Pilz DD503-000-0-0-0-110-230VAC User Manual

Operating Manual PMCtendo DD5

Operating Manual PMCtendo DD5

PMCtendo DD5

Servo amplifiers

Operating Manual — No. 1002236-EN-01

This document is a translation of the original document.

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.

Pilz

®

, PIT®, PMI®, PNOZ®, Primo®, PSEN®, PSS®, PVIS®, SafetyBUS p®, SafetyEYE®,
SafetyNET p®, the spirit of safety® are registered and protected trademarks of
Pilz GmbH & Co. KG in some countries.

SD means Secure Digital.

Preface

Contents

Contents

Contents Page

Chapter 1 Introduction

1.1 Validity of the documentation 1-1

1.1.1 Retaining the documentation 1-1

1.2 Overview of documentation 1-2

1.3 Definition of symbols 1-3

Chapter 2 Overview

2.1 Unit structure 2-1

2.1.1 Unit features 2-1

2.1.1.1 Power element 2-1

2.1.1.2 Control element 2-2

2.2 Front view 2-4

2.3 Plan view 2-5

2.4 Scope of supply 2-6

2.5 Type code 2-7

2.6 Type label 2-8

Chapter 3 Safety

3.1 Intended use 3-1

3.1.1 Hazard analysis 3-1

3.1.2 Electrical data 3-1

3.1.3 Environmental conditions 3-1

3.1.4 Guidelines for UL approval 3-2

3.1.5 Safety function STO 3-2

3.1.6 Use of qualified personnel 3-3

3.1.7 Warranty and liability 3-4

3.1.8 Disposal 3-4

3.2 Safety during operation 3-5

3.3 Standards 3-6

3.4 Stop and E-STOP functions 3-8

3.4.1 Stop functions 3-8

3.4.2 E-STOP functions 3-8

Chapter 4 Function description

4.1 Overview 4-1

4.2 Power element 4-3

4.2.1 Mains voltage 4-3

4.2.2 Motor connection 4-5

4.2.3 Motor holding brake 4-6

4.2.4 Brake resistor 4-8

4.2.5 Intermediate circuit 4-9

4.3 Control element 4-11

4.3.1 Supply voltage 24 VDC 4-11

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1

Contents

4.3.2 Digital inputs and outputs 4-11

4.3.2.1 Overview 4-11

4.3.2.2 Digital inputs 4-12

4.3.2.3 Digital outputs 4-13

4.3.3 Safety function STO 4-14

4.3.3.1 Safety information 4-14

4.3.3.2 Signal states 4-15

4.3.3.3 Connection example 4-16

4.3.4 Analogue inputs 4-17

4.3.5 Encoder systems 4-18

4.3.5.1 Overview 4-18

4.3.5.2 Resolver 4-21

4.3.5.3 SinCos encoder 4-22

4.3.5.4 Incremental encoder 4-24

4.3.5.5 Absolute encoder with SSI interface 4-25

4.3.6 Electronic gearing 4-26

4.3.6.1 Stepper motor control systems (pulse/di­rection)

4.3.6.2 Master-Slave mode 4-27

4.3.7 Encoder emulation 4-28

4.3.8 Communication interfaces 4-31

4.3.8.1 RS232 interface 4-31

4.3.8.2 CANopen interface 4-31

4.3.9 Tools 4-32

4.4 Expansion cards 4-34

4.4.1 Expansion card I/O-14/08 4-34

4.4.2 Expansion card for PROFIBUS-DP inter­face

4.4.3 Expansion card for SERCOS interface 4-36

4.4.4 Expansion card for DeviceNet 4-38

4.4.5 Fieldbus junction box 4-41

4.5 Switch on/switch off behaviour 4-43

4.5.1 Normal operation 4-44

4.5.2 Fault condition 4-45

4.6 Implementation of stop categories 4-47

4.6.1 Stop Category 0 4-47

4.6.2 Stop Category 1 4-49

4.6.3 Stop Category 2 4-51

4-27

4-36

Chapter 5 Installation

5.1 General requirements 5-1

5.2 Dimensions 5-2

5.3 Installing the servo amplifier 5-3

5.4 Installing the expansion cards 5-5

5.5 Installing the fieldbus junction box 5-6

