Stober MDS 5000 Training manual

I/O Terminal Module
Commissioning Instructions Installation
Connecting
V 5.6-H or later
09/2013 en

ID 441758.052
Commissioning Instructions I/O Terminal Module
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Table of contents
Table of contents
1 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Notes on Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Component part of the product . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Operation in accordance with its intended use . . . . . . . . . . 5
2.3 Qualified personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.4 Installation and connection . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.5 Commissioning, operation and service . . . . . . . . . . . . . . . . 8
2.6 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.7 Presentation of notes on safety . . . . . . . . . . . . . . . . . . . . . . 9
3 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4 Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.1 X100-X103: Analog and Binary Signals. . . . . . . . . . . . . . . . 13
4.2 Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.2.1 X120. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.2.2 X140. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.2.3 BE encoder and BA encoder simulation . . . . . . . . . . . . . . . 27
4.3 X141: Motor temperature sensor . . . . . . . . . . . . . . . . . . . . . 29

Overview
Commissioning Instructions I/O Terminal Module
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1Overview
I/O terminal module for standard SEA 5001
ID No. 49576
Description
• 2 analog inputs
• 2 analog outputs
• 5 binary inputs
• 2 binary outputs
I/O terminal module for resolver REA 5001
ID No. 49854
Terminals:
• 2 analog inputs
• 2 analog outputs
• 5 binary inputs
• 2 binary outputs
Encoder:
•Resolver
• EnDat® encoder 2.1 Sin-Cos
• TTL incremental encoder (simulation and evalutation)
• SSI encoder (simulation and evalutation)
• Stepper motor signals (simulation and evalutation)
The adapter is included with the REA 5001.
Inverter HW status of the inverter SEA 5001 REA 5001 XEA 5001
MDS 5000A 200 or higher Yes Yes HW status 11 or higher for the
accessories
MDS 5000 up to 199 Yes Yes Yes
Inverter HW status of the inverter SEA 5001 REA 5001 XEA 5001
SDS 5000A 200 or higher Yes Yes HW status 11 or higher for the
accessories
SDS 5000 up to 199 Yes Yes HW status 11 or higher for the
accessories

Overview
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Commissioning Instructions I/O Terminal Module
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I/O terminal module for expanded XEA 5001
ID No. 49015
Terminals
• 3 analog inputs
• 2 analog outputs
• 13 binary inputs
• 10 binary outputs
Encoder:
• TTL incremental encoder (simulation and evaluation)
• Stepper motor signals (simulation and evaluation)
• SSI encoder (simulation and evaluation)
SSI connection cable X120
ID No. 49482
Description: For coupling the SSI interface X120 on the XEA 5001, 0.3 m

Notes on Safety
Commissioning Instructions I/O Terminal Module
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2 Notes on Safety
The devices may cause risks. For these reasons, comply with the following:
• The safety notes listed in the following sections and points
• The technical rules and regulations.
In addition, always read the appropriate documentation. STÖBER ANTRIEBSTECHNIK GmbH + Co. KG
accepts no liability for damages caused by non-adherence to the instructions or applicable regulations.
Subject to technical changes to improve the devices without prior notice. This documentation is purely a
product description. It does not represent promised properties in the sense of warranty law.
2.1 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 documentation with the
product.
2.2 Operation in accordance with its intended use
The SEA 5001, REA 5001 and XEA 5001 accessories are only intended for use with POSIDRIVE®
MDS 5000 and POSIDYN® SDS 5000.
Use with other devices is not permitted

Notes on Safety
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2.3 Qualified personnel
Since the devices may harbor residual risks, all configuration, transportation, installation and commissioning
tasks including operation and disposal may only be performed by trained personnel who are aware of the
possible risks.
Personnel must have the qualifications required for the job. The following table lists examples of occupational
qualifications for the jobs:
Tab. 2-1: examples of occupational qualifications
In addition, the valid regulations, the legal requirements, the reference books, this technical documentation
and, in particular, the safety information contained therein must be carefully
•read
• understood and
• complied with
Activity Possible occupational qualifications
Transportation and storage Worker skilled in storage logistics or comparable
training
Configuration - Graduate engineer (electro-technology or
electrical power technology)
- Technician (m/f) (electro-technology)
Installation and connection Electronics technician (m/f)
Commissioning 
(of a standard application)
- Technician (m/f) (electro-technology)
- Master electro technician (m/f)
Programming Graduate engineer (electro-technology or
electrical power technology)
Operation - Technician (m/f) (electro-technology)
- Master electro technician (m/f)
Disposal Electronics technician (m/f)

