Pilz Cable PMCprimoDrive User Manual
PMCtendo AC
Motors
Operating Manual – Item No. 21 894-02
All rights to this documentation are reserved by Pilz GmbH & Co. KG. Copies may be made
for internal purposes.
Suggestions and comments for improving this documentation will be gratefully received.
The names of products, goods and technologies used in this documentation are registered
trademarks of the respective companies. Automation Workbench
®
PNOZ
, Primo®, PSS®, SafetyBUS p® are registered trademarks of Pilz GmbH & Co. KG.
®
, Pilz®, PIT®, PMI®,
Contents
Introduction 1-1
Validity of documentation 1-2
Overview of documentation 1-3
Definition of symbols 1-4
Overview 2-1
View of servo motor 2-1
Features 2-1
Type label 2-2
Order references 2-4
Safety 3-1
Intended use 3-1
Safety guidelines 3-1
Use of qualified personnel 3-2
EMCD 3-2
Warranty and liability 3-2
Disposal 3-2
Function Description 4-1
Structure 4-1
Servo amplifier 4-1
Motor feedback system 4-2
Operating mode 4-2
Overload protection 4-2
Holding brake 4-3
Motor shaft and bearings 4-3
Transport and Storage 5-1
Transport 5-1
Storage 5-1
1Operating Manual: PMCtendo AC
Contents
Installation 6-1
Preparing for installation 6-1
Mounting location 6-1
Mounting position 6-1
Motor 6-2
Carrying out the installation 6-2
Wiring 7-1
General requirements 7-1
Cabling 7-1
Cable cross sections 7-1
Earthing, shielding and EMC 7-2
Pin assignment and connection 7-3
Motor feedback connections 7-3
Resolver 7-3
Hiperface encoder 7-5
Connections for supply voltage, thermal switch and holding brake 7-6
General 7-6
Terminal box on servo motors AC1 and AC2 7-6
Terminal box on servo motors AC3 and AC4 7-8
Round connector for servo motors AC1 and AC2 7-9
Round connector for servo motors AC3 and AC4 7-10
Connecting the supply voltage 7-11
Connecting the holding brake 7-12
Commissioning 8-1
General requirements 8-1
Check installation and wiring 8-2
Commissioning the drive unit 8-3
Troubleshooting guidelines 8-4
Maintenance and Repair 9-1
General guidelines for maintenance and repair 9-1
Maintenance intervals 9-2
Changing the servo motor 9-3
2 Operating Manual: PMCtendo AC
Glossary 10-1
Appendix 11-1
Changes in the documentation 11-1
Changes in Version 21 894-01 11-1
Changes in Version 21 894-02 11-1
Technical Details 12-1
General technical details 12-1
Derating 12-3
Derating diagram: Installation height 12-3
Derating diagram: Ambient temperature 12-4
Derating diagram: Operating time 12-5
Type-specific technical details 12-6
Key to the designations used in the table header 12-6
Servo motors PMCtendo AC1 12-8
Performance data: PMCtendo AC1 12-8
Mechanical data: PMCtendo AC1 12-11
Dimensions: PMCtendo AC1 12-14
Dimensioned drawing: PMCtendo AC1 12-16
Servo motors PMCtendo AC2 12-17
Performance data: PMCtendo AC2 12-17
Mechanical data: PMCtendo AC2 12-20
Dimensions: PMCtendo AC2 12-25
Dimensioned drawing: PMCtendo AC2 12-27
Servo motors PMCtendo AC3 12-29
Performance data: PMCtendo AC3 12-29
Mechanical data: PMCtendo AC3 12-30
Dimensions: PMCtendo AC3 12-32
Dimensioned drawing: PMCtendo AC3 12-33
Servo motors PMCtendo AC4 12-34
Performance data: PMCtendo AC4 12-34
Mechanical data: PMCtendo AC4 12-35
Dimensions: PMCtendo AC4 12-36
Dimensioned drawing: PMCtendo AC4 12-37
3Operating Manual: PMCtendo AC
Introduction
This operating manual describes the 3-phase synchronous servo motors PMCtendo AC.
The servo motors PMCtendo AC are divided into the following series:
• PMCtendo AC1
Servo motors for universal use, for large power ratings
• PMCtendo AC2
Servo motors for universal use
• PMCtendo AC3
Servo motors with low moment of inertia, dynamic version
• PMCtendo AC4
Compact servo motors, highly dynamic version
Please also refer to the operating manual for the servo amplifier you are using.
This operating manual is intended for instruction and should be retained for future
reference.