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Contents

Chapter 6 Wiring

6.1 Connector description 6-1

6.2 Block diagram 6-2

6.3 Wiring guidelines 6-4

6.3.1 Protection against contact 6-5

6.3.1.1 Leakage current 6-5

6.3.1.2 Residual current devices FI 6-6

6.3.1.3 Isolating transformer 6-7

6.3.2 Connection cables 6-7

6.4 Wiring procedure 6-9

6.5 EMC-compliant wiring 6-10

6.5.1 Earthing 6-10

6.5.2 Shielding 6-10

6.5.2.1 Shield connection on the front plate 6-11

6.5.2.2 Motor connection 6-12

6.5.3 Filters 6-12

6.5.4 Chokes 6-13

6.6 Power element 6-14

6.6.1 Mains voltage 6-14

6.6.2 Motor with brake 6-15

6.6.3 External brake resistor 6-17

6.6.4 Intermediate circuit 6-17

6.7 Control element 6-20

6.7.1 Supply voltage 24 VDC 6-20

6.7.2 Digital inputs 6-21

6.7.3 Digital outputs 6-22

6.7.4 Analogue inputs 6-23

6.7.5 Encoder systems 6-24

6.7.5.1 Resolver 6-24

6.7.5.2 SinCos encoder with HIPERFACE inter-

6.7.5.3 SinCos encoder with EnDat 2.1 interface 6-27

6.7.5.4 SinCos encoder with EnDat 2.2 interface 6-28

6.7.5.5 SinCos encoder with BISS interface, ana-

6.7.5.6 SinCos encoder with BISS interface, digital 6-31

6.7.5.7 SinCos encoder with SSI interface 6-33

6.7.5.8 SinCos encoder without data track 6-34

6.7.5.9 Incremental encoder ROD (AquadB) 5 V,

6.7.5.10 Incremental encoder ROD (AquadB) 5 V,

6.7.5.11 Absolute encoder with SSI interface 6-41

6.7.5.12 Electronic gearing, Master-Slave mode 6-43

6.7.5.13 Encoder emulation 6-46

6-25

face

6-30

logue

6-36

350 kHz

6-38

1.5 MHz

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3

Contents

6.7.6 Communication interfaces 6-48

6.7.6.1 RS232 interface 6-48

6.7.6.2 CANopen interface 6-49

6.8 Expansion cards 6-52

6.8.1 Expansion card I/O-14/08 6-52

6.8.2 Expansion card for PROFIBUS-DP inter­face

6.8.3 Expansion card for SERCOS interface 6-54

6.8.4 Expansion card for DeviceNet 6-55

6.8.5 Fieldbus junction box 6-57

Chapter 7 Commissioning

7.1 Safety information 7-1

7.2 Commissioning the servo amplifier 7-3

7.2.1 Gather the project data 7-3

7.2.2 Wire components 7-3

7.2.3 Preparing for commissioning 7-5

7.2.4 Connect 24 VDC supply voltage 7-5

7.2.5 Establish communication PMCtendo DD5
<-> PC

7.2.6 Set parameters for the servo amplifier 7-6

7.2.7 Perform the first test run 7-8

7.3 LEDs and keys 7-9

7.3.1 Key functions 7-9

7.3.2 Standard menu 7-9

7.3.3 Advanced menu 7-10

7.4 Messages/errors 7-12

7.4.1 Status messages 7-12

7.4.2 Error messages 7-12

7.4.3 Warning messages 7-13

6-54

7-5

Chapter 8 Technical details

8.1 PMCtendo DD5.03/230V 8-1

8.2 PMCtendo DD5.06/230V 8-4

8.3 PMCtendo DD5.10/230V 8-5

8.4 PMCtendo DD5.01/480V 8-6

8.5 PMCtendo DD5.03/480V 8-7

8.6 PMCtendo DD5.06/480V 8-8

Chapter 9 Appendix

9.1 Glossary 9-1

9.2 Abbreviations 9-2

9.3 Index 9-4

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1 Introduction

1.1 Validity of the documentation

11000IntroductionIntroduction1-1.1Validity of the documentation1100Validity of th e documentation1-BA_Einfuehrung_1

This documentation is valid for the product PMCtendo DD5. It is valid
until new documentation is published.

