WEISS EF2 Series User manual

MANUAL
ELECTRICAL SYSTEM DOCUMENTATION
ROTARY INDEXING TABLE CONTROLER
EN_06_2016
EF2

Document: Manual
Revision: R06-2016
Version: V01
This document is referred to as "instructions" in the following text.
These instructions are valid for the product designated subsequent.
Product: Rotary indexing table controller
Type: EF2...B
This document has been prepared by
WEISS GmbH, Siemensstrasse 17, D-74722 Buchen
© Copyright
All rights in this document are the copyright of WEISS GmbH. This document may not be copied or reproduced, in
whole or in part, without the written permission of WEISS GmbH. This document is only intended for the user of the
product described and may not be passed on to third parties, in particular competitors.

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TABLE OF CONTENTS
1 INTRODUCTION ............................................................................................................................................. 7
1.1 Definition ................................................................................................................................................ 7
1.2 Intended use .......................................................................................................................................... 7
1.3 Target group .......................................................................................................................................... 7
1.4 Controller components ........................................................................................................................... 8
1.5 Further applicable documents ............................................................................................................. 11
1.6 Manual ................................................................................................................................................. 11
1.6.1 Validity ................................................................................................................................................. 11
1.6.2 Standard scope .................................................................................................................................... 11
1.6.3 Explanation of safety instructions in this manual ................................................................................. 12
1.6.4 Legend ................................................................................................................................................. 12
1.6.5 Figures ................................................................................................................................................. 12
1.6.6 Directory of valid pages ....................................................................................................................... 12
2 SAFETY ......................................................................................................................................................... 13
2.1 Fundamental safety instructions .......................................................................................................... 13
2.1.1 Operator‘s obligation to exercise diligence .......................................................................................... 13
2.1.2 Technical safety ................................................................................................................................... 14
2.1.3 Electrostatic safety ............................................................................................................................... 15
2.1.4 Ambient and operating conditions ....................................................................................................... 15
2.2 Emergency-off circuit ........................................................................................................................... 15
2.3 Residual hazards ................................................................................................................................. 16
3 COMPONENT DESCRIPTIONS .................................................................................................................... 18
3.1 Power Modules PM240-2 .................................................................................................................... 18
3.1.1 Safety instructions ............................................................................................................................... 18
3.1.2 Power Module PM240-2; frame size FSA ............................................................................................ 19
3.1.3 Power Module PM240-2; frame size FSB ............................................................................................ 20
3.1.4 Technical data ..................................................................................................................................... 21
3.1.5 Overview Power Module PM240-2 ...................................................................................................... 23
3.2 External braking resistor (option) ......................................................................................................... 24
3.2.1 Technical data ..................................................................................................................................... 24
3.3 Motor contactor .................................................................................................................................... 25
3.3.1 Technical data ..................................................................................................................................... 25
3.4 Safety relay .......................................................................................................................................... 26
3.4.1 Technical data ..................................................................................................................................... 27
3.5 Terminal Module TM15 ........................................................................................................................ 28
3.6 Brake Relay ......................................................................................................................................... 29
3.6.1 Technical data ..................................................................................................................................... 29
3.6.2 Brake Relay connection example ........................................................................................................ 30
3.7 SIMOTION D410-2 Control Unit .......................................................................................................... 31
3.7.1 Technical data ..................................................................................................................................... 32
3.7.2 MAC Addresses ................................................................................................................................... 33
3.7.3 CompactFlash Card ............................................................................................................................. 33
4 FUNCTION AND SIGNAL DESCRIPTIONS ................................................................................................. 34
4.1 Signal description of the software inputs ............................................................................................. 34
4.2 Signal description of the software outputs ........................................................................................... 36
4.3 Functions and signals TM15 ................................................................................................................ 38
4.3.1 Terminal Module TM15 connection example ....................................................................................... 38