Operating Manual: PMCtendo AC 1-1
Introduction
Validity of documentation
This documentation is valid for
• PMCtendo AC1 from Version 1.0
• PMCtendo AC2 from Version 1.0
• PMCtendo AC3 from Version 1.0
• PMCtendo AC4 from Version 1.0
It is valid until new documentation is published. The latest documentation is always
enclosed with the unit.
Operating Manual: PMCtendo AC1-2
Overview of documentation
1 Introduction
The introduction is designed to familiarise you with the contents, structure and
specific order of this operating manual.
2 Overview
This chapter provides information on the most important features of the
servo motors PMCtendo AC.
3 Safety
This chapter must be read as it contains important information on safety regulations
and intended use.
4 Function Description
This chapter describes the servo motors PMCtendo AC and their components.
5 Transport, Unpacking, Storage
This chapter describes the procedures required when handling the servo motors.
6 Installation
This chapter explains how to install the servo motors PMCtendo AC.
7 Wiring
This chapter contains information and requirements for the electrical installation and
the servo motor connection.
8 Commissioning
This chapter describes the different requirements and options during
commissioning.
9 Maintenance and Repair
This chapter contains information and requirements for maintaining and repairing a
servo motor.
10 Glossary
This section explains the most important specialist terms that are used.
11 Appendix
12 Technical Details
Operating Manual: PMCtendo AC 1-3
Introduction
Definition of symbols
Information in this manual that is of particular importance can be identified as follows:
DANGER!
This warning must be heeded! It warns of a hazardous situation that poses an
immediate threat of serious injury and death and indicates preventive measures that
can be taken.
WARNING!
This warning must be heeded! It warns of a hazardous situation which could lead to
serious injury or death and indicates preventive measures that can be taken.
CAUTION!
This refers to a hazard that can lead to a less serious or minor injury plus material
damage, and also provides information on preventive measures that can be taken.
NOTICE
This describes a situation in which the unit(s) could be damaged and also provides
information on preventive measures that can be taken.
INFORMATION
This gives advice on applications and provides information on special features, as well
as highlighting areas within the text that are of particular importance.
Operating Manual: PMCtendo AC1-4
Overview
View of servo motor
Fig. 2-1: Servo motor PMCtendo AC (example)
Terminal box
(example)
Type label
Mounting holes
Motor shaft
(drive end)
Mounting holes
Features
The servo motors PMCtendo AC are particularly suitable for
• Printing and packaging machines
• Minor axes on machine tools
• Woodworking machines
• Lift drives and travelling drives
• Robotics and palletising systems
• Applications with high requirements for dynamics and controllability
The servo motors PMCtendo AC have the following features:
• 3-phase synchronous motors with permanently energised rotor (rare earth permanent
magnet)
• Sinusoidal electromotive force (EMF)
The 3 lines are connected internally in star configuration
• Motor feedback system, either
- 2-pole resolver
- Hiperface single-turn for SinCos encoder
- Hiperface multi-turn for SinCos encoder
• Drive shaft, either
- With feather key groove
- Without feather key groove, smooth shaft
• Overload protection through motor temperature monitoring
- Thermal switch (N/C contact) in the motor winding
2-1Operating Manual: PMCtendo AC
Overview
Type label
• Holding brake (optional)
- Backlash-free permanent magnet holding brake for safe standstill of the axis when
the supply to the servo motor is switched off
• Type B5
The type label contains all the key data for a servo motor.
Fig. 2-2: Type label for a servo motor PMCtendo AC (example)
Description
Type
M
0
I
0
n
N
SN
M
N
I
max
n
max
Date
U
IN
2p
Th.Cl.
IP
Brake
Feedback
Ident.No.
Key
Type of servo motor and servo motor's
order reference
(see section entitled “Order references”)
Constant standstill torque
Constant standstill current
Rated speed
Serial number
Rated torque
Peak current
Maximum speed
Code for the date of manufacture
(see table: “Code for the date of manufacture”)
Regenerated voltage
Number of motor poles
Heat class
Protection type
Data for holding brake
(see chapter entitled “Technical Details”)
Encoder type
(see table: “Encoder types”)
Material number
Information in the example
PMCtendo AC
2.72/1/M/1/1/4/H/3
8.0 Nm
4.8 A
3000/min
123456
7.0 Nm
18.4 A
4000/min
A5
296 V
6 (3 pairs of poles)
F
65
24 VDC/0.96A/27.0Nm
SRM
9175973
2-2 Operating Manual: PMCtendo AC
Code for the data of manufacture
The 2-digit code on the type label is structured as follows:
<Code for the year> <Code for the month>
Code
A
B
C
D
E
F
H
J
K
L
M
N
P
R
S
T
U
V
W
X
A
Year
2000
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
2011
2012
2013
2014
2015
2016
2017
2018
2019
2020
Code
1
2
3
4
5
6
7
8
9
O
N
D
Month
January
February
March
April
May
June
July
August
September
October
November
December
Encoder types
The type label distinguishes between the following encoder types:
Description
Res2
SRS
SRM
Encoder type
2-pole resolver
Encoder system for Hiperface single-turn
Encoder system for Hiperface multi-turn
2-3Operating Manual: PMCtendo AC
Overview
Order references
Type
Motor
size
Brake Feedback Type Con-
nection
PMCtendo AC...