Notes on Safety
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2.4 Installation and connection
Installation and connection work are only permitted after the device has been isolated from the power!
The accessory installation instructions allow the following actions during the installation of accessories:
• The housing in the upper slot can be opened
• The housing in the bottom slot can be opened.
Opening the housing in another place or for other purposes is not permitted.
The accessory installation instructions allow the following actions during the installation of accessories:
• The housing in the upper slot can be opened.
Opening the housing in another place or for other purposes is not permitted.
Use only copper lines. For the line cross sections to be used, refer to DIN VDE 0298-4 or DIN EN 60204-1
Appendix D and Appendix G.
Protect the device from falling parts (pieces of wire, leads, metal parts, and so on) during installation or other
tasks in the switching cabinet. Parts with conductive properties inside the inverter can cause short circuits or
device failure.
The motor must have an integrated temperature monitor with basic isolation in acc. with EN 61800-5-1 or
external motor overload protection must be used.
The permissible protection class is protective ground. Operation is not permitted unless the protective
conductor is connected in accordance with the regulations.
Comply with the applicable instructions for installation and commissioning of motor and brakes.

Notes on Safety
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2.5 Commissioning, operation and service
Remove additional coverings before commissioning so that the device cannot overheat. During installation,
provide the free spaces specified in the projecting manuals to prevent the inverter from overheating.
The housing of the drive controller must be closed before you turn on the supply voltage. When the supply
voltage is on, dangerous voltages can be present on the connection terminals and the cables and motor
terminals connected to them. Remember that the device is not necessarily de-energized after all indicators
have gone off.
When network voltage is applied, the following are prohibited:
• Opening the housing
• Connecting or disconnecting the connection terminals
• Installing accessories
Before carrying out any work on the machine, observe all the following five safety regulations in the above-
mentioned sequence:
1. Enable. Ensure that you also activate the auxiliary circuits.
2. Secure against switching on.
3. Ensure that the parts are de-energized.
4. Earth and short-circuit.
5. Cover or isolate any live neighboring parts.
You can then start your work on the drive controller. Repairs may only be performed by STÖBER
ANTRIEBSTECHNIK GmbH + Co. KG.
Send defective devices together with a fault description to:
STÖBER ANTRIEBSTECHNIK GmbH + Co. KG
Department VS-EL
Kieselbronner Str.12
75177 Pforzheim
GERMANY
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
Information
Please note that the discharge time for the intermediate circuit
capacitors is 5 min. You can only ensure that the parts are de-
energized after this time.

Notes on Safety
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2.7 Presentation of notes on safety
NOTICE
Notice
means that property damage may occur
if the stated precautionary measures are not taken.
CAUTION!
Caution
with warning triangle means that minor injury may occur
if the stated precautionary measures are not taken.
WARNING!
Warning
means that there may be a serious danger of death
if the stated precautionary measures are not taken.
DANGER!
Danger
means that serious danger of death exists
if the stated precautionary measures are not taken.
Information
indicates important information about the product or a highlighted
portion of the documentation which requires special attention.

Installation
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3 Installation
WARNING!
Danger of injury/death and property damage due to electric shock!
Before installing accessories, turn off all voltage supplies! Then wait 5 minutes for the DC link capacitors
to discharge. Never begin with accessory installation until after this!
NOTICE
Danger of property damage from incorrect installation of the devices!
It is essential to comply with the following installation instructions to avoid damage to the devices.
You will need one of the following accessory parts before you can connect binary and analog signals to the
inverter. Installation is the same for all four accessory parts.
• SEA 5001, ID no. 49576
• REA 5001, ID no. 49854
• XEA 5001, ID no. 49015
You will need:
• A Phillips screwdriver
• The screws which are pre-mounted on the accessory.
Information
Note that the installation of accessories is identical in POSIDRIVE®
MDS 5000 and POSIDYN® SDS 5000. Only POSIDRIVE®
MDS 5000 is shown in the installation instructions for clarity.
Installation of an SEA 5001, REA 5001 or XEA 5001 in an MDS 5000
1. Unlock the snap catch on the inverter cover:

Installation
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2. Lift up the upper end of the cover from the inverter:
3. Lift the cover up and remove it from the inverter:
4. Insert the accessory part at a slant with the gold contacts in front. The gold
contacts must be in front of the black terminal block.