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4.4 Time sequence diagrams .................................................................................................................... 39
4.4.1 Example for time sequence diagram of the signal "Start cycle CW" .................................................... 39
4.4.2 Example for time sequence diagram of the signal "Start level CW" .................................................... 40
4.5 Interface assignment D410-2 ............................................................................................................... 41
4.5.1 Interface X120 ..................................................................................................................................... 41
4.5.2 Interface X121 ..................................................................................................................................... 42
4.5.3 Interface X124 ..................................................................................................................................... 42
4.5.4 Interface X127 ..................................................................................................................................... 43
4.5.5 Interface X130 ..................................................................................................................................... 43
4.5.6 Interface X131 ..................................................................................................................................... 44
4.6 Interface assignment TM15 ................................................................................................................. 45
4.6.1 Interface X520 ..................................................................................................................................... 45
4.6.2 Interface X521 ..................................................................................................................................... 45
4.6.3 Interface X522 ..................................................................................................................................... 46
5 SAFETY FUNCTIONS ................................................................................................................................... 47
5.1 Integrated safety functions (SIL2) ........................................................................................................ 47
5.2 Extended safety functions (SIL3) ......................................................................................................... 47
6 INSTALLATION ............................................................................................................................................. 51
6.1 External braking resistor (option) ......................................................................................................... 51
6.1.1 Dimensions, hole patterns ................................................................................................................... 51
6.1.2 Mounting / Connecting the braking resistor ......................................................................................... 54
6.2 Power Module PM240-2; frame size FSA / FSB ..................................................................................55
6.2.1 Dimensions, hole patterns ................................................................................................................... 56
6.2.1.1 Frame size EF2037 to EF2220 ................................................................................................ 56
6.2.1.2 Frame size EF2300 ................................................................................................................. 57
6.2.2 Mounting the shielding plate ................................................................................................................ 58
6.2.3 Mounting / Connecting the power module ........................................................................................... 59
6.2.4 EMC-compliant installation .................................................................................................................. 60
6.2.4.1 Power mains connection 1 AC 200 V - 240 V / 0.37 kW ......................................................... 61
6.2.4.2 Power mains connection 3 AC 380 V - 480 V / 1.5 kW ........................................................... 62
6.2.4.3 Power mains connection 3AC 380 V - 480 V / 2.2 - 3.0 kW .................................................... 63
6.2.5 Connecting the motor .......................................................................................................................... 64
6.2.5.1 Permissible motors .................................................................................................................. 65
6.2.5.2 Motor connection PM240-2, frame size FSA ........................................................................... 65
6.2.5.3 Motor connection PM240-2, frame size FSB ........................................................................... 66
6.3 Brake Relay ......................................................................................................................................... 67
6.3.1 Mounting the brake relay ..................................................................................................................... 67
6.4 Safety relay .......................................................................................................................................... 68
6.4.1 Mounting Safety Relay 3SK1122-1CB41 ............................................................................................. 68
6.5 Terminal Module TM15 ........................................................................................................................ 69
6.5.1 Mounting Terminal Module TM15 ........................................................................................................ 69
6.6 SIMOTION D410-2 Control Unit .......................................................................................................... 70
6.6.1 Mounting the control unit ..................................................................................................................... 70
6.6.2 Inserting the CF card ........................................................................................................................... 71
6.6.3 Creating a shield connection ............................................................................................................... 72
7 EF2 - PC CONNECTION ............................................................................................................................... 73
7.1 Presettings ........................................................................................................................................... 73
7.2 Ethernet communication via TCP/IP (via switch) ................................................................................. 75