This operating manual explains the function and operation, describes
the installation and provides guidelines on how to connect the product

][Einfhrung_Dokumente_b eachten

PMCtendo DD5.

Please also refer to the following documents from the motion control
range:

 The online help for the PDrive commissioning software describes how

to set the parameters for the servo amplifier.

 The "PMCprimo CAN Networking" manual contains guidelines for

networking multiple PMCprimo control systems and additional CAN­open devices.

All these manuals can be found on the supplied CD-ROM: "Motion Con­trol Documentation".

You will need to be conversant with the information in these documents
in order to fully understand this manual.

BA_Einfuehrung_DD5

This operating manual is valid for the following products:

 PMCtendo DD5 from Version 1.1

1.1.1 Retaining the documentation

Retaining the documentation1-Einf Aufbewahren

This documentation is intended for instruction and should be retained
for future reference.

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1-1

1 Introduction

1.2 Overview of documentation

1.2Overview of documentation1200Overview of documentation1-][Einfuehrung_Uebersicht_1

1 Introduction

The introduction is designed to familiarise you with the contents, struc­ture and specific order of this manual.

2 Overview

This chapter provides information on the product's most important fea­tures.

3 Safety

This chapter must be read as it contains important information on in­tended use.

4 Function Description

This chapter describes the product's individual components.

5 Installation

This chapter explains how to install the product.

6 Wiring

This chapter describes the product's wiring.

7 Commissioning

This chapter describes how to commission the product.

8 Technical Details

9 Appendix

This chapter contains a glossary, a list of the abbreviations used and the
index.

1-2

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1 Introduction

1.3 Definition of symbols

1.3Definition of symbols1300Definition of symbols1-Einfhrung Zeichen

Information that is particularly important is 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
that could lead to serious injury and 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. It also highlights areas within the text that are of partic­ular importance.

INFORMATION

This gives advice on applications and provides information on
special features.

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1-3

1 Introduction

1-4

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2 Overview

2.1 Unit structure

22000OverviewOverview2-2.1Unit structure2100Unit structure2-

2.1.1 Unit features

Unit features2-][Ueber_Geraeteaufbau_DD5

The compact servo amplifier PMCtendo DD5 consists of

 A power element
 A control element with

– Inputs and outputs
– Sequence control
– Control loops for current, speed and position
– Interfaces for communication with the periphery

Unit types:

 Units with various mains voltages and output currents

2.1.1.1 Power element

Power element2-Ueber_Merkmale_Leistungsteil_DD5

][Ueber_Merkmale_Entstoerfilter

The servo amplifier's power element has the following features:

 Connection to earthed three-phase supplies, rated voltage range and

continuous output current:
– 230V series: 1 x 110 V - 3 x 230 V (3 A, 6 A, 10 A)
– 480V series: 3 x 208 V – 3 x 480 V (1,5 A, 3 A, 6 A)

 TN network and TT network with earthed star point, symmetrical rated

current, connection to other networks only with isolating transformer

 B6 rectifier bridge integrated directly on the three-phase, earthed net-

work, mains filter and start-up circuit

 Single-phase supply possible (e.g. for commissioning or set-up

mode)

 Fuse protection (e.g. blow-out fuse) through user
 All shield connections directly on the servo amplifier
 Max. intermediate circuit voltage in generator mode:

– 230V series: 135 – 450 VDC
– 480V series: 260 – 900 VDC
– Can be connected in parallel

 Brake chopper, brake power distributed over several amplifiers on the

same intermediate circuit

 Internal brake resistor is standard, external brake resistor available on

request

 Inverted rectifier with isolated current measurement and IGBT transis-

tors

 Connection of synchronous servo motors, linear motors, asynchro-

nous motors

 Fan installed on the following device types:

– 230 V series: 6 A, 10 A
– 480 V series: 3 A, 6 A

 Integrated noise suppression filters in accordance with EN 61800-3

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2-1

2 Overview

2.1 Unit structure

2.1.1.2 Control element

Control element2-Ueber_Allgemein_Steuerteil

][Ueber_Merkmale_Versorg_24_VDC_DD5

][Ueber_Merkmale_Entstoerfilter

Ueber_Merkmale_Geber

Ueber_Merkmale_Ein_Aus_DD5

][Ueber_Merkmale_dig_Regelung_protego_D

The servo amplifier's control element has the following features:

Supply voltage

 24 VDC supply voltage for control element, digital outputs and motor

holding brake

 Integrated noise suppression filters in accordance with EN 61800-3

Encoder systems

Integrated evaluation of the following encoder systems

 Resolver
 Incremental encoder
 SinCos encoder

®

– with HIPERFACE

interface
– with EnDat interface 2.1 and 2.2
– with BISS interface
– with SSI interface

Inputs and outputs

 2 analogue voltage inputs

– Differential input
– Signal range: ±10 V, referenced to earth

 4 digital inputs
 2 digital outputs
 1 volt-free relay contact to display operational readiness
 1 input for safety functions STO

2-2

Digital control

 Digital control loop
 Digital speed regulator
 Digital position controller
 Pulse/direction interface for connecting a servo motor to a stepper

motor controller

][Ueber_Merkmale_Parametrierung

Parameter setting

 Via the serial interface, using the PDrive commissioning software
 Via the CAN interface, using the motion control system PMCprimo C

together with the commissioning software PDrive and CoDeSys (de­velopment environment in accordance with IEC 61131-3)

][Ueber_Merkmale_Bedienung_protego_D

Operation and display

 Servo amplifier operated via two keys
 Three-digit LED display for status and messages

Ueber_Merkmale_integrierte_Sicherheit_DD5

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2 Overview

2.1 Unit structure

Ueber_Merkmale_Erweiterungen_DD5

Integrated safety

 Device safety

– Safe electrical isolation between mains voltage/motor connection

and control element, in accordance with EN 61800-5-1

– Soft start, overvoltage detection, short circuit protection, phase

failure monitoring

– Temperature monitoring of servo amplifier and motor (when using

Pilz motors with ready-made cables)

 Protection of personnel and plant

– Safety function STO – Safe torque off

Single-channel without feedback: Up to PL d (Cat. 2) of
EN ISO 13849-1 and SIL CL 2 of EN/IEC 62061

Expansion cards

 1 slot for expansion cards:

–I/O
– PROFIBUS
–SERCOS II
– DeviceNet

Fieldbus junction box

 CAN Adapter: Splits the combined RS232/CANopen interface on the

PMCtendo DD5 into one RS232 interface and two CANopen interfac­es wired in parallel

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2-3

2 Overview

BR
BR

BTB/RTO 1
BTB/RTO 2
Analog-In1+ 3
Analog-In1- 4
Analog-In2+ 5
Analog-In2- 6
AGND 7
Digital-In1 8
Digital-In2 9
Digital-In3 10
Digital-In4 11
ENABLE 12
Digital-Out1 13
Digital-Out2 14

+24 V 1
+24 V 2
DGND 3
DGND 4

5

STO-ENABLE

n.c.

xt

nt

2

1

3

4

5

6

7

9

8

2.2 Front view

2.2Front view2200Front view2-Uebersicht_Front

Front view of the PMCtendo DD5

Key:

1: LED display for messages
2: Buttons
3: External brake resistor, intermediate circuit
4: Mains voltage, power element
5: Connection for earth conductor PE
6: Connection for motor
7: Connection for motor brake
8: Supply voltage 24 VDC and safety function STO
9: Inputs and outputs, ENABLE, operational readiness

2-4

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2 Overview

X1X2X5X6

10

11

12

13

14

2.3 Plan view

2.3Plan view2300Plan view2-Uebersicht_Drauf

Plan view of the PMCtendo DD5

Key:

10: Expansion cards
11: Connection for incremental encoder, sine/cosine en­coder, pulse/direction 24 V
12: Connection for resolver
13: Connection for encoder emulation, Master-Slave
mode, stepper motor control system
14: RS232 interface for commissioning and parameter set­ting or CANopen controller

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2-5

2 Overview

2.4 Scope of supply

2.4Scope of supply2400Scope of supply2-Uebersicht_L ieferumfang

This is what you receive when you order a servo amplifier from the series
PMCtendo DD5:

 Servo amplifier PMCtendo DD5
 Mating connectors X0, X3, X4, X8
 Operating manual on CD-ROM
 Software manual PDrive on CD-ROM
 Software tools "PMCprimo Motion Control Tools" on CD-ROM

INFORMATION

The D-Sub mating connectors and the motor connector are not
supplied with the unit! They are available as accessories.