Installation
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5. Slide the gold contacts into the black connector.
6. Secure the accessory part to the inverter with the mounting screws:
You have now installed the accessory.

Connection
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4 Connection
4.1 X100-X103: Analog and Binary Signals
WARNING!
Danger of machine malfunction due to EMC interference!
Do not use cables longer than 30 m (leads to binary inputs, binary outputs, analog inputs and analog
outputs)!
Terminal description – X100 – SEA 5001, REA 5000, REA 5001, XEA 5001
NOTICE
Machine movement due to unexpected target value
If the analog input is not switched, the inverter will detect a target value default of +5V.
Always operate the inverter with a switched analog input.
Information
Remember that the scanning time and update rate TA min depend
on the complexity of the user program on the inverter. Both times
can assume the values 1, 2, 4, 8, 16 or 32 ms depending on the
scope of the user program. Also consider the setting of parameter
A150 cycle time.

Connection
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Pin Designation Function Data
1 AE1+ + Input of the analog input AE1 
Resolution:
• SEA 5001: 10 bits + sign
• REA 5001 and XEA 5001: 
15 bits + sign
Reference: Pin 3
UE= ± 10 V
Ri= 40 kΩ
TA min = 1 ms
UE max against Pin 3 = 30 V
UE max against prot. cond. = 15 V
UE max against AGND = 30 V
2 AE1-Shunt Current input; shunt connection
Pin 2 must be jumpered with pin 1.
Reference: Pin 3
IE= ± 20 mA
Ri= 510 Ω
Scan time: TA min = 1 ms
3 AE1- Inverted input of analog input AE1 UE max against Pin 1 = 30 V
UE max against prot. cond. = 15 V
UE max against AGND = 30 V
4 AE2+ + Input of analog input AE2;
Resolution:
• SEA 5001, XEA 5001: 
10 bits + sign
• REA 5001: 15 bits + sign
Reference: Pin 5
UE= ± 10 V
Ri= 40 kΩ
TA min = 1 ms
UE max against Pin 5 = 30 V
UE max against prot. cond. = 15 V
UE max against AGND = 30 V
5 AE2- Inverted input of analog input AE2 UE max against Pin 4 = 30 V
UE max against prot. cond. = 15 V
UE max against AGND = 30 V
6 AA1 Analog output 1


Reference: Pin 8
IA max = 10 mA
TA min = 1 ms
Ri= 20 Ω
Resolution:
• MDS 5000: 10 bits + sign
• MDS 5000A, SDS 5000,
SDS 5000A: 11 bits + sign
7 AA2 Analog output 2
8 AGND Reference ground for analog
signals
—
12345678
maximum conductor cross-section
Connection type maximum conductor cross-section
[mm2]
rigid 1,5
flexible 1,5

Connection
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Terminal description X101 - SEA 5001, REA 5001, XEA 5001
Flexible with cable end, without plastic
sleeve
1,5
Flexible with cable end, with plastic
sleeve
0,5
2 leads with the same cross-section
with double cable end
—
maximum conductor cross-section
Connection type maximum conductor cross-section
[mm2]
Pin Designation Function Data
9 GND 18 V Reference ground for pin 19 —
10 DGND Reference ground for pins 11 to
18
—
11 BE1
Binary input
High level: 12–30 V
Low level: 0–8 V
UE max = 30 V
TA min = 1 ms (with timestamp)
IE max = 16 mA at UE max
12 BE2
13 BE3a)
14 BE4a)
15 BE5a)
16 BA1 Binary output IA max = 50 mA at 45 °C, 40 mA at 55 °C
TA min = 1 ms
17 BA2
18 24 V-In
24 V power:
• For XEA 5001 and
• For binary outputs with SEA
5001 and REA 5001
Input area: 18–28.8 V
19 18 V-Out Auxiliary voltage 18 V UA= 16–18 V
IA max = 50 mA
a) BE3, BE4 and BE5 can be used as encoder inputs. See chapter 4.2.3 BE encoder and BA encoder simulation. On the
REA 5001 these inputs can be converted to TTL level with sliding switches S0, S1 and S2.
910 11 12 13 14 15 16 17 18 19
maximum conductor cross-section
Connection type maximum conductor cross-section
[mm2]
rigid 1,5
flexible 1,5
Flexible with cable end, without plastic
sleeve
1,5
Flexible with cable end, with plastic
sleeve
0,5