Series
PMCtendo AC1
PMCtendo AC2
PMCtendo AC3
PMCtendo AC4
Code
1
2
3
4
Code for motor size
21 ... AB
Brake
Without brake
With brake
Feedback
2-pole resolver
Code
0
1
Code
5
(standard)
Hiperface
L
single-turn
Hiperface
M
multi-turn
Type
B5, shaft end with
Code
1
feather key
(standard)
B5, shaft end
2
without feather key
[1] Connection direction: see section entitled “Definition of motor ends”
Connection
direction
Code
1
2
3
4
6
Code
M
H
Code
1
2
4
5
6
Code
1
Speed
1200 min
2000 min
3000 min
4000 min
6000 min
Voltage
230 V
400 V
Connection direction [1]
To right
To left
Upwards
To B-end
To A-end
Connection
Connector for motor and
feedback on housing
2
Terminal box with cable
for motor and connector
for feedback
3
Terminal box with
connector for motor and
feedback
4
Cable for motor and
feedback
6
Angled connector for
motor and feedback
7
Angled swivel connector
for motor and feedback
Voltage Speed
-1
-1
-1
-1
-1
2-4 Operating Manual: PMCtendo AC
Safety
Intended use
The servo motors are designed for incorporation into a machine or for assembly with
other components to form a plant or machine. They must be operated in conjunction
with servo amplifiers with speed, torque or position control.
The servo motors may not be operated directly on the mains. The servo motors must be
operated via a suitable servo amplifier which has been set with the correct parameters
(e.g. PMCtendo DD, PMCprimo Drive from Pilz).
The thermal switch incorporated into the motor winding must be monitored and
evaluated.
The following is deemed improper use:
• Any component, technical or electrical modification
• Use outside the areas described in this manual
• Use outside the documented technical details (see chapter entitled “Technical
Details”).
Safety guidelines
Failure to keep to these guidelines will render all warranty and liability claims invalid:
• All health and safety / accident prevention regulations for the particular area of
• The unit must not be put into service until it can be guaranteed that the plant or
application must be observed.
machine into which the servo motor has been incorporated meets the requirements of
the EU Directive 98/37/EC (Machinery Directive) as a whole.
3-1Operating Manual: PMCtendo AC
Safety
Use of qualified personnel
Assembly, installation, commissioning, operation, maintenance and decommissioning
may only be undertaken by qualified personnel. Qualified personnel are people who,
because they are:
• Qualified electrical engineers
• And/or have received training from qualified electrical engineers,
are suitably experienced to operate devices, systems, plant and machinery in
accordance with the general standards and guidelines for safety technology.
EMCD
The servo motors are designed for use in an industrial environment. Interference may
occur if used in a domestic environment in conjunction with servo amplifiers.
Warranty and liability
Disposal
All claims to warranty and liability will be rendered invalid if:
• The servo motor is used contrary to the purpose for which it was intended
• Damage can be attributed to not having followed the guidelines in the manual
• Operating personnel are not suitably qualified
• Any type of modification has been made.
The servo motor must be disposed of properly when it reaches the end of its service life.
3-2 Operating Manual: PMCtendo AC
Function Description
Structure
PMCtendo AC servo motors are 3-phase, brushless synchronous motors with
permanently energised rotor. The rotor contains rare earth permanent magnets made of
neodymium iron boron. The rare earth magnetic material is a major factor in enabling
these servo motors to be operated with high dynamics.
The 3-phase, stator winding is designed for sinusoidal commutation and enables a high
efficiency factor, while at the same time having optimum true running characteristics.
PMCtendo AC servo motors are totally enclosed, self-cooled motors and correspond to
type IC410 (in accordance with IEC 60034-6).
Servo amplifier
A suitable servo amplifier is required for commutation (e.g. PMCtendo DD, PMCprimo
Drive from Pilz). Commutation occurs electronically within the servo amplifier.