2-6

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2 Overview

Always state when ordering Type

Supply voltage

Order number PMCtendo DD5. _ _ / _ _ _ / 0 / 0 / 0 / _ _ _ _ VAC

3 A 03

Current

Hardware options
None
I/O-14/08
SERCOS II
PROFIBUS
DeviceNet

000 100 200 300

Size230V series

6 A

10 A

06

10

1.5 A 01

Current

Size480V series

3 A
6 A0306

230V series

480V series

110...230 VAC

208...480 VAC

400

2.5 Type code

2.5Type code2500Type code2-Typenschlüssel

Fig. 2-1: Type code

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2-7

2 Overview

2.6 Type label

2.6Type label2600Type label2-Typ enschild

The type label is situated on the side of the servo amplifier.

Fig. 2-2: Type label

Key:

 Type: Type code
 Ident. No.: Order number
 Ser. No.: Serial number
 Prod.version: Product version
 Firmware: Firmware version
 Mains Voltage: Mains voltage
 Power: Power
 Inorm: Continuous output current
 YOM: Year of manufacture
 Firmware: Firmware version
 Prot. type: Protection type
 Ambient temp: Ambient temperature

2-8

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3 Safety

3.1 Intended use

33000SafetySafety3-3.1Intended use3100Intended use3-Sicherheit_Bestimmung_DD5

][Sicherheit_Bestimmung_Ausschluss

The servo amplifiers PMCtendo DD5 are designed to drive suitable
brushless, synchronous servo motors and asynchronous motors with
speed, torque and/or position control.

The following is deemed improper use:

 Any component, technical or electrical modification to the servo am-

plifier

 Use of the servo amplifier outside the areas described in this manual
 Use of the servo amplifier outside the documented technical details

(see chapter entitled “Technical Details”)

Intended use includes making the installation and wiring EMC-compli­ant. Please refer to the guidelines stated in this manual.

3.1.1 Hazard analysis

Hazard analysis3-][Sicherheit_Bestimmung_Gefahrenanalyse

The machine manufacturer must produce a hazard analysis for the ma­chine. He must take appropriate measures to ensure that unexpected
movements do not lead to hazardous situations for either people or
equipment.

3.1.2 Electrical data

Electrical data3-][Sicherheit_Bestimmung_elektrisch_protego_D

Please note the electrical requirements stated in the chapters entitled
“Technical Details”, “Wiring” and “Function Description”.

3.1.3 Environmental conditions

Environmental conditions3-][Sicherheit_Bestimmung_Umgebung

Please note the following conditions for using the servo amplifier:

 Operation of the servo amplifier is forbidden in the following condi-

tions:
– Potentially explosive areas
– Environments containing corrosive and/or conductive acids, alka-

– Where there is a direct connection to unearthed or asymmetrically

–On ships and offshore installations

line solutions, oils, fumes or dusts

earthed mains supplies with U

> 240 V. See chapter entitled “Wir-

N

ing”, section on “Mains voltage”.

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3-1

3 Safety

3.1 Intended use

 The servo amplifier may only be operated in an enclosed control cab-

inet in compliance with the ambient conditions defined under “Tech­nical details”. Ventilation or cooling may be required to maintain the

][EMV_Wohnumgebung

3.1.4 Guidelines for UL approval

Guidelines for UL approval3-Sicherheit_Bestimmung_UL_DD5

control cabinet temperature below 40 °C.

Please note the following guidelines for UL approval:

 Only use copper wiring that can withstand temperatures of 60°/75°C.
 Only use Class 1 wiring or comparable.
 Clamping torque for power connection terminals:

X0, X8, X9: 0.5 - 0.6 Nm

 Only use the servo amplifier in max. pollution degree 2 environments.
 The servo amplifier can be used on supply networks that are able to

provide no more th a n 4 2 kA symmetrical at a maximum voltage of 480
VAC.

