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Motion Control PMC

1. Abbreviation Meaning AGND Analog ground AS Restart lock option BTB RTO Ready to operate CAN Fieldbus CANopen CE Communit Europeenne CLK Clock signal COM Serial interface for a PC AT DGND Digital ground for 24V and digital I O DIN German Institute for Industrial Standards Disk Magnetic storage diskette hard disk EEPROM Electrically erasable programmable memory EMC Electromagnetic compatibility EMI Electromagnetic interference EN European Standard ESD Electrostatic discharge F SMA Fiber Optic Cable connector according to IEC 60874 2 IEC International Electrotechnical Commission IGBT Insulated gate bipolar transistor INC Incremental interface ISO International Organization for Standardization LED Light emitting diode MB Megabyte NI Zero pulse PC Personal computer PELV Protected low voltage PLC Programmable logic controller PWM Pulse width modulation RAM Volatile memory RBallast RBR Ballast resistor 7 regen resistor RBext External regen resistor RBint Internal regen resistor RES Resolver ROD digital encoder S1 continuous operation S3 Intermittent operation SRAM Static RAM SSI Synchronous serial interface UL Underwriters Laboratories VAC Alternating voltage V DC DC voltage VDE Society of German Electrical Technicians Danger to personnel from Danger to Important AN electricity and its effects N maschinery g
2. 38 Connector assignments general 36 D DE BUS NK sansen 46 POND gt ui UE MM EM 25 DIGFOUTI o 62 DIFECHVESs ui 8 BIE 016 t e aio 112 E ECND ceptus 25 zu pmm 29 Emergency Stop strategies 28 zie P E H 02 Encoder Emulation 64 Error Messages nennen 100 Error messages Ai 98 External fUSINQ 21 External regen restistor 48 F melins 90 Page 118 12 Appendix G GIOUNd sY dugjero Pee D tai 33 Guide to installation of expansion cards 102 H mI PRU UNE T 51 UNIV illa 112 Expansion card 103 Incremental encoder esee 54 78 SONG Aae 30 SNE RIO ana 30 Interface cable 72 K Keypad operation 94 L LED EN n DC 94 M Maintenance eene 112 Master encoder supply 45 Master Slave i 66 MODBUS 2 80 Motor connection with brake 47 P Package supplied 13 PN T 93 Software description 92 Hh oc 16 Expansion card 106 Programmable digital i
3. __ m VCC Enc EGND AGND EGND VCC Enc See encoder datasheet X11 4 X11 3 X11 2 X11 1 Master encoder MODBUS CAN 1A CAN 1B CAN2 Profibus DP S Page 78 Installation manual for PMCtendo DD5 PMCprimo Drive3 9 Interfaces 9 15 2 Absolute encoder SSI e Reference ground is EGND terminal X10 Pin 2 e Number of bits 13 32 e Format Binary or Gray e Clock frequency SSI Clock 100 kHz or 300 kHz set with command FS e Maximum voltage range tracks ref to EGND 5 V DC PMCprimo Drive3 X11 4 150R 2 aa DATA i asp a 1 DATA I DATA I l Tiefpass SSI encoder 1 CLOCK I I Va K RS485 um 6 I CLOCK CLOCK I 5 a EE c VCC Enc X10 2 1 I EGND AGND EGND EGND VCC Enc See encoder datasheet X11 4 X11 3 X11 2 X11 1 Master encoder MODBUS CAN 1A CAN 1B CAN2 Profibus DP S sg o e GEO owe Installation manual for PMC tendo DD5 PMCprimo Drive3 Page 79 9 16 9 16 1 9 16 2 Page 80 9 Interfaces Panel interface Modbus X11 3 These interface is available only at a PMCprimo Drive3 General At the PMCprimo Drive3 MODBUS panels can be connected e g our PMI 315 A special adapter cable is required which can be orderd from us In Standalone mode see PMCprimo programming manual at every control one panel can be connected In networked systems CAN the panel has to be connected to the host system Only th
4. Pull a cable tie by the slot in the shielding rail on the front panel of the servo amplifier Press the shielding of the cable firmly against the front panel with the cable tie LL y Mene 1 E pm AN JT er g mm 1g i 9 cable tie Page 38 Installation manual for PMCtendo DD5 PMCprimo Drive3 8 Installation 8 4 5 2 Technical data for connecting cables Further information on the chemical mechanical and electrical characteristics of the cables can be obtained from our customer service Observe the rules in the section Conductor cross sections on page 22 To reach the max permitted cable length you must use cable material that matches the capacitance requirements listed below 8 4 5 3 Insulation material Sheating PUR polyurethane code 11Y Core insulation PETP polyesteraphtalate code 12Y 8 4 5 4 Capacitance Motor cable less than 150 pF m Resolver Encoder cable less than 120 pF m 8 4 5 5 Technical data e The brackets in the core definition indicate the shielding e All cables are suitable for use as trailing cables e The technical data refer to use as moveable cables e Operating life 1 million bending cycles Cores max Use for Operating Outside Bending mm length temp range diameter radius m C mm mm 4x1 0 50 motor 30 80 10 100 power 4x1 5 50 motor 30 80 10 5 105 power 4x1 0 2x0 75 50 motor incl 30 80 10 5
5. PMCtendo DD5 PMCprimo Drive3 Incremental encoder 5 CN A N 3 5 PRIA Meet __ fa e Q e I A DUI I 2 II NI EI E r O Null Ul EM I RS 485 NI 8 I I VAR E E 1 GND ol cwp 1 E 6 B i Tu Spur B Ul RS 485 _ B _ t ii TN N Motor X1 X2 l E M 8 Lon II i thermal control imei C min 5VDC 5mA Er Ves Vu ooo X6 X5 X2 PC ROD Resolver CAN SSI Page 54 OOOOOOOO O 0000000 X1 HIPERFACE ComCoder Hall EnDat ACURO Sine Encoder Installation manual for PMCtendo DD5 PMCprimo Drive3 9 Interfaces 9 6 7 Sine Encoder without data channel X1 An sine cosine encoder without data channel can be used as standard motor feedback Select feedback type 7 SinCos 5V with W amp S Drive executes wake amp shake to calculate the necessary start up information for the position controller every time the 24V auxiliary voltage is switched on The thermostat contact in the motor is connected via the encoder cable to X1 and evaluated there If lead lengths of more than 50m are planned please consult our customer service Frequency limit 350 kHz Don t use this feedback type with vertical load hanging load PMCtendo DD5 PMCprimo Drive3 Encoder n RT en H ad H ra til TT 15 Up Sense 10 OV 4 5V 5 VP max 250mA 2 OV 7 UM thermal control min 5VDC 5mA ome oto 0000 0000000
6. X6 X5 X2 PC ROD Resolver HIPERFACE CAN SSI ComCoder Hall EnDat ACURO Sine Encoder Installation manual for PMC tendo DD5 PMCprimo Drive3 Page 55 9 Interfaces 9 7 Digital and analog inputs and outputs 9 7 1 Analog inputs X3 The servo amplifier is fitted with two programmable differential inputs for analog setpoints AGND X3 7 must always be joined to the GND of the controls as a ground reference 9 7 1 1 Technical characteristics e Differential input voltage max 10 V e Ground reference AGND terminal X3 7 e Input resistance 10 kQ e Common mode voltage range for both inputs 10 V e Update rate 62 5 us PMCtendo DD5 PMCprimo Drive3 control T setpoint 1 10V ref to CNC GND CNC GND setpoint 2 10V ref to CNC GND BTB RTO BTB RTO Analog In 1 Analog In 1 Analog In 2 Analog In 2 AGND DIGITAL IN1 DIGITAL IN2 DIGITAL IN3 DIGITAL IN4 ENABLE DIGITAL OUT1 DIGITAL OUT2 24V 24V DGND DGND AS ENABLE X4 24V AS Page 56 Installation manual for PMCtendo DD5 PMCprimo Drive3 9 Interfaces 9 7 1 2 Analog In 1 input terminals X3 3 4 Differential input voltage max 10 V resolution 14 bit scalable Standard setting speed setpoint PMCtendo DD5 only 9 7 1 3 Analog In 2 input terminals X3 5 6 Differential input voltage max 10 V resolution 12 bit scalable Standard setting torque setpoint PMCtendo DD5 only Application examples for setpoint i
7. 37 l resistor DGND O GND encoder evaluation lt 3 5 CAN Master LLL com coma PC gt I 1 0 14 08 QD PE connection protective earth PROFIBUS CAN Adapter PMCprimo shieia connection via plug Je chassis ground connection panel e shield connection at the front panel Aa L1 L2 L5 Installation manual for PMCtendo DD5 PMCprimo Drive3 8 Installation 8 4 2 Connection diagram PMCprimo Drive3 X11 4 Master encoder SSI Increm Encoder X11 3 MODBUS Profibus PMCprimo CAN 1B PMCprimo CAN 1A 24 V X10 Installation manual for PMC tendo DD5 PMCprimo Drive3 PMCprimo Drive3 Control 24 V ref to l O GND pe 3 I O GND Digital1 Digital2 Digital3 Digital4 Digital5 Digital6 Digital7 Digital8 X11 4 CAN2 X11 5 Expansion card Ethernet option Compact SS Flash qp PE connection protective earth ue chassis ground connection panel shield connection via plug shield connection at the front panel Page 35 8 Installation 8 4 3 Connector assignments general X6 PC CAN X5 ROD SSI X2 RESOLVER X1 COMCODER pulse direction ENDAT master slave HIPERFACE G BISS 3 g 399 82 amp o e EFPL NDO x0 QN 0 l 10 x 0 QN 000000001l A ad OOOOOOO BTB RTO BTB RTO Analog In 1 Analog In 1 Analog In 2 Analog In 2 AGND DIGITAL IN1 DIGITAL IN2
8. Addressing time minimum 4ms Starting delay maximum 2ms Response time of digital outputs max 10ms LEDs Two LEDs are mounted next to the terminals on the expansion card The green LED signals that the 24V auxiliary supply is available for the expansion card The red LED signals faults in the outputs from the expansion card overload of switching components short circuit Entering a motion block number Motion block number binary Motion block number decimal A6 AS A4 A3 A2 A1 174 0 1 0 1 1 1 Installation manual for PMC tendo DD5 PMCprimo Drive3 Page 103 11 1 2 5 Page 104 Connector assignments 11 Expansions and Accessories The functions are adjustable with the setup software PDrive In the table below the default values are described Connector X11A Pin Dir Default Description Function 1 In A0 Motion block number LSB 2 In A1 Motion block number 21 3 In A2 Motion block number 22 4 In A3 Motion block number 23 9 In A4 Motion block number 24 6 In A5 Motion block number 25 f In A6 Motion block number 26 8 In A7 Motion block number MSB Polls the home switch If a digital input on the base unit is used as a 9 In Reference home input then the input on the expansion card will not be eval
9. DIGITAL IN3 DIGITAL IN4 ENABLE DIGITAL OUT1 DIGITAL OUT2 View looking at the face of the built in connectors X4 24V AS 24V 24V DGND DGND AS ENABLE OFAN a 00000 10 7 15 gf 230 V 400 480 V X8 DC Bus XO Mains X9 motor brake X9 motor brake XO Mains X8 DC Bus pc ilo PE 110 Tal 1 Broke PE il i dc ka N C 2 o L3 2 o 0 2 Brake 13 29 Jl N C 211 Jl DC Rge 3 9 L2 3 9 Fe 3 PE L2 3 U DC Ree 3L 0 Rew 4 9 EP AL Lt 4 U2 Li fl R nt 4 A0 L RB 5 9 0 5 v2 RB 5 o 6 w2 I Coding Keys Page 36 Installation manual for PMCtendo DD5 PMCprimo Drive3 8 Installation 8 4 4 ONO oaARWBN Connector assignments PMCprimo Drive3 X11 5 Ethernet X11 6 CompactFlash Pp X11 4 Master encoder SSI X11 3 MODBUS RS422 X11 2 CAN 1A X11 1 CAN 1B CAN 2 Profibus DP S _ E SE OG E Z225 zzz Option X10 VO View looking at the face of the built in connectors o o o o o o o o o o o o o o o o o o o Installation manual for PMC tendo DD5 PMCprimo Drive3 Page 37 8 Installation 8 4 5 Notes on connection technology 8 4 5 1 Shielding connection to the front panel Remove the outside shroud of the cable and the shielding braid on the desired core length cable tie Secure the cores with a cable tie Remove the outside shroud of the line on a length from for instance 30mm without damaging the shielding braid
10. Enable OV The example shows a circuit diagram with two separated work areas connected to one emergency stop circuit For each work area individually safe stop of the drives is switched by a protective screen The safety switchgears used in the example fulfill at least the safety category 3 according to DIN 954 1 33 Consider the wiring instructions on page 85 Page 88 Installation manual for PMCtendo DD5 PMCprimo Drive3 9 Interfaces 9 20 4 3 9 20 4 4 Installation manual for PMC tendo DD5 PMCprimo Drive3 Functional test With initial starting and after each interference into the wiring of the drive or after exchange of one or several components of the drive the function of the restart lock must be tested First Method 1 Stop drive with setpoint OV keep servo amplifier enabled Do not enter hazardous area 2 Activate the restart lock AS e g by opening protective screen voltage at X4 5 OV Now the BTB RTO contact opens the net contactor releases and the servoamplifier displays error F27 Second Method 1 Stop all drives with setpoint OV disable servo amplifier 2 Activate the restart lock AS e g by opening protective screen voltage at X4 5 OV Now the servo amplifier displays S Mains supply circuit mains 3 3 im i PE a a ae HEN 3 3 3 I j T 1 Il DC Bus Link 3 3 3 3 3 F8 p AVAL MASA ms OF jc f f CX N N X N N Nag M Lm switch 1 x
11. Profibus DP S JO SEI Option Using the Profibus interface with PMCprimo With Profibus 16 bus variables can be used for data exchange See PMCprimo programming manual bus variables e Adress range bus variables Bx to Bx 16 x 1 3 5 offset adjustable with CD e Data width 16 Bit 22 Bytes resp 1 Word including sign e Data range 32768 to 32767 Hex 0x8000 to Ox7FFF Defining bus variables to trigger variables user programs may be executed on a data change of the variables Installation manual for PMC tendo DD5 PMCprimo Drive3 Page 81 9 17 3 Page 82 9 Interfaces Example using Profibus DP After setting the slave address command CD 11 lt address gt the PMCprimo Drive3 has to be restarted The following message appears when the module is recognized START Ser Nr 3094 Version 2 007 Sep 1 2004 10 37 49 Operate Mode STANDALONE Channel Channel Channel Channel Channel Channel Channel Channel Channel Channel O 00000000 Profibus DP IC found ii found found found found found found found found Onan OB QD 5 found 10 found In this example the bus variables B1 up to B16 are read and written 16 Words 32 Bytes at all Subsequent the Profibus DP Master has to be configured to IN OUT 32 Byte 16 word The GSD file is named HSM_1810 gsd Example Profibus Master Simulator from Fa Bihl und Wiedemann Configuration Editor Module List
12. Proportional gain of a control loop Maximum value for speed normalization at 10V Switch limiting the traverse path of the machine implemented as n c break contact The complete assembly of all connected parts or devices of which at least one is movable Data packet with all the position control parameters which are required for a motion task Machine with several independently driven axes Free movement of air for cooling Optical connection between two electrically independent systems Control loop with purely proportional behavior Compensation for the lag between the electro magnetic and magnetic fields in the motor Control loop with proportional and differential behavior Regulates the difference between the position setpoint and the actual position to 0 Output speed setpoint electrically decoupled electrical isolation System protection device with phase monitoring Maximum power which can be dissipated in the regen circuit Converts superfluous energy fed back by the motor during braking regenerated energy into heat New start of the microprocessor Conversion of the analog resolver signals into digital information Operation with a periodic change of direction Ferrite rings for interference suppression Incremental position output Control device for regulating the speed torque and position of a servomotor Limits for the rate of change of the speed setpoint here electrically conductive connection between two p
13. lt threshold exceeded n02 regen power reached preset regen power limit n03 S fault exceeded preset following error limit n04 response monitoring response monitoring fieldbus has been activated n05 supply phase mains supply phase missing n06 SW limit switch 1 passed software limit switch 1 n07 SW limit switch 2 passed software limit switch 2 n08 motion task error a faulty motion task was started n09 no reference point no reference point Home set at start of motion task n10 PSTOP PSTOP limit switch activated n11 NSTOP NSTOP limit switch activated n12 motor default values only for ENDAT or HIPERFACE discrepancy between loaded motor number saved in the encoder and the amplifier motor default values loaded n13 expansion card expansion card not operating correctly n14 SinCos feedback SinCos commutation wake amp shake not completed will be canceled when amplifier is enabled and wake amp shake carried out n15 table error fault according to speed current table INXMODE 35 n16 summarized warning summarized warning for n17 to n31 n17 fieldbus sync sync is not logged in n18 multiturn overflow max number of motor turns exceeded n19 n31 reserve reserve n32 firmware beta version firmware is an unreleased beta version A reset RESET is present on input DIGITAL INx these warning messages result in a controlled shut down of the drive braking by emergency stop ramp Installation manual for PMC tendo DD5 PMCprimo Drive3 You can f
14. on the enclosed CD ROM Note 33 The termination 120 Q for CAN 2 is activated with a DIP switch ON Expansion card X11 6 CompactFlash C X11 5 Ethernet Installation manual for PMC tendo DD5 PMCprimo Drive3 Page 77 9 Interfaces 9 15 Master encoder interface X11 4 These interface is available only at a PMCprimo Drive3 The PMCprimo Drive3 is designed for use with incremental or SSI encoders The encoder type can easily be changed with the FS command With SSI encoders the number of data bits can be set with NB The direction of each encoder input can be changed with the command CW Setting the direction bit reverses the direction of the encoder without wiring If a reference signal occurs the actual encoder position is stored see reference inputs page 60 This is useful for product referencing For further details see PMCprimo programming manual The master encoder is supplied via terminal X10 pins 1 and 2 See page 45 9 15 1 Incremental encoder ROD e Reference ground is EGND terminal X10 Pin 2 e For encoders with differential line drivers track A B and Z 0 Index e Quadrature encoder x1 x2 and x4 e Maximum input frequency 1 MHz e Minimum track width Z track 200 ns e Maximum voltage range tracks ref to EGND 5 V DC PMCprimo Drive3 EE Incremental encoder m m S P
