Pilz PMCprimo Drive2 Installation Manual
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Motion Control PMC
PMCprimo Drive2
Installation Manual – Item No. 21 486-02
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1 General conditions
1.1 Copyright
Copyright 2005 Pilz GmbH & 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 & Co. KG.
1.2 Notes
Pilz GmbH & 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 General conditions
1.3 Previous editions
Edition Comments
V1 Initial release
V2 Revision
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2 Table of contents
2 Table of contents
1 General conditions ........................................................................................... 2
1.1 Copyright ................................................................................................................. 2
1.2 Notes ....................................................................................................................... 2
1.3 Previous editions ..................................................................................................... 2
2 Table of contents.............................................................................................. 3
3 Type key ............................................................................................................ 6
4 Safety instructions ........................................................................................... 7
5 European directives and standards................................................................ 8
6 Abbreviations and symbols............................................................................. 10
7 General .............................................................................................................. 11
7.1 About this manual.................................................................................................... 11
7.2 Requirements .......................................................................................................... 11
7.3 Prescribed use (Use as directed) of the control....................................................... 11
7.4 Instrument description .............................................................................................13
7.4.1 Scope of delivery.............................................................................................. 13
7.4.2 Accessories ...................................................................................................... 13
7.4.3 The PMCprimo Drive2 family............................................................................ 14
7.4.3.1 Performance data ....................................................................................14
7.4.3.2 Fieldbus Interface ....................................................................................14
7.4.3.3 Soft-PLC CoDeSys®................................................................................ 14
7.4.3.4 Interfaces ................................................................................................. 14
7.4.3.5 Power supplies ........................................................................................ 14
7.4.3.6 Power section ..........................................................................................15
7.4.3.7 Electrical supply.......................................................................................15
7.4.3.8 Power input filter ...................................................................................... 15
7.4.3.9 Operation and programming .................................................................... 15
7.4.3.10 Integrated safety.....................................................................................15
7.5 Connection to different mains supply networks .......................................................16
7.6 Block diagram – part 1............................................................................................. 17
7.7 Block diagram – part 2............................................................................................. 18
7.8 Components of a servo system ............................................................................... 19
7.9 Technical data .........................................................................................................20
7.9.1 External fusing.................................................................................................. 21
7.9.2 Permissible ambient conditions ventilation, mounting position ......................... 21
7.9.3 Conductor cross-sections ................................................................................. 22
7.9.4 LED-Display .....................................................................................................22
7.10 Grounding system ................................................................................................... 23
7.11 Control for motor-holding brake .............................................................................. 23
7.12 Regen circuit ........................................................................................................... 25
7.13 Switch-on and switch-off behaviour......................................................................... 26
7.13.1 Stop function to EN 60204 (VDE 0113) .......................................................... 26
7.13.2 Emergency Stop strategies ............................................................................ 27
7.13.2.1 Category 0.............................................................................................. 27
7.13.2.2 Category 1.............................................................................................. 27
7.14 Option -AS .............................................................................................................. 28
7.14.1 General........................................................................................................... 28
7.14.2 Prescribed use................................................................................................ 28
7.14.3 Functional description..................................................................................... 29
7.14.4 Block diagram.................................................................................................30
7.14.5 Signal diagram ............................................................................................... 30
7.14.6 Installation and Commissioning......................................................................31
7.14.6.1 Safety instructions ..................................................................................31
7.14.6.2 Application example................................................................................ 31
7.14.6.3 Connection diagram................................................................................ 31
8 Installation......................................................................................................... 32
8.1 Important instructions .............................................................................................. 32
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2 Table of contents
8.2 Assembly.................................................................................................................33
8.3 Dimensions.............................................................................................................. 34
8.4 Wiring ......................................................................................................................35
8.4.1 Connection diagram PMCprimo Drive2 - part 1................................................37
8.4.2 Connection diagram PMCprimo Drive2- part 2.................................................38
8.4.3 Pin assignments overview ................................................................................ 39
8.4.4 Pin assignments - details.................................................................................. 40
8.4.5 Pin assignments Modbus/Profibus ...................................................................41
8.4.6 Notes on connection techniques....................................................................... 42
8.5 Key operation for parameter setting ........................................................................43
8.5.1 Comparison to the key operation with PMCtendo DD4 .................................... 43
8.5.2 Basic key operation .......................................................................................... 43
8.5.3 Menu operation................................................................................................. 43
8.5.4 LED Display...................................................................................................... 44
8.5.5 Automatic detection in PMCprimo ....................................................................44
9 Interfaces........................................................................................................... 45
9.1 Power supply...........................................................................................................45
9.1.1 Mains supply (X0)............................................................................................. 45
9.1.2 24V-auxiliary supply (X4).................................................................................. 46
9.1.3 24V-Supply (X10) ............................................................................................. 47
9.1.4 Master encoder supply (X10) .......................................................................... 48
9.1.5 DC-link (X7)......................................................................................................49
9.2 Motor connection with brake (X9)............................................................................49
9.2.1 Lead length < 25m............................................................................................ 49