WARNING!

In a residential environment this product may cause high-fre­quency noise, so that suppression measures may be required.

3.1.5 Safety function STO

Safety function STO3-][Sicherheit_Bestimmung_STO_DD5

][Sicherheit_Bestimmung_Gefahr

The safety function "safe torque off" (Safe Torque Off, STO) activates
the pulse disabler on the servo amplifier and removes the power to the
motor. It meets the requirements in accordance with EN 61800-5-2.

The input STO-ENABLE meets the requirements of EN ISO 13849-1: PL
d (Cat. 2) and EN/IEC 62061: SIL CL 2.

The safety function "safe torque off" corresponds to a category 0 stop
(uncontrolled stop) in accordance with EN 60204-1.

The safety function STO may not be used when the drive is to be
stopped for the following reasons:

 Cleaning, maintenance and repair work, or long interruptions in oper-

ation: Remove the voltage and secure the entire plant (main switch).

 E-STOP: Switch off the mains contactor (E-STOP pushbutton).

3-2

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3 Safety

3.1 Intended use

Sicherheit_Gefahr_Haltebremse

DANGER!
Risk from rotating motor after STO has been triggered!

The safety function STO switches the motor to torque-free. On
motors without a safe holding brake, moving parts present a
threat to life.
Use an additional mechanical measure to block the drives safely
(e.g. with the motor holding brake), particularly with suspended
loads.

DANGER!
Risk from non-safety-related activation of the motor holding
brake!

Activation of a holding brake via output BR+/BR- of the servo
amplifier is not safety-related. Depending on the application,
hazardous motor movements may cause serious injury or death.
A motor holding brake activated by the servo amplifier alone is
not suitable for personal protection.
Block the drive through an additional mechanical holding brake,
which is activated safely (e.g. with the safety card PMCprotego
S1).

3.1.6 Use of qualified personnel

Use of qualified personnel3-Sich Qualif. Personal

The products may only be assembled, installed, programmed, commis­sioned, operated, maintained and decommissioned by competent per­sons.

A competent person is someone who, because of their training, experi­ence and current professional activity, has the specialist knowledge re­quired to test, assess and operate the work equipment, devices,
systems, plant and machinery in accordance with the general standards
and guidelines for safety technology.

It is the company's responsibility only to employ personnel who:

 Are familiar with the basic regulations concerning health and safety /

accident prevention

 Have read and understood the safety guidelines given in this descrip-

tion

 Have a good knowledge of the generic and specialist standards ap-

plicable to the specific application.

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

3-3

3 Safety

3.1 Intended use

3.1.7 Warranty and liability

Warranty and liability3-Sich Gewhrleistung

3.1.8 Disposal

Disposal3-Si ch Entsorgung

All claims to warranty and liability will be rendered invalid if:

 The product was used contrary to the purpose for which it is 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 (e.g. exchanging compo-

nents on the PCB boards, soldering work etc.).

 In safety-related applications, please comply with the mission time t

M

in the safety-related characteristic data.

 When decommissioning, please comply with local regulations regard-

ing the disposal of electronic devices (e.g. Electrical and Electronic
Equipment Act).

3-4

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

3 Safety

3.2 Safety during operation

3.2Safety during operation3200Safety during operation3-][Sicherheit_Bestimmung_Betrieb_1

DANGER!

While the units are in operation there is a risk of death or serious injury
and material damage.

 Do not open or touch the units during operation.
 Keep all covers and cabinet doors closed during operation.
 When the units are switched on, they should only be touched during

commissioning by qualified staff.

 During operation the servo amplifiers may contain live, uninsulated

components, depending on their protection type.

 Control and power connections may still carry voltage, even when the

motor is not rotating.

 Surfaces on the servo amplifiers may become hot during operation.

Sicherheit_Bestimmung_Betrieb_DD5

Temperatures may reach more than 80° C.

DANGER!

In unfavourable conditions arcing may occur, causing potential injury to
persons and damage to electrical contacts.

 For this reason, never unplug the electrical connections on the servo

amplifier while voltage is applied.