The servo motor and servo amplifier should always be regarded as one cohesive
system. The most important selection criteria are:
• Constant standstill torque M0 [Nm]
• Constant standstill current I0 [A]
• Rated speed nN [min-1]
• Mass moment of inertia of motor and load J [kgcm²]
• Effective torque (calculated) M
• Regenerative energy in braking mode
rms
[Nm]
When selecting the servo amplifier, please consider both the static and the dynamic
load (acceleration/braking).
Operating Manual: PMCtendo AC 4-1
Function Description
Motor feedback system
PMCtendo AC servo motors may be equipped with one of the following motor feedback
systems:
• Resolver (2-pole)
The resolver determines the absolute position of the rotor to the stator within a
revolution and signals this information to the servo amplifier. This feeds sinusoidal
currents to the winding on the servo amplifier, depending on the rotor position.
• Hiperface-compatible feedback system for SinCos encoder
A Hiperface-compatible feedback system operates with differential signals in
accordance with the RS 485 specification.
The absolute position of the rotor to the stator is determined on power up and is
signalled to the counter in the servo amplifier via the parameter channel. The counter
then continues to count incrementally, based on this absolute value. For this purpose
the analogue sine/cosine voltage is transmitted via the process data channel and is
converted within the servo amplifier.
- Hiperface single-turn for SinCos encoder
With the Hiperface single-turn, only one shaft revolution is triggered. One shaft
resolution is transmitted in 32 768 steps.
- Hiperface multi-turn for SinCos encoder
With the Hiperface multi-turn, several shaft revolutions are triggered. A maximum of
4096 revolutions can be transmitted, each in 32 768 steps.
Operating mode
PMCtendo AC servo motors are designed for continuous duty. This corresponds to
operating mode S1 (in accordance with DIN EN 60 034-1).
Overload protection
PMCtendo AC servo motors have overload protection, which protects the stator winding
from damage in the case of constant overload. The motor temperature is monitored via a
thermal switch in the stator winding. The contact on the thermal switch is opened when
the winding temperature is exceeded. The switch does not protect against temporary
high overload.
The thermal switch incorporated into the motor winding must be monitored and
evaluated by the servo amplifier.
4-2 Operating Manual: PMCtendo AC
Holding brake
As an option, the PMCtendo AC servo motors may be supplied with a built-in holding
brake, for backlash-free holding of the axis at standstill or when the supply to the plant or
machine is switched off. The permanent magnet brake blocks the rotor when the supply
voltage is switched off. Once the brake is released, the rotor can move without residual
torque.
INFORMATION
Only use the holding brake when the axes are at standstill!
It may not be used for dynamic braking mode. Make sure you read the holding brake
information provided in the chapters entitled “Wiring” and “Technical Details”.
The holding brake does not guarantee personal protection!
Personal protection can only be achieved by using a second brake and through
additional higher level design measures (e.g. guard).
Motor shaft and bearings
PMCtendo AC servo motors are available with two different types of shaft end (drive
end):
• Shaft end with feather key groove
Rotor balancing is performed using a half feather key. These shaft ends are suitable
for low loads. Under continuous duty with varying torques or strong reverse mode, the
feather key may become unseated. If this is the case the true running quality is
reduced; there is backlash. Increasing deformation can break the feather key and
damage the drive shaft.
• Smooth shaft end
With a frictional connection, torque transfer must only be achieved through surface
pressure. This guarantees a safe, backlash-free force transfer.
• Bearings
The bearings are lubricated with maintenance-free grease which is resistant to high
temperatures.
Operating Manual: PMCtendo AC 4-3
Function Description
Notes
4-4 Operating Manual: PMCtendo AC
Transport and Storage
Transport
The servo motors must be transported in such a way that no damage can occur.
INFORMATION
Be sure to avoid any impact, jerky movements or heavy vibration during transportation.
Storage
If a servo motor is not to be put into service immediately upon delivery, make absolutely
sure that it is stored correctly.
The servo motors should only be stored in an enclosed room that is dry, dust free and
ventilated. Please refer to the information provided under “Technical Details”.
Do not remove anti-corrosion coatings on the shaft ends, flange surfaces, etc. While in
storage, these should be inspected at defined intervals and any damage made good.
The storage site should not be liable to vibration. When servo motors are kept in storage
we recommend that the rotor is rotated at defined intervals to prevent corrosion on the
bearings.
If the servo motor has been in storage for more than 3 months, rotate the servo motor in
both directions at low speed (< 100 min-1) to ensure that the lubricant on the bearings is
distributed equally.