9.2.2 Lead length > 25m............................................................................................ 50
9.3 External regen resistor (X8)..................................................................................... 51
9.4 Feedback................................................................................................................. 52
9.4.1 Resolver connection (X2) ................................................................................. 52
9.4.2 HIPERFACE Encoder (X1)...............................................................................53
9.5 Encoder emulations.................................................................................................54
9.5.1 Incremental encoder emulation ROD (X5)........................................................ 54
9.5.2 Application example .........................................................................................54
9.5.3 SSI emulation (X5) ...........................................................................................55
9.5.4 Application example .........................................................................................55
9.6 RS232 interface, PC interface (X6) .........................................................................56
9.6.1 General............................................................................................................. 56
9.6.2 Pin assignment of the null-modem cable..........................................................57
9.7 Digital signals ..........................................................................................................59
9.7.1 Digital inputs I1:1 - I1:8 (X10) ........................................................................... 59
9.7.2 Digital inputs I2:1 - I2:4 (X3) ............................................................................. 60
9.7.3 Digital ENABLE input (X3)................................................................................61
9.7.4 Digital outputs O1:1 - O1:8 (X10) ....................................................................62
9.7.5 Digital outputs Digital-Out 1+2 (X3) .................................................................. 63
9.7.6 Relay output (X3)..............................................................................................64
9.8 Analog signals ......................................................................................................... 65
9.8.1 Analog outputs AO2 and AO3 (X3)................................................................... 65
9.8.2 Analog inputs AI1 and AI2 (X3) ........................................................................66
9.9 CAN bus interface (X11/2 and X11/1) .....................................................................67
9.9.1 General............................................................................................................. 67
9.9.2 Connecting PMCprimo Drive2 systems............................................................67
9.9.3 CAN bus cable.................................................................................................. 68
9.9.4 Speciality 1st node ...........................................................................................68
9.9.5 Speciality last node........................................................................................... 68
9.9.6 Fault detection..................................................................................................68
9.9.7 Connecting external CANopen bus devices ..................................................... 68
9.10 Master encoder interface / CAN2 (X11/4) ...............................................................69
9.10.1 CAN 2 interface .............................................................................................. 70
9.10.2 Jumper settings .............................................................................................. 71
9.10.3 Incremental encoder.......................................................................................72
9.10.4 Absolute encoder (SSI) ..................................................................................73
9.11 Bus interface (X11/3) ..............................................................................................74
9.11.1 General........................................................................................................... 74
9.11.2 MODBUS Interface......................................................................................... 74
9.11.3 Profibus interface (Option).............................................................................. 75
9.11.4 Using the MODBUS / Profibus interface with PMCprimo................................ 75
9.11.5 Example: Profibus DP slave module ..............................................................75
9.12 Virtual inputs and outputs........................................................................................ 77
9.12.1 Terms ............................................................................................................. 77
9.12.2 Application example .......................................................................................77
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2 Table of contents
10 Commissioning................................................................................................. 78
10.1 Important notes ....................................................................................................... 78
10.2 Setup software PDRIVE..........................................................................................80
10.2.1 Use as directed............................................................................................... 80
10.2.2 Software description....................................................................................... 80
10.2.3 Hardware requirements .................................................................................. 80
10.2.4 Minimum requirements for the PC:.................................................................80
10.2.5 Installation under WINDOWS 95 / 98 / NT / 2000 / XP................................... 80
10.2.6 Working with PDRIVE..................................................................................... 80
10.3 Parametrization of the PMCprimo Drive2................................................................81
10.4 Programming of the PMCprimo Drive2 ................................................................... 81
10.5 Error messages....................................................................................................... 82
10.5.1 Error messages PMCprimo ............................................................................82
10.5.2 Error messages amplifier................................................................................ 83
10.6 Warnings.................................................................................................................84
10.7 Status messages..................................................................................................... 85
10.7.1 Status messages PMCprimo .......................................................................... 85
10.7.2 Status messages drive ................................................................................... 85
11 Appendix ........................................................................................................... 86
11.1 Notes on EMC problems ......................................................................................... 86
11.1.1 Cable screening.............................................................................................. 86
11.1.2 Metallic, large area connections ..................................................................... 87
11.1.3 PE connection, earthing, grounding................................................................ 87
11.1.4 Motor choke.................................................................................................... 87
11.1.5 Expansion board............................................................................................. 88
11.1.6 Ethernet interface of the expansion board X11/5 ........................................... 88
11.1.6.1 General...................................................................................................88
11.1.6.2 Interface.................................................................................................. 89
11.1.6.3 Configuration IP address ........................................................................90
11.2 Change of the buffer battery ...................................................................................92
11.3 Transport, storage, maintenance, disposal ............................................................. 93
11.4 Removing faults ......................................................................................................94
11.5 Index ....................................................................................................................... 96
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3 Type key
3 Type key
Page 6 Installation manual PMCprimo Drive2
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4 Safety instructions
4 Safety instructions
Only properly qualified personnel are permitted to perform activities such as
transport, installation, commissioning and maintenance. Properly qualified
persons are those who are familiar with the transport, assembly, installation,
commissioning and operation of the product, and who have the appropriate
qualifications for their job. The 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 A2
Read this documentation before carrying out installation and commissioning.
Incorrect handling of the PMCprimo Drive
damage. It is vital that you keep to the technical data and information on
connection requirements (on the nameplate and in the documentation).