 After disconnecting the servo amplifier from the mains voltages, wait

at least five minutes before touching any parts that carry voltage (e.g.
contacts) or loosening the connections.

 After the mains voltages have been switched off, capacitors continue

to carry hazardous voltages for up to 5 min.

 To be safe, measure the voltage in the intermediate circuit and wait

until the voltage has dropped below 40 VDC.

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

3-5

3 Safety

3.3 Standards

3.3Standards3300Standards3-][Sicherheit_Normen

Servo amplifiers are components designed for incorporation into electri­cal plant or machinery within the industrial sector. The servo amplifier
may not be used for its intended purpose until it has been established
that the plant or machinery complies with the provisions of the following
directives:

 EU Machinery Directive (2006/42/EC)
 EU EMC Directive (2004/108/EC)
 EU Low Voltage Directive (2006/95/EC)

Standards for compliance with the EU Machinery Directive (2006/
42/EC)

 EN 60204-1:2007 (Safety and electrical equipment of machines)
 EN 12100:2009 (Safety of machinery)

The machine manufacturer must produce a hazard analysis for the ma­chine and take appropriate measures to ensure that unexpected move­ments do not cause injury to people or damage to equipment.

Standards for compliance with the EU Low Voltage Directive (2006/
95/EC)

 EN 60204-1:2007 (Safety and electrical equipment of machines)
 EN 60439-1:2005 (Low voltage switchgear and controlgear assem-

blies)

 EN 61800-5-1:2007 (Adjustable speed electrical power drive systems

- Safety requirements)

Standards for compliance with the EU EMC Directive (2004/108/EC)

 EN 61000-6-1/2:2006 (Immunity for residential, commercial and light-

industrial environments)

 EN 61000-6-3/4:2007 (Emission standard for residential, commercial

and light-industrial environments)

 EN 61800-3:2004 (Adjustable speed electrical power drive systems -

EMC requirements)

It is the manufacturer's responsibility to comply with the limit values for
the plant or machinery as required by EMC legislation. This documenta­tion contains tips on how to make your installation EMC-compliant (such
as shielding, earthing, how to manage the connectors and lay the ca­bles).

3-6

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

3 Safety

3.3 Standards

UL conformity

 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 are intended to elim­inate the risk of these devices causing a fire.

 UL 840

UL 840 describes the fulfilment by design of clearance and creepage
distances on electrical equipment and printed circuit boards.

Functional safety standards

 EN 61800-5-2:2007 (Adjustable speed electrical power drive systems

– Safety requirements – Functional)

 EN ISO 13849-1:2008 (Safety of machinery – Safety-related parts of

control systems)

 EN 61508-1:1998 (Functional safety of electrical/electronic/program-

mable electronic safety-related systems – General requirements)

 EN 61508-2: 2000 (Functional safety of electrical/electronic/program-

mable electronic safety-related systems – Requirements)

 EN 61508-3:1998 (Functional safety of electrical/electronic/program-

mable electronic safety-related systems – Software requirements)

 EN 61508-4:1998 (Functional safety of electrical/electronic/program-

mable electronic safety-related systems – Definitions and abbrevia­tions)

 IEC 62061:2005 (Safety of machinery - Functional safety of safety-re-

lated electrical, electronic and programmable electronic control sys­tems)

The machine or plant manufacturer must check to see whether any ad­ditional standards or EU directives are applicable for his plant or ma­chinery.

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

3-7

3 Safety

3.4 Stop and E-STOP functions

3.4Stop and E-STOP function s3400St op and E-STOP funct ions3-

3.4.1 Stop functions

Stop functions3-][Sicherheit_Stopp

The stop function is used to bring the machine to a standstill in normal
operation.

The stop functions are defined in EN 60204-1 (VDE 0113), paragraphs

9.2.2, 9.2.5.3.

Category 0

Stopping by immediate removal of power to the machine actuators (un­controlled stop).

Category 1

A controlled stop, with power to the machine actuators available to
achieve the stop and then removal of power when the stop is achieved.

Category 2

A controlled stop, with power left available to the machine actuators.

The stop category shall be determined from the hazard analysis of the
machine.

Appropriate measures to ensure a reliable stop are also required.