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8 OPERATION / DESCRIPTION OF WEISS SOFTWARE .............................................................................. 76
8.1 Start page ............................................................................................................................................ 77
8.1.1 User interface on the start page .......................................................................................................... 78
8.1.2 Login .................................................................................................................................................... 79
8.2 Overview .............................................................................................................................................. 80
8.3 Machine configuration .......................................................................................................................... 81
8.3.1 Ethernet interface ................................................................................................................................ 81
8.3.2 Reset factory settings .......................................................................................................................... 82
8.3.3 Configuration diagram ......................................................................................................................... 83
8.3.4 Indexer configuration ........................................................................................................................... 84
8.3.4.1 Start indexer configuration ....................................................................................................... 84
8.3.4.2 Indexer configuration via file .................................................................................................... 86
8.3.4.3 Comment regarding indexer configuration data file ................................................................. 88
8.3.5 I/O configuration .................................................................................................................................. 89
8.3.5.1 Start I/O configuration .............................................................................................................. 89
8.3.5.2 EF1 compatible configuration .................................................................................................. 98
8.3.5.3 Comment regarding I/O configuration data file ...................................................................... 106
8.3.6 Dynamic parameters .......................................................................................................................... 107
8.3.7 I/O mapping ....................................................................................................................................... 108
8.3.8 Fieldbus data mapping ...................................................................................................................... 109
8.4 Maintenance ...................................................................................................................................... 110
8.4.1 Configuration file / Diagnostic file ...................................................................................................... 111
8.4.1.1 Request diagnostic file .......................................................................................................... 111
8.4.1.2 Request configuration file (controller internal backup file) ..................................................... 112
8.4.2 Licenses ............................................................................................................................................. 113
8.4.3 User manager .................................................................................................................................... 114
8.5 Operation and Monitoring .................................................................................................................. 115
8.5.1 I/O monitoring .................................................................................................................................... 115
8.5.1.1 Monitoring inputs and outputs ............................................................................................... 115
8.5.1.2 Forcing via the "Request authority of control" button ............................................................ 116
8.5.1.3 Forcing via the "Open separate user screen" button: ............................................................ 117
8.5.2 Fieldbus data monitor ........................................................................................................................ 118
8.5.3 Manual operation ............................................................................................................................... 119
8.5.3.1 Manual operation: Opening a second browser window ......................................................... 120
8.5.3.2 Manual operation: Setting inputs ........................................................................................... 121
8.5.3.3 Manual operation: Measuring cycle quick stop ...................................................................... 122
8.5.3.4 Manual operation: Optimization of stop delay time ................................................................ 124
8.5.3.5 Manual operation: Continuous mode ..................................................................................... 125
8.5.4 Statistical data ................................................................................................................................... 126
8.5.5 Messages .......................................................................................................................................... 127
8.5.6 Siemens default pages ...................................................................................................................... 128
8.6 Help ................................................................................................................................................... 128
9 EXTENDED OPTIONS ................................................................................................................................ 129
9.1 HW limit switch .................................................................................................................................. 129
10 COMMUNICATION WITH A HIGHER-LEVEL CONTROLLER .................................................................. 130
10.1 Profibus DP ........................................................................................................................................ 130
10.1.1Interface X21 ..................................................................................................................................... 133
10.2 Profinet IO RT .................................................................................................................................... 134
10.2.1Interface X150 ................................................................................................................................... 138

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11 DIAGNOSTICS ............................................................................................................................................ 139
11.1 Messages .......................................................................................................................................... 139
11.2 Error and state indicators ................................................................................................................... 140
11.3 Error messages ................................................................................................................................. 141
12 STANDARDS AND APPROVALS .............................................................................................................. 149
12.1 CE marking ........................................................................................................................................ 149
12.2 Electromagnetic compatibility ............................................................................................................ 149
12.3 cULus approval .................................................................................................................................. 150
13 APPENDIX ................................................................................................................................................... 151
13.1 EF2...B; 0.37 kW Controller connection examples ............................................................................ 151
13.1.1SIL2 Power Module connection example .......................................................................................... 151
13.1.2SIL2 D410-2 Interface I/O connection example ................................................................................. 152
13.1.3SIL2 Interface I/O Module TM15 (option) connection example ......................................................... 153
13.1.4SIL3 Power Module connection example .......................................................................................... 154
13.1.5SIL3 D410-2 Interface I/O connection example ................................................................................. 155
13.1.6SIL3 Safety relais connection example .............................................................................................. 156
13.1.7SIL3 Interface I/O Module TM15 (option) connection example ......................................................... 157
13.2 EF2...B; 1.5 kW to 3.0 kW Controllers connection examples ............................................................ 158
13.2.1SIL2 Power Module connection example .......................................................................................... 158
13.2.2SIL2 D410-2 Interface I/O connection example ................................................................................. 159
13.2.3SIL2 Interface I/O Module TM15 (option) connection example ......................................................... 160
13.2.4SIL3 Power Module connection example .......................................................................................... 161
13.2.5SIL3 D410-2 Interface I/O connection example ................................................................................. 162
13.2.6SIL3 Safety relais connection example .............................................................................................. 163
13.2.7SIL3 Interface I/O Module TM15 (option) connection example ......................................................... 164
13.3 Illustration index ................................................................................................................................. 165
13.4 Index .................................................................................................................................................. 167
13.5 Personal notes ................................................................................................................................... 170