15. power output voltage interne Zahlimpulse 1 Impuls 1 27 Umdr Rectified and smoothed power voltage Removal of the ENABLE signal 0V or open electrical connection between a phase and the protective earth PE Enable signal for the servo amplifier 24V CANopen PROFIBUS SERCOS etc Maximum value for the speed normalization at 10V Special format for representing binary numbers Brake in the motor that can only be used when the motor is at standstill Monitoring of the r m s current that is actually required Temperature and age dependent alteration of an analog input Position signaling by 2 signals with 90 phase difference i e in quadrature is not an absolute position output The effective value of the peak current The r m s value of the continuous current Installation manual for PMCtendo DD5 PMCprimo Drive3 12 Appendix Kp P gain Limit speed final speed Limit switch Machine Motion block Multi axis system Natural convection Optocoupler P controller Phase shift Pl controller Position controller Potential isolation Power contactor Pulse power of the regen circuit regen circuit Reset Resolver digital converter Reversing mode Ring core ROD interface Servo amplifier Setpoint ramps Short circuit Speed controller SSl interface Supply filter Tachometer voltage Thermostat contact Tn l integration time Zero pulse Installation manual for PMC tendo DD5 PMCprimo Drive3
16. 208V_10 3 x 480V 1 5A 3A and 6A e Instrument width 70 mm e Shielding connection directly on the servo amplifier e Two analog inputs e Integrated CANopen default 500 kBaud for integration in CAN bus systems and for setting parameters for several drives via the PC interface of one of the amplifiers e Integrated RS232 integrated pulse direction interface e Integrated restart lock AS for personnel safety gt p 85 Power section e Directly on grounded 3 phase supply 110V 10 or 230V_10 up to 480V TN network or TT network with grounded neutral point 5000 A max symmetrical current rating connection to other supply types only via isolating transformer gt p 17 e B6 bridge rectifier integral supply filter and soft start circuit e Single phase supply operation possible e g for setup e Fusing e g fusible cutout to be provided by the user e Shielding All shielding connections are made directly on the amplifier e Output stage IGBT module with floating current measurement e Regen circuit with dynamic distribution of the regenerated power between several amplifiers on the same DC bus link circuit Internal regen resistor as standard external regen resistors if required e DC bus link voltage 135 450 V DC or 260 900 V DC can be connected in parallel e Interference suppression filters are integrated for the electrical supply feed and the 24V auxiliary supply voltage with motor cable lt
17. AGND not joined to the controller GND of the controls adjust offset analog I O join AGND and controller GND n12 message Motor default values loaded Motor numbers stored in the encoder and amplifier do not match the parameters that have been set default values for the motor have been loaded SAVE automatically stores the motor number in the EEPROM n14 message SinCos feedback SinCos commutation wake amp shake not completed ENABLE the amplifier Installation manual for PMC tendo DD5 PMCprimo Drive3 Page 115 12 3 Page 116 Glossary C Clock Common mode voltage CONNECT modules Counts Continuous power of regen circuit Current controller counts DC bus link Disable Earth short ENABLE Fieldbus interface Final speed limit speed GRAY code Holding brake It threshold Input drift Incremental encoder interface Ipeak peak current Irms effective current 12 Appendix Clock signal The maximum amplitude of a disturbance on both inputs which a differential input can eliminate Modules built into the servo amplifier with integra ted position control that provide special versions of the interface for the connection to the higher level control Internal count pulses 1 pulse 1 2 turn 1 Mean power that can be dissipated in the regen circuit Regulates the difference between the current setpoint and the actual value to 0 Output
18. DD5 resp PMCprimo Drive3 you will receive e Mating connectors XO X3 X4 X8 X9 only 230V amplifiers e Assembly Installation and Setup instructions e Setup software PMCprimo Motion Control Tools on CD ROM e User manual PDrive and PMCprimo programming manual on CD ROM 7 4 2 Common accessories e Synchronous servomotor of the series PMCtendo AC1 PMCtendo AC2 or PMCtendo AC3 e Motor cable prefabricated or both power connectors separately with the motor cable as a cut off length e Feedback cable prefabricated or both feedback connectors separately with the feedback cable as a cut off length e External regen resistor e Motor choke e Line filter curve B e Communication cable to the PC for setting parameters from a PC 7 4 3 Accessories for PMCprimo Drive3 e MODBUS panel PMI series and communication cable e CAN cables different length available e Software keys for Motion Generator Soft PLC or CNC functionality e Ethernet cabel e Adapter cabel Modbus Profibus e PMCprimo expansion board see page 109 e CompactFlash cards e Profibus DP Slave Interface Profibus IC e Master encoder Installation manual for PMC tendo DD5 PMCprimo Drive3 Page 13 7 4 4 7 4 4 1 7 4 4 2 7 4 4 3 Page 14 7 General The PMCtendo DD5 family of digital servo amplifiers Standard version e Two voltage classes with large nominal voltage range Series 230V 1 x 110V 10 3 x 230V 7 3A 6A and 10A Series 480V 3 x
19. Motor off mode Status Channel 7 9 CH7 0 Motor off mode CH8 0 Motor off mode CH9 0 Motor off mode Status Channel 10 D CH10 0 Motor off mode Installation manual for PMC tendo DD5 PMCprimo Drive3 Page 101 11 Expansions and Accessories Expansions and Accessories 11 11 1 Expansion Cards 11 1 1 Guide to installation of expansion cards e Use a suitable screwdriver to lever off the cover of the option slot e guo em EE g c 9 Take care that no small items such as screws fall into the open option slot e Lever off the small metall sheet and push it back to the small slot Dispose the big metall sheet AKK ms f J 4 p e Push the expansion card carefully into the provided guide rails of the main slot without twisting it Ss A l e le A SG T OLE Y E SERCOS Interface pP Ut d A EN T ENO 0 0 e te Press the expansion card firmly into the slot until the front cover touches the fixing lugs e This ensures that the connectors make good contact Screw the screws on the front cover into the threads in the fixing lugs Installation manual for PMCtendo DD5 PMCprimo Drive3 Page 102 11 Expansions and Accessories This section describes the additional features that the expansion card 1 0 14 08 provides for the If you ordered the expansion card together with the servo amplifier then it will be delivered al
20. Seren switch 2 ZZZZI a ev Page 89 F SA STEEN EV ee 10 10 1 Page 90 10 Setup Setup Important notes Only professional personnel with extensive knowledge in the fields of electrical engineering and drive technology are allowed to setup the servo amplifier The procedure for setup is described as an example Depending on the application a different procedure may be appropriate or necessary In multi axis systems set up each servo amplifier individually Before setting up the manufacturer of the machine must generate a hazard analysis for the machine and take appropriate measures to ensure that unforeseen movements cannot cause injury or damage to any person or property Check that all connection components that are live in operation are safely protected against bodily contact The equipment produces potentially lethal voltages up to 900V Never undo the electrical connections to the servo amplifier while it is live Capacitors can still have dangerous residual charges up to 300 seconds after switching off the supply voltage The heat sink and front panel of the amplifier can reach temperatures up to 80 C in operation Check the heat sink temperature Wait until the heat sink has cooled down to 40 C before touching it If the servo amplifier has been stored for more than 1 year it will be necessary to re form the capacitors in the DC bus link circuit To do this disconnect all electrical connections and app
21. amplifier to a third party stepper motor controller Parameter setting for the slave amplifier is carried out with the aid of the setup software electrical gearing The number of steps can be adjusted so that the servo amplifier can be adapted to match the step direction signals of any stepper controller Various monitoring signals can be generated The analog inputs are out of action 9 10 1 Speed profile and signal diagram vi a 0 a a 0 a 0 a a 0 AD p QM Pulse LAO I AE MM Equivalences path traversed s velocity v acceleration a number of pulses pulse frequency rate of change of pulse frequency Note Using an A quad B encoder provides better EMC noise immunity Is Installation manual for PMC tendo DD5 PMCprimo Drive3 Page 69 9 10 2 Page 70 9 Interfaces Connection to a stepper controller with 5V signal level X5 This interface can be used to connect the servo amplifier to a stepper motor controller with a 5V signal level It uses the SubD connector X5 Frequency limit 1 5 MHz PMCtendo DD5 Master Y Pulse NV Pulse os a a RS 485 AN Pulse d AGND lo Direction Direction dif Q o Direction VJ Jd et te O 6 X6 AD X2 X4 ie ROD Resolver HIPERFACE SOM SS ComCoder Hall EnDat ACURO Sine Encoder Installation manual for PMCtendo DD5 PMCprimo Drive3 9 Interfaces 9 10
22. c3 Mi setpoint offset mV m CJ Tn speed control ms KP speed control baudrate c o C3 E3 EE Dj LO IE LO J amp 8nA8SNS cl lo wo wo wo o D el Lo o o o le C CJ CJ ru gt station adress Page 95 10 4 3 10 4 4 10 4 5 Page 96 10 Setup Keypad operation PMCprimo Drive3 The key operation for PMCprimo Drive3 is like the key operation for PMCtendo DD5 This means that the two keys are used in the same way and also the menus are named similarly Basic key operation For accessing the menu press the right key while switching on the 24 V power supply Then this parameters can be set with the menu The operating mode 0 Standalone 2 Node and 3 Host Node When changing the operate mode between 2 and 3 then the application program in the flash memory is not erased The memory is even not erased if mode 0 is selected by a mistake The CAN node number depending from the operating mode Standalone from 1 to 127 Node from 1 to 60 Host Node Not available because node number is fixed The CAN Baud rate Except for code 6 333kBit s and code 8 666kBit s all baud rates for PMCtendo DD5 see table page 93 are supported The proportional Gain Kp GV command for the velocity loop of the drive Save parameters After changing the parameter and returning from the function the changed parameter have to be saved with the menu for saving Then the system has to be s
23. current to brake A 1 5 Master encoder supply V 5 24V see datasheet encoder V 12 IN SUDDEN mA 10 each PMCprimo client Connection technology Control signals Combicon connector Power signals Combicon connector Resolver input SubD 9pol socket Incremental encoder input SubD 15pol socket PC interface CAN X6 X11 2 SubD 9pol plug CAN X11 1 Master encoder CAN 2 option SubD 9pol socket Encoder emulation ROD SSI SubD 9pol plug Modbus Ethernet RJ45 socket Recommended tightening torques Connector Tightening torque XO X8 X9 0 5 0 6 Nm Grounding bolt 3 5 Nm Fusing Internal fusing Circuit Internal fuse Auxiliary voltage 24V X4 3 15 A slow Auxiliary voltage 24V X10 electronic Regen resistor electronic External fusing Wire fuses or similar 1 5A 3A 6A 10A AC supply feed Fus X0 1 2 3 6 AT FRx 6 10 AT FRx 10 24V feed FH1 2 Max 8 AF FRx 12 Regen resistor Fg X8 2 4 6 AT FRS 6 6 AT FRS 6 x S or S R for 480V applications x Nor N R for 230V applications Installation manual for PMC tendo DD5 PMCprimo Drive3 Page 21 7 7 6 7 0 0 Page 22 7 General Permissible ambient temperatures ventilation mounting position Storage hints gt p 112 Transport hints gt p 112 Supply voltage tolerances Supply input 230V series 1x110V 10 1x230V 9 50 60 Hz 3x110V 10 3x230V 50 60 Hz 480V series 3x208V 1o 3x 480V 9 50 60 Hz Aux
24. gt d Internal power supply EGND X10 X11 4 VCC En Master encoder EGNDz supply CompactFlash Ethernet 2 CAN Installation manual for PMC tendo DD5 PMCprimo Drive3 Page 41 9 Interfaces 9 3 9 3 1 9 3 1 1 9 3 1 2 Electrical supply Mains electrical supply connection X0 X8 DC Bus dc iff 0 Nc 2 0 DC R et l Reg 4 E JL RB SRI x9 motor brake 1 1 Brake XO Mains ra 2 Brake PE 1110 ra if 3 PE L3 200 0 4 u2 L2 3h 0 Fall 5 v2 Li 400 ole w2 Three phase e Directly to 3 phase supply network filter is integrated e Fusing e g fusible cut outs to be provided by the user gt p 21 PMCtendo DD5 PMCprimo Drive3 A 110 230V 50 60Hz Two phase without neutral PMCtendo DD5 PMCprimo Drive3 A 110 230V 50 60Hz A 110 230V 50 60Hz 208 480V 50 60Hz A 110 230V 50 60Hz Installation manual for PMCtendo DD5 PMCprimo Drive3 Page 42 9 Interfaces 9 3 1 3 Singel phase with neutral PMCtendo DD5 PMCprimo Drive3 A 110 230V 110 230V 50 60Hz 50 60Hz 9 3 2 24V auxiliary supply X4 e External 24V DC power supply electrically isolated e g via an isolating transformer e Required current rating gt p 19 e Integrated EMC filter for the 24V auxiliary supply PMCtendo DD5 PMCprimo Drive3 BTB RTO BTB RTO Analog In 1 Anal
25. label on outside of box Storage only in the manufacturer s original recyclable packaging the servo amplifiers contain electrostatically sensitive components which can be damaged by incorrect handling Discharge yourself before touching the servo amplifier Avoid contact with highly insulating materials artificial fabrics plastic films etc Place the servo amplifier on a conductive surface max stacking height 8 cartons storage temperature 25 to 55 C max rate of change 20 C hour humidity 5 95 relative humidity no condensation storage duration lt 1 year without restriction gt 1 year capacitors must be re formed before setting up and operating the servo amplifier To do this remove all electrical connections and apply single phase 230V AC for about 30 minutes to the terminals L1 L2 Maintenance the instruments do not require any maintenance opening the instruments invalidates the warranty Cleaning if the casing is dirty clean with isopropanol or similar do not immerse or spray if there is dirt inside the unit must be cleaned by the manufacturer dirty protective grill on fan clean with a dry brush Disposal you can dismantle the servo amplifier into its principal components by unscrewing it aluminum heat sink steel housing sections electronics boards disposal should be carried out by a certified disposal company We can give you suitable addresses on reques
26. type CR1225 Procedure Remove all connectors Unscrew both M3 screws Remove the PMCprimo board Connect the 24 V voltage supply X10 pin 2 3 Replace battery observe polarity Disconnect 24 V voltage supply Reinstall the PMCprimo board and screw both M3 screws Connect all connectors Check The display BATT expires and shows the actual status of the control eS o cu DA EL i d N eS tH eereeree A CH o ojoo 09 20 2280 0 SLA gt t ol yar A PEDER rei Installation manual for PMC tendo DD5 PMCprimo Drive3 Page 111 12 Appendix 12 Appendix 12 1 Transport storage maintenance disposal Transport only by qualified personnel only in the manufacturer s original recyclable packaging avoid shocks temperature 25 to 70 C max rate of change 20 C hour humidity max 95 relative humidity no condensation The servo amplifiers contain electrostatically sensitive components that can be damaged by incorrect handling Discharge yourself before touching the servo amplifier Avoid contact with highly insulating materials such as artificial fabrics and plastic films Place the servo amplifier on a conductive surface ifthe packaging is damaged check the unit for visible damage In such an event inform the shipper and the manufacturer Packaging recyclable cardboard with inserts dimensions HxWxD 115x365x275mm labeling instrument
27. 07 PMCtendo DD5 PMCprimo Drive3 Pin No see below rg Orto X6 X5 X2 X1 PC ROD Resolver HIPERFACE CAN SSI ComCoder Hall EnDat ACURO Sine Encoder Interface cable between the PC and servo amplifier View looking at the solder side of the SubD sockets on the cable PC RS232 X6 RS232 X6 Sub D 9 Pol Sub D 25 Pol Sub D 9 Pol Sub D 9 Pol female female female Installation manual for PMCtendo DD5 PMCprimo Drive3 9 Interfaces 9 12 CANopen Interface X6 Is These interface can be used only at a PMCtendo DDS The interface for connection to the CAN bus default 500 kBaud The integrated profile is based on the CANopen DS301 communication profile and the DS402 drive profile The following functions are available in connection with the position controller Jogging with variable speed homing run Zeroing to reference start motion task start direct task digital setpoint provision data transmission functions and many others Detailed information can be found in the CANopen manual The interface is at the same electrical potential as the RS232 interface The analog setpoint inputs can still be used With the optional CAN adapter expansion card the two interfaces for RS232 and CAN which otherwise use the same connector X6 are separated out onto three connectors with termination gt p 107 PMCtendo DD5 CAN Server Client X6 9 CANH E 6 CANL 5
28. 1 Byte Current Configuration INZOUT 32 Byte 16 word 2 Byte 1 word 4 Byte 2 word 8 Byte 4 word 16 Byte 8 word 32 Bute 16 word 1 Bute 2 Bute 1 word 4 Byte 2 word F PR B Byte 4 word 16 Rute I B8 mnd Default Parameter Curent Parameter o Cancel Cancel After starting the Profibus communication the bus variables can be set or read More information can be found in the PMCprimo programming manual Installation manual for PMCtendo DD5 PMCprimo Drive3 9 Interfaces 9 18 Is 9 18 1 9 18 2 Is 9 18 3 Ethernet Interface X11 5 These interface is available only at a PMCprimo Drive3 with option expansion card General The Ethernet interface of the expansion board RJ45 X11 5 is a fast alternative to the RS232 transfer With the terminal software PTerm data can transmitted with a speed of 100 Mbit s The PMCprimo Drive3 can also be programmed and monitored locally in a Ethernet network without direct presence of a programmer Interface PMCprimo Drive3 X11 5 1 1 Twisted pair cable Expansion card X11 6 CompactFlash C m X11 5 Ethernet Pin 1 Tx send data 32 MxD send data inverted 3 RxD receive data 6 RxD receive data inverted _ Note For direct connection of the Ethernet interface with a PC you must use a crossover cable The shown cable here is only for use with a hub