The PMCprimo Drive2
be damaged by incorrect handling. Discharge your body before touching the
PMCprimo Drive2. Avoid contact with highly insulating materials (synthetic fibre,
plastic film etc.). Place the PMCprimo Drive2
Do not open the units. Keep all covers and switchgear cabinet doors closed during
operation. Otherwise there are deadly hazards, with the possibility of severe
danger to health or material damage.
During operation, PMCprimo Drives, according to their degree of enclosure
protection, may have uncovered live components. Control and power connections
may be live, even if the motor is not rotating.
PMCprimo Drives
used for cooling, it can reach temperatures above 80°C.
Never undo the electrical connections to the PMCprimo Drive2
is a danger of electric arcing with damage to contacts and danger to persons.
Wait at least five minutes after disconnecting the PMCprimo Drive2
supply voltage before touching live sections of the equipment (e.g. contacts) or
undoing 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-link circuit and wait until it has fallen below 40V.
Based on the guideline 94/9/EC (ATEX guideline) this product is not suitable for the
application in potential explosive areas without evaluation of the conformity.
contains electrostatically sensitive components which may
may have hot surfaces during operation. Since the front panel is
can lead to personal injury or material
on a conductive surface.
while it is live. There
from the mains
Installation manual PMCprimo Drive2 Page 7
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5 European directives and standards
Servo amplifiers are components that are intended to be incorporated into electrical plant and
machines forindustrial use. When the servoamplifiers are built into machines or plant, the intended
operation of the amplifier is forbidden until it has been established that the machine or plant fulfills
the requirements of the EC Machinery Directive 98/37/EG and the EC Directive on EMC
(89/336/EEC).
To fulfill the EC Machinery directive (98/37/EG), the following standards have to be applied: EN
60204-1 (Safety and electrical equipment of machines) EN 292 (Safety of machines)
The manufacturer of the machine must produce a hazard analysis for the machine and take
appropriate measures to ensure that unforeseen movements do not result in personal injury
or material damage.
To fulfill the Low Voltage Directive 73/23/EEC, the following standards have to be applied:
EN 60204-1 (Safety and electrical equipment of machines)
EN 50178 (Equipment of high voltage plant with electronic devices)
EN 60439-1 (Low-voltage switchgear and controlgear assemblies)
To fulfill the EC EMC regulations (89/336/EEC), the following standards have to be applied:
EN 61000-6-1 or EN 61000-6-2 (noise immunity within the domestic range/industrial range)
EN 61000-6-3 or EN 61000-6-4 (noise emission within the domestic range/industrial range)
The manufacturer of the machine or plant is responsible for ensuring that they meet the limits
required by the EMC regulations. Advice on the correct installation for EMC – such as shielding,
grounding, arrangement ofconnectors and cable routing – can be found in this documentation.
The machine / plant manufacturer must examine whether with its machine / plant still further
or other standards or EEC guidelines are to be used.
5 European directives and standards
ce- conformance
Conformity with the EC Directive on EMC 89/336/EEC and the Low Voltage Directive 73/23/EEC is
mandatory for servoamplifiers supplied within the European Union. To fulfill the EMC directive, the
standard EN 61800-3 is applied.
In the reference to noise immunity and noise emission the servoamplifier fulfills the requirement to
the category second environment (industrial environment).
The servo amplifiers have been tested by an authorized testing laboratory in a defined configuration
with the system components which 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 that the regulatory requirements are fulfilled.
To fulfill the Low Voltage Directive, the standard EN 50178 has to be applied.
Page 8 Installation manual PMCprimo Drive2
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5 European directives and standards
UL and cUL- Conformance
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 fulfillment 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) fire inspector through the type testing and regular check-ups.
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 fulfillment 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 fulfillment by design of air and insulation creepage spacings for electrical
equipment and printed circuit boards.
Installation manual PMCprimo Drive2 Page 9
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6 Abbreviations and symbols
The abbreviations used in this manual are explained in the table below.
Abbrev. Meaning
AGND Analog ground
BTB/RTO Ready to operate
CAN Controller area network- Bus system
CE Communité Europeenne
CLK Clock
COM Serial interface of a PC-AT
DGND Digital ground
DIN Deutsches Institut für Normung
Drive Servo amplifier
EGND Ground for PMCprimo Drive2, RS232 and encoder
EMC Electromagnetic compatibility
EN Europäische Norm
ESD Electrostatic discharge
IEC International Electrotechnical Commission
IGBT Insulated Gate Bipolar Transistor
ISO International Standardization Organization
MODBUS Serial protocol for operator manuals
NI Zero pulse
RBallast Regen resistor
RBext External regen resistor
RBint Internal regen resistor
RES Revolver
PLC Programmable logic controller
SRAM Static RAM
SSI Synchronous serial interface
TN/TT-Netz Mains standard DIN 57100 T310
UL Underwriter Laboratories
V AC AC voltage
V DC DC voltage
VDE Verein deutscher Elektrotechniker
VGA Grafical display with min. 640x480 pixels
XGND Ground for the 24V supply
6 Abbreviations and symbols
Meaning/Description
This symbol indicates the possibility of a danger, risk to life and/or health.
