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ITEM C 3-Series User Manual

ITEM C 3-Series
160 pages
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item Industrietechnik GmbH Telephone: +49-(0)212-6580-0
Friedenstraße 107-109 Fax: +49-(0)212-6580-310
42699 Solingen
E-mail: info@item24.com
Germany
http://www.item24.com
Product Manual
item Servo Positioning Controller C 3-Series
designed for Functional Safety

Table of Contents

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ITEM C 3-Series Specifications

General IconGeneral
CategoryController
Operating Voltage3.3V
Analog Input Pins12
Operating Temperature-40°C to +85°C
Communication InterfacesUART, SPI, I2C, USB

Summary

Product Manual

item Servo Positioning Controller C 3-Series

Product manual for item Servo Positioning Controller C 3-Series.

Translation of the original instructions

Copyrights

Trademarks

Revision Information

1 General

1.1 Documentation

Information regarding the product manual and other related manuals.

1.2 Scope of supply

Details the items included in the standard scope of supply.

2 Safety notes for electrical drives and controllers

2.1 Symbols

Explanation of symbols used for warnings and information.

2.2 General notes

General safety precautions and responsibilities for operation.

2.3 Hazards resulting from misuse

Identifies potential dangers from incorrect use of the device.

2.4 Safety instructions

Comprehensive safety guidelines for device operation and installation.

2.4.1 General safety instructions

Essential safety guidelines for general operation and setup.

2.4.2 Safety notes for assembly and maintenance

Crucial safety advice for installation, maintenance, and repair tasks.

2.4.3 Protection against contact with electrical parts

Measures to prevent injury from contact with electrical components.

2.4.4 Protection against electric shock by way of protective extra-low voltage (PELV)

Guidance on safety related to extra-low voltage (PELV) protection.

2.4.5 Protection against dangerous movements

Safety measures to prevent injury from unintended motor movements.

2.4.6 Protection against contact with hot parts

Precautions for avoiding burns from hot device surfaces.

2.4.7 Protection during the handling and installation of the devices

Safety instructions for safe handling and installation of the equipment.

3 Product description

3.1 General

Overview of the item Servo Positioning Controller C Series features.

3.2 Power supply

Details on the three-phase AC power input and its characteristics.

3.2.1 Three-phase AC power supply

Details on the three-phase AC power input and its characteristics.

3.2.2 DC bus circuit linking, DC supply

Information on connecting DC bus circuits and DC supply options.

3.2.3 Mains fuse

Specification for the required mains fuse or circuit breaker.

3.3 Brake chopper

Explanation of the integrated brake chopper and braking resistor functionality.

3.4 Communication interfaces

Overview of the device's communication interfaces and their functions.

3.4.1 Serial interface [X5]

Details on the RS232/RS485 serial interface for parameterization.

3.4.2 USB interface [X19]

Information on the USB interface for PC communication and control.

3.4.3 UDP interface [X18]

Details on the UDP interface for Ethernet fieldbus system connection.

3.4.4 CAN interface [X4]

Information on the CANopen interface and application profile.

3.4.5 Technology module: Profibus

Description of the PROFIBUS-DP technology module and its functions.

3.4.6 Technology module: EtherCAT

Details on the EtherCAT technology module for fieldbus connection.

3.4.7 I/O functions and device control

Overview of digital and analogue I/O functions and device control capabilities.

4 Technical data

4.1 General technical data

General technical specifications including ambient conditions and certifications.

4.2 Control elements and display elements

Description of front panel LEDs, seven-segment display, and reset button.

4.3 Power supply [X9]

Technical data related to the power supply connector.

4.4 Motor connector [X6]

Technical data related to the motor connector.

4.4.1 Current derating

Explanation of current derating factors for the servo positioning controller.

4.5 Angle encoder connector [X2A] and [X2B]

Information on angle encoder connectors and their supported types.

4.5.1 Resolver connector [X2A]

Pin assignment and technical data for the resolver connector.

4.5.2 Encoder connector [X2B]

Pin assignment and technical data for encoder connectors.

4.6 Communication interfaces

Technical data for various communication interfaces.

4.6.1 RS232 [X5]

Technical data for the RS232 serial communication interface.

4.6.2 USB [X19]

Technical data for the USB interface.

4.6.3 Ethernet [X18]

Technical data for the Ethernet interface.

4.6.4 CAN bus [X4]

Technical data for the CAN bus interface.

4.6.5 SD/MMC card

Technical data for SD/MMC card functionality.