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INTRODUCTION | 1.1 Definition
1 INTRODUCTION
1.1 Definition
Rotary indexing table controller EF2...B
The EF2...B rotary indexing table controller is used for the easy to operate and time-optimised control of rotary inde-
xing tables of the TC and TR series in all frame sizes.
The controller is optimally designed for operation with the TC and TR rotary indexing tables and offers you the follo-
wing benefits:
•Optimally tuned frequency converter control for electro-mechanical WEISS rotary indexing tables
•Intuitive, web-based user interface for fast commissioning
•No brake wear, soft start-up from intermediate positions minimizes the impact on the gearing
•Increased performance through fully automatic optimisation cycle
•Remote support and remote diagnostics options
•Worldwide use due to various power supply configurations
•Compact hardware (all-in-one)
•Fieldbus connection: PROFIBUS and PROFINET on board
•Interface: Digital I/O optional with TM15 module
•Integrated safety function SIL2 / PLd
•SIL3 / PLe available with additional measures
1.2 Intended use
The components for the controller and drive are approved for industrial and commercial application in industrial
mains supply.
All information regarding the technical data and the permissible conditions at the location of use must be complied
with.
Commissioning (starting the intended operation) of the machine in which the components described here are to be
installed is not allowed until the conformity of the machine with the EMC Directive 2014/30/EC and the Machinery
Directive 2006/42/EC has been determined.
The operation of the controller is permissible only in enclosed housings or in superordinate control cabinets with clo-
sed protective covers while using all protective equipment.
1.3 Target group
These instructions are intended for persons who are responsible for planning, installation, as well as maintenance
and service, and have the adequate qualification and skills to perform these tasks.
Handling the components of the controller is permitted only by qualified and trained personnel who know and comply
with all safety instructions as stated on the components and in the relevant technical user documentation.

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INTRODUCTION | 1.4 Controller components
1.4 Controller components
Fig. 1: Controller components
The components of the controller are delivered as individual modules. Their assembly and wiring are the responsibi-
lity of the user.
Pos. Component Type / Characteristics
(1) Control unit SIMOTION D410-2
(2)
(3)
Power module PM240-2
(frame size FSA)
(frame size FSB)
(4) External Braking resistor Koch (Option)
(5) Module TM15 Option: for digital inputs/outputs
(6) Motor contactor Option: for applications up to SIL3 / PLe
(7) Safety relay Option: for applications up to SIL3 / PLe
1
4
2 3
5 6 7
FSA
FSB

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INTRODUCTION | 1.4 Controller components
Fig. 2: Block diagram of EF2...B controller with PM240-2 FSA
PM240-2 FSA
L1
L2
L3
Ethernet
Digital I/O
24 VDC
Fieldbus
(Profibus / Profinet)
TC
TR
PM-IF
24 VDC
Safe Brake Relay

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INTRODUCTION | 1.4 Controller components
Fig. 3: Block diagram of EF2...B controller with PM240-2 FSB
PM240-2 FSB
L1
L2
L3
Ethernet
Digital I/O
24 VDC
Fieldbus
(Profibus / Profinet)
TC
TR
PM-IF
Safe Brake Relay
24 VDC