Ignorance may seriously affect health and cause dangerous injuries.
This symbol indicates the possibility of a danger, risk to life and/or health from
electricity and its effects.
•
⇒
This symbol indicates important instructions regarding the correct use of the
product. Ignorance may affect the performance of the machinery and/or the
connected system.
This symbol indicates special user tips and/or important useful information.
These will support optimum use of the product and functions.
Emphasis
see page (or cross reference)
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7 General
7 General
7.1 About this manual
This manual describes the digital control system PMCprimo Drive2.
Here you can find information about:
• Technical data of the PMCprimo Drive2 from page 20
• Assembly and installation from page 32
• Interfaces from page 45
• Commissioning of the PMCprimo Drive2 from page 78
The programming of the PMCprimo-motion control-systems is described explicitely in the
PMCprimo programming manual.
Useful hints about linking controls and CANopen devices via CAN bus can be found in the
manual „PMCprimo CAN network“.
Both manuals are part on the CD-ROM PMCprimo Motion Control Tools.
7.2 Requirements
Transport: only by personnel with knowledge in handling electrostatically
sensitive components.
Installation: only by electrically qualified personnel
Commissioning: only by personnel with extensive knowledge of electrical
engineering technology
7.3 Prescribed use (Use as directed) of the control
The servo amplifiers are components which are built into electrical equipment or machines, and can
only be used as integral components of such equipment.
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.
The PMCprimo Drive2 family of servo amplifiers can be connected directly to symmetrically earthed
(grounded) three-phase industrial mains supply networks [TN-system, TT-system with earthed
(grounded) neutral point, not more than 5000 rms symmetrical amperes, 480 VAC maximum].
The servo amplifiers must not be operated directly on power supply networks >230 V without an
earth (ground) or with an asymmetrical earth (ground).
Connection to different mains supply networks (with additional isolating transformer) (page 16).
Periodic overvoltages between outer conductor (L1, L2, L3) and housing of the servo amplifier may
not exceed 1000 V (peak value).
Transient overvoltages (< 50µs) between the outer conductors may not exceed 1000 V.
Transient overvoltages (< 50µs) between outer conductors and housing may not exceed 2000 V.
If the servo amplifiers are used in residential areas, or in business or commercial premises, then
additional filter measures must be implemented by the user.
The PMCprimo Drive2 family of servo amplifiers is intended to drive specific brushless synchronous
servomotors, with closed-loop control of torque, speed and/or position. Asynchronous and linear
motors can also be used. The rated voltage of the motors must be at least as high as the DC-link
voltage of the servo amplifier.
The servo amplifiers may only be operated in a closed switchgear cabinet, taking into account the
ambient conditions defined on page 21 and the dimensions shown on page 34. Ventilation or
cooling may be necessary to prevent enclosure ambient from exceeding 45 °C (113 °F).
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Page 11
Use only copper wire. Wire size may be determined from EN 60204 (or table 310-16 of the NEC
60 °C or 75 °C column for AWG size).
We only guarantee the conformance of the servo amplifiers with the standards for industrial areas,
if the components (motors, cables, amplifiers etc) are delivered by Pilz GmbH & Co. KG.
7 General
Page 12
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7 General
7.4 Instrument description
7.4.1 Scope of delivery
When you order a PMCprimo Drive2 from us, you will receive:
• PMCprimo Drive2 - size 01..20
• Mating connectors X3, X4, X0A, X0B, X7, X8
The mating motor connector X9 is not part of the package!
• Assembly, installation- and commissioning instructions
• Setup software package PMCprimo Motion Control Tools on CD-ROM
• Software manual PDrive and PMCprimo programming manual on CD-ROM
7.4.2 Accessories
• Servo motor PMCtendo AC1 or PMCtendo AC2
• Motor cable (pre-assembled), or both motor connectors separately with motor cable as cut-off
length
• Feedback cable (pre-assembled) or both feedback connectors separately with feedback cable
as cut-off length
• External regen resistor
• Communication cable to the PC for parameterisation (Null modem cable)
• MODBUS panel and communication cable; Panel (2 line till Touch screen)
• CAN cables
• Software keys for Motion Generator or Soft-PLC
• Ethernet cables
• Adapter cable Modbus/Profibus
• Expansion card (page 88)
• CompactFlash Cards
• Profibus DPS-small IC
• Master encoder
• Expansion board (page 88)
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7 General
