide first aid to all injured persons.
• Call a doctor or your in-house paramedic.
• Notify your manager.
• Follow the instructions from your managers and first-aid staff.
3.2 The device
Functional status The Dynamic Energy Storage Unit may only be operated in a fully functional state.
Before using it, ensure that the Dynamic Energy Storage Unit is in proper working
condition.
Hot surfaces The housing may heat up to 80° C in operation. Do not touch the housing.
Warning symbols Warning symbols are attached to the housing. Any damaged warning symbols must
immediately be replaced.
Housing The housing must not be opened.
Functional faults No electrical equipment may be used near to the Dynamic Energy Storage Unit
which could impair its function.
Vibrations The Dynamic Energy Storage Unit may not be subject to any shock or vibration.

Operating Manual PMCenergy SD
1004547-EN-01
Basic safety instructions
English
15
Requirements
Underwriters
Laboratories (UL)
• Only use 60/75° C copper-stranded wire.
• Marking for proper connection of the power supply, the electrical load and its
regulation.
• For use in the following environment classification:
Pollution Degree 2.
• Maximum ambient temperature (air): 40° C.

Operating Manual PMCenergy SD
1004547-EN-01
Transport / Storage / Installation
English
16
4T RANSPORT / S TORAGE / I NSTALLATION
4.1 Checking the delivery
The Dynamic Energy Storage Unit leaves the factory in a tested and perfect condition.
Special packaging, consisting of cardboard, corrugated cardboard and protective
film, ensures safe transport.
There is a packing label on the outside of the packaging. This contains instructions
for transport, storage and proper handling which must be followed.
Any transport damage is the responsibility of the transport company.
Scope of delivery • 1 × Dynamic Energy Storage Unit
• 1 × Operating Manual Dynamic Energy Storage Unit
Please see the delivery note for the exact scope of delivery.
Checking the delivery:
⌧ Check the packaging for damage.
⌧ Immediately notify the transport company about any damage to the packaging
and/or the Dynamic Energy Storage Unit.
 The transport company must receive a written damage report within 7 days.
4.2 Transporting the Dynamic Energy Storage Unit
⌧ Transport the Dynamic Energy Storage Unit to where it is to be installed in its
original packaging.
⌧ Avoid heavy vibrations and hard knocks.
4.3 Storing the Dynamic Energy Storage Unit
The Dynamic Energy Storage Unit must be stored in clean, dry areas.
Temperatures between -10° C and 85° C are permissible.
Any temperature fluctuations must not exceed 30 K per hour.
4.4 Unpacking the Dynamic Energy Storage Unit
⌧ Carefully remove the Dynamic Energy Storage Unit from its packaging.
⌧ Check that nothing is missing and that it is undamaged.
⌧ Dispose of the packaging in accordance with local regulations for cardboard boxes
and recyclable materials.

Operating Manual PMCenergy SD
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Transport / Storage / Installation
English
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4.5 Installing the Dynamic Energy Storage Unit
Basic information • The Dynamic Energy Storage Unit is intended to be installed in an electrical cabinet.
• The Dynamic Energy Storage Unit must be protected against foreign bodies from
falling in through the cabinet.
• The unit is installed directly on a mounting surface in the switch cabinet.
• The Dynamic Energy Storage Unit needs to be installed right next to the applica-
tion (frequency converter, servo controller) due to the length of the connecting
cable (max. 1 m).
Spacing During installation, the following spacings to other modules must be maintained:
• at the side: at least 20 mm.
• above and below: at least 100 mm.
Installation
Fig. 4: Drilling template
⌧ Install the Dynamic Energy Storage Unit according to the drilling template,
vertically, using four bolts (M6).
 The power connection is at the bottom.
⌧ Check that it is firmly seated.
There is a risk of damage.
The Dynamic Energy Storage Unit must not be mounted upside
down.
⌧ Install the Dynamic Energy Storage Unit vertically.

Operating Manual PMCenergy SD
1004547-EN-01
Transport / Storage / Installation
English
18
4.6 Earthing the Dynamic Energy Storage Unit
Fig. 5: Earthing connection (on the bottom of the housing)
⌧ Earth the Dynamic Energy Storage Unit at its earthing connection  (wire cross-
section according to national standards).
⌧ For screened cables, the screen must also be connected to the earthing connection.
⌧ Carry out a safety inspection according to German standard BGV A3.
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Operating Manual PMCenergy SD
1004547-EN-01
Commissioning
English
19
5C OMMISSIONING
5.1 Connecting the Dynamic Energy Storage Unit
Basic information • The places of operation must be dry and dust-free.
• The air supplied must not contain any electrically-conductive dust, gas or vapour
which could impair functionality. Corresponding remedial measures must be taken
if necessary.
• The Dynamic Energy Storage Unit may only be operated in ambient temperatures
from 0 - 40 °C.
• The Dynamic Energy Storage Unit may only be operated in connection with an ap-
plication which has direct access to the DC link capacity.
• The connecting wires (cross-section to comply with your national standards) be-
tween the Dynamic Energy Storage Unit and the application must not be longer
than 1.0 m, must be laid as a twisted pair and must be proof against short-circuits.
Fig. 6: Connection diagram
1 Application (servo amplifier)
2 Dynamic Energy Storage Unit
D ANGER !
There is a danger of fatal injury.
Danger from electric shock.
The Dynamic Energy Storage Unit may become live if used in
an incorrect area.
⌧ Do not use the Dynamic Energy Storage Unit in IT networks
(IT (Isolated Terra) = floating supplies.)
W ARNING !
There is a risk of injury!
The housing may heat up to 80° C in operation.
⌧ If you have to work on the Dynamic Energy Storage Unit,
wear heat-resistant safety gloves.
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Operating Manual PMCenergy SD
1004547-EN-01
Commissioning
English
20
The commissioning
procedure
Fig. 7: Connecting terminals on the bottom of the housing
⌧ Determine the polarity of the DC link connections.
⌧ De-energise the DC link.
⌧ Make sure that there is no voltage on the DC link.
⌧ Remove the discharge bridge  between "–DC"  (black terminal) and "BR" 
(grey terminal).
⌧ Make sure that there is no voltage between "–DC"  (black terminal) and "+DC" 
(red terminal).
This procedure applies for "automatic setting of the operating
voltage on the DC link".
The brake resistor line is not connected in case for "fixed setting
of operating voltage on the DC link".
There is a risk of damage.
If a brake resistor is installed in the application, due to the the
parallel connection with the brake resistor installed in the
Dynamic Energy Storage Unit the current through the two resis-
tors may become excessive and destroy the brake transistor in
the application.
⌧ See the data sheet for the brake resistor.
⌧ If necessary, modify your application or consult the manufac-
turer.
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