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INTRODUCTION | 1.5 Further applicable documents
1.5 Further applicable documents
In addition to this manual, further documents are required for installation of the controller and safe operation of a
machine with this controller. Compliance with the information in these documents must be regarded.
Operating manual, mechanics documentation rotary indexing table TC / TR
Siemens_Documentations on the CF card
1.6 Manual
This manual describes the components of the controller and the installation and commissioning of a rotary indexing
table with the EF2...B controller.
We reserve the right to undertake modifications because of technical developments to the data and illustrations con-
tained in these instructions.
The operating manual and the associated valid documentation are not subject to an automatic revision service.
Information on the respective current edition can be obtained from the manufacturer.
Local regulations must be observed.
This manual describes how to use the controller and contains important information that will support you in using the
device as intended.
This manual describes the handling of the machine and contains important instructions and information to assist you
in correct use of the machine.
A PDF file with these instructions is also available on the CF card of the controller.
Safety instructions in individual chapters should be observed.
The manual is to be kept for further use and must be handed over to subsequent owners, users or end customers.
1.6.1 Validity
These instructions are valid for EF2 controllers of the series:
1.6.2 Standard scope
The scope of the functionality described in this document can differ from the scope of the functionality of the drive
system that is actually delivered.
Other functions that are not explained in this document may be available in the drive system. However, there is no
entitlement to these functions when the equipment is first delivered or when it is being serviced.
The documentation may also contain descriptions of functions that are not available in a particular product version of
the drive system. The functionalities of the supplied drive system should only be taken from the purchase order
documents.
Extensions or changes made by the machine manufacturer must be documented by the machine manufacturer.
•EF2037B For motors up to 0.25 kW
•EF2150B For motors up to 1.1 kW
•EF2220B For motors up to 1.5 kW
•EF2300B For motors up to 3.0 kW

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INTRODUCTION | 1.6 Manual
1.6.3 Explanation of safety instructions in this manual
This manual contains instructions that you should observe for your personal safety and to avoid material damage.
Safety instructions for your personal safety are highlighted by a sign containing a warning triangle and signal word.
The associated text describes the hazard involved, avoidance options and the consequences which may result from
failure to observe the safety instructions.
General instructions or instructions relating to possible material damage are highlighted by a sign without a warning
triangle.
They are, depending on the degree of risk involved, illustrated as follows:
1.6.4 Legend
Symbols and abbreviations with the following meaning are used in this manual to make its content more clear:
1. Indicates a numbered list.
a) Indicates the second level of a numbered list.
•Indicates a list.
Indicates the second level of a list.
The book symbol before a section of text indicates further applicable documents.
The information symbol before a section of text marks an additional note or an important tip for use.
1.6.5 Figures
The figures used show the parts of the controller as examples. There may be differences between the illustrations
and the actual delivered controller.
1.6.6 List of valid pages
Pages of this manual including the title page: 172
DANGER
A warning triangle with the signal word DANGER indicates an immediate hazar-
dous situation, which, if not avoided, will lead to fatalities or severe injuries.
WARNING
A warning triangle with the signal word WARNING indicates a potential hazar-
dous situation, which, if not avoided, can lead to fatalities or severe injuries.
CAUTION
A warning triangle with the signal word CAUTION indicates a potential hazar-
dous situation, which, if not avoided, can lead to light or medium injuries.
NOTICE
A sign with the signal word NOTICE indicates potential material damage or pro-
vides additional information, which should be observedwhen operating thema-
chine.

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SAFETY | 2.1 Basic safety instructions
2SAFETY
2.1 Basic safety instructions
The controller corresponds to the state of the art and the applicable stipulations of the VDE. It provides a high level
of safety.
This safety can only be achieved during actual operation, however, when all associated necessary measures have
been performed. The operator is obliged to plan these measures and to inspect their execution.
Only suitably qualified personnel may install, commission, and maintain the machine.
This personnel must take into account the information provided in the technical customer documentation for the pro-
duct, and be familiar with and observe the specified danger and warning notices.
2.1.1 Operator‘s obligation to exercise diligence
The operator must ensure that
•The controller and the machine controlled by it are only used as intended.
•The controller and the machine controlled by it are only operated in perfect working condition and the mechanical
and electrical safety equipment are present.
•this manual and all other applicable documentation is maintained at all times in legible condition and is accessi-
ble at the iinstallation site of the machine. Ensure that all personnel who must carry out tasks on the machine
have access the manuals at all times..
•all safety instructions and warnings affixed to the product are not removed and must remain legible.
•national accident prevention guidelines and company-internal guidelines are complied with.
•VDE regulations are complied with.
•the EMC legislation is complied with during installation.

