ITEM C 1-Series

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Safety notes for electrical drives and controllers

Page 18

Professional control process design is a prerequisite for sound functioning of the servo positioning controller!

DANGER!

Inappropriate handling of the servo positioning controller and non-compliance with the warnings as well as

inappropriate intervention in the safety features may result in property damage, personal injuries, electric

shock or in extreme cases even death.

Main Page

Table of Contents4
General14
Documentation14
Scope of Supply15
Table 1: Scope of Supply15
Table 2: Connector Set: POWER Connector15
Table 3: Connector Set: DSUB Connector15
Table 4: Connector Set: Shield Connector15
Safety Notes for Electrical Drives and Controllers16
Used Symbols16
General Notes17
Danger Resulting from Misuse19
Safety Notes20
General Safety Notes20
Safety Notes for Assembly and Maintenance22
Protection against Contact with Electrical Parts24
Protection against Electrical Shock by Means of Protective Extra-Low Voltage24
(Pelv)24
Protection against Dangerous Movements25
Protection against Contact with Hot Parts26
Protection During Handling and Assembly27
Product Description28
General28
Figure 1: Type Key28
Power Supply31
Single-Phase AC Supply with Active PFC31
Behaviour During Switch-On31
Behaviour During Normal Operation and Control Characteristics32
Figure 2: Schematic Setup of PFC Stage32
DC Bus Coupling, DC Supply33
DC Bus Coupling33
DC Supply33
Mains Fuse33
Brake Chopper34
Communication Interfaces34
Serial Interface [X5]35
USB Interface [X19]35
UDP Interface [X18]35
CAN Interface [X4]35
Technology Module: PROFIBUS36
Technology Module: Ethercat36
I/O Functions and Device Control36
Technical Data37
General Technical Data37
Table 5: Technical Data: Ambient Conditions and Qualification37
Table 6: Technical Data: Dimensions and Weight37
Table 7: Technical Data: Cable Specifications38
Table 8: Technical Data: Motor Temperature Monitoring38
Operating and Display Elements39
Table 9: Display Elements and RESET Button39
Supply [X9]40
Table 10: Technical Data: Performance Data [X9]40
Table 11: Technical Data: Internal Brake Resistor [X9]40
Table 12: Technical Data: External Brake Resistor [X9]40
Figure 3: Performance Curve of the PFC Stage41
Table 13: Performance Data of PFC Stage41
Motor Connection [X6]42
Current Derating42
Table 14: Technical Data: Motor Connection [X6]42
Table 15: Controller C 1-02: Rated Current for an Ambient Temperature of ≤ 40 °C44
Table 16: Controller C 1-05: Rated Current for an Ambient Temperature of ≤ 40 °C44
Table 17: Controller C 1-08: Rated Current for Blocked or Slowly Rotated Servo Motor45
Table 18: Controller C 1-08: Rated Current for Rotated Servo Motor46
Motor Feedback Connection [X2A]47
Resolver Connection [X2A]48
Encoder Connection [X2B]48
Table 19: Technical Data: Resolver [X2A]48
Table 20: Technical Data: Resolver Interface [X2A]48
Communication Interfaces51
Rs232 [X5]51
Usb [X19]51
Ethernet [X18]51
CAN Bus [X4]51
Table 21: Technical Data: RS232 [X5]51
Table 22: Technical Data: USB [X19]51
Table 23: Technical Data: Ethernet [X18]51
Table 24: Technical Data: CAN Bus [X4]51
SD/MMC Card52
I/O Interface [X1]52
Table 25: Technical Data: SD/MMC Card52
Table 26: Technical Data: Digital Inputs and Outputs [X1]52
Incremental Encoder Input [X10]53
Table 27: Technical Data: Analog Inputs and Outputs [X1]53
Table 28: Technical Data: Incremental Encoder Input [X10]53
Incremental Encoder Output [X11]54
Table 29: Technical Data: Incremental Encoder Output [X11]54
Function Overview55
Motors55
Synchronous Servo Motors55
Linear Motors55
Functions of the Item Servo Positioning Controller C 1-Series56
Compatibility56
Figure 4: Control Scheme of the Item C 1-Series56
Pulse Width Modulation (PWM)57
Setpoint Management57
Torque-Controlled Mode58
Speed-Controlled Mode58
Torque-Limited Speed Control58
Synchronization to the External Clock Signal58
Load Torque Compensation for Vertical Axes59
Positioning and Position Control59
Synchronisation, Electronic Gearing59
Brake Management59
Positioning Control60
Overview60
Relative Positioning61
Absolute Positioning61
Driving Profile Generator61
Figure 5: Driving Profiles of Item Servo Positioning Controller C 1-Series61
Homing62
Positioning Sequences63
Optional Stop Input63
Contouring Control with Linear Interpolation63
Figure 6: Path Program63
Time-Synchronized Multi-Axis Positioning64
Figure 7: Linear Interpolation between Two Data Values64
Functional Safety Technology65
General65
DIP Switch66
Table 31: Table Overview of the DIP Switch Functionality66
Assignment of the DIP Switch67
Table 32: Fieldbus Specific Assignment of the DIP Switches68
Integrated Safety Technology (Schematic Representation)69
Figure 8: Schematic Representation of the Integrated Safety Technology69
Module Variants70
FBA Module70
Figure 9: FBA Module: Front View70
FSM 2.0 - STO (Safe Torque Off)71
Mechanical Installation72
Important Notes72