4.6.6 I/O interface [X1]

Technical data for digital and analogue I/O interface.

4.6.7 Incremental encoder input [X10]

Technical data for the incremental encoder input.

4.6.8 Incremental encoder output [X11]

Technical data for the incremental encoder output.

5 Function overview

5.1 Motors

Description of motor types supported by the controller.

5.1.1 Synchronous servomotors

Description of synchronous servomotors used with the controller.

5.1.2 Linear motors

Suitability of the controller for linear drive applications.

5.2 Functions of the item Servo Positioning Controller C 3-Series

Overview of the controller's core functions and capabilities.

5.2.1 Compatibility

Comparison of characteristics with previous item C Series models.

5.2.2 Pulse width modulation (PWM)

Explanation of PWM control and modulation types.

5.2.3 Setpoint management

Configuration of setpoints for torque and speed control modes.

5.2.4 Torque-controlled mode

Details on operating the controller in torque-controlled mode.

5.2.5 Speed-controlled mode

Explanation of the speed-controlled mode and its parameters.

5.2.6 Torque-limited speed control

Functionality of torque-limited speed control operation.

5.2.7 Synchronisation with external clock signals

How to synchronise the device with external clock signals.

5.2.8 Load torque compensation in the case of vertical axes

Compensation for load torque in vertical axis applications.

5.2.9 Positioning and position control

Operation of the controller in positioning mode with position control.

5.2.10 Synchronisation, electronic gear unit

Using the controller for synchronization and electronic gear unit functions.

5.2.11 Brake management

Control and operation of the holding brake by the controller.

5.3 Positioning control

Detailed explanation of the positioning control capabilities.

5.3.1 Overview

General overview of the positioning control functionality.

5.3.2 Relative positioning

Explanation of relative positioning methods and applications.

5.3.3 Absolute positioning

Details on absolute positioning processes and requirements.

5.3.4 Motion profile generator

Description of motion profiles like time-optimal and jerk-limited.

5.3.5 Homing

Procedures and methods for device homing operations.

5.3.6 Positioning sequences

Creating and executing sequences of position sets.

5.3.7 Optional stop input

Functionality of the optional stop input for interrupting positioning.

5.3.8 Contouring control with linear interpolation

Using linear interpolation for contouring control in multi-axis applications.

5.3.9 Time-synchronised multi-axis positioning

Enabling simultaneous movements for multi-axis applications via clock sync.

6 Functional safety technology

6.1 General

Introduction to functional safety and its importance in automation.

6.1.1 DIP switch

Overview of the DIP switch functionality for fieldbus parameterization.

6.1.2 Assignment of the DIP switch

Mapping DIP switch positions to fieldbus parameter functions.

6.2 Integrated safety technology (schematic representation)

Schematic diagram of the integrated safety technology system.

6.3 Module variants

Description of available module variants for the system.

6.3.1 FBA module

Description and function of the Fieldbus Activation Module (FBA).

6.3.2 FSM 2.0 – STO (Safe Torque Off)

Information on the FSM 2.0 STO safety function.

7 Mechanical installation

7.1 Important notes

Key considerations and guidelines for mechanical installation.

7.2 Device view

Front view illustration and labeling of the device.

7.3 Installation

Instructions for mounting the servo positioning controller.

8 Electrical installation

8.1 Connector configuration

Overview of connectors for power supply, motor, and feedback.

8.2 item C 3-Series – complete system

Diagram and components for a complete system setup.

8.3 Connector: power supply [X9]

Details and configuration for the power supply connector.

8.3.1 Configuration on the device [X9]

Device configuration for the power supply connector.

8.3.2 Mating connector [X9]

Details of the mating connector for the power supply.

8.3.3 Pin assignment [X9]

Pin assignment details for the power supply connector.

8.3.4 Cable type and configuration [X9]

Recommended cable types and configurations for the power supply.

8.3.5 Connection notes [X9]

Important notes for connecting the power supply connector.

8.4 Connector: motor [X6]

Details and configuration for the motor connector.

8.4.1 Configuration on the device [X6]

Device configuration for the motor connector.

8.4.2 Mating connector [X6]

Details of the mating connector for the motor.

8.4.3 Pin assignment [X6]

Pin assignment details for the motor connector.

8.4.4 Cable type and configuration [X6]

Recommended cable types and configurations for the motor.

8.4.5 Connection notes [X6]

Important notes for connecting the motor connector.

8.5 Connector: I/O communication [X1]

Details and configuration for the I/O communication connector.