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SAFETY | 2.1 Basic safety instructions
2.1.2 Technical safety
WARNING
During operation, electrical equipment and motors have parts and components with hazardous voltage levels, which
touched, can cause severe bodily injury or death.
All work on the electrical system must be carried out when the system has been disconnected from the power supply
(de-energized).
In combination with the drive system, the controllers are generally approved for operation on TN and TT systems
with a grounded neutral point.
During operation on IT systems, the occurrence of a first fault between an active part and the ground must be
signalled by a monitoring device. In accordance with HD 60364-4-41, it is recommended that the first fault be elimi-
nated as quickly as practically possible.
Operation in different networks is not permissible.
In systems with a grounded external conductor, an isolating transformer with grounded neutral point (secondary
side) must be connected between the mains and the drive system to protect the motor insulation from excessive
stress. The majority of TT systems have a grounded external conductor, so in this case an isolating transformer
must be used.
Flawless and safe operation of the controller assumes proper transportation in the transportation packaging, correct
long-term storage in the transport packaging, proper setup and installation, as well as careful operation and mainte-
nance.
In addition to the danger and warning information provided in the technical customer documentation, the applicable
national, local, and system-specific regulations and requirements must also be taken into account.
To ensure compliance with EN 61800-5-1 and UL 508, only safety extra-low voltages may be connected to connec-
tions and terminals on the electronic modules.
Using protection against direct contact via DVC A (PELV) is only permissible in areas with potential equalization and
in dry rooms indoors. If these conditions are not fulfilled, then other protective measures against electric shock must
be taken (e.g. touch protection).
NOTICE
As part of routine material tests, the controller components will undergoes a voltage test in accordance with EN
61800-5-1. Before the voltage test is performed on the electrical equipment of machines acc. to EN 60204-1, Sec-
tion 19.4, all connectors of the controller component must be disconnected / unplugged to prevent the equipment
from being damaged.
Motors should be connected according to the wiring schematic supplied with the motor (refer to the connection
examples for motor modules). Direct connection to the three-phase supply is not permitted because it would
damage the motors.
Operating the equipment in the immediate vicinity (<1.8 m) of mobile telephones with a transmitter power of >1 W
may cause the components to malfunction.

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SAFETY | 2.2 Emergency Stop Circuit
2.1.3 Electrostatic safety
2.1.4 Ambient and operating conditions
2.2 Emergency Stop Circuit
For immediate shutdown and to prevent unexpected startup, an emergency stop circuit must be used.
The design of a suitable safety concept for operation of a machine with the described controller is the
responsibility of the operator.
NOTICE
Electrostatic sensitive devices (ESDs) are individual components, integrated circuits, or modules that may be dama-
ged by either electrostatic fields or electrostatic discharge.
Regulations for handling ESD components:
When handling electronic components, make sure that personnel, workstations, and pakkaging are well grounded!
Personnel may only come into contact with electronic components, if
•they are grounded with an ESD wrist band, or
•they are in ESD areas with conductive flooring, ESD shoes or ESD grounding straps.
Electronic modules should only be touched if absolutely necessary.
They must only be handled on the front panel or, in the case of circuit boards, at the edge.
Electronic modules must not come into contact with plastics or items of clothing containing synthetic fibres.
Electronic modules must only be placed on conductive surfaces (work surfaces with ESD surface, conductive ESD
foam, ESD packing bag, ESD transport container).
Do not place electronic modules near display units, monitors, or television sets (minimum distance from screen > 10
cm).
Measurements can only be taken on electronic modules when the measuring device is grounded (e.g. via protective
conductors) or, in the case of an isolated measuring device, when the measuring probe is briefly discharged before
measurements are taken (e.g. by touching a bare metal housing).
NOTICE
The components must be protected against conductive contamination, for example:
- Compliance with the standards (chapter 12 „Standards and approvals“ on page 149)
- Inspection of the safety equipment
- Installation in a cabinet with a degree of protection IP54B according to EN 60529
Under the circumstances that conductive contamination at the installation site can definitely be excluded, a lower
degree of cabinet protection may be permitted.