7.4.3 The PMCprimo Drive2 family
7.4.3.1 Performance data
• Position controller with 1 ms cycle time
• Digital current controller (space vector, pulse-width modulation, 62,5 µs)
• Evaluation of the resolver signals or sine-cosine signals of a HIPERFACE encoder
• 9 axes in system: 1 Motor direct, as well as 8 other axes channels for controlling further axes
• Each axis can operate in virtual motor mode
• Software gearbox
• Software differential and clutch
• Internal map generator (motion generator) as an option
• Product referencing
• Tension control
• Up to 8 cam
• Soft positioning („s-curves“)
7.4.3.2 Fieldbus Interface
• CAN-Bus with 500 kBit/s or 1 MBit/s (CANopen) – linking up to 60 PMCprimo-motion controlsystems
• Modbus interface - devices like panels
• Option: Profibus DP (small) – easy communication with SoftPLC
• Option: Ethernet 10/100 Mbit/s
• Option: second CAN interface
7.4.3.3 Soft-PLC CoDeSys®
• Soft-PLC CoDeSys® as an option
• Fully PLC functionality specified in IEC 61131-3
• PLC and PMCprimo - combined in one system
7.4.3.4 Interfaces
• 12 digital inputs, 24 V, electrically isolated
• 8 digital outputs, 24 V, short circuit protected and electrically isolated
• 2 analog outputs with ± 10 V output range
• 2 analog inputs with ± 10 V input range
• 1 input for master encoder (incremental / SSI)
7.4.3.5 Power supplies
• 24 V power supply
• Common power supply for all master encoders
Page 14
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7 General
7.4.3.6 Power section
• Power supply: B6 rectifier bridge, directly off 3-phase earthed supply system,
integral power input filter and inrush circuit
• All shielding connections directly on the amplifier
• Output stage: IGBT- module with isolated current measurement
• Regen circuit: with dynamic distribution of the regen power between several
amplifiers on the same DC-link circuit. Internal regen resistor as
standard, external regen resistors if required
• DC-link voltage 260 — 900 V DC, can be paralleled
7.4.3.7 Electrical supply
• Directly off grounded 3 phase system,
230V-10% ... 480V +10% ,50 Hz,
208V-10% ... 480V +10% ,60 Hz
TN-system or TT-system with grounded neutral point, not more than 5000 rms
symmetrical amperes
• 6 current ratings (1.5 A , 3 A , 6 A , 10 A , 14 A, 20 A)
• single-phase supply (e.g. for commissioning or setting-up) is possible
7.4.3.8 Power input filter
• Interference suppression filter for the supply input (to Class A) is integrated)
• Interference suppression filter for the 24V aux. supply (to Class A) is integrated
7.4.3.9 Operation and programming
• Comfortable programming with the software package PMCprimo Motion Control Tools under
Windows 98/NT/2000/XP.
• Fully programmable with any ASCII-Terminal
7.4.3.10 Integrated safety
• Safe electrical separation to EN 50178 between the power input / motor connections and the
signal electronics, provided by appropriate insulation/creepage distances and complete
electrical isolation
• Softstart, overvoltage recognition, short-circuit protection, phase-failure monitoring
• Temperature monitoring of PMCprimo Drive2 and motor (when using motors from the
PMCtendo AC series with our pre-assembled cables)
• -AS- built-in safety relay (personnel-safety starting lock-out).
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Page 15
7 General
7.5 Connection to different mains supply networks
On this page you'll find all possible connection variations to different mains supply networks.
An isolating transformer is always required for 400...480V mains networks without
earth(ground) and for networks with asymmetrical earth(ground).
Page 16
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7 General
7.6 Block diagram – part 1
Installation manual PMCprimo Drive2
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7 General
7.7 Block diagram – part 2
Page 18
Installation manual PMCprimo Drive2
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7 General
7.8 Components of a servo system
Installation manual PMCprimo Drive2
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7 General
7.9 Technical data
Rated data DIM
Rated supply voltage V~ 3 x 230V-10% ... 480V+10%, 50 ... 60 Hz
Rated installed load for S1 operation kVA 1 2 4 7 10 14
Rated DC-link voltage V= 310 - 675
Rated output current (rms value, ± 3%)
Peak output current (max. ca. 5s, ± 3%)
Clock frequency of the output stage kHz 8
Technical data for regen circuit —
Overvoltage protection threshold V 450...900
Form factor of the output current
(at rated data and min. load inductance)
Bandwidth of subordinate current controller kHz > 1,2
Residual voltage drop at rated current V 5
Quiescent dissipation, output stage disabled W 15
Dissipation at rated current (incl. power
supply losses, without regen dissipation)
Internal fusing (external fusing ⇒ page 21)
Auxiliary supply 24V — internal 3.15 AT
Regen resistor — internal electronic
Inputs
Analog inputs (X3), resolution 14bit (AI1) and
12bit (AI2)