Category 0 or 1 stops shall be operational regardless of the operating
mode. A Category 0 stop shall take priority. Stop functions shall operate
by de-energising the relevant circuit and shall override related start func­tions.

Where required, facilities to connect protective devices and interlocks
shall be provided. Where applicable, the stop function shall signal that
such a condition exists. The reset of the stop function shall not initiate
any hazardous conditions.

3-8

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

3 Safety

3.4 Stop and E-STOP functions

3.4.2 E-STOP functions

E-STOP functions3-][Sicherheit_Not_Halt

The E-STOP functions are used to stop the machine as quickly as
possible in the case of danger. The E-STOP function can be initiated by
the action of a single person. It must be functional and available at all
times. The user should not have to consider how to operate the device.

The E-STOP function is defined in EN 60204-1 (VDE 0113), paragraph

9.2.5.4.

In addition to the requirements for stop, the emergency stop has the fol­lowing requirements:

 The E-STOP shall override all other functions and operations in all

modes.

 Power to the machine actuators which can cause hazardous condi-

tions shall be removed as quickly as possible without creating other
hazards (e.g. by the provision of mechanical means of stopping re­quiring no external power, by reverse current braking for a Category 1
stop)

 Reset shall not initiate a restart.

Where required, facilities to connect additional emergency stop devices
shall be provided (see EN 60204-1, "Requirements of E-STOP devic­es"). The E-STOP shall function as either a Category 0 or Category 1
stop. The choice of the category of the emergency stop shall be deter­mined by the risk assessment of the machine.

Category 0

Where a Category 0 stop is used for the emergency stop function, it shall
have only hardwired, electromechanical components. Its operation shall
not depend on electronic logic (hardware or software) or on the trans­mission of commands over a communications network or link. The drive
shall be shut down using an electromechanical circuit. If the connected
servo motor has an integrated brake, this must always be controlled by
an electromechanical circuit as well.

Category 1

Where a Category 1 stop is used for the emergency stop function, final
removal of power to the machine actuators shall be ensured and shall
be by means of electromechanical components. The motor shall be
brought to a standstill by switching off the mains voltage and via con­trolled, electronic braking. The 24 V supply voltage to the servo amplifier

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

3-9

3 Safety

3.4 Stop and E-STOP functions

must be maintained. The circuit that is used will depend on the require­ments of the respective application.

Brakes on servo motors usually only operate as a holding brake.

The necessary dynamic braking torque must be tested in order to guar­antee an E-STOP function. If a holding brake meets the dynamic require­ments, the fact that this application will cause increased wear must be
taken into account.

3-10

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

4 Function description

4.1 Overview

44000Function descriptionFunction description4-4.1Overview4100Overview4-][Funktion_Uebersicht_DD5

The PMCtendo DD5 is a digital servo amplifier which drives servo mo­tors with speed, torque and/or position control. It is suitable for closed
loop operation of brushless, synchronous servo motors and asynchro­nous motors.

The servo amplifier consists of

 A power element, which converts the fixed voltage and frequency of

the mains into a variable voltage and frequency for driving the motor

 A control element with

– Sequence control and control loops for rotational speed/velocity

and position

– Interfaces for communication with the periphery or the commis-

sioning software PDrive
– Digital inputs and outputs
– Analogue inputs
– Safety circuits
– Bus interfaces (CANopen, PROFIBUS, SERCOS, DeviceNet)
– RS232 interface for parameter setting and commissioning

][Funktion_Uebersicht_DD5_Blockschaltbild

The following illustration shows the components that make up the servo
amplifier.

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

4-1

4 Function description

D

A

RS 232

CAN

A

D

Resolver

Encoder

M3

PWM

I

A

D

I

24 V

Filter

Filter

PC

CAN Master

Digital
inputs

Digital
outputs

Ready for
operation

Analogue
inputs

Safety function
STO

Incremental encoder

Control

Regulation

Monitoring

Communication

Control element

Power element

Charging
circuit

Rectifier

Inverted rectifier

Mains voltage

Filter

Brake
chopper

Supply voltage

Holding brake

Fan

Intermediate circuit
capacitors

4.1 Overview

4-2

Fig. 4-1: Block diagram PMCtendo DD5

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]