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SAFETY | 2.3 Residual hazards
2.3 Residual hazards
When carrying out a risk assessment of a machine in accordance with the EC Machinery Directive, the machine
manufacturer must consider the following residual risks which originate at the components of the controller and the
drive:
•Unintentional movements of driven machine components during commissioning, operation, maintenance, and
repairs caused by, for example:
Hardware malfunctions and/or software errors in the sensors, controllers, actuators, and connection techno-
logy
Response times of the controller and drive
Operating and/or ambient conditions which are not within the scope of the specification
Condensation/conductive contamination
Parameterization, programming, cabling, and installation errors
Use of radio devices / cellular phones in the immediate vicinity of the controller
External influences / damage
•Extreme temperatures as well as emissions of light, noise, particles, or gases caused by, for example:
Component malfunctions
Software errors
Operating and/or ambient conditions which are not within the scope of the specification
External influences / damage
•Hazardous shock voltages caused by, for example:
Component malfunctions
Influence of electrostatic charges
Induction of voltages in moving motors
Operating and/or ambient conditions which are not within the scope of the specification
Condensation/conductive contamination
External influences / damage
•Electrical, magnetic and electromagnetic fields generated in operation that can pose a danger to persons with a
pacemaker, implants or metal replacements, etc. if they are too close
•Release of environmental pollutants or emissions as a result of improper operation of the system and/or improper
disposal of components
For more information about residual risks of the components in the controller, refer to the relevant chapters in
this document.

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SAFETY | 2.3 Residual hazards
WARNING
Electric shock
Power and control connections can still conduct electricity even if the machine is at a standstill. Work on electrical
equipment should only be performed by qualified electricians in compliance with the instructions in the operating
manual for the electrical system documentation. Electrical connections for the machine should only be disconnected
or plugged in when the power supply is deactivated and secured against reactivation. Touching energised compon-
ents can lead to serious or fatal injuries.
Residual energy
After the frequency converter has been disconnected from the power supply, a residual charge may still be present.
After shutting downthe device and before disconnecting the plugs, wait at least five minutes and then check whether
the capacitor has been discharged to a voltage of < 65V DC at the "DCP" and "DCN" terminals. The fact that the
LEDs on the drive are off is not an indication that the unit is disconnected from the line supply and there is no voltage.
Touching live parts can result in death or serious injury.
Electrical, magnetic, or electromagnetic fields
Electrical, magnetic and electromagnetic fields (EMFs) generated in operation can pose danger to persons who are
present in the immediate vicinity of the product - especially to persons with pacemakers, implants, or similar devices.
The relevant directives and standards have to be observed by the machine / plant operators and persons present in
the vicinity of the product! These are, for example, EMF Directive 2004/40/EEC and standards EN 12198-1 to -3 for
the European Economic Area (EEA) and in the Federal Republic of Germany, the accident prevention regulation
BGV 11 and the associated rule BGR 11 "Electromagnetic fields" from the German employer's liability accident
insurance association.
They state that a hazard analysis must be performed for every workplace and measures must be derived from it and
appliedinordertoreducedangersandtheir impactonpersons,andthatexposureanddangerzonesmustbe defined
and observed.
The relevant safety instructions in each chapter must be observed.
Danger to life due to high leakage currents if the external protective conductor is interrupted
The drive components generate a high leakage current trough the protective conductor. Touching conductive parts
can cause death or serious injuries if the protective conductor is interrupted.
The protective conductor (PE) must meet the following conditions:
• The protective conductor (PE) is routed so that it is protected against mechanical damage.
• The protective conductor (PE) must have a cross-section of ≥ 10 mm2Cu or ≥ 16 mm2Al.
• If the protective conductor (PE) in the connection cable does not meet this minimum cross section, then an addi-
tional ground conductor needs to be routed parallel to the protective conductor (PE) and with a fixed connection to
the machine.
• The protective conductor (PE) corresponds to the local regulations with increased leakage current.
RCD
When using the EF2 controller, RCDs are not suitable for establishing safety circuits for the protection of persons
against electrical hazards.
The implementation of suitable protective measures is the responsibility of the operator.
Switching elements (main switches, contactors), for switching the power drive system on and off must have a max.
delay time of 35 ms between the closing/opening of the individual main contacts.
Risk of injury due to absent safety equipment.
Safety equipment and covers that have been removed for maintenance purposes must be put back into place before
switching the machine back on. Operation without safety equipment and covers is prohibited.
The implementation of a safety concept is the responsibility of the operator. The operator must plan for and provide
sufficient protective measures such as fences, light barriers, emergency-stop circuits, covers, warning signs, etc.
CAUTION
Risk of injuries due to burning.
Depending on their design, components (motor, frequency converter) may have hot surfaces during operation.
Operating temperatures > 60° C are possible. Touching hot components will lead to burns.