29. 105 brake 4x1 5 2x0 75 50 motor incl 30 80 11 5 120 brake 4x 2x0 25 100 Resolver 30 80 ft 70 7x 2x0 25 50 Encoder 30 80 9 9 90 North America supplies cables up to 39 meters Europe supplies cables up to max length N Motor cables longer than 25m only with motor choke You can order a special motor choke from us Installation manual for PMC tendo DD5 PMCprimo Drive3 Page 39 9 Interfaces 9 Interfaces All the important interfaces are presented in this chapter The precise position of the connectors and terminals can be seen on page 34 The block diagram below just provides an overview 9 1 Block diagram general XO L1 2352 L3 RS232 5 PE Lem I EMI X5 p D ROD SS pra p Input rectifier x3 N DIGITAL IN1 t DIGITAL IN2 i Inrush circuit DIGITAL IN3 YK DIGITAL IN4 of aT X8 ENABLE Intermediate circuit De DIGITAL OUT1 M i DIGITAL OUT2 r7 De R BTB RTO r Ront dl Controller EE EA 3 X4 AS ENABLE i AK Jl Power stage DGND NENNEN uA w2 20K i in X9 Analog In 1 V1 20K Analog In 1 Ea Resolver Analog In 2 Analog In 2 20K 20K AGND i COMES BRAKE BRAKE x9 Internal power supply Page 40 Installation manual for PMCtendo DD5 PMCprimo Drive3 9 Interfaces 9 2 Block diagram PMCprimo Drive3 PMCprimo expansion card X10 Me 4 fast response inputs Option X10 24 V
30. 10m for general availability as per EN 61800 3 with motor cable 10m for 2nd environmental category as per EN 61800 3 Integrated safety e Appropriate insulation creepage distances and electrical isolation ensure safe electrical separation as per EN 50178 between the power input motor connections and the signal electronics e Soft start overvoltage detection short circuit protection phase failure monitoring e Temperature monitoring of the servo amplifier and motor if our motors and prefabricated cables are used Installation manual for PMCtendo DD5 PMCprimo Drive3 7 General 7 4 4 4 7 4 4 5 7 4 4 6 7 4 4 7 7 4 4 8 Auxiliary supply voltage 24V DC e Electrically isolated internal fusing from an external 24V DC power supply unit with for instance isolating transformer or uninterruptible power supply Operation and parameter setting e With our user friendly setup software PDrive for setup via the serial interface of a PC e fnoPC is available direct operation by two keys on the servo amplifier and a 3 character LED display e Fully programmable via RS232 interface Completely digital control e Digital current controller space vector pulse width modulation 62 5 us e Adjustable digital speed controller 62 5 us e Integrated position controller with adaptation possibilities for all applications 250 us e Integrated step direction interface for connecting a servomotor to a stepper controller e Eva
31. 3 Connection to a stepper controller with 24V signal level X3 This interface can be used to connect the servo amplifier to a stepper motor controller with a 24V signal level It uses the digital inputs DIGITAL IN 1 and 2 on connector X3 Frequency limit 100 kHz PMCtendo DD5 Master o direction f lc E direction es pulse l o lg E pulse 24V ref to GND O e GND BTB RTO BTB RTO Analog In 1 Analog In 1 Analog In 2 Analog In 2 AGND DIGITAL IN1 DIGITAL IN2 DIGITAL IN3 DIGITAL IN4 ENABLE DIGITAL OUT1 DIGITAL OUT2 24V 24V DGND DGND AS ENABLE X4 24V AS Installation manual for PMC tendo DD5 PMCprimo Drive3 Page 71 9 11 9 11 1 Page 72 9 Interfaces RS232 interface PC connection X6 Operating position control and motion block parameters can be set up by using the setup software PDrive on an ordinary commercial PC Connect the PC interface X6 of the servo amplifier to a serial interface on the PC via a null modem cable while the supply to the equipment is switched off Do not use a null modem power link cable This interface has the same electrical potential as the CANopen interface The interface is selected and set up in the setup software PDrive Further notes on page 92 With the optional CAN adapter expansion card the two interfaces for RS232 and CAN which would otherwise use the same connector X6 are separated out onto three connectors p 1
32. 8 Programmable digital outputs DIGITAL OUT 1 2 You can use the digital outputs DIGITAL OUT1 terminal X3 13 and DIGITAL OUT2 terminal X3 14 to output messages from pre programmed functions that are stored in the servo amplifier A list of these pre programmed functions can be found on the I O digital screen page of our setup software PDrive If an input is to be freshly assigned to a pre programmed function then the parameter set must be saved in the EEPROM of the servo amplifier and a reset has to be carried out with the amplifier setup software PDrive Installation manual for PMCtendo DD5 PMCprimo Drive3 9 Interfaces 9 7 5 Digital outputs X10 DS These outputs are available only at a PMCprimo Drive3 All digital outputs are electrically isolated through optocouplers 9 7 5 1 Technical characteristics e Reference ground is EGND terminal X10 pin 2 e All digital outputs are overload and shortcircuit protected e High side outputs 24V 0 1 A each output PMCprimo Drive3 control Digital 1 24V ref to EGND O C Digital 2 T O d Digital 3 Digital 4 Digital 5 Digital 6 Digital 7 Digital 8 m A IN EGND l O GND X10 I O VCC Enc 1 EGND 2 24V 3 11 1 4 11 2 5 11 3 6 11 4 7 11 5 8 11 6 9 11 7 10 11 8 11 01 1 12 1213 01 3 14 01 4 15 01 5 16 01 6 17 01 7 18 01 8 19 o o o o o o o o o o o o o o o o o o o 9 7 5 2 Application e
33. 8 1 DC and X8 3 RBext Can be connected in parallel whereby the regen power is divided between all the amplifiers that are connected to the same DC bus link circuit PMCtendo DD5 PMCtendo DD5 PMCprimo Drives PMCprimo Drive3 X8 X8 1 DC 1 DE to other servo amplifiers X8 DC Bus dc 1ko Nc 2 9 DC Re SIL UN Rent 4 00 JL RB SH tI X9 motor brake 0 1 Brake XO Mains a 2 Brake PE 1 0 ral 3 PE L3 20 0 4 U2 L2 3 f o rill s v2 Li 4p 1 jr ole w2 Only servo amplifiers with mains supply from the same mains identical mains supply N voltage may be connected by the DC bus link Page 46 Installation manual for PMCtendo DD5 PMCprimo Drive3 9 Interfaces 9 4 Motor connection with brake X9 X8 DC Bus dc 1 01 n c 2 1 DC Reet 3 I Ram 4 0 JL RB SRI X9 motor brake 1 1 Brake XO Mains 1 2 Brakes PE 1 0 Jl a 3 PE L3 200 ra 4 u2 L2 31 1 rn ll 5 v2 L 4f 0 alle we Cable length lt 25 meters PMCtendo DD5 PMCprimo Drive3 Cable length gt 25m PMCtendo DD5 PMCprimo Drive3 gt 1 Brake f an e e E E Brake O at pr I E C e I _ ut Al U2 cu n gt li V2 D motor choke O L For cable lengths above 25m up to max 50m a motor choke must be wired into the motor cable close to the amplifier Installation manual for PMC tendo DD5 PMCprimo Drive3 Page 47 9 Interfaces 9 5
34. AGND i VJ Va CAN ISO 11898 fesa OLO X6 X5 x2 X1 PC ROD Resolver HIPERFACE CAN SSI ComCoder Hall EnDat ACURO Sine Encoder 9 12 1 CAN bus cable To meet ISO 11898 a bus cable with a characteristic impedance of 120 Q should be used The maximum usable cable length for reliable communication decreases with increasing transmission speed As a guide you can use the following values which we have measured but they are not to be taken as assured limits Cable data Characteristic impedance 100 120 Q Cable capacitance max 60 nF km Lead loop resistance 159 8 O km Cable length depending on the transmission rate Transmission rate kBaud max cable length m 1000 10 500 70 250 115 Lower cable capacitance max 30 nF km and lower lead resistance loop resistance 115 Q km make it possible to achieve greater distances Characteristic impedance 150 50 gt terminating resistor 150 50 Installation manual for PMC tendo DD5 PMCprimo Drive3 Page 73 9 Interfaces For EMC reasons the SubD connector housing must fulfill the following requirements e metal or metalized housing e provision for cable shielding connection on the housing large area connection Shield Shield according to line impedance about 1200 Page 74 Installation manual for PMCtendo DD5 PMCprimo Drive3 9 Interfaces 9 13 CAN bus Interface X11 1 X11 2 189 9 13 1 General These interface is
35. BLE X4 24V AS Page 58 Installation manual for PMCtendo DD5 PMCprimo Drive3 9 Interfaces 9 7 2 2 9 7 2 3 9 7 2 4 ENABLE input The output stage of the servo amplifier is enabled by applying the ENABLE signal terminal X3 12 24V input active high In the disabled state low signal the connected motor has no torque AS ENABLE input An additional digital input AS Enable releases the power output stage of the amplifier as long as a 24V signal is applied to this input If the AS Enable input goes open circuit then power will no longer be supplied to the motor the drive will lose all torque and coast down to a stop A fail safe brake function for the drive if one is required must be ensured through a mechanical brake since electrical braking with the aid of the drive is no longer possible You can thus achieve a restart lock out for personnel safety by using the AS enable input in conjunction with an external safety circuit You can find further information and connection examples on page 85 This input is not compatible with IEC 61131 2 Programmable digital inputs You can use the DIGITAL IN1 to DIGITAL IN4 digital inputs to initiate pre programmed functions that are stored in the servo amplifier A list of these pre programmed functions can be found on the Digital I O screen page of our setup software PDrive If an input was freshly assigned to a pre programmed function then the data set must be sav
36. Configuration IP address To establish a connection to a PMCprimo Drive3 an IP address must configured for the control This is done with the CD command see PMCprimo programming manual Installation manual for PMC tendo DD5 PMCprimo Drive3 Page 83 9 Interfaces 9 19 Compact Flash Interface X11 5 These interface is available only at a PMCprimo Drive3 with option expansion card 9 19 1 General With the Compact Flash Interface programs can easily exchanged between two servo amplifiers of the PMCprimo Drive3 series We recommend to use only compact flash cards from leading manufacturers More information can be found in the User manual for primoFTP and CompactFlash 9 19 2 Interface Expansion card X11 6 CompactFlash L1 X11 5 Ethernet Page 84 Installation manual for PMCtendo DD5 PMCprimo Drive3 9 Interfaces 9 20 9 20 1 9 20 2 9 20 3 Personnel safe restart lock AS A frequently required application task is the protection of personnel against the restarting of drives This can be achieved by an electronic inhibit or with mechanical elements positively driven relay contacts When positively driven relay contacts where used either the net contactor in the mains supply circuit switched off or the motor was disconnected from the servo amplifier by an additional contactor The disadvantages of this method are e the DC bus link has to be charged up again at restart e wear on the contacts
37. D5 only If the motor oscillates the parameter Kp on the menu page Speed controller must be reduced motor is in danger Optimize speed current and position controllers see Online Help See setup instructions in the corresponding manual on the CD ROM Page 91 10 3 10 3 1 10 3 2 10 3 3 10 3 4 10 3 5 Page 92 10 Setup Setup software PDrive This chapter describes the installation of the setup software PDrive for the PMCtendo DD5 and PMCprimo Drive3 The parameter settings are described detailed in the software manual for PDrive The programming is described in the PMCprimo programming manual Both manuals can be found on the CD ROM PMCprimo Motion Control Tools Use as directed The setup software PDRIVE is intended to be used for setting up and storing the operational parameters for the PMCtendo DD5 und PMCprimo Only professional personnel who have the relevant expertise described on page 11 are permitted to carry out online parameter setting for a drive which is running Sets of data which are stored on data media are not safe against unintended alteration by other persons After loading a set of data you must therefore check all parameters thoroughly before enabling the PMCtendo DD5 and PMCprimo Drive3 Software description The parameters of the PMCtendo DD5 and PMCprimo Drive3 must be adapted to the requirements of the installation This parametrization is done with the setup software PDrive whi
38. External regen restistor X8 Remove the plug in link between the terminals X8 5 Rg and X8 4 Rpint PMCtendo DD5 PMCprimo Drive3 remove bridge D X8 DC Bus doc 11 1 l nc 2 0 DC Rage SIL Rent 4 00 JL RB 50 x9 motor brake 0 1 Brake XO Mains Ht 2 Brake PE 1100 Jl fa 3 PE L3 201 ra I 4 u2 L2 3t rill s v2 ut 4l rj re w2 Page 48 Installation manual for PMCtendo DD5 PMCprimo Drive3 9 Interfaces 9 6 Feedback Feedback system Conn See Remark Resolver X2 p 49 2 to 36 polig ComCoder X1 p 50 JA B Zero Hall Incremental or sine encoder with Hall X p 51 A B Zero Hall Sine Cosine Zero Hall Sine Encoder with EnDat HIPERFACE X1 p 52 Sine Cosine Clock Data ACURO Encoder X1 p 53 Data BISS Sine encoder without data channel X1 p 55 Sine Cosine Zero Incremental encoder A quad B X5 p 54 A B Zero 9 6 1 Resolver X2 Our rotatory servomotors PMCtendo AC1 AC2 AC3 are fitted as standard with 2 pole hollow shaft resolvers It is possible to connect resolvers with 2 to 36 poles to the PMCtendoDD5 and PMCprimo Drive3 The thermostat contact in the motor is connected via the resolver cable to X2 and evaluated there If cable lengths of more than 100 meters are planned please contact our customer support PMCtendo DD5 PMCprimo Drive3 PMCtendo AC1 AC2 AC3 Resolver Sine Cosine depending on mounting situation Sine Cosine dependin
39. MCtendo DD5 PMCprimo Drive3 9 Interfaces 9 7 4 Digital outputs X3 All digital outputs are electrically isolated through optocouplers 9 7 4 1 Technical characteristics e Ground reference is Digital GND DGND terminals X4 3 and X4 4 e DIGITAL OUT1 and 2 Open Emitter max 30V DC 10mA e BTB RTO Relay output max 30V DC or 42V AC 0 5A e Update rate 250 us PMCtendo DD5 PMCprimo Drive3 control BTB RTO 1 1k HI 24V Jett 240 STE safety circuit BTB RTO 2 13 DIGITAL OUT1 Digital 1 4 DIGITAL OUTQJ 1 Digital 2 O GND BTB RTO BTB RTO Analog In 1 Analog In 1 Analog In 2 Analog In 2 AGND DIGITAL IN1 DIGITAL IN2 DIGITAL IN3 DIGITAL IN4 ENABLE DIGITAL OUT1 DIGITAL OUT2 24V 24V AS ENABLE X4 24V AS Installation manual for PMC tendo DD5 PMCprimo Drive3 Page 61 9 7 4 2 9 7 4 3 Page 62 9 Interfaces Ready to operate contact BTB RTO Operational readiness terminals X3 1 and X3 2 is signaled by a floating relay contact The contact is closed when the servo amplifier is ready for operation and the signal is not influenced by the enable signal the l t limit or the regen threshold All faults cause the BTB RTO contact to open and the output stage to be switched off if the BTB RTO contact is open the output stage is inhibited gt no power output A list of the error messages can be found on page 9
40. S Enable Apply 24V DC to terminal X4 1 and teminal X10 3 PMCprimo Drive3 ground terminal X4 3 and teminal X10 2 PMCprimo Drive3 After the initialization procedure about 0 5 sec the status will be shown in the LED display gt p 98 Select the interface to which the servo amplifier is connected The parameters which are stored in the SRAM of the servo amplifier are then transferred to the PC It is especially important to check the following parameters If these critical values are not set properly the system may be damaged or destroyed Set to the actual electrical supply voltage at least as high as the DC bus link voltage of the amplifier must match the motor see motor manual must match the feedback device in the motor maximum is the motor standstill current lo on nameplate maximum is 4 x motor standstill current lo maximum is the rated motor speed on nameplate maximum is the permitted regen resistor dissipation unique address see manual for setup software PDrive Make sure that any unintended movement of the drive cannot cause and danger to personnel or machinery Use the ON OFF button of the contactor controls Apply OV to terminals X3 3 4 or X3 5 6 respectively PMCtendo DD5 only Apply 24V DC 500 ms after switching on the supply power to terminal X3 12 motor stands with standstill torque Mo Apply a small analog setpoint about 0 5V is recommended to terminals X3 3 4 or X3 5 6 respectively PMCtendo D
41. Standards 8 6 Abbreviations and symbols 10 7 General 11 7 1 About this manual nennen nennen nennen nnns 11 7 2 Selling 11 7 3 Useasdirected iii 11 7 4 Instrument descriptioN nennen 13 7 4 1 Package supplied nennen 13 7 42 Common accessorieS i 13 7 4 3 Accessories for PMCprimo DriVve3 i 13 7 4 4 The PMCtendo DD5 family of digital servo amplifiers 14 7 4 5 The PMCprimo Drive3 family of digital servo amplifiers 16 7 5 Connection to various electrical supply networks 17 7 6 Components of a servo systemM mener 18 LE TEMME VAA TR 19 7 7 1 Technical data 230 V series 19 7 7 2 Technical data 480 V series 20 7 7 3 Inputs outputs ei 21 T 4 Recommended tightening torques 21 i FN 21 7 1 6 Permissible ambient temperatures ventilation mounting position 22 7 7 7 Conductorcross sectionsS i 22 7 7 0 BEDS Amm 23 7 8 Control circuit for motor holding brake 24 7 9 Grounding system Me 25 TAD REGN CIRCUIT unne 25 7 10 1 Functional descriptionN 25 7102 Technical Dada 26 7 11 Switch on and switch off behavi
42. The maximum permissible cable length is 100 meters Connections and signals for the incremental encoder interface Default count direction UP when the motor shaft is rotating clockwise looking at the shaft s nd PMCtendo DD5 PMCprimo Drive3 Control o s tock o Q NI O D Mise p er O Q O GND o stack B o Q NI AGND B B oe gt So oe a eco m om m m a according to line impedance alajaja Edge spacing a 2 0 20 us 5V Em um um um um EE BEEN H Edge steepness tv lt 0 1 us NENNEN Delay Nl td lt 0 1 us IAUI gt 2V 20mA UJ OT lt Suna a a I aot Installation manual for PMCtendo DD5 PMCprimo Drive3 9 Interfaces 9 8 2 SSI output X5 The SSI interface synchronous serial absolute encoder emulation is part of the standard package Select encoder function SSI Encoder screen page The servo amplifier calculates the motor shaft position from the cyclic absolute signals of the resolver or encoder From this information a SSI date Stegmann patent specification DE 3445617C2 is provided Max 32 bits are transferred The l
43. UL cUL certified servo amplifiers Underwriters Laboratories Inc fulfil the relevant U S and Canadian standard in this case UL 840 and UL 508C This standard describes the fulfilment by design of minimum requirements for electrically operated power conversion equipment such as frequency converters and servo amplifiers which is intended to eliminate the risk of fire electric shock or injury to persons being caused by such equipment The technical conformance with the U S and Canadian standard is determined by an independent UL cUL inspector through the type testing and regular checkups Apart from the notes on installation and safety in the documentation the customer does not have to observe any other points in direct connection with the UL cUL certification of the equipment UL 508C UL 508C describes the fulfilment by design of minimum requirements for electrically operated power conversion equipment such as frequency converters and servo amplifiers which is intended to eliminate the risk of fire being caused by such equipment UL 840 UL 840 describes the fulfilment by design of air and insulation creepage spacings for electrical equipment and printed circuit boards Installation manual for PMC tendo DD5 PMCprimo Drive3 Page 9 Page 10 6 Abbreviations and symbols Abbreviations and symbols The abbreviations and symbols used in this manual are explained in the table below