Figure 10: Item Servo Positioning Controller C 1-Series: Installation Space73
View of the Device74
Figure 11: Item Servo Positioning Controller C 1-02: Front View74
Figure 12: Item Servo Positioning Controller C 1-02: Top View75
Figure 13: Item Servo Positioning Controller C 1-02: Bottom View75
Mounting76
Figure 14: Item Servo Positioning Controller C 1-Series: Mounting Plate76
Electrical Installation77
Connector Configuration77
Figure 15: Connection to Power Supply and Motor77
Item C 1-Series Complete System78
Figure 16: Complete Setup of the Item C 1-Series with Motor and PC79
Connection: Power Supply [X9]80
Device Side [X9]80
Counterplug [X9]80
Pin Assignment [X9]81
Cable Type and Design [X9]81
Table 33: Pin Assignment: [X9]81
Connection Notes [X9]82
Figure 17: Supply [X9]82
Connection: Motor [X6]83
Device Side [X6]83
Counterplug [X6]83
Pin Assignment [X6]84
Cable Type and Design [X6]84
Table 34: Pin Assignment: [X6]84
Connection Notes [X6]85
Figure 18: Motor Connection [X6]85
Figure 19: Connecting a Holding Brake with High Current Draw (> 1A) to the Device86
Connection: I/O Communication [X1]87
Figure 20: Basic Circuit Diagram Connector [X1]88
Device Side [X1]89
Counterplug [X1]89
Pin Assignment [X1]90
Table 35: Pin Assignment: I/O Communication [X1]90
Cable Type and Design [X1]91
Connection Notes [X1]91
Connection: Resolver [X2A]92
Device Side [X2A]92
Counterplug [X2A]92
Pin Assignment [X2A]92
Table 36: Pin Assignment: [X2A]92
Cable Type and Design [X2A]93
Connection Notes [X2A]93
Figure 21: Pin Assignment: Resolver Connection [X2A]93
Connection: CAN-Bus [X4]94
Device Side [X4]94
Counterplug [X4]94
Pin Assignment [X4]94
Table 37: Pin Assignment: CAN-Bus [X4]94
Cable Type and Design [X4]95
Connection Notes [X4]95
Figure 22: Cabling Example for CAN-Bus95
Figure 23: Integrated CAN Terminating Resistor96
Connection: RS232/COM [X5]97
Device Side [X5]97
Counterplug [X5]97
Pin Assignment [X5]97
Table 38: Pin Assignment: RS232 Interface [X5]97
Cable Type and Design [X5]98
Connection Notes [X5]98
Figure 24: Pin Assignment: RS232 Null Modem Cable [X5]98
Connection: USB [X19]99
Device Side [X19]99
Counterplug [X19]99
Pin Assignment [X19]99
Cable Type and Design [X19]99
Figure 25: Pin Assignment: USB Interface [X19], Front View99
Table 39: Pin Assignment: USB Interface [X19]99
SD/MMC Card100
Supported Card Types100
Supported Functions100
Supported File Systems100
File Names100
Pin Assignment SD/MMC Card101
Table 40: Pin Assignment: SD Card101
Table 41: Pin Assignment: MMC Card101
BOOT-DIP-Switch102
Figure 26: Pin Assignment: SC/MMC Card102
Notes on Safe and EMC-Compliant Installation103
Definitions and Terms103
General Information on EMC103
EMC Areas: First and Second Environment104
EMC-Compliant Cabling104
Table 42: EMC Requirements: First and Second Environment104
Operation with Long Motor Cables105
ESD Protection106
Additional Requirements for the Servo Drives Concerning the Ul Approval107
Circuit Protection107
Wiring and Environment Regards107
Motor Temperature Sensor107
Initial Operation108
General Notes on Connection108
Tools / Material108
Connecting the Motor108
Connecting the Item Servo Positioning Controller C 1-Series to the Power Supply109
Connecting the PC (Serial Interface)109
Connecting the PC (USB Interface, Alternative)109
Checking Operability109
Service Functions and Error Messages110
Protection and Service Functions110
Overview110
Overcurrent and Short-Circuit Monitoring110
Overvoltage Monitoring for the DC Bus111
Temperature Monitoring of the Heat Sink111
Monitoring of the Motor111
I²T Monitoring111
Power Monitoring for the Brake Chopper112
I²T Monitoring for the PFC Stage112
Initial Operation Status112
Rapid Discharge of the DC Bus112
Operating Hours Counter112
Display of Operating Mode and Error Messages113
Operating Mode and Error Display113
Table 43: Operating Mode and Error Display113
Error Messages114
Table 44: Error Messages115
Technology Modules147
PROFIBUS-DP Interface147
Product Description147
Technical Data147
Table 45: Technical Data: PROFIBUS-DP Interface: Ambient Conditions, Dimensions and Weight147
Figure 27: PROFIBUS-DP Interface: Front View148
Table 46: Technical Data: PROFIBUS-DP Interface: Interfaces and Communication148
Pin Assignments and Cable Specifications149
Pin Assignment149
Counterplug149
Cable Type and Configuration149
Table 47: Pin Assignment: PROFIBUS-DP Interface149
Termination and Bus Terminating Resistors150
Figure 28: PROFIBUS-DP Interface: Connection with External Terminating Resistors150
Ethercat151
Product Description151
Characteristics of the Ethercat Technology Module151
Technical Data152
Figure 29: Ethercat Module: Front View152
Table 48: Technical Data: Ehtercat Module: Ambient Conditions, Dimensions and Weight152
Table 49: Display Elements152
Table 50: Signal Level and Differential Voltage153
Figure 30: Servo Positioning Controller with Integrated Technology Module154

ITEM C 1-Series - Page 18

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