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COMPONENT DESCRIPTIONS | 3.1 Power Modules PM240-2
3 COMPONENT DESCRIPTIONS
3.1 Power Modules PM240-2
The power modules are designed as follows:
•Mains-side diode rectifier
•DC-link electrolytic capacitors with pre-charging circuit
•Output inverter IGBT
•Braking chopper for (external) braking resistor
•24 V DC / 1 A power supply
•Gating unit, actual value acquisition
•Fan to cool the power semiconductors
The power modules cover a power range from 0.37 kW to 3.0 kW (versions without line filter).
3.1.1 Safety instructions
WARNING
Electric shock
After all voltages have been disconnected, a hazardous voltage may still be present in the power unit for up to 5
minutes. The cover for the terminals may only be opened after this time has elapsed.
The DC-link discharge time must be legible on the component in the corresponding national language.
Damaged components may not be operated further. Non-observance can result in damage and accidents.
The drive components generate high leakage currents in the protective conductor. The components must only be
operated in cabinets or in closed electrical operating areas and must be connected with the protective conductor. In
order to provide protection against electric shock, the protective conductor connection on the cabinet or machine
must be implemented in accordance with one of the following measures:
- Fixed connection and protective conductor connection with cross sectional areas ≥ 10 mm2 Cu or ≥ 16 mm2 Al
- Stationary connection and automatic shutdown of the power supply if the protective conductor is interrupted
Ground / Protective ground
The power module housing must always be grounded. If the power module is not correctly grounded, then extremely
hazardous states can develop which, under certain circumstances, can result in death.
NOTICE
Connection authorization
Powermodules havebeen designedfor use inindustrialenvironments and generate current harmonics on the mains
side as a result of the rectifier circuit.
When connecting a machine with integrated power modules to the public low-voltage line supply, authorization is
required in advance from the local power supply company (utility company) if:
- the rated input current of the machine ≥ 16 A per conductor, and
- the rated input current of the machine does not comply with the requirements specified in EN 61000-3-2 regarding
current harmonics.

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COMPONENT DESCRIPTIONS | 3.1 Power Modules PM240-2
3.1.2 Power Module PM240-2; frame size FSA
Fig. 4: Interfaces of Power Module PM240-2; frame size FSA
The connections for mains, brake resistor and motor are detachable plug connections and are located on the
bottom side of the power module.
Refer to the device manual of the manufacturer for further information.
Pos. Interface Description
(1) L / N Power mains connection
(2) PE Protective ground connection for the line supply cable
(3) DCN / DCP DC bus negative / DC bus positive
(4) DCP / R2 Braking resistor connection
(5) PE Protective ground connection for the motor cable
(6) U2 / V2 / W2 Motor connection
(7) PM-IF Power module interface
(8) - Brake relay connection
(9) - Shield terminal connection set
(10) - Brake Relay
12
3 4
5 6
7
9
8
10
DCP DCN R2

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COMPONENT DESCRIPTIONS | 3.1 Power Modules PM240-2
3.1.3 Power Module PM240-2; frame size FSB
Fig. 5: Interfaces of Power Module PM240-2; frame size FSB
The connections for mains, brake resistor and motor are detachable plug connections and are located on the
bottom side of the power module.
Refer to the device manual of the manufacturer for further information.
Pos. Interface Description
(1) L1 / L2 / L3 Power mains connection
(2) PE Protective ground connection for the line supply cable
(3) DCN / DCP DC bus negative / DC bus positive
(4) DCP / R2 Braking resistor connection
(5) PE Protective ground connection for the motor cable
(6) U2 / V2 / W2 Motor connection
(7) PM-IF Power module interface
(8) - Brake relay connection
(9) - Shield terminal connection set
(10) - Brake Relay
1 2
5 6
7
9
8
10
3 4
DCP DCN R2