44. US RS422 interface connecting panels e Option Profibus DP slave modul easy communication with PLC e Option Ethernet 10 100 Mbit s e Option 2nd CANpen interface 7 4 5 3 Soft SPS CoDeSys e Soft SPS CoDeSys as an option e Fully PLC functionality specified in IEC 61131 3 e PLC and PMCprimo combined in one system 7 4 5 4 Interfaces e 8 digital inputs 24 V electrically isolated e Odigital outputs 24 V short circuit protected and electrically isolated e 1 input for a master encoder incremental absolut SSI 7 4 5 5 Power supplies e 24 V power supply e Individual power supply for all master encoders Page 16 Installation manual for PMCtendo DD5 PMCprimo Drive3 7 General 7 5 Connection to various electrical supply networks This page illustrates all the possible connection variations for different electrical supply networks An isolating transformer is always required for 400 480V networks that are asymmetrically grounded or not grounded 230V series 480V series 400 480V mains PE 110 230V mains 110 230V mains 110 230V mains 110 230V mains 110 250V mains Installation manual for PMC tendo DD5 PMCprimo Drive3 Page 17 pilz 7 6 Components of a servo system 7 General master encoder z m e ee e i paz panel PLC cme Vol x E v 1 i dic 2 2 3 3 4 5 E p e 6 E 7 7 gu 8 5 Y 9 9 10 10 i Ar
45. _A_A_A_A__A_A_A_ 1G31 GO ew LXOOOOQOOOOQOGOOOOQODOQOODOODOQOOQQO T Switch over time Data t 300nsec Output IAUI gt 2V 20mA Period T 600 ns Input IAUI gt 0 3V Time Out tp 1 3us 10us SSITOUT Installation manual for PMC tendo DD5 PMCprimo Drive3 Page 65 9 9 9 9 1 1 9 9 2 Page 66 9 Interfaces Master slave operation encoder master control These function is available only at a PMCtendo DD5 This interface can be used to link several amplifiers together in master slave operation Parameter setting for the slave amplifier is carried out with the aid of the setup software electrical gearing The resolution no of pulses turn can be adjusted and the analog setpoint inputs are out of action Signal diagram for encoders with RS422 or 24V output tv tv alaloa A ALVA NANI s ADA Pig DEA ZZ 0 Connection to a PMCtendo DD5 master 5V signal level X5 This interface can be used to link several amplifiers together in master slave operation Up to 16 slave amplifiers can be controlled by the master via the encoder output The SubD connector X5 is used for this purpose Frequency limit 1 5 MHz transition time tv lt 0 1us PMCtendo DD5 PMCtendo DD5 Master G PO o0 x2 X1 X6 X5 PC ROD Resolver HIPERFACE CAN SSI ComCoder Hall EnDat ACURO Sine Encoder Installation manual for PMCtendo DD5 PMCprimo Drive3 9 Interfaces 9 9 3 Connection to incremental encoder
46. ace PC connection X6 rrrrrrnnrrrrnnnrenrnnnrenrnnrrernnsrennnnnne 72 9 11 1 Interface cable between the PC and servo amplifier 72 9 12 CANopen Interface X6 i 73 9 12 1 CAN bus cable iii 73 9 13 CAN bus Interface X11 1 X11 2 essere 75 NT 5 M ME ee 75 9 13 2 Connecting PMCprimo Drive3 systems 75 91355 Speciality TSU 1006 lilla 76 9 13 4 Speciality last node sees 76 9 13 5 Fault detection E HR 76 9 13 6 Connecting external CANopen bus devices 76 9 14 CAN bus Interface X11 4 eecccceeeeeeeeeeeeesaeeeeeseeeeesseeeeessaeseesaaeees TI 9 15 Master encoder interface X11 4 78 9 15 1 Incremental encoder ROD i 78 9 15 2 Absolute encoder SSI eese nee 79 9 16 Panel interface Modbus X11 3 i 80 SEIOMMCIIIIII EEE ee eee 80 9 16 2 MEI CE NETTE 80 9 17 Profibus DP Slave interface X11 3 81 VIT 81 9 17 2 Using the Profibus interface with PMCprimo 81 9 17 3 Example using Profibus DP 82 9 18 Ethernet Interface X11 5 e 83 9 18 1 GEA eee 83 9 18 2 Interface ii 83 9 18 3 Configuration IP address nenne 83 9 19 Compact Flash Interface X11 5 rrnrrnnnnnnrrrrnnrrn
47. ance l Bandwidth of current controller kHz gt 1 2 Residual voltage drop at rated current V 4 Thermal dissipation output stage disabled W 12 Thermal dissipation at rated current incl PSU W 35 60 90 losses without regen dissipation Mechanical Weight kg ca 2 6 Height without connectors mm 275 278 Width mm 70 Depth without connectors mm 171 Depth with connectors mm lt 200 at reduced current Installation manual for PMC tendo DD5 PMCprimo Drive3 Page 19 7 General 7 1 2 Technical data 480 V series Rated data DIM PMCtendo DD5 PMCprimo Drive3 Size 1 5A 3A 6A Do voltage grounded supply phase to V 3 x 208V 10 480V 1 50 60 Hz Rated input power for S1 operation kVA 1 2 2 5 5 Max DC bus link voltage V 900 Rated output current rms value 3 at 3x208V Arms 2 5 6 at 3x230V Arms 2 5 6 at 3x400V Arms 1 5 4 6 at 3x480V Arms 1 5 3 6 Peak output current rated current x 2 for approx 5s 3 at 3x208V Arms 14 5 7 5 12 at 3x230V Arms 4 5 7 5 12 at 3x400V Arms 4 5 7 5 12 at 3x480V Arms 4 5 7 5 12 Switching frequency of the output stage kHz 8 16 Technical data for regen circuit gt p 26 Threshold for overvoltage switch off VDC 455 800 900 Motor inductance min at 3x208V mH lad 4 6 2 9 at 3x230V mH 8 5 5 1 3 2 at 3x400V MH 14 8 8 9 5 6 at 3x480V MH 17 8 10 7 6 7 Switching frequency of the output stage mH Consult our customer support Technical data for regen ci
48. as low impedance with metalized connector housings or shield connection clamps wherever possible Notes on connection techniques can be found on page 38 Feedback lines may not be extended since thereby the shielding would be interrupted and the signal processing could be disturbed Lines between amplifiers and external regen resistor must be shielded Install all power cables with an adequate cross section as per EN 60204 p 39 and use the requested cable material p 39 to reach max cable length Wire the BTB RTO contact in series into the safety circuit of the installation The safety circuit must operate the supply contactor This is the only way to ensure monitoring of the servo amplifier Ensure that there is an adequate flow of cool filtered air into the bottom of the control cabinet or use a heat exchanger Please refer to page 22 It is permissible to use the setup software to alter the settings of the servo amplifier Any other alterations will invalidate the warranty Never disconnect the electrical connections to the servo amplifier while it is live In unfavorable circumstances this could cause destruction of the electronics Residual charges in the capacitors can have dangerous levels up to 300 seconds after switching off the electrical supply fallen below 40V N Measure the bus voltage on the DC bus link DC DC and wait until the voltage has Control and power connections can still be live even if the moto
49. available only at a PMCprimo Drive3 With the CAN bus interfaces CAN 1B X11 1 and CAN 1A X11 2 multiple PMCprimo motion control systems can be connected together Additional safety signals provide fault detection Furthermore PMCtendo DD5 and PMCprimo Drive3 can be linked together PMCprimo Drive3 X11 1 2 d CAN d a 6 4 d 9 d X11 4 X11 3 X11 2 Master encoder MODBUS CAN 1A CAN2 Profibus DP S EGO 9 13 2 Connecting PMCprimo Drive3 systems CANH CANL CAN GND CAN GND CAN ERROR CAN BTB CAN POWER X11 1 CAN 1B PMCprimo Drive3 y y x CAN On each system CAN 1A X11 1 and CAN 1B X11 2 of the next system are joined together in the way as shown below Termination Feed Lead PMCprimo Drive3 PMCprimo Drive3 Installation manual for PMC tendo DD5 PMCprimo Drive3 Page 75 9 13 3 9 13 4 9 13 5 9 13 6 Page 76 9 Interfaces Speciality 1st node e The 1st node is supplied with 12V at CAN 1A X1 1 2 pin 9 referred to Pin 3 CAN GND The power requirement is about 10mA each node e An additional resistor 10 KQ 250 mW metal 1 between Pin 1 and Pin 4 is necessary Speciality last node e The last node needs a jumper bridge 0 Q at CAN 1B X11 1 between Pin 4 and Pin 9 You can order pre assembled cables from us CAN bus cable 1 1 250 mm CAN bus cable 1 1 700 mm CAN feedlead CAN terminatio
50. ave interface Puls direction interface RS232 PC CAN interface X6 Digital and analoge in outputs Master encoder PMCprimo Drive3 Panels PMCprimo Drive3 Profibus interface PMCprimo Drive3 Ethernet interface PMCprimo Drive3 CAN bus interface PMCprimo Drive3 Restart lock AS Expansion cards 1 O 14 08 PROFIBUS CAN adapter PMCprimo Installation manual for PMC tendo DD5 PMCprimo Drive3 page 42 page 47 page 49 page 49 page 50 page 51 page 52 page 53 page 54 page 55 page 64 page 65 page 66 page 69 page 72 page 73 page 56 page 78 page 80 page 81 page 83 Seite 75 page 85 page 103 page 106 page 107 page 109 Page 33 8 4 1 Page 34 8 Installation Connection diagram general PMCtendo DD5 PMCprimo Drive3 Control thermal control 3 10V d included Comcoder XSanalog In 1 S 4 referred to Analog In 1 CNC GND digital I I 7 Feedback d AGND CNC GND 5 4 Analog In 2 F T A aa referred to CNC GND sputo Analog In 2 thermal control CNC GND included X2 24V referred ri j 8 to OV GND Resolver b Resolver DIGITAL IN1 A DIGITAL IN2 10 x DIGITAL IN3 n 11 DIGITAL IN4 12 ENABLE O 13 DIGITAL OUT1 14 DIGITAL OUT2 BRAKE dene BTB RTO 2 circuit Remove jumper if external regen resistor is connected 4 X4 r 7 7 4 Fen N 5 AS ENABLE I Regeneration F T L
51. bi 13 f i 14 15 1 Em 16 2 sr 3 18 1 5 me v g x4 M 2 XX LESGR PMCprimo Drive PMCprimo Drive3 L1 L2 L3 mains motor PMCtendo AC Page 18 Installation manual for PMCtendo DD5 PMCprimo Drive3 7 General 1 7 7 7 1 Technical data Technical data 230 V series Rated data DIM PMCtendo DD5 PMCprimo Drive3 Size 3A 6A 10A Rated supply voltage grounded supply phase to V 1 x 110V 10 1 x 280V 79 phase 3 x 110V 10 3 x 230v 9 50 60 Hz Rated input power for S1 operation kVA 1 1 2 4 4 Max DC bus link voltage V 450 Rated output current rms value 3 at 1x110V Arms 3 3 3 at 3x115V Arms 3 5 8 10 at 3x230V Arms 3 6 10 at 1x230 240V Arms 3 4 Peak output current rated current x 2 for approx 5s 3 at 1x110V Arms 5 5 5 at 3x115V Arms 9 15 20 at 3x230V Arms 9 15 20 at 1x230 240V Arms 9 9 9 Switching frequency of the output stage kHz 8 16 Technical data for regen circuit gt p 26 Threshold for overvoltage switch off VDC 235 455 Motor inductance min at 1x110V MH 3 7 3 7 3 7 at 3x115V mH 2 1 1 3 1 0 at 3x230V mH 4 3 2 6 1 9 at 1x230 240V mH 4 3 4 3 4 3 Motor inductance max mH Consult our customer support Form factor of the output current rated 1 01 conditions min load induct
52. ch provides the communication between PC and PMCtendo DD5 or PMCprimo Drive3 With very little effort you can alter parameters and instantly observe the effect on the drive since there is a continuous online connection to the drive With the tool PSCOPE you can easily watch the drive current the speed and the position error Sets of data can be stored on data media archived and loaded again Sets of data which are stored on data media can be printed We supply you with motor specific default sets of data for all the reasonable combinations of PMCtendo DD5 or PMCprimo Drive3 and motor In most applications you will be able to use these default values to get your drive running without any problems Hardware requirements The PC interface X6 RS232 of the servo amplifier is connected to the serial interface of the PC by a null modem cable p 72 The interface in the servo amplifier is electrically isolated by an optocoupler Minimum requirements for the PC Prozessor l Pentium III or higher Operating system WINDOWS 2000 XP Grafics adapter 1024 x 768 color Drives i Hard disk 100 MB free CDROM drive Main memory at least 256MB Interface one free serial interface COM1 or COM2 Installation under WINDOWS 2000 XP On the CD ROM an installation program called SETUP EXE can be found which makes it easy to install the setup software on your PC Start SETUP EXE and follow the instructions Installation manual for PMCten
53. do DD5 PMCprimo Drive3 10 Setup 10 3 6 10 4 10 4 1 10 4 1 1 10 4 1 2 Working with PDrive The parameter settings and using the tools are described detailed in the software manual for PDRIVE MN PDrive Nicht verbunden Untitled Datei Kommunikation Ansicht Programme Service Extras UAW 8 WE H Bp BSOGCOCOGSYU a 7 Setup IE Basiseinstellungen IE Einheiten E CAN Feldbus IE Feedback EE Motor IE Stromregler E Drehzahlregler IE Lageregler IE Elektronisches Getriebe 8 Encoder E Digital 1 0 E Analog I O Positionieren IE Einrichtbetrieb ES Positionierdaten 88 Fahrauftr ge EE Positionsregister i Status Monitor Welcome to PDrive Auswahl Servoregler Standalone CANopen OFFLINE Modus Servoregler Erweiterungskarte Freigabe Achse x E Hardware Software PC lt gt Drive verbinden O Drehzahl digital vl 2 CHA WWwP280068 Dr cken Sie F1 um Hilfe zu erhalten Parametrization of the PMCtendo DD5 and PMCprimo Drive3 To facilitate the parametrization der PMCtendo DD5 and PMCprimo Drive3 a motor database is supplied with the drive You can find the parameters for a lot of possible combinations between the PMCtendo DD5 or PMCprimo Drive3 and the motors of the PMCtendo AC1 AC2 and AC3 series An exact description of all parameters and the possibilities for optimizing the control loop characteristics can be found in the software
54. e host s MODBUS interface is active in this mode Interface The communication uses a 5 core cable RS422 full duplex The communication parameters are e 9600 Baud 8N1 no handshake With the command BM the baud rate can be changed s PMCprimo programming manual Pin assignment for a PMCprimo Drive3 PMI 315 Pinout without adapter cable MODBUS panel e g PMI 315 RS485 AGND X11 4 X11 3 X11 2 X11 1 Master encoder MODBUS CAN 1A CAN 1B CAN2 Profibus DP S Installation manual for PMCtendo DD5 PMCprimo Drive3 9 Interfaces 9 17 32 9 17 1 9 17 2 Profibus DP Slave interface X11 3 These interface is available only at a PMCprimo Drive3 with option Profibus General The PMCprimo Drive3 is alternatively delivered with a Profibus DP slave interface The MODBUS RS422 interface will be disabled This is done by changing the hardware settings jumper on the PMCprimo board see page 110 A special adapter cable is required which can be orderd from us All settings for the Profibus slave adresse adress range are made with command CD see PMCprimo programming manual The required GSD file HMS 1810 GSD is located on the CD ROM PMCprimo Drive3 Pinout without adapter cable Profibus DP master X8 5 AN N 3 ef external termination necessary 8 1 Lu X11 4 X11 3 X11 2 X11 1 Master encoder MODBUS CAN 1A CAN 1B CAN2
55. e manner The 24V auxiliary supply remains switched on Installation manual for PMCtendo DD5 PMCprimo Drive3 8 Installation 8 Installation 8 1 Important notes Protect the servo amplifier from impermissible stresses In particular do not let any components become bent or any insulation distances altered during transport and handling Avoid contact with electronic components and contacts Check the combination of servo amplifier and motor Compare the rated voltage and current of the units Implement the wiring according to the connection diagram on page 34 Make sure that the maximum permissible rated voltage at the terminals L1 L2 L3 or DC DC is not exceeded by more than 1096 even in the most unfavorable circumstances see EN 60204 1 Section 4 3 1 An excessive voltage on these terminals can lead to destruction of the regen circuit and the servo amplifier The fusing of the AC supply input and 24V supply must be installed by the user p 21 Take care that the servo amplifier and motor are properly grounded Do not use painted i e non conductive mounting plates Route power and control cables separately We recommend a distance of at least 200mm This improves the interference immunity required by EMC regulations If a motor power cable is used that includes cores for brake control the brake control cores must be separately shielded Ground the shielding at both ends p 34 Ground all shielding with large are
56. eading data bit contains the number of revolutions and are selectable from 12 to 16 bits The following max 16 bits contain the resolution and are not variable The following table shows the allocation of the SSI date depending upon selected number of revolutions Resolution Resolution variable SSIREVOL 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 14 1311211111019181716151413 121110 13 121111101918171615141312111011511411311211111019181716151413121110 12 111101918171615141312 11 0 11 1019181716151413 2 1 0 The signal sequence can be output in Gray code or in Binary standard code The servo amplifier can be adjusted to the clock frequency of your SSl evaluation with the setup software PDrive cycle time 1 3 us or 10 us The drivers operate off an internal supply voltage 9 8 2 1 Connection and signals for the SSI interface Default count direction UP when the motor shaft is rotating clockwise looking at the end of the motor shaft PMCtendo DD5 PMCprimo Drive3 Control RAE P gt l F l IG RS 485 DATA DO DATA I I 1 LI 1 II il iI 1 AGND of GND 1 LI I CLOCK _ EE e ka e Va CLOCK Va 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 Clock Monoflop IT l I tp LI 251 t 20 Binary WX X XXX AAAA_A_A_A_ A_A_A_A_A_A_A_A_A_A_A_A_A
57. ed in the EEPROM of the servo amplifier and a reset has to be carried out with the amplifier setup software PDrive for example Note for a PMCprimo Drive3 The digitale inputs DIGITAL IN1 to DIGITAL IN4 are denoted as E2 1 to E2 4 on a PMCprimo Drive3 Installation manual for PMC tendo DD5 PMCprimo Drive3 Page 59 9 Interfaces 9 7 3 Digital Inputs 11 1 11 8 X10 These inputs are available only at a PMCprimo Drive3 23 All digital inputs are electrically isolated through optocouplers 9 7 3 1 Technical characteristics e Reference ground is EGND terminal X10 Pin 2 e Logic is PLC compatible e HIGH level 11 24V 10 mA LOW level 0 V 11 V 0 mA e The inputs 11 1 to 11 4 are fast inputs lt 1 us for e g product referencing e 11 1 and 11 2 will be additionally mapped to both inputs E2 7 and E2 8 see PMCprimo programming manual PMCprimo Drive3 internal 12 7 ted Connesso a control fast inputs 24V ref to O GND l O GND X10 I O VCC Enc EGND 24 V 11 1 1 2 11 3 11 4 11 5 11 6 9 11 7 10 11 8 11 O1 1 12 012 13 O1 3 14 O1 4 15 O1 5 16 O1 6 17 O1 7 18 O1 8 19 ceo 40 00 WD o o o o o o o o o o o o o o o o o o o 9 7 3 2 Fast inputs 11 1 to 11 4 These four fast inputs can be used for special functions like referencing and initialisation Addidional information can be found in the PMCprimo programming manual Page 60 Installation manual for P