Common-mode voltage max. V ±10
Input resistance
Digital inputs (X3) according to IEC 1131
Digital inputs (X10) according to IEC 1131
Outputs
Output current digital outputs (X10), each
channel
Output current digital outputs (X3) mA max 10 (open collector)
Voltage range analog outputs (X3) ,
resolution 10 Bit
Output resistance
Max. output current, brake A 2
Master encoder PMCprimo Drive2
Input resistance
Transfer rate MHz 1
Pulse width (Z-track incremental encoder) ns mind. 200
Power dissipation
without brake, no load
with brake, no load
Encoder supply - 5-24 V, see datasheet encoder
12V supply CAN mA 10 each client
Arms 1,5 3 6 10 14 20
Arms 3 6 12 20 28 40
01 03 06 10 14 20
— 1.01
W 30 40 60 90 160 200
V ±10
kΩ
mA max. 100 (overload protection)
V ± 10
kΩ
Ω
V 24 (-0% +15%) 24 V supply supply, electrically isolated
mA 1000
V 24 (-0% +15%) 24 V supply supply, electrically isolated
mA 3000
PMCprimo Drive2
⇒ S. 24
20
2.2
200
Page 20
Installation manual PMCprimo Drive2
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7 General
Connections DIM
Control signals (X3) — Combicon 5.08 / 18pole , 2,5mm²
24 V supply (X4) — Combicon 5.08 / 4 pole , 2,5mm²
24 V supply (X10) — Combicon 3.5 / 11 pole , 1mm²
Encoder supply (X10) — Combicon 3.5 / 11 pole , 1mm²
Digital inputs (X10) — Combicon 3.5 / 11 pole , 1mm²
Digital outputs (X10) — Combicon 3.5 / 8 pole , 1mm²
Power signals (X0,X7,X8,X9) — Power Combicon 7.62 / 4x4 + 1x6-pole, 4mm²
Resolver input (X2) — SUB-D 9pol. (plug)
HIPERFACE input (X1) — SUB-D 15pol. (plug)
PC interface (X6) — SUB-D 9pol. (socket)
Encoder emulation, ROD/SSI (X5) — SUB-D 9pole (plug)
Master encoder (X11/4) / CAN2 (Option) — SUB-D 9pole (socket)
MODBUS (X11/3) / Profibus (Option) — RJ45
CAN-1A (X11/2) — SUB-D 9pole (plug)
CAN-1B (X11/1) — SUB-D 9pole (socket)
Mechanical
Weight kg 4 5 7,5
Height without connectors mm 275
Width mm 70 100 120
Depth without connectors mm 265
01 03 06 10 14 20
PMCprimo Drive2
7.9.1 External fusing
Fusible cutouts or similay
AC supply FN1/2/3 6 AT 10 AT 20 AT
24V supply FH1/2 max. 16 AF
Regen resistor FB1/2 4 AF 6 AF 6 AF
PMCprimo Drive2
01 / 03
PMCprimo Drive2
06 / 10
7.9.2 Permissible ambient conditions ventilation, mounting position
Storage temperature/humidity,duration
Transport temperature / humidity
Supply voltage tolerances
Input power
Aux. power supply
Ambient temperature in operation
Humidity in operation rel. humidity 85%, no condensation
Site altitude up to 1000m a.m.s.l. without restriction
Pollution level Pollution level 2 to EN60204/EN50178
Enclosure protection IP 20
Mounting position
Ventilation built-in fan
Vibration Vibration: 1g sinuid according to 60068-2-Fc
⇒ S. 93
⇒ S. 93
min 3x230V
24 V DC (-0% +15%)
0...+45°C at rated data
1000...2500m a.m.s.l. with power derating 1.5%/100m
generally vertical. ⇒S. 33
Shock: 15g, 11ms, 60068-27-Ea
-10%
AC / max 3x 480V
+10%,
50 ... 60 Hz
Make sure that there is sufficient forced ventilation within the switchgear cabinet!
PMCprimo Drive2
14 / 20
Installation manual PMCprimo Drive2
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7 General
7.9.3 Conductor cross-sections
Following EN 60204 (for AWG: table 310-16 of the NEC 60°C or 75°C column), we recommend:
AC connection PMCprimo Drive2 sz. 01-10 : 1,5 mm²
DC-link PMCprimo Drive2 sz. 01-10 : 1,5 mm²
Motor cables up to 25 m length PMCprimo Drive2 sz. 01-10 : 1 - 1,5mm²
Motor cables 25 to 100 m length
Resolver, thermostat-motor 8x0.25 mm² twisted pairs, shielded, max.100m,
HIPERFACE Encoder, thermostatmotor
Analog In- and outputs, AGND 0.25 mm² , twisted pairs, shielded
Control signals, BTB, DGND 0.5 mm²
Holding brake (Motor) min. 0.75 mm², shielded, check voltage drop
+24 V / XGND max. 2.5 mm², check voltage drop
24 V (X10) EGND / VCC Enc. Max. 1 mm2, check voltage drop
PMCprimo Drive2 sz. 14/20 : 4 mm²
PMCprimo Drive2 sz 14/20 : 4 mm²
PMCprimo Drive2 sz. 14/20 : 2,5 mm²
PMCprimo Drive2 sz. 01-10 : 1 mm²
PMCprimo Drive2 sz. 14/20 : 2,5 mm²
capacitance <120pF/m
10x0.14 mm² twisted pairs, shielded, max.100m,
capacitance <120pF/m
600V, 105°C, twisted
shielded for length >
20 cm
shielded,
capacitance<150pF/m
shielded with motor
choke MD400
7.9.4 LED-Display
A 3-character LED displays the servo amplifiers firmware version after switching on the 24V supply
for two seconds (e.g. “2.46”).
Afterwards the status of up to 10 axes is shown (or just “run”).
When an error occurs the error number is displayed (⇒ S. 83 ).
Page 22
Installation manual PMCprimo Drive2
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7 General
7.10 Grounding system
AGND
DGND
XGND
EGND
ground for analog inputs and outputs, internal analog ground
ground for digital inputs and outputs ( X3), optically isolated
ground for 24V aux. supply (X4)
ground for encoder-emulation, RS232, digital In-and outputs (X10); power supply PMCprimo
Drive2 and master encoder, optically and inductively isolated
The potential isolation is shown in the block diagram (⇒ S. 17/18).