Operating Manual: PMCtendo AC 5-1
Transport and Storage
Notes
5-2 Operating Manual: PMCtendo AC
Installation
Preparing for installation
Secure the installation site in accordance with the regulations (barrier, warning signs
etc.). Installation may only be carried out by qualified personnel.
Mounting location
Please note the following when selecting the location:
• The mounting location must be free from conductive and aggressive materials.
• The unit may only be mounted on a flat, vibration-free and warp-resistant substructure.
• It is essential to comply with the ambient temperature (see chapter entitled “Technical
Details”).
Ensure there is sufficient heat dissipation; if necessary, additional ventilation should
be provided for the servo motor.
Mounting position
Permitted mounting positions:
Design
Permitted mounting positions
B5
IM B5
IM V1
IM V3
INFORMATION
• The mounting position IM V3 (DIN EN 60034-7) is not recommended in conjunction
with gear units!
• With the mounting position IM V3 (DIN EN 60034-7), ensure that liquids cannot
penetrate into the bearings, whether during installation or during operation.
Operating Manual: PMCtendo AC 6-1
Installation
Motor
• Check the servo motor for any transport damage. Never install a servo motor that
shows clear signs of damage!
• Ensure that any anti-corrosion agents and/or contamination on the shaft end (drive
end) are thoroughly removed. This can be done using a standard solvent. Make sure
that the solvent cannot come into contact with the gaskets and/or bearings, otherwise
materials may be damaged!
Carrying out the installation
WARNING!
Electric shock
Contact with live parts will result in serious injury.
The motor should always be installed with the supply voltage switched off. Switch off
the supply voltages to all connected devices!
Hazardous values may still be present up to 5 minutes after the voltage is switched off,
due to residual charges in the servo amplifier’s capacitors.
When the shaft is rotating (externally driven, running down) the motor acts as a
generator. This means that hazardous voltages will be present at the connection
terminals.
If possible, only use backlash-free, frictionally engaged chucks or clutches.
Use the tightening thread provided in the motor shaft to tighten the clutches, gears or
belt pulleys and, if possible, warm up the drive elements. Do not use excessive force as
this will damage bearings, feedback and the motor shaft.
Spacing washer
Tightening thread
Fig. 6-1: Tightening thread in the motor shaft
Please note:
• Align the clutch correctly
Misalignment can cause undue vibration and can damage the ball bearings and
clutch!
6-2 Operating Manual: PMCtendo AC
• Mechanical overdefinition of the motor shaft bearing should be avoided
A rigid clutch and/or an external additional bearing (e.g. in the gear unit) can cause
excess mechanical stress on the motor shaft.
• Do not fasten or attach temperature-sensitive components to the motor
CAUTION!
Burns
Contact with the motor surface during operation will result in injury.
During operation, the surface temperature of the servo motor can exceed 65 °C!
Safety measures should be put in place to protect against contact during operation,
whether accidental or intentional.
Operating Manual: PMCtendo AC 6-3
Installation
Notes
6-4 Operating Manual: PMCtendo AC
Wiring
General requirements
Secure the site in accordance with the regulations (barrier, warning signs etc.). Wiring
may only be carried out by qualified personnel.
• Please refer to the information and specifications stated in the operating manual of the
servo amplifier you are using.
CAUTION!
Uncontrolled movements of the servo motor will result in injury
Incorrect wiring of the servo motor and/or motor feedback can trigger uncontrolled
movements and result in material and/or personal injury.
• If necessary, consider the trailing capability of the cables you are using.
Cabling
It is possible to differentiate between cables according to their function. The following
groups exist:
• Group 1: Data and supply lines for DC voltages below 60 V and AC voltages
below 25 V
• Group 2: Data and supply lines for DC voltages from 60 V to 400 V and AC voltages
from 25 V to 400 V.
• Group 3: Supply lines above 400 V
Cabling inside buildings:
• The cable groups listed above should be laid separately.
• Cables of the same group can be laid within the same cable duct.
• Cables from group 1 and group 2 should be laid in separate groups or in cable ducts
• Cables from group 1 and group 3 should be laid in separate groups or in cable ducts
• Data lines and control lines should be laid as close as possible to an earthed surface.
Cable cross sections
Please refer to the information stated in the operating manual of the servo amplifier you
are using. The cable cross sections you select should depend on the current supplied by
the servo amplifier.
which are at least 10 cm apart.
which are at least 50 cm apart.
Operating Manual: PMCtendo AC 7-1
Loading...