58. egen resistor external Ohm 66 66 Continuous power in regen circuit RBext max kW 1 1 Pulse power in regen circuit RBext max 1s kW 0 75 3 Switch on upper threshold of regen circuit V 400 720 840 Overvoltage F02 V 455 800 900 E Regen resistor internal Ohm 91 91 91 amp Continuous power in regen circuit RBint W o 20 20 20 2c Pulse power in regen circuit RBint max 1s kW 2 1 T 9 eo Regen resistor external Ohm 91 91 91 Continuous power in regen circuit RBext max kW 0 3 0 3 0 3 Pulse power in regen circuit RBext max 1s kW 2 1 7 9 Switch on upper threshold of regen circuit V 400 720 840 Overvoltage F02 V 455 800 900 g lt Regen resistor internal Ohm 91 91 91 so Continuous power in regen circuit RBint W o 50 50 50 gt b Pulse power in regen circuit RBint max 1s kW 2 1 T 9 a Regen resistor external Ohm 91 91 91 Continuous power in regen circuit RBext max kW 1 0 1 0 1 0 Pulse power in regen circuit RBext max 1s kW 2 1 T 9 Partially other resistance values are possible Please ask our customer support Installation manual for PMCtendo DD5 PMCprimo Drive3 7 General 7 11 7 11 1 Switch on and switch off behavior The diagram below illustrates the correct functional sequence for switching the servo amplifier on and off U 24V X4 t BTB RTO X3 1 2 t L1 L2 L3 XO t X7 t ENABLE X3 12 t Stop function as per EN 60204 VDE 0113 If a fault occu
59. en exceeded improve ventilation F14 message Output stage fault motor cable has a short circuit or earth ground short motor has short circuit or earth ground short output module is overheated output stage is faulty short circuit or short to ground in the external regen resistor replace cable replace motor improve ventilation return the servo amplifier to the manufacturer for repair remove short circuit ground short F16 message Mains BTB RTO enable was applied although the supply voltage was not present at least 2 supply phases missed only ENABLE the servo amplifier when the electrical supply voltage has been switched on check the electrical supply F17 message AID converter error in the analog digital conver sion usually caused by EMC interference reduce EMC interference check shielding and grounding F25 message Commutatiion error wrong cable used offset is too large wake amp shake missed check cable check resolver pole number RESPOLES motor pole number MPOLES and offset MPHASE execute wake amp shake F27 message error AS AS enable AND HW enable have been set at the same time check programming and wiring of the PLC control system Motor does not rotate servo amplifier not enabled software enable not set break in setpoint cable motor phases swapped brake not released drive
60. eneral 33 notes effects warning gt S see page A special emphasis Installation manual for PMCtendo DD5 PMCprimo Drive3 7 General 7 1 7 2 7 3 General About this manual This manual describes the PMCtendo DD5 and PMCprimo Drive3 series of digital servo amplifiers In this manual you can find information about e Technical description of the PMCtendo DD5 and PMCprimo Drive3 Chapter 7 7 e Assembly installation Chapter 8 e Interfaces Chapter 9 e Setup Chapter 10 e Accessories Chapter 11 e Transport storage maintenance and disposal Chapter 12 The programming of the PMCprimo Drive3 is described explicitely in the PMCprimo programming manual The parameterisation of the PMCtendo DD5 is described in detail in the PDrive user manual Useful hints about linking controls and CANopen devices via CAN bus can be found in the manual PMCprimo CAN network All manuals are part on the CD ROM PMCprimo Motion Control Tools Requirements This manual addresses personnel with the following qualifications Transport only by personnel with knowledge of handling electrostatically sensitive components Installation only by electrically qualified personnel Setup only by qualified personnel with extensive knowledge of electrical engineering and drive technology Use as directed Servo amplifiers are components that are built into electrical plant or machines and can only be operated as
61. er with EnDat or HIPERFACE X1 esses 52 9 6 5 Acuro Encoder BISS Interface X1 53 9 6 6 Incremental encoder X5 nennen 54 9 6 7 Sine Encoder without data channel X1 55 9 7 Digital and analog inputs and outputs ceeeeceeeeeeeeeeeeeeeseeeeeaaees 56 SENE voies X3 e 56 9 7 2 Digital Inputs X3 X4 nnns 58 9 7 3 Digital Inputs 11 1 115810 60 9 7 4 Digital outputs X3 nennen nnns 61 9 7 5 Digital outputs X10 63 98 Encoder einllaliolisssdnomdsditsiendnnisus adt Miranda MIA ub Rd a Bas aM oM apad a 64 9 8 1 Incremental encoder output A quad B X5 rrrrrnnrrnnnnrrerrnnrrrrnnsrennnnnrr 64 982 botes t T 65 9 9 MMaster slave operation encoder master control 66 9 9 2 Connection to a PMCtendo DD5 master 5V signal level X5 66 9 9 3 Connection to incremental encoder master with 24V signal level X3 67 9 9 4 Connection to a sine encoder master X1 68 9 10 Interface for stepper motor controllers step and direction 69 9 10 1 Speed profile and signal diagram 69 9 10 2 Connection to a stepper controller with 5V signal level X5 70 9 10 3 Connection to a stepper controller with 24V signal level X3 71 9 11 RS232 interf
62. g on mounting situation Reference ge BEN 95555523 X6 X5 x2 X1 PC ROD Resolver HIPERFACE CAN SSI ComCoder Hall EnDat ACURO Sine Encoder Installation manual for PMC tendo DD5 PMCprimo Drive3 Page 49 9 6 2 ComCoder X1 9 Interfaces As an option our motors can be equipped with a ComCoder as feedback unit For the commutation hall sensors are used and for the resolution an incremental encoder The thermostat contact in the motor is connected via the ComCoder cable to X1 and evaluated there If cable lengths of more than 25m are planned please consult our customer service Frequency limit A B 350 kHz PMCtendo DD5 PMCprimo Drive3 10k TT um 1 i ded EST 1 i i Up SV 5 max 250mA OV X6 X5 PC ROD CAN SSI Page 50 x1 Comcoder 1 3 ll thermal control min 5VDC 5mA ome oto 0000 0000000 X2 Resolver HIPERFACE ComCoder Hall EnDat ACURO Sine Encoder Installation manual for PMCtendo DD5 PMCprimo Drive3 9 Interfaces 9 6 3 Incremental or Sine Encoder with hall sensors X1 Feedback devices incremental or sine cosine which don t deliver an absolute information for commutation can be used as complete feedback system combined with an additional Hall encoder All signals are connected to X1 If cable lengths of more than 25m are planned please consult our customer service Frequency limit A B 350 kHz PMCtendo DD5 PMCprimo Dri
63. hases Regulates the difference between the speed setpoint and the actual value to 0 Output current setpoint Cyclically absolute serial position output Device to divert interference on the power supply cables to PET Voltage proportional to the actual speed Temperature sensitive switch built into the motor winding Integral component of a control loop Output once per turn from incremental encoders used to zero the machine Page 117 12 4 Index 2 24V auxiliary supply Interface 43 Expansion CAN MORES 107 A ACUR Bloo aan 53 PIN dla 25 Ambient temperature 22 Analog INPpuUtSs 56 AS ENABLE input rorrorrororranrrnnnrennnrenrnnnnrnnnnnnnnr 59 ASSCMDI reale 31 B sor A 93 Block diagram general 40 PE RH eens 24 BTB RI O 2 O 62 Buffer battery 111 C CAN Fault detection 76 CAN DUS ase 75 Station address 93 CAN BUS rni 77 CAN bus cable JE 73 CNN licia 73 CE conformance 8 COD 16 COMCOoder sssclhulbosdlii m 50 Components of a servo system 18 Conductor cross section 22 Connection diagram general 34 connection techNology
64. he fixing lugs of the option slot e Place the expansion module onto the option slot e Screw the screws into the threads of the distance pieces e Plug the Sub D9 socket into connector X6 on the PMCtendo DD5 Connection technology Standard shielded cables can be used for the RS232 and CAN interfaces If the servo amplifier is the last device on the CAN bus then the switch for the bus termination must be set to ON Otherwise the switch must be set to OFF condition as delivered Installation manual for PMC tendo DD5 PMCprimo Drive3 Page 107 11 Expansions and Accessories 11 1 4 3 Connector assignments RS232 CAN1 CAN2 X6A Pin Signal X6B X6C Pin Signal 1 1 CAN ERROR 2 RxD 2 CAN Low 3 TxD 3 CAN GND 4 4 CAN BTB 5 GND 5 6 6 CAN GND 7 7 CAN High 8 8 9 9 CAN POWER only when connecting with multi PMCprimo devices in CAN main net 11 1 4 4 Connection diagram c Term O X6A RS232 X6B CAN X6C CAN2 O Feed Z a CAN le Page 108 Installation manual for PMCtendo DD5 PMCprimo Drive3 11 Expansions and Accessories 11 1 5 11 1 5 1 PMCprimo board and PMCprimo expansion card The PMCprimo board upgrades the PMCtendo DD5 to a motion control device with a lot of interfaces and nearly unlimited functionality The installation of the PMCprimo card is described in the Installation and Operating Instructions for PMCprimo board This chapter gi
65. heck feedback unit and settings F05 message Undervoltage supply voltage is not present or too low when the servo amplifier is enabled only ENABLE the servo amplifier when the electrical supply voltage has been switched on delay 500 msec F06 message Motor temperature motor thermostat has been activated feedback connector is loose or a break in the feedback cable wait till motor has cooled down then check why it became so hot screw connector up tight or use new feedback cable F07 message Aux voltage the aux voltage produced by the servo amplifier is incorrect return the servo amplifier to the manufacturer for repair F08 message motor phases swapped correct motor phase sequence Overspeed feedback device set up incorrectly set up the correct offset F09 message checksum error save data to EEPROM again to force EEPROM a new calculation Installation manual for PMC tendo DD5 PMCprimo Drive3 Page 113 Page 114 12 Appendix F11 message brake short circuit in the supply cable for the motor holding brake motor holding brake is faulty fault in brake cable no brake connected although the brake parameter is set to WITH remove the short circuit replace motor check shielding of brake cable set brake parameter to WITHOUT F13 message Internal temp permissible internal temperature has be
66. iliary supply without brake and fan with brake or fan 20 V DC 30V DC 24 V DC 0 15 check voltage drop Ambient temperature in operation 0 40 C under rated conditions 40 55 C with power derating 2 596 K Humidity in operation rel humidity 8596 no condensation Site altitude up to 1000 meters a m s l without restriction 1000 2500 meters a m s l with power derating 1 5 100meters Pollution level Pollution level 2 as per IEC 60664 1 2 5 1 Enclosure protection IP 20 Mounting position vertical gt p 30 Ventilation 1A and 3A types all other types natural convection built on fan Make sure that there is sufficient forced ventilation within the control cabinet Conductor cross sections Following EN 60204 we recommend for single axis systems AC connection 1 5 mm 14AWG 600V 105 C DC bus linkRegen resistor 1 5 mm 14AWG 1000V 105 C shielded for lengths gt 20cm Motor cables up to 25 m 1 5 MMP 1 1 5 mm 14AWG 600V 105 C shielded C lt 150pF m Motor cables 25m to 50 m 1 mm 14AWG 600V 105 C shielded with motor choke C 150pF m Resolver motor thermostat 4x2x0 25 mm max 100m twisted pairs shielded 22AWG C 120pF m Encoder motor thermostat 7x2x0 25 mm max 50m twisted pairs shielded 22AWG Setpoints AGND 8x2x0 25 mm max 25m twisted pairs shielded 22AWG C
67. ind further information on handling errors from page 113 and in the ASCII command reference part of the setup software s online help system Page 99 10 8 Page 100 10 Setup Error messages PMCprimo Drive3 Errors which occur are shown in coded form by an error number in the LED display on the front panel ticker All error messages are also displayed on the connected terminal program PTerm x axis number Number Description O S C m Position enor SSS High position limit ago Lowpositonimi O O SooS S 005 Reference timeout SS 2706 Referenceoutofimis O oO oo S xF20_ Heat sink temperature too high imitis set by manufacturer to 80 C et Overvoltage in DCi OS S xF22 Feedback error cable break short circu short to ground 423 Undervotage inDCink 0 Motor temperature too high limit is set by manufacturer to145 C 4725 Aux voltagenotOK 900 xF26 Overspeed motor running away speed is too high 228 HaswEpromchecsumemo lt o o xF29 Braker cable break short circuit shortto ground x30 Motor phase missing cable break or simia 31 intemal temperature toohigh Fault in the output stage 24733 Ptmaxvaueexceeded O O O o xF34 20r3 3 phases missing in the supply feed Error in the analog digital conversion xF36 Regen circuit faulty or incorrect setting A supply phase is missing can be switched off for 2 phase o
68. integral components of such plant or machines The manufacturer of the machine must generate a hazard analysis for the machine and take appropriate measures to ensure that unforeseen movements cannot cause injury or damage to any person or property Servo amplifiers in the PMCprimo Drive3 and PMCtendo DD5 series can be supplied from 3 phase grounded earthed industrial supply networks TN system TT system with grounded neutral point no more than 5000A symmetrical rated current at 230V or 480V 10 The servo amplifiers must not be operated directly on non grounded supply networks or on asymmetrically grounded supplies with a voltage gt 230V Connection to other types of supply networks with an additional isolating transformer is described on p 17 Periodic overvoltages between phases L1 L2 L3 and the housing of the servo amplifier must not exceed 1000V crest In accordance with EN 61800 voltage spikes lt 50us between phases must not exceed 1000V Voltage spikes lt 50us between a phase and the housing must not exceed 2000V Installation manual for PMC tendo DD5 PMCprimo Drive3 Page 11 Page 12 7 General If the servo amplifiers are used in residential areas in business commercial areas or in small industrial operations then additional filter measures must be implemented by the user The PMCprimo Drive3 and PMCtendo DD5 family of servo amplifiers is exclusively intended for driving suitable brushless synchronous serv
69. is mechanically blocked motor pole no set incorrectly feedback set up incorrectly apply ENABLE signal set software enable check setpoint cable correct motor phase sequence check brake control check mechanism set motor pole no set up feedback correctly Motor oscillates gain is too high speed controller feedback cable shielding broken AGND not wired up reduce Kp speed controller replace feedback cable join AGND to CNC GND Drive reports following error Irms OF Ipeak Set too low accel decel ramp is too long increase lms or lpeak Keep within motor ratings shorten ramp Motor overheating Irms Ipeak IS set too high reduce lims peak Installation manual for PMCtendo DD5 PMCprimo Drive3 12 Appendix Drive too soft Kp speed controller too low Tn speed controller too high ARLPF ARHPF too high ARLP2 too high increase Kp speed controller use motor default value for Tn speed controller reduce ARLPF ARHPF reduce ARLP2 Drive runs roughly Kp speed controller too high Tn speed controller too low ARLPF ARHPF too low ARLP2 too low reduce Kp speed controller use motor default value for Tn speed controller increase ARLPF ARHPF increase ARLP2 Axis drifts atsetpoint 0V offset not correctly adjusted for analog setpoint provision
70. l acceptable following error window 6 Out PosReg1 default SW limit 1 indicated by a HIGH signal 7 Out PosReg2 default SW limit 2 indicated by a HIGH signal 8 Out PosReg3 Can only be adjusted by ASCII commands setup software 9 Out PosReg4 Can only be adjusted by ASCII commands setup software 10 Out PosReg5 Can only be adjusted by ASCII commands setup software 11 24V DC Supply voltage for output signals 12 O GND Digital GND for the control system Installation manual for PMCtendo DD5 PMCprimo Drive3 11 Expansions and Accessories 11 1 2 6 Connection diagram PMCtendo DD5 Control 24V ref to O GND AO C A1 q A2 Q A3 binary coded q A4 motion task No C AS C A6 C A7 C Reference Home C FError clear Q Start MT next C Start Jog v x q MT Restart e Start MT 1 0 q InPos Ci Next InPos PosRegO d FError q PosRegl q PosReg2 q PosReg3 q PosReg4 q PosReg5 q 24V e O GND Installation manual for PMC tendo DD5 PMCprimo Drive3 Page 105 11 1 3 11 1 3 1 11 1 3 2 11 1 3 3 Page 106 11 Expansions and Accessories Expansion card PROFIBUS This section describes the PROFIBUS expansion card for the Information on the range of functions and the software protocol can be found in our manual Communication Profile PROFIBUS DP The PROFIBUS expansion card has two 9 pin SubD sockets wired in parallel The supply voltage for the e
71. lation 8 4 A A Wiring Only professional staff who are qualified in electrical engineering are allowed to install the servo amplifier The installation procedure is described as an example A different procedure may be appropriate or necessary depending on the application of the equipments We provide further know how through training courses on request Warning Only install and wire up the equipment when it is not live i e when neither the electrical supply nor the 24 V auxiliary voltage nor the supply voltages of any other connected equipment is switched on Take care that the cabinet is safely disconnected with a lock out warning signs etc The individual voltages will be switched on for the first time during setup The ground symbol which you will find in all the wiring diagrams indicates that you must take care to provide an electrically conductive connection with the largest feasible surface area between the unit indicated and the mounting plate in the control cabinet This connection is for the effective grounding of HF interference and must not be confused with the PE symbol c protective earth safety measure as per EN 60204 Use the following connection diagrams Overview Mains Motor Feedback Resolver Comcoder Incremental encoder Encoder with Hall Encoder with EnDat HIPERFACE Acuro BISS Incremental encoder Encoder without data channel Encoder Emulation ROD A quad B SSI Master Sl
72. ldern Germany 199 Telephone 49 711 3409 0 more than automation he Telefax 449 711 3409 133 Reng E Mail pilz gmbhOpilz de safe automation 21 590 01 2007 03 Printed in Germany