7.11 Control for motor-holding brake
A 24V / max. 2A holding brake in the motor can be controlled directly by the PMCprimo Drive2.
This function does not ensure personnel safety! (s. Option –AS- page 28)
The brake function must be enabled through the setup software PDRIVE with the parameter
„brake“.
In the diagram below you can see the time and functional relationships between the ENABLE
signal, speed setpoint, speed and braking force.
Installation manual PMCprimo Drive2
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Page 23
During the internal ENABLE delay time of 100ms the speed setpoint of the PMCprimo Drive2 is
internally driven down a 10ms ramp to 0V. The brake output is switched on when 3% of the final
speed is reached. The rise (fbrH) and fall (fbrL) times of the holding brake which is built into the
motors are different for the various types of motor (see motor manual). A description of the interface
can be found on page 49.
A safe (for personnel) operation of the holding brake requires an additional “make” (n.o.) contact in
the brake circuit and a suppressor device (varistor) for the recommended brake circuit diagram
7 General
Page 24
Installation manual PMCprimo Drive2
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7 General
7.12 Regen circuit
During braking with the aid of the motor, energy is fed back to the PMCprimo Drive2. This energy is
converted into heat in the regen resistor. The regen circuit (thresholds) are adjusted to the supply
voltage with the help of the setup software PDRIVE.
Our applications department can help you with the calculation of the regen power which is required.
A description of the interface can be found on page 50 .
Internal regen resistor: PMCprimo Drive2 sz. 01/03 66 Ohm
PMCprimo Drive2 sz. 06-20 33 Ohm
External regen resistor: PMCprimo Drive2 sz. 01-20 33 Ohm
Functional description:
1. Individual amplifiers, not coupled through the DC-link (DC+, DC-)
The circuit starts to respond at a DC-link voltage of 400V, 720V or 840V (depending on the supply
voltage). If the energy which is fed back from the motor, as an average over time or as a peak
value, is higher than the preset regen power, then the PMCprimo Drive2 will output the status
“regen power exceeded” and the regen circuit will be switched off. At the next internal check of the
DC-link voltage (after a few ms) an overvoltage will be detected and the PMCprimo Drive2 will be
switched off with the error message “Overvoltage” (⇒ page 82).
BTB/RTO contact (terminal X3, Pin2+3) will be opened at the same time (⇒page 64)
2. Several servo amplifiers coupled through the DC-link circuit (DC+, DC-)
Thanks to the built-in regen circuit with its patented w-characteristic, several amplifiers (even with
different current ratings) can be operated off a common DC-link, if they have a common supply
voltage. This is achieved by an automatic adjustment of the regen thresholds (which vary, because
of tolerances). The regen energy is distributed equally among all the amplifiers. The combined
power of all the amplifiers is always available, as continuous or peak power. The switch-off takes
place as described under 1. (above) for the PMCprimo Drive2 with the lowest switch-off threshold
(resulting from tolerances). The RTO (BTB) contact of this amplifier (terminals X3, Pin2+3) will be
opened at the same time (⇒ S. 64).
Regen circuit: technical data
Supply voltage
3 x 230 V Upper switch-on level of regen circuit V 400 – 430
Switch-off level of regen circuit V 380 – 410
Continuous power of regen circuit (RBint) W 80 200
Continuous power of regen circuit (RBext) max. kW 0,25 0,75
Pulse power, internal (RBint max. 1s) kW 2,5 5
Pulse power, external (RBext max. 1s) kW 5
3 x 400 V Upper switch-on level of regen circuit V 720 – 750
Switch-off level of regen circuit V 680 – 710
Continuous power of regen circuit (RBint) W 80 200
Continuous power of regen circuit (RBext) max. kW 0,4 1,2
Pulse power, internal (RBint max. 1s) kW 8 16
Pulse power, external (RBext max. 1s) kW 16
3 x 480 V Upper switch-on level of regen circuit V 840 – 870
Switch-off level of regen circuit V 800 – 830
Continuous power of regen circuit (RBint) W 80 200
Continuous power of regen circuit (RBext) max. kW 0,5 1,5
Pulse power, internal (RBint max. 1s) kW 10,5 21
Pulse power, external (RBext max. 1s) kW 21
Rated data
PMCprimo Drive2
DIM 01 - 03 06 - 20
Installation manual PMCprimo Drive2
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Page 25
7 General
7.13 Switch-on and switch-off behaviour
The diagram below illustrates the correct functional sequence for switching the PMCprimo Drive2
on and off.
7.13.1 Stop function to EN 60204 (VDE 0113)
If a fault occurs (⇒ S. 81) ) the output stage of the PMCprimo Drive2 is switched off and the
BTB/RTO contact is opened. Instruments which are equipped with a selected “Brake” function use
a special sequence for switching off the output stage (⇒ S. 49).
The -AS- option can be used to switch off the drive via a positive-action (BG-approved) safety relay,
so that personnel safety is ensured at the drive shaft.
The stop functions are defined in EN 60204 (VDE 0113), Para. 9.2.2, 9.2.5.3.