Connection
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TTL/HTL switchover REA 5001
The identification of the switches and the assignment of the switch positions to the function (HTL/TTL) are
shown on the PCB cover of the REA 5001.
Terminal description X102 – XEA 5001
NOTICE
Machine movement due to unexpected target value
If the analog input is not switched, the inverter will detect a target value default of +5V.
Always operate the inverter with a switched analog input.
2 leads with the same cross-section
with double cable end
—
Switch TTL/HTL Conversion
S0 BE3
S1 BE4
S2 BE5
maximum conductor cross-section
Connection type maximum conductor cross-section
[mm2]
REA 5001
S0
S1
S2

Connection
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Terminal description X103 A – XEA 5001
Pin Designation Function Data
1 AE3+ + Input of analog input AE3
Difference input voltage
Resolution: 10 bits + sign
Reference: pin 2
UE= ± 10 V
Ri= 40 kΩ
TA min=1 ms
UE max against pin 2 = 30 V
UE max against protective conductor =
15 V
UE max against AGND = 30 V
2 AE3- Inverted input of analog input AE3 UE max against pin 1 = 30 V 
UE max against protective conductor =
15 V
UE max against AGND = 30 V
12
maximum conductor cross-section
Connection type maximum conductor cross-section
[mm2]
rigid 1,5
flexible 1,5
Flexible with cable end, without plastic
sleeve
1,5
Flexible with cable end, with plastic
sleeve
0,5
2 leads with the same cross-section
with double cable end
—
Pin Designation Function Data
1 BA3
Binary output IA max = 50 mA
TA min = 1 ms
2 BA4
3 BA5
4 BA6
maximum conductor cross-section
Connection type maximum conductor cross-section
[mm2]
rigid 1,5
flexible 1,5
4
1
2
3

Connection
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Terminal description X103 B - XEA 5001
Flexible with cable end, without plastic
sleeve
1,5
Flexible with cable end, with plastic
sleeve
0,75
2 leads with the same cross-section
with double cable end
—
Information
When the 24 V power fails, binary inputs BE6 to BE13 have signal
status 0 (regardless of the physical signal state).
maximum conductor cross-section
Connection type maximum conductor cross-section
[mm2]
Pin Designation Function Data
5 BA7
Binary output IA max = 50 mA
TA min = 1 ms
6 BA8
7 BA9
8 BA10
9 BE6 Binary input
Bezug: Reference: pin 10 of terminal
X101
High level: 12–30 V
Low level: 0–8 V
UE max = 30 V
TA min = 1 ms
IE max = 3 mA at UE max
9
7
8
5
6
maximum conductor cross-section
Connection type maximum conductor cross-section
[mm2]
rigid 1,5
flexible 1,5
Flexible with cable end, without plastic
sleeve
1,5
Flexible with cable end, with plastic
sleeve
0,75
2 leads with the same cross-section
with double cable end
—

Connection
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Terminal description X103 C – XEA 5001
Pin Designation Function Data
10 BE7
Binary input
Reference: pin 10 of terminal X101
High level: 12–30 V
Low level: 0–8 V
UE max = 30 V
TA min = 1 ms
IE max = 3 mA at UE max
11 BE8
12 BE9
13 BE10
14 BE11
15 BE12
16 BE13
10
11
12
13
14
15
16
maximum conductor cross-section
Connection type maximum conductor cross-section
[mm2]
rigid 1,5
flexible 1,5
Flexible with cable end, without plastic
sleeve
1,5
Flexible with cable end, with plastic
sleeve
0,75
2 leads with the same cross-section
with double cable end
—

Connection
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Examples of connection
1
2
3
6
7
8
X100
Inverter
Potentiometer
R10K AE1+
AA1
AE1-Shunt
AA2 (+ 10 V)
AE1-
AGND
SEA 5001
REA 5001
XEA 5001
1
2
3
6
7
8
X100
Current
(0 - 20 mA, 4 - 20 mA)
Inverter
AE1+
AA1
AE1-Shunt
AA2
AE1-
AGND
SEA 5001
REA 5001
XEA 5001
0 (4) -
20 mA
1
2
3
6
7
8
X100
Inverter
Voltage
max. ± 10 V)(
AE1+
AA1
AE1-Shunt
AA2
AE1-
AGND
SEA 5001
REA 5001
XEA 5001
0-5V
0-10V
max. ± 10 V
1
2
3
6
7
8
X100
Inverter
Analog output voltage
AE1+
AA1
AE1-Shunt
AA2
AE1-
AGND
SEA 5001
REA 5001
XEA 5001
V