8.5.1 Configuration on the device [X1]

Device configuration for the I/O communication connector.

8.5.2 Mating connector [X1]

Details of the mating connector for I/O communication.

8.5.3 Pin assignment [X1]

Pin assignment details for the I/O communication connector.

8.5.4 Cable type and configuration [X1]

Recommended cable types and configurations for I/O communication.

8.5.5 Connection notes [X1]

Important notes for connecting the I/O communication connector.

8.6 Connector: resolver [X2A]

Details and configuration for the resolver connector.

8.6.1 Configuration on the device [X2A]

Device configuration for the resolver connector.

8.6.2 Mating connector [X2A]

Details of the mating connector for the resolver.

8.6.3 Pin assignment [X2A]

Pin assignment details for the resolver connector.

8.6.4 Cable type and configuration [X2A]

Recommended cable types and configurations for the resolver.

8.6.5 Connection notes [X2A]

Important notes for connecting the resolver connector.

8.7 Connector: encoder [X2B]

Details and configuration for the encoder connector.

8.7.1 Configuration on the device [X2B]

Device configuration for the encoder connector.

8.7.2 Mating connector [X2B]

Details of the mating connector for the encoder.

8.7.3 Pin assignment [X2B]

Pin assignment details for the encoder connector.

8.7.4 Cable type and configuration [X2B]

Recommended cable types and configurations for the encoder.

8.7.5 Connection notes [X2B]

Important notes for connecting the encoder connector.

8.8 Connector: Incremental encoder input [X10]

Details and configuration for the incremental encoder input.

8.8.1 Configuration on the device [X10]

Device configuration for the incremental encoder input connector.

8.8.2 Mating connector [X10]

Details of the mating connector for the incremental encoder input.

8.8.3 Pin assignment [X10]

Pin assignment details for the incremental encoder input.

8.8.4 Cable type and configuration [X10]

Recommended cable types and configurations for the input.

8.8.5 Connection notes [X10]

Important notes for connecting the incremental encoder input.

8.9 Connector: Incremental encoder output [X11]

Details and configuration for the incremental encoder output.

8.9.1 Configuration on the device [X11]

Device configuration for the incremental encoder output connector.

8.9.2 Mating connector [X11]

Details of the mating connector for the incremental encoder output.

8.9.3 Pin assignment [X11]

Pin assignment details for the incremental encoder output.

8.9.4 Cable type and configuration [X11]

Recommended cable types and configurations for the output.

8.9.5 Connection notes [X11]

Important notes for connecting the incremental encoder output.

8.10 Connector: CAN bus [X4]

Details and configuration for the CAN bus connector.

8.10.1 Configuration on the device [X4]

Device configuration for the CAN bus connector.

8.10.2 Mating connector [X4]

Details of the mating connector for the CAN bus.

8.10.3 Pin assignment [X4]

Pin assignment details for the CAN bus connector.

8.10.4 Cable type and configuration [X4]

Recommended cable types and configurations for CAN bus.

8.10.5 Connection notes [X4]

Important notes for connecting the CAN bus.

8.11 Connector: RS232/COM [X5]

Details and configuration for the RS232/COM connector.

8.11.1 Configuration on the device [X5]

Device configuration for the RS232/COM connector.

8.11.2 Mating connector [X5]

Details of the mating connector for RS232/COM.

8.11.3 Pin assignment [X5]

Pin assignment details for the RS232/COM connector.

8.11.4 Cable type and configuration [X5]

Recommended cable types and configurations for RS232/COM.

8.11.5 Connection notes [X5]

Important notes for connecting the RS232/COM connector.

8.12 Connector: USB [X19]

Details and configuration for the USB connector.

8.12.1 Configuration on the device [X19]

Device configuration for the USB connector.

8.12.2 Mating connector [X19]

Details of the mating connector for the USB.

8.12.3 USB [X19]

Pin assignment details for the USB connector.

8.12.4 Cable type and configuration [X19]

Recommended cable types and configurations for USB.

8.13 SD/MMC card

Information and specifications for SD/MMC card usage.

8.13.1 Supported card types

List of supported SD/MMC card types.

8.13.2 Supported functions

Functions supported by SD/MMC cards.

8.13.3 Supported file systems

Supported file systems for SD/MMC cards.

8.13.4 File names

Rules for file and directory naming on SD/MMC cards.

8.13.5 Pin assignment SD/MMC card

Pin assignment details for SD and MMC cards.

8.13.6 BOOT-DIP switch

Function of the BOOT-DIP switch for firmware