There are three categories of stop functions:
Category 0: Shut down by immediately switching off the supply of energy to the drive
machinery (i.e. an uncontrolled shut-down);
Category 1: A controlled shut-down, during which the supply of energy to the drive
machinery is maintained to perform the shut-down, and where the energy
supply is only interrupted when the shut-down has been completed;
Category 2: A controlled shut-down, where the supply of energy to the drive machinery
is maintained.
Every machine must be equipped with a stop function to Category 0. Stop functions to Categories 1
and/or 2 must be provided if the safety or functional requirements of the machine make this
necessary.
Page 26
Installation manual PMCprimo Drive2
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7 General
7.13.2 Emergency Stop strategies
The Emergency Stop function is defined in EN 60204 (VDE 0113), Para. 9.2.5.4.
You can find wiring recommendations in our application note “Stop and Emergency Stop
functions with PMCtendo DD4”.
7.13.2.1 Category 0
The controller is switched to “disable”, the electrical supply (400VAC) is disconnected. The drive
must be held by an electromagnetic holding device (brake).
In multiaxis systems with connected DC-link bus (intermediate circuit) the motor leads have to be
disconnected by a changeover switch (contactor, e.g. Siemens 3RT1516-1BB40) and shortcircuited
by resistors connected in a star configuration
7.13.2.2 Category 1
If hazardous conditions can result from an emergency stop switch-off with an unbraked rundown,
then the drive can be switched off by a controlled shut-down.
Stop Category 1 permits electromotive braking with a switch-off when zero speed has been
reached.
Safe shutdown can be achieved, when the loss of the mains supply is not rated as a fault and the
control takes over the disabling of the PMCprimo Drive2.
In the normal situation, only the supply power is switched off in a safe manner.
The 24V auxiliary supply remains switched on.
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7 General
7.14 Option -AS
7.14.1 General
A frequently required application task is the protection of personnel against the restarting of drives.
This can not be achieved by an electronic inhibit, but must be implemented with mechanical
elements (positively driven relay contacts).
To get round this problem, up to now either the main contactor in the mains supply line was
switched off, or another contactor was used to disconnect the motor from the PMCprimo Drive2.
The disadvantages of this method are:
• the DC-link has to be charged up again at restart
• wear on the contacts of the contactors, caused by switching under load
• extensive wiring required, with additional switching components
The -AS- option avoids these disadvantages. A safety relay in the servo amplifier is activated either
by the PLC or manually. Positively driven contacts provide a safe disconnection of the PMCprimo
Drive2, the setpoint input of the PMCprimo Drive2 is inhibited, and a signal is sent to the safety.
The advantages of the Option -AS-:
• the DC-link remains charged up, since the mains supply line remains active
• only low voltages are switched, so there is no contact wear
• very little wiring is required
• the functionality and the personnel safety when using the circuit recommendations in this
documentation have been approved by the trade liability association
7.14.2 Prescribed use
The -AS- restart lock is exclusively intended to provide safety for personnel, by preventing the
restart of a system.
To achieve this personnel safety, the wiring of the safety circuits must meet the safety requirements
of EN60204, EN292 and VDI 2853.
The -AS- restart lock must only be activated,
• when the motor is no longer rotating (speed = 0 rpm).
Drives with a suspended load must have an additional safe mechanical blocking (e.g. by a
motor-holding brake).
• when the monitoring contacts (KSO1/2 and BTB/RTO) for all PMCprimo Drives are wired into
the control signal loop (to recognize a cable break).
The -AS- restart lock may only be controlled by a CNC if the control of the internal safety relay is
arranged for redundant monitoring
The -AS- restart lock must not be used if the drive is to be made inactive for the following reasons:
1. - cleaning, maintenance and repair operations
- long inoperative periods
In such cases, the entire system should be disconnected from the supply by the personnel,
and secured (main switch).)
2. - emergency-stop situations
In an emergency-stop situation, the main contactor is switched off (by the emergency-stop
button or the BTB-contact in the safety circuit).)
Page 28
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7 General
7.14.3 Functional description
An additional connector (X12) is mounted on the front panel of the PMCprimo Drive2. The coil
connections and a make (n.o.) contact of a safety relay are made available through 4 terminals on
this connector.
The 24V DC safety relay in the servo amplifier (TÜV approved) is controlled externally. All the relay
contacts have positive action.
Two contacts switch off the driver supply of the output stage in the PMCprimo Drive2, and short the
internal setpoint signal to AGND (0 V).
The make (n.o.) contact used for monitoring is looped into the control circuit.
If the safety relay is not energized, then the monitoring contact is open and the PMCprimo Drive2 is
ready for operation.
If the drive is electronically braked, the PMCprimo Drive2 is disabled and the motor-holding brake is
on, then the safety relay is energized (manually or by the controls).
The supply voltage for the driver circuit of the output stage is switched off in a safe manner, the
internal setpoint is shorted to 0V, and the monitoring contact bridges the safety logic in the control
circuit of the system (monitoring of protective doors etc.)
Even if the output stage or driver is destroyed, it is impossible to start the motor.
If the safety relay itself is faulty, then the monitoring contact cannot bridge the safety logic of the
system. Opening the protective devices will then switch off the system.
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