73. lls the requirements of the EC Machinery Directive 98 37 EC the EC EMC Directive 89 336 EEC and the EC Low Voltage Directive 73 23 EEC Standards to be applied for conformance with the EC Machinery Directive 98 37 EC EN 60204 1 Safety and Electrical Equipment in Machines EN 292 Safety of Machines The manufacturer of the machine must generate a hazard analysis for the machine and must implement appropriate measures to ensure that unforeseen movements cannot cause injury or damage to any person or property Standards to be applied for conformance with the EC Low Voltage Directive 73 23 EEC EN 60204 1 Safety and Electrical Equipment in Machines EN 50178 Electronic Equipment in Power Installations EN 60439 1 Low Voltage Switchgear Combinations Standards to be applied for conformance with the EC EMC Directive 89 336 EEC EN 61000 6 1 EN 61000 6 2 Interference Immunity in Residential amp Industrial Areas EN 61000 6 3 EN 61000 6 4 Interference Generation in Residential amp Industrial Areas The manufacturer of the machine plant is responsible for ensuring that it meets the limits required by the EMC regulations Advice on the correct installation for EMC such as shielding grounding treatment of connectors and cable layout can be found in this documentation The machine plant manufacturer must check whether other standards or EC Directives must be applied to the machine plant CE conformance Conformance wi
74. luation of resolver signals and sine cosine signals of high resolution encoders e Encoder emulation incremental compatible with A quad B or SSI Comfort functions e 2 programmable analog inputs e 4 programmable digital inputs e 2 programmable digital outputs e programmable logical combinations of digital signals Expansions e 1 0 14 08 expansion card gt p 103 e PROFIBUS DP expansion card gt p 106 e PMOprimo board and PMCprimo expansion card gt p 109 e CAN adapter expansion module separated connectors for CAN bus and RS232 gt p 107 Installation manual for PMC tendo DD5 PMCprimo Drive3 Page 15 7 General 7 4 5 The PMCprimo Drive3 family of digital servo amplifiers In addition to the PMCtendo DD5 functionality the PMCprimo Drive3 offers further possibilities 7 4 5 1 Performance data e Position controller with 1 ms cycle time using 10 axis e Oaxesin system 1 Motor direct as well as 8 other channels for controlling further axes e Input for one master encoder incremental absolut SSI or via CAN e Each axis can operate in virtual motor mode e Software gearbox e Software differential and clutch e Internal map generator motion generator as an option e Product referencing e Tension control e CNC function DIN 66025 as an option e Upto 8 CAM e Soft positioning 7 4 5 2 Fieldbus Interface e CAN Bus with 500 kBit s or 1 MBit s CANopen linking up to 60 PMCprimo motion control systems e MODB
75. ly single phase 230V AC to terminals L1 L2 of the servo amplifier for about 30 minutes This will re form the capacitors Additional information on setting up the equipment The adaptation of parameters and the effects on the control loop behavior are described in the manual and the online help of the setup software PDrive The setting up of any expansion card that may be fitted is described in the corresponding manual on the CD ROM We can provide further know how through training courses on request Installation manual for PMCtendo DD5 PMCprimo Drive3 10 Setup 10 2 Guide to setup The following instructions should help you to carry out the setup in a sensible order without endangering people or machinery Check installation Block the Enablesignals Switch on 24V auxiliary supply Switch on PC start setup software PDrive Check the displayed parameters and correct if necessary Supply voltage Rated motor voltage Motor pole no Feedback IRMs IPEAK Limit speed Regen power Station address Check safety devices Switch on supply power Apply 0V command Enable Setpoint Optimization Set up the expansion card Installation manual for PMC tendo DD5 PMCprimo Drive3 See p 29 Disconnect the servo amplifier from the supply Apply OV to terminal X3 12 Enable and to terminal X4 5 A
76. manual PDrive Multi axis systems Station address for CAN bus During setup it makes sense to use the keypad on the front panel to preset the station addresses for the individual amplifiers and the Baud rate for communication p 94 Baud rate for CAN bus After changing the station address and baud rate you must turn the 24V auxiliary supply for the servo amplifier off and on again Coding of the Baud rate in the LED display Coding Baud rate in kBit s Coding Baud rate in kBit s 0 10 5 250 1 20 6 333 2 50 7 500 3 100 8 666 4 125 9 800 10 1000 not PMCprimo Drive3 Installation manual for PMC tendo DD5 PMCprimo Drive3 Page 93 10 4 2 10 4 2 1 10 4 2 2 Page 94 10 Setup Keypad operation PMCtendo DD5 This section illustrates the two possible operating menus and the use of the keys on the front panel Normally the only presents the standard menu for your use If you want to operate the amplifier via the detailed menu you must keep the right key pressed while switching on the 24V supply Keypad operation The two keys can be used to perform the following functions Key symbol functions press once move up one menu item increase number by one press twice in rapid succession increase number by ten press once move down one menu item decrease number by one press twice in rapid succession decrease number by ten hold right key p
77. manual for PMCtendo DD5 PMCprimo Drive3 4 Safety instructions 4 Safety instructions Only properly qualified personnel are permitted to perform activities such as transport installation setup and maintenance Properly qualified persons are those who are familiar with the transport assembly installation setup and operation of the product and who have the appropriate qualifications for their job Qualified personnel must know and observe IEC 364 and CENELEC HD 384 or DIN VDE 0100 IEC Report 664 or DIN VDE 0110 National Accident Prevention Regulations or BGV A3 Read this documentation before carrying out installation and setup Incorrect handling of the servo amplifier can lead to personal injury or material damage It is vital that you keep to the technical data and information on connection requirements on the nameplate and in the documentation The servo amplifiers contain electrostatically sensitive components that may be damaged by incorrect handling Ground yourself before touching the servo amplifier by touching any unpainted metal surface that is itself grounded Avoid contact with highly insulating materials such as artificial fabrics or plastic film Place the servo amplifier on a conductive surface The manufacturer of the machine must generate a hazard analysis for the machine and take appropriate measures to ensure that unforeseen movements cannot cause injury or damage to any person or property Do not open the u
78. master with 24V signal level X3 This interface can be used to operate the PMCtendo DD5 as a slave mastered by an encoder with a 24V signal level master slave operation This uses the digital inputs DIGITAL IN 1 and 2 on connector X3 Frequency limit 100 kHz transition time tv lt 0 1us PMCtendo DD5 incremental encoder ot A my E track A LI DIGITAL IN2 9 3 E track B 24V ref to GND X4 4 e GND BTB RTO BTB RTO Analog In 1 Analog In 1 Analog In 2 Analog In 2 AGND DIGITAL IN1 DIGITAL IN2 DIGITAL IN3 DIGITAL IN4 ENABLE DIGITAL OUT1 DIGITAL OUT2 24V 24V DGND DGND AS ENABLE X4 24V AS Installation manual for PMC tendo DD5 PMCprimo Drive3 Page 67 9 Interfaces 9 9 4 Connection to a sine encoder master X1 This interface can be used to operate the PMCtendo DD5 as a slave mastered by a sine cosine encoder master slave operation This uses the SubD connector X1 Frequency limit A B 350 kHz PMCtendo DD5 Encoder B LS z Up voltage supply OV 5V 5 max 250mA OV oa ozio 0000 0000000 X1 X6 X5 X2 PC ROD Resolver H IPERFACE CAN SSI ComCoder Hall EnDat ACURO Sine Encoder Page 68 Installation manual for PMCtendo DD5 PMCprimo Drive3 9 Interfaces 9 10 Interface for stepper motor controllers step and direction Is These function is available only at a PMCtendo DD5 This interface can be used to connect the servo
79. n Power supply 12 V Fault detection The following faults will be detected e Missing or defect 12V CAN power supply e Malfunction of a bus node e Break of the CAN bus cable Connecting external CANopen bus devices It is possible to connect external CANopen devices with PMCprimo motion control systems With e g a CAN I O module you can increase the number of inputs and outputs in the system A CANopen encoder or CANopen panel can also be used Much more examples and hints can be found on the manual PMCprimo CAN network on the enclosed CD ROM Installation manual for PMCtendo DD5 PMCprimo Drive3 9 Interfaces 9 14 CAN bus Interface X11 4 Is These interface is available only at a PMCprimo Drive3 with option expansion card The connector X11 4 can be used with the option expansion card see p 109 as a second CAN interface CAN 2 The master encoder input X11 4 is diabled This is done by changing the hardware settings jumper See page 109 for more information PMCprimo Drive3 PMCtendo DD5 X11 4 U CANH ae I INE CANL EB e o CAN GND IU CAN ISO 11898 X11 4 X11 3 X11 2 X11 1 Master encoder MODBUS CAN 1A CAN 1B CAN2 Profibus DP S JOE O PL O Option With the second CAN 2 interface up to 8 PMCtendo DD5 servo ampilfier can be linked with one PMCprimo Drive3 Much more examples and notes can be found on the manual PMCprimo CAN network
80. ne make them necessary You can find further information and implementation examples in the Application Note Stop and Emergency Stop Functions Installation manual for PMC tendo DD5 PMCprimo Drive3 Page 27 7 11 2 7 11 2 1 7 11 2 2 7 11 2 3 Page 28 7 General Emergency Stop strategies The Emergency Stop function is defined in EN 60204 VDE 0113 Para 9 2 5 4 Implementation of the Emergency Stop function Wiring recommendation can be found in the Application Note Stop and Emergency Stop Functions Category 0 The controller enable is switched to disable the electrical supply is disconnected The drive must be held by an electromechanical holding device brake In multi axis systems with a coupled DC bus link the motor cable must also be disconnected by a changeover switch a contactor such as the Siemens 3RT1516 1BB40 and short circuited by resistors connected in a star configuration Category 1 If hazardous conditions can result from an Emergency Stop switch off with an uncontrolled run down the drive can be switched off after a controlled shutdown Stop Category 1 permits electromotoric i e regenerative braking with a switch off when zero speed has been reached Safe shutdown can be achieved if the loss of the electrical supply is not evaluated as a fault and the control system takes over the disabling of the servo amplifier In normal circumstances only the supply power is switched off in a saf
81. nits Keep all covers and control cabinet doors closed during operation Otherwise there are deadly hazards with the risk of death severe danger to health or material damage Servo amplifiers may have uncovered live parts during operation depending on their degree of enclosure protection Control and power connections may be live even when the motor is not rotating Servo amplifiers may have hot surfaces during operation Temperatures may rise to above 80 C 176 F Never undo the electrical connections to the servo amplifier while it is live In unfavorable circumstances this may cause electrical arcing with damage to contacts and danger to persons After disconnecting the servo amplifier wait at least five minutes before touching live sections of the equipment such as contacts or undoing any connections Capacitors can still have dangerous voltages present up to five minutes after switching off the supply voltages To be sure measure the voltage in the DC bus link circuit and wait until it has fallen below 40V Installation manual for PMC tendo DD5 PMCprimo Drive3 Page 7 Page 8 5 European Directives and Standards European Directives and Standards Servo amplifiers are components that are intended to be incorporated into electrical plant and machines for industrial use When the servo amplifiers are built into machines or plant the amplifier must not be used until it has been established that the machine or equipment fulfi
82. nput Analog In 2 PMCtendo DD5 only e adjustable external current limit e reduced sensitivity input for setting up jog operation e pre control override 9 7 1 4 Defining the direction of rotation PMCtendo DD5 only Standard setting clockwise rotation of the motor shaft looking at the shaft end e Positive voltage between terminal X3 3 and terminal X3 4 or e Positive voltage between terminal X3 5 and terminal X3 6 To reverse the direction of rotation swap the connections to terminals X3 3 4 or X3 5 6 respectively or change the ROTATION DIRECTION parameter in the Position controller screen page Installation manual for PMC tendo DD5 PMCprimo Drive3 Page 57 9 Interfaces 9 7 2 Digital Inputs X3 X4 All digital inputs are electrically isolated via optocouplers 9 7 2 1 Technical characteristics e Ground reference is Digital GND DGND terminals X4 3 and X4 4 e The inputs at X3 are PLC compatible IEC 61131 2 Type 1 High 11 30 V 2 11 mA Low 3 5 V 1mA e Update rate Software 250 us Hardware 2us PMCtendo DD5 PMCprimo Drive3 Controls DIGITAL IN2 9 DIGITAL IN DIGITAL IN4 11 ENABLE 12 ENABLE 24V against CNC GND AS ENABLE 5 D 1 0 GND BTB RTO BTB RTO Analog In 1 Analog In 1 Analog In 2 Analog In 2 AGND DIGITAL IN1 DIGITAL IN2 DIGITAL IN3 DIGITAL IN4 ENABLE DIGITAL OUT1 DIGITAL OUT2 24V 24V DGND DGND AS ENA
83. nputs 59 PERM 97 Puls direction essere 69 R Regen circuit i 25 Resolver iii 49 ROL 64 Bey 20 94 fad QE 72 S Safety instructions en 7 orbc 90 Setup software PDTriVe 92 SINGOS Encoder sciita 55 olo cM Gu 30 iol P PP 65 stacking height 112 A RaO E REEERE REE 8 Status Messages i 101 viro me EEE EEE 112 storage duration i 112 Storage temperature 112 Installation manual for PMCtendo DD5 PMCprimo Drive3 12 Appendix SUV e RR E 17 Supply voltage 22 Switch on and switch off behavior 27 T Technical data i 19 Tightening torques 21 Li ion roi 112 Ibl m 6 Installation manual for PMC tendo DD5 PMCprimo Drive3 U Use as directed ispiri dia iaia 11 V Vee 30 W Warning messages i 99 MING 30 Page 119 pu gt www In many countries we are www pilz com represented by our subsidiaries and sales partners p gt Technical support Please refer to our Homepage 49 711 3409 444 for further details or contact our headquarters Pilz GmbH amp Co KG Sichere Automation Felix Wankel StraBe 2 73760 Ostfi
84. of the contactors caused by switching under load e extensive wiring required with additional switching components The restart lock AS avoids these disadvantages The conceptual examination of the function safe stop called restart lock AS in the following was accomplished by the BG Institute for Occupational Safety and Health and the classification in category 3 according to EN 954 1 was confirmed Advantages of the restart lock AS e the DC bus link remains charged up since the mains supply line remains active e only low voltages are switched so there is no contact wear e very little wiring is required e the functionality and the personnel safety when using the circuit recommendations in this documentation have been approved by the Trade Liability Association Technical data and pinning Input voltage 20V 30V Input current 40mA 75MA leff Peak current 220mA Is X4 24V AS 24V 1 24V 2 DGND 3 4 5 DGND AS ENABLE interlock safety switchgear Since the servo amplifier meets enclosure IP20 you must select the environment ensuring a safe operation of the servo amplifier The environment must meet enclosure IP54 at least Environment Wiring If the wiring leads outside the demanded enclosure IP54 the cables must be laid durably firmly protected from outside damage e g laying in a cable duct in different sheathed cables or protected individually by grounding connecti
85. og In 1 Analog In 24 Analog In 2 AGND DIGITAL IN1 DIGITAL IN2 DIGITAL IN3 DIGITAL IN4 ENABLE DIGITAL OUT1 DIGITAL OUT2 24V 24V DGND DGND AS ENABLE X4 24V AS Installation manual for PMC tendo DD5 PMCprimo Drive3 Page 43 9 3 3 Page 44 9 Interfaces 24V supply X10 These connectors are available only at a PMCprimo Drive3 e Electrically isolated external 24V DC supply e g with insulating transformer e 24 V can be taken from terminal X4 otherwise external fusing necessary e Required current rating gt p 19 e See important notes to commissioning p 91 PMCprimo Drive3 alternative 24 V from terminal X4 Pin 2 3 X10 VO VCC Enc 1 EGND 2 24V 3 11 1 4 1 2 5 11 3 6 11 4 7 11 5 8 11 6 9 11 7 10 11 8 11 O1 1 12 01 2 13 01 3 14 01 4 15 01 5 16 01 6 17 O1 7 18 01 8 19 o o o o o o o o o o o o o o o o o o o Installation manual for PMCtendo DD5 PMCprimo Drive3 9 Interfaces 9 3 4 Master encoder supply X10 33 These connectors are available only at a PMCprimo Drive3 e Individual power supply for the connected encoder e Voltage range See encoder datasheet e External fusing provided by the user PMCprimo Drive3 VCC Enc See encoder datasheet X10 I O o o o o o o o o o o o o o o o o o o o Installation manual for PMC tendo DD5 PMCprimo Drive3 Page 45 9 Interfaces 9 3 5 DC bus link X8 Terminals X
86. omotors and asynchronous motors with closed loop control of torque speed and or position The rated voltage of the motors must be at least as high as the DC bus link voltage produced by the servo amplifier The servo amplifiers must only be operated in a closed control cabinet taking into account the ambient conditions defined on page 22 Ventilation or cooling may be necessary to keep the temperature within the cabinet below 40 C Use only copper conductors for wiring The conductor cross sections can be derived from the standard EN 60204 alternatively for AWG cross sections NEC Table 310 16 60 C or 75 C column We only guarantee the conformance of the servo system with the standards cited on p 8 if the components servo amplifier motor cables etc are those supplied by us Restart lock for personnel safety The servo amplifier has an integrated personnel safe restart lock which meets the requirements of safety category 3 according to EN 954 1 The conceptual examination of the function safe stop called restart lock AS in the following was accomplished by the BG Institute for Occupational Safety and Health and the classification in category 3 according to EN 954 1 was confirmed Please consider the specifications on page 85 when you use this function Installation manual for PMCtendo DD5 PMCprimo Drive3 7 General 7 4 Instrument description 7 4 1 Package supplied When you order an amplifier from the series PMCtendo
87. on If wiring remains within the demanded enclosure then it has to meet the requirements of the standard EN 60204 1 section 14 3 Installation manual for PMC tendo DD5 PMCprimo Drive3 Page 85 9 20 4 Page 86 9 Interfaces Functional description If the restart lock AS is not needed then the input AS ENABLE must be connected directly with 24VDC The restart lock is then passed by and cannot not be used In case of use of the restart lock the input AS Enable must be connected to the exit of a security control or a safety relay which meets at least to the requirements of the category 3 after EN 954 1 see the connection diagram on page 85 Possible states of the servo amplifier in connection with restart lock AS AS ENABLE ENABLE Display Motor has torque Safety Kat 3 OV OV S no yes OV 24V F27 no yes 24V OV normal status e g 06 no no 24V 24V normal status e g E06 yes NO If the restart lock is engaged during operation by separating input AS ENABLE from 24VDC the motor runs down out of control and the servo amplifier displays the error F27 There is no possibility of braking the drive controlled If a controlled braking before the use of the restart lock is necessary the drive must be braked and the input AS ENABLE has to be separated from 24VDC time delayed The restart lock AS does not provide an electrical separation from the power output If access to the motor power
88. ontrol signals BTB DGND 0 25 mm 22AWG twisted pairs shielded Holding brake motor 0 5 mm 20AWG 24 V DGND min 0 75 mm 18AWG 600V 105 C shielded check voltage drop 24 V DGND max 2 5 mm 12AWG check voltage drop For multi axis systems observe the specific operating conditions for your system Observe the technical data for cables on page p 22 North America supplies cables up to 39 meters Europe supplies cables up to max length Installation manual for PMCtendo DD5 PMCprimo Drive3 7 General 7 7 8 LED display 7 7 8 1 PMCtendo DD5 A 3 character LED display indicates the status of the amplifier after switching on the 24V supply gt p 94 When the keys on the front panel are used the parameter and function numbers are shown as well as the numbers for any errors that may occur gt p 98 7 7 8 2 PMCprimo Drive3 A 3 character LED displays the servo amplifiers firmware version after switching on the 24V supply for two seconds e g 5 18 Afterwards the status of up to 10 axes is shown or just run gt p 101 When an error occurs the error number is displayed gt p 100 Installation manual for PMC tendo DD5 PMCprimo Drive3 Page 23 7 8 Page 24 7 General Control circuit for motor holding brake A 24V max 1 5A holding brake in the motor can be controlled directly by the amplifier Check voltage drop measure the voltage at brake in
89. or i 27 7 11 1 Stop function as per EN 60204 VDE 0113 eeeeeeeeeeess 27 7 11 2 Emergency Stop strategies nnne 28 8 Installation 29 OT MAE NOLES NOR 29 8 2 Guide to installation and wiring 30 8 3 Assembly EEE 31 od DENNE mE 32 or NN 33 8 4 1 Connection diagram general 34 8 4 2 Connection diagram PMCprimo Drive i 35 8 4 3 Connector assignments general 36 8 4 4 Connector assignments PMCprimo Drive3 37 8 4 5 Notes on connection TECHNOIlOGY ccecccceeceeseeeeeeeeeceeeeeeeeeeseeeseeeenaaees 38 9 Interfaces 40 9 1 Block diagram general ii 40 9 2 Block diagram PMCprimo Drive 41 9 3 Electrical SupplY ii 42 Installation manual for PMC tendo DD5 PMCprimo Drive3 Page 3 2 Table of contents 9 3 1 Mains electrical supply connection XO rrrrrrrrnnnrrnrnnrrenrnnrrrvnnerennnnnnen 42 9 3 2 24V auxiliary supply X4 nnne 43 9 33 24V SUDDIV X10 Lekende 44 9 3 4 Master encoder supply X10 45 9 39 DG DUSINK XAO vane 46 9 4 Motor connection with brake XQ 47 9 5 External regen restistor X8 emnes 48 SEMEL Em 49 961 Resolver X2 iioii e roS clelia pica 49 9 02 eii us Lee 50 9 6 3 Incremental or Sine Encoder with hall sensors X1 51 9 6 4 Sine Encod
90. peration System software not responding correctly ENABLE not active Commutation error The error messages xF20 xF39 result in the BTB RTO contact being opened and the output stage of the PMCprimo Drive3 being switched off motor looses all torque If a motor holding brake is installed it will be activated Example of an error message ticker TFG Error code 1F01 Channel 1 Position error With the command CD17 1 as of firmware version 2 004 the 7 segment display can be configured to just show run when there is no error With CD17 0 the previous display will be activated Installation manual for PMCtendo DD5 PMCprimo Drive3 10 Setup 10 9 Status messages PMCprimo Drive3 The LED Display shows the actual state of 3 channels at the same time for one second then it switches to the next three channels if enabled with the CD command P Positioncontrolmode fpe 0 Motor off mode MO 1 Velocity control mode VC 2 JMoWngionewposton MAMR 4 Execingapostionmappng pm S Stopping under normal deceleration sr e initializing to reference position Nes 93 Wai WA We Wi et Example of a status message enabled with CD command Status Channel 1 3 CH1 P Position control mode CH2 4 Executing a position map CH3 4 Executing a position map Status Channel 4 6 CH4 0 Motor off mode CH5 0 Motor off mode CH6 0
91. pilz more than automation safe automation PMCtendo DD5 PMCprimo Drive3 1 General conditions 1 General conditions 1 1 Copyright Copyright 2006 Pilz GmbH amp Co KG All rights reserved No part of this document may be reproduced in any form print photocopy microfilm or any other format or modified duplicated by electronic means without written authorization by Pilz GmbH amp Co KG 1 2 Notes Pilz GmbH amp Co KG reserves the right to make amendments to this document at any time The examples given serve only as illustrations No guarantee is given for their suitability in particular applications Although the utmost care has been taken in the production of this document no liability can be accepted for any mistakes that it may contain We welcome any suggestions for the improvement of our products or documentation We reserve the right to make technical changes which lead to the improvement of the product 1 3 Previous editions Initial release E Page 2 Installation manual for PMCtendo DD5 PMCprimo Drive3 2 Table of contents 2 Table of contents 1 General conditions 2 Wed OOD ur 2 NOE 2 1 3 Previouseditions nennen nennen nnne nnne nnn nnns 2 2 Table of contents 3 Type key 6 31 Type PMCGENdO DDS 6 3 2 Type PMCprimo Drive3 i 6 4 Safety instructions 7 5 European Directives and
92. ptically isolated EGND digital inputs outputs X10 24V supply PMCprimo Drive3 supply master encoder optically isolated Regen circuit During braking with the aid of the motor energy is fed back into the servo amplifier This regenerative energy hence the term regen circuit is dissipated as heat in the regen resistor The regen resistor is switched in by the regen circuit The setup software PDrive can be used to adapt the regen circuit thresholds according to the electrical supply voltage Our customer service can help you with the calculation of the regen power that is necessary for your system A description of the interface can be found on page 48 Functional description 1 Individual amplifiers not coupled through the DC bus link circuit DC DC If the energy fed back from the motor has an average or peak power that exceeds the preset level for the regen power rating then the servo amplifier generates the warning n02 regen power exceeded and the regen circuit is switched off The next internal check of the DC bus link voltage after a few milliseconds detects an overvoltage and the servo amplifier is switched off with the error message Overvoltage F02 gt p 98 The BTB RTO contact terminals X3 2 3 will be opened at the same time p 62 2 Several servo amplifiers coupled through the DC bus link DC DC Thanks to the built in regen circuit several amplifiers even with different current
93. put and check brake function brake and no brake This function does not ensure personnel safety The brake function must be enabled through the BRAKE parameter screen page Motor setting WITH In the diagram below you can see the timing and functional relationships between the ENABLE signal speed setpoint speed and braking force U Analog In terminal t ENABLE terminal t SW internal A Speed t ENABLE internal t BRAKE terminal t Braking force t During the internal ENABLE delay time of 100ms the speed setpoint of the servo amplifier is internally driven down an adjustable ramp to OV The output for the brake is switched on when the speed has fallen to 396 of the preset final speed at the latest after 1 second The rise forn and fall fp times of the holding brake that is built into the motor are different for the various types of motor see motor manual A description of the interface can be found on page 47 Operation of the brake in a manner that provides personnel safety requires an additional make contact in the brake circuit and a suppressor device such as a varistor for the brake circuit Recommended circuit J I Ne External safety circuit Installation manual for PMCtendo DD5 PMCprimo Drive3 7 General 7 9 7 10 7 10 1 Grounding system AGND analog inputs internal analog ground encoder emulation RS232 CAN X6 DGND digital inputs outputs and the 24V supply o
94. r is not rotating Installation manual for PMC tendo DD5 PMCprimo Drive3 Page 29 8 2 Page 30 8 Installation Guide to installation and wiring The following notes should help you to carry out the installation in a sensible sequence without overlooking anything important Site Ventilation Assembly Cable selection Grounding Shielding Wiring Final check In a closed control cabinet Please refer to page 22 The site must be free from conductive or corrosive materials For the mounting position in the cabinet gt p 30 Check that the ventilation of the servo amplifier is unimpeded and keep within the permitted ambient temperature p 22 Keep the required space clear above and below the servo amplifier gt p 30 Assemble the servo amplifier and power supply close together on the conductive grounded mounting plate in the cabinet Select cables in accordance with EN 60204 gt p 39 For EMC compliant shielding and grounding p 38 Ground the mounting plate motor housing and CNC GND of the control system Notes on connection techniques 38 Route power leads and control cables separately Wire the BTB RTO contact in series into the safety circuit of the system Connect the digital control inputs and outputs Connect up AGND also if fieldbuses are used Connect the analog input source if required Connect the feedback de
95. ratings can be operated off a common DC bus link without requiring any additional measures The combined peak and continuos power of all amplifiers is always available The switch off on overvoltage takes place as described under 1 above for the amplifier that has the lowest switch off threshold resulting from tolerances Technical data of the regen circuits dependent on the amplifiers type and the mains voltage situation see table on the next page Installation manual for PMC tendo DD5 PMCprimo Drive3 Page 25 7 10 2 Page 26 Technical Data 7 General Regen circuit Supply voltage Rated data DIM 115V 230 V 400 V 480 V Switch on upper threshold of regen circuit V 200 400 Overvoltage F02 V 235 455 E Regen resistor internal Ohm 66 66 Continuous power in regen circuit RBint W 20 20 n gt Pulse power in regen circuit RBint max 1s kW 0 75 3 o Regen resistor external Ohm 66 66 Continuous power in regen circuit RBext max kW 0 3 0 3 Pulse power in regen circuit RBext max 1s kW 0 75 3 Switch on upper threshold of regen circuit V 200 400 Overvoltage F02 V 235 455 og Regen resistor internal Ohm 66 66 m gt Continuous power in regen circuit RBint W 50 50 o 2 S Pulse power in regen circuit RBint max 1s kW 0 75 3 o J R
96. rature too highlimit is set by manufacturer to 80 F02 overvoltage overvoltage in DC bus linklimit depends on the electrical supply voltage F03 following error message from the position controller F04 feedback cable break short circuit short to ground F05 undervoltage undervoltage in DC bus linklimit is set by manufacturer to 100V F06 motor temperature motor temperature too high or temp sensor defect F07 reserved reserved F08 overspeed motor runs away speed is too high F09 EEPROM checksum error F10 signal failure X5 signal failure X5 cable break or similar F11 brake cable break short circuit short to ground F12 motor phase motor phase missing cable break or similar F13 ambient temperature ambient temperature too high F14 output stage fault in the power output stage F15 lt max lt maximum value exceeded F16 mains BTB RTO 2 or 3 phases missing in the mains supply feed F17 A D converter error in the analog digital conversion normally caused by extreme electromagnetic interference F18 regen regen circuit faulty or incorrect setting F19 DC bus link DC bus link breakdown F20 slot error slot error depends on the type of expansion card see ASCII command reference F21 handling error Handling error on the expansion card F22 reserved reserved F23 CAN bus off severe CAN bus communication error F24 warning warning is displayed as fault F25 commutation error commutation error F26 limit switch hardware limi
97. rcuit 1 01 Threshold for overvoltage switch off kHz 212 Motor inductance min V 5 Switching frequency of the output stage W 12 Thermal dissipation at rated current incl PSU W AO 60 90 losses without regen dissipation Mechanical Weight kg ca 2 Height without connectors mm 275 278 Width mm 70 Depth without connectors mm 171 Depth with connectors mm lt 235 Page 20 at reduced current Installation manual for PMCtendo DD5 PMCprimo Drive3 7 General 7 7 3 7 7 4 7 7 5 7 7 5 1 7 7 5 2 Inputs outputs Analog inputs 1 2 resolution 14 12 bit V 10 Max common mode voltage V 10 Input resistance to AGND kQ 20 Digital control inputs V as per EN 61131 2 Type 1 max 30VDC Digital control outputs active high V open Emitter max 30VDC 10mA V DC max 30 AC max 42 BTB RTO output relay contacts mA 500 Digital inputs X10 V as per EN 61131 2 Type 2 max 30VDC Digital outputs X10 V open Emitter max 30VDC 100mA Auxiliary supply voltage electrically isolated V 20 30 without brake fan A 1 3 Auxiliary supply voltage electrically isolated with V 24 0 15 brake fan check voltage drop A 2 8 Max output
98. ready inserted into the expansion slot of the servo amplifier and screwed in place The 1 0 14 08 provides you with 14 additional digital inputs and 8 digital outputs The functions of the inputs and outputs are adjustable with the setup software The I Os are used to initiate the motion tasks that are stored in the servo amplifier and to evaluate signals from the integrated position control in the higher level control system The functions of the inputs and signal outputs correspond to the functions that can be assigned to the digital I Os on connector X3 All inputs and outputs are electrically isolated from the servo III Lj b h LA in edes san 11 1 2 Expansion card l O 14 08 amplifier by optocouplers 11 1 2 1 Front view 11 1 2 2 Technical data 11 1 2 3 11 1 2 4 Control inputs 24V TmA PLC compatible IEC 1131 Signal output 24V max 500mA PLC compatible IEC 1131 Supply inputs to IEC 1131 24V 18 36V 100mA plus total current of the outputs depends on the input wiring of the controls The 24V DC voltage must be supplied by an electrically isolated power supply e g with isolating transformer Fusing external 4 AT Connectors MiniCombicon 12 pin coded on PIN1 and 12 Cables Data up to 50m long 22 x 0 5 mm unshielded Supply 2 x 1mm check voltage drop Waiting time between 2 motion tasks depends on the response time of the control system
99. ressed and then press left key as well to enter a number Return function Status display Switch on Data are being read from EnDat Input AS Enable OV 24V switched on unit indicates software version after 1 sec shift to status 2 3 or 4 status 2 24V switched on unit indicates current here 6A flashing dot OG status 3 24V switched on mains supply switched on status 1 unit indicates current and mains supply on flashing dot status 4 24V and mains supply on unit enabled unit indicates current mains supply on and enable flashing dot ME m i m a m s fault warning signal each error warning that has occurred will be indicated successively for 4 blinks each Parameters Installation manual for PMCtendo DD5 PMCprimo Drive3 10 Setup 10 4 2 3 10 4 2 4 Installation manual for PMC tendo DD5 PMCprimo Drive3 Standard menu State Advanced menu N UD rj mi p SON C 10 0903 09 station adress the entry will be stored automatically when you exit the input field serial number 9 digit number divided in 3 blocks decimal dot indicates number of block 2 ASCII command M Reset macros are newly compiled ASCII command RSTVAR parameter will be reset to default values save data to EEPROM load data from EEPROM brake or Sis positon output motor type see reference guide motor database F m m DI DE
100. rnnnrrnvnnnrennnnrrrvnnsrennnnnee 84 BRE pf EE A E A E 84 VPN 84 9 20 Personnel safe restart lock AS 85 9 20 1 Technical data and pinning i 85 9 20 2 aen e TE 85 EI P 85 9 20 4 Functional descriptioN 86 Page 4 Installation manual for PMCtendo DD5 PMCprimo Drive3 2 Table of contents 10 Setup 10 1 Important notes nnne 10 2 Guide t NN 10 3 Setup software PDrive i 10 3 1 Use as directed iii 10 3 2 Software description i 10 3 3 Hardware requirements e 10 3 4 Minimum requirements for the PCi 10 3 5 Installation under WINDOWS 2000 XP 10 306 Working with PDING ceri 10 4 Parametrization of the PMCtendo DD5 and PMCprimo Drive3 10 4 1 Multi axis systems rica 10 4 2 Keypad operation PMCtendo DDD ii 10 4 3 Keypad operation PMCprimo Drive3 i 10 4 4 BASIC key operation sisi 104 S ED T ee 10 5 Programming of the PMCprimo Drive 10 6 Error messages PMCtendo DDB 10 7 Warning messages PMCtendo DD53 10 8 Error messages PMCprimo DriVve3 10 9 Status messages PMCprimo Drive3 11 Expansions and Accessories 11 1 Expansion Cards sila 11 1 1 Guide to installation of e
101. rs gt p 98 then the output stage of the servo amplifier is switched off and the BTB RTO contact is opened In addition a global error signal can be generated at one of the digital outputs terminals X3 16 and X3 17 see online help for the setup software PDrive These signals can be used by the higher level control system to finish the current PLC cycle or to shut down the drive with additional brake or similar On a PMCprimo Drive3 additionally a plaintext message will be generated and an error variable is set too This allows the user to define a special error program which will be executed Devices with activated holding Brake function use a special sequence for switching off the output stage p 24 The Stop functions are defined in EN 60204 VDE 0113 Paras 9 2 2 9 2 5 3 There are three categories of stop functions Category 0 Shutdown by an immediate switch off of the energy supply to the drive machinery i e an uncontrolled shutdown Category 1 A controlled shutdown during which the supply of energy to the drive machinery is maintained as long as shutdown is being carried out and only interrupted when standstill has been reached Category 2 A controlled shutdown during which the supply of energy to the drive machinery is maintained Every machine must be equipped with a Category 0 stop function Stop functions to Categories 1 and or 2 must be provided if the safety of functional requirements of the machi
102. rs can be fitted with a single turn or multi turn ACURO encoder with BISS interface The encoder is used by the as a feedback device for drive tasks that require highly precise positioning or extremely smooth running The thermostat contact in the motor is connected via the encoder cable to X1 and evaluated there If lead lengths of more than 50m are planned please consult our customer service PMCtendo DD5 PMCprimo Drive3 ACURO Encoder X1 A 5 Garn s UN A 8 EFE E UT Up Sense 10 OV P Up SV 5 3 M max 250mMA oy rs Z kei 7 thermal control ui min 5VDC 5mA Z o ea esses o X2 X1 X6 X5 PC ROD Resolver HIPERFACE CAN SSI ComCoder Hall EnDat ACURO Sine Encoder Installation manual for PMC tendo DD5 PMCprimo Drive3 Page 53 9 Interfaces 9 6 6 Incremental encoder X5 An incremental encoder can be used as standard motor feedback Select feedback type 19 ROD 5V with W amp S Drive executes wake amp shake to calculate the necessary start up information for the position controller every time the 24V auxiliary voltage is switched on If lead lengths of more than 50m are planned and for questions concerning the power supply of the encoder please consult our customer service The thermostat contact in the motor is connected to X1 see p 50 or X2 see p 49 Frequency limit 1 5 MHz Don t use this feedback type with vertical load hanging load
103. t Page 112 Installation manual for PMCtendo DD5 PMCprimo Drive3 12 Appendix 12 2 Finding and removing faults The table below should be regarded as a First aid box There may be a wide variety of reasons for the fault depending on the conditions in your installation In multi axis systems there may be further hidden causes of a fault Our customer service can give you further assistance with problems wrong PC interface selected Fault Possible causes Measures HMI Message wrong cable used use null modem cable Communication cable plugged into wrong position plug cable into the correct sockets on fault on servo amplifier or PC the servo amplifier and PC select correct interface F01 message Heat sink temperature permissible heat sink tempe rature exceeded improve ventilation F02 message Overvoltage regen power is insufficient Regen power limit was reached and the regen resistor was switched off This causes excessive voltage in the DC bus link circuit supply voltage too high reduce the RAMP braking time Use an external regen resistor with a higher power rating and adjust the regen power parameter use a supply transformer F04 message Feedback Unit feedback connector not properly inserted feedback cable is broken crushed or otherwise damaged feedback unit is damaged or wrongly configured check connectors check cables c
104. t switch error on homing move F27 AS operational error with AS input for AS Enable and ENABLE have been set at the same time F28 fieldbus error fieldbus error see ASCII command reference F29 fieldbus error fieldbus communication is disturbed see ASCII command reference F30 emergency timeout Timeout emergency stop F31 reserve reserve F32 system error system software not responding correctly these error messages can be cleared without a reset by using the ASCII command CLRFAULT If only one of these errors is present and the RESET button or the I O RESET function is used only the CLRFAULT command will be executed You can find further information on handling errors from page 113 and in the ASCII command reference part of the setup software s online help system Installation manual for PMCtendo DD5 PMCprimo Drive3 10 Setup 10 7 Warning messages PMCtendo DD5 Faults which occur but which do not cause a switch off of the amplifier output stage BTB RTO contact remains closed are indicated in the LED display on the front panel by a coded warning number Detailled description see ASCII command reference Number Designation Explanation E SIAIP status Messages status messages no error see p 94 status Message amplifier is updating the startup configuration status Message status message no error programming mode n01
105. terminals is necessary the servo amplifier must be disconnected from mains supply considering the discharging time of the intermediate circuit Since the restart lock is a single channel system erroneous engaging will not be recognized When wiring the input AS ENABLE within one enclosure it must be paid attention to the fact that the used cables and the enclosure meet the requirements of EN 60204 1 If the wiring leads outside the demanded enclosure the cables must be laid durably firmly and protected from outside damage Installation manual for PMCtendo DD5 PMCprimo Drive3 9 Interfaces 9 20 4 1 Signal diagram sequence The diagram shows how to use restart lock AS to ensure a safe stop of the drive and error free operation of the servo amplifier N speed t U Enable X3 12 t 2400us s AS Enable X4 5 t 1 Brake the drive in a controlled manner speed setpoint OV 2 When speed 0 rpm disable the servo amplifier Enable OV 3 Activate the restart lock AS AS Enable OV Suspended loads can set themselves to motion on motors without brake because the motor loses all torque when restart lock AS is engaged AS Enable open and or OV Installation manual for PMC tendo DD5 PMCprimo Drive3 Page 87 9 Interfaces 9 20 4 2 Control circuit T 24VDC Al Emergency stop circuit acc PNOZ X2 Netzsch tz to EN 954 1 categoty 4 A2 YI Y2 j A1 S11S12 S21 S2213 23 AS Enable PNOZ X2 1 AS
106. th the EC EMC Directive 89 336 EEC and the Low Voltage Directive 73 23 EEC is mandatory for the supply of servo amplifiers within the European Community Product standard EN 61800 3 is applied to ensure conformance with the EMC Directive The Declaration of Conformity form can be found on our website download area Concerning noise immunity the servo amplifier meets the requirements to the 2nd environmental category industrial environment For noise emission the amplifier meets the requirement to a product of the category C2 motor cable lt 10m Warning This product can cause high frequency interferences in non industrial environments which can require measures for interference suppression With a motor cable length from 10m onwards the servo amplifier meets the requirement to the category C3 The servo amplifiers have been tested by an authorized testing laboratory in a defined configuration using the system components that are described in this documentation Any divergence from the configuration and installation described in this documentation means that you will be responsible for carrying out new measurements to ensure conformance with regulatory requirements The standard EN 50178 is applied to ensure conformance with the Low Voltage Directive Installation manual for PMCtendo DD5 PMCprimo Drive3 5 European Directives and Standards Conformance with UL and cUL This servo amplifier is listed under UL file number E306065
107. uated 10 In F Clears the warning of a following error n03 or the response error clear pi monitoring n04 The following task that is defined in the motion task by Start with I O is started The target position of the present motion task must 11 In Start MT Next be reached before the following task can be started The next motion block can also be started by an appropriately configured digital input on the base unit Starts the Jog Mode with a defined speed x is the speed saved 12 In Start Jogv x in the servo amplifier for the function Jog Mode A rising edge starts the motion a falling edge cancels the motion Connector X11B 1 In MT Restart Continues the motion task that was previously interrupted 2 In Start MT I O Starts the motion task that is addressed by A0 A7 connector X11A 1 8 When the target position for a motion task has been reached the 3 Out InPos InPosition window this is signaled by the output of a HIGH signal A cable break will not be detected The start of each motion task in an automatically executed sequence of motion tasks is signaled by an inversion of the output 4 Out Next InPos signal The output produces a LOW signal at the start of the first motion task of the sequence The form of the message can be varied by using ASCII commands PosReg 0 Can only be adjusted by ASCII commands setup software A LOW signal indicates that the position has gone outside the 5 Out F error
108. ve3 ROD AqB Encoder B B cosinus B SV 5 max 250mA OV thermal control min 5VDC 5mA d bead Emme X6 X5 x2 X1 PC ROD Resolver HIPERFACE CAN SSI ComCoder Hall EnDat ACURO Sine Encoder Installation manual for PMC tendo DD5 PMCprimo Drive3 Page 51 9 Interfaces 9 6 4 Sine Encoder with EnDat or HIPERFACE X1 As an option our servomotors can be fitted with a single turn or multi turn sine cosine encoder Preferred types are the ECN1313 and EQN1325 encoders The encoder is used by the as a feedback device for drive tasks that require highly precise positioning or extremely smooth running The thermostat contact in the motor is connected via the encoder cable to X1 and evaluated there If cable lengths of more than 50m are planned please consult our customer service Frequency limit A B 350 kHz Pinout valid for PMCtendo DD5 PMCtendo AC1 AC2 AC3 PMCprimo Drive3 with HIPERFACE i EnDat IHIPERFACE 10k WH lt SIN F gt TED IS Ma REFSIN 10k 5 I et AE COS REFCOS S RS485 15v TT RD Up legs 2 2 power supply 15V BU Z kal 7 mc pi thermal control min 15VDC 5mA 9 peg Go X6 X5 PC ROD Resolver HIPERFACE CAN SSI ComCoder Hall EnDat ACURO Sine Encoder Page 52 Installation manual for PMCtendo DD5 PMCprimo Drive3 9 Interfaces 9 6 5 Acuro Encoder BISS Interface X1 As an option our servomoto
109. ves information about e Changing connector X11 4 Master encoder CAN2 interface e Changing connector X11 3 MODBUS RS422 Profibus DP slave interface e Replacing the buffer battery on the PMCprimo expansion card ESD danger ESD Electrostatic Discharge ESDS Electrostatic Sensitive Devices Motion control units contain electrostatic sensitive devices which will be damaged by electrostatic discharge Therefore servicing shall only be performed in ESD safe areas and by ESD protected personnel Change X11 4 Master encoder CAN2 interface Four jumpers have to be set NAM 2 B 2 B JP2 H JP1 e n e Lari HH Master encoder CAN 2 a lle le Standard GOA EIN OC DES PMCprimo board Installation manual for PMC tendo DD5 PMCprimo Drive3 Page 109 11 Expansions and Accessories 11 1 5 2 Change X11 3 MODBUS Profibus DP After installing the Profibus DP module three jumpers have to be set MODBUS Standard je e m e ojm o ojm JP6 JP5 JP4 Profibus DP 3 I gt Profibus DP Modul N E irag en Ae de UU o L dv EDEA OG OREO es C79 C55 J4 R47 C29 PMCprimo board Page 110 Installation manual for PMCtendo DD5 PMCprimo Drive3 11 Expansions and Accessories 11 1 5 3 pilz Replacing the buffer battery The buffer battery has to be replaced when BATT appears in the display With present 24 V supply voltage the buffer memory remains intact Battery
110. vice Connect the encoder emulation if required Connect the expansion card see corresponding notes from page 102 on Connect the motor cable Connect shielding to EMC connectors shield connection at both ends Use the motor choke if cable gt 25 meters Connect motor holding brake connect shielding to EMC connector shield connection at both ends f required connect the external regen resistor with fusing Connect the auxiliary supply maximum permissible voltage values gt p 19 Connect the main electrical supply maximum permissible voltage values p 19 Connect the PC gt p 72 Final check of the implementation of the wiring against the wiring diagrams that have been used Installation manual for PMCtendo DD5 PMCprimo Drive3 8 Installation 8 3 Assembly Material 3 x M5 hexagon socket screws to DIN 912 Tool required 4 mm Allen key Cable duct gt 40mm gt 75mm gt 75mm gt 40mm gt 3 gt 22 21 6 i 8 LD 10 12 gt 3 400 480V gt 230mm 115 230V gt 200mm 400 480V gt 9 115 230V 7 9 Cabinet door mounting panel conductive zinc coated 5mm o N M5 screw for hex key DIN 912 PMCtendo DD5 PMCprimo Drive3 Installation manual for PMC tendo DD5 PMCprimo Drive3 Page 31 SSIS 8 Installation 8 3 1 Dimensions 1998 246mm Page 32 Installation manual for PMCtendo DD5 PMCprimo Drive3 8 Instal
111. witched off and on to enable the changed settings LED Display AV to CAN node number AW to Baud rate Save parameters in Flash Installation manual for PMCtendo DD5 PMCprimo Drive3 10 Setup 10 5 Programming of the PMCprimo Drive3 All programming of the PMCprimo Drive3 is done with the terminal program PTERM or as an option with the soft PLC development system CoDeSys from 3S A succesful optimation of the PMCprimo Drive3 position controller is only possible after 33 an well done optimation of the current and speed controllers with PDRIVE For further details see the the PMCprimo programming manual Installation manual for PMC tendo DD5 PMCprimo Drive3 Page 97 10 6 Page 98 10 Setup Error messages PMCtendo DD5 Any errors that occur are shown in coded form by an error number in the LED display on the front panel All error messages result in the BTB RTO contact being opened and the output stage of the amplifier being switched off motor loses all torque and the motor holding brake is activated Detailled description see ASCII command reference Number Designation Explanation E S A P status Messages status messages no error see p 94 bs status Message amplifier is updating the startup configuration status Message status message no error programming mode F01 heatsink temperature heat sink tempe
112. xample The digital outputs can be used for CAM functions or timer outputs More information can be found in the PMCprimo programming manual Installation manual for PMC tendo DD5 PMCprimo Drive3 Page 63 9 8 9 8 1 9 8 1 1 Page 64 9 Interfaces Encoder emulation Incremental encoder output A quad B X5 The incremental encoder interface is part of the standard package Select encoder function ROD A Quad B Encoder Encoder screen page The servo amplifier calculates the motor shaft position from the cyclic absolute signals of the resolver or encoder generating incremental encoder compatible pulses from this information Pulse outputs on the SubD connector X5 are 2 signals A and B with 90 phase difference i e in quadrature hence the alternative term A quad B output with a zero pulse The resolution before multiplication can be set by the RESOLUTION function Enc function Feedback system Resolution lines Zero pulse NI ENCMODE Resolver 16 1024 once per turn ROD 1 only at A B 1 EnDat HIPERFACE 16 4096 and once per turn 8192 524288 2 only at A B 1 ROD Inkremental encoder 2 2 multiplication encoder sognal passed interpolation 3 without data channel TTL line x encoder resolution through X1 to X5 Use the NI OFFSET parameter to adjust save the zero pulse position within one mechanical turn The drivers operate off an internal supply voltage
113. xpansion card is provided by the servo amplifier Front view 9 oS am X12 A X12 B O o Connection technology Cable selection cable routing shielding bus connector bus termination and transmission times are all described in the Installation Guidelines for PROFIBUS DP FMS from PNO the PROFIBUS User Organization Connection diagram PMCtendo DD5 PROFIBUS Installation manual for PMCtendo DD5 PMCprimo Drive3 11 Expansions and Accessories 11 1 4 11 1 4 1 11 1 4 2 Expansion module CAN adapter Connector X6 of the PMCtendo DD5 is assigned to the signals for the RS232 interface and the CAN interface It is therefore not the standard pin assignment for these interfaces and a special cable is required to be able to use both interfaces simultaneously The CAN adapter expansion module provides the interfaces on separate Sub D connectors The two CAN connectors are wired in parallel A termination resistor 120 Q for the CAN bus can be switched into circuit if the PMCtendo DD5 is at the end of the bus When using the PMCtendo DD5 in combination with several PMCprimo devices in the CAN main net the switch FEED is needed Much more details about connection systems via CAN are included in the manual PMCprimo CAN network Installation The modul must be placed onto the option slot after levering off the cover of the option slot and replacing the small cover see p 102 e Screw the distance pieces into t
114. xpansion cardS 11 1 2 Expansion card 1 O 14 08 ii 11 1 3 Expansion card PROFIBUS rrarunronrrronnornnnrevrnnrenrnnennnnnennnrennnnennnsnennnne 11 1 4 Expansion module CAN adapter 11 1 5 PMCprimo board and PMCprimo expansion card 12 Appendix 12 1 Transport storage maintenance disposal 12 2 Finding and removing faultSs gt GN 5 doo OE EE Installation manual for PMC tendo DD5 PMCprimo Drive3 Page 5 3 2 Page 6 3 Type key Type key Type PMCtendo DD5 Tyee Voge PMCtendo DD5 T T 230V series current Size 115 230VAC 230V series 208 480VAC 480V series Design Standard basic device with AS ou slot VO extension D1 extension Profibus DP S Bus system standard CANopen D1 14 digital inputs 8 digital outputs Type PMCprimo Drive3 iss PMCprimoDrive 1 1 VAC T 115 230VAC 230V series 208 480VAC 480V series 230V series current size 6A 06 480V series current size 1 expansion card 1 Profibus DP S Small Bus systems standard CANopen Modbus 1 Expansion card with Compactflash Ethernet Second CAN bus Realtime clock Battery buffered RAM 2 In case of an activated Profibus DP IC the Modbus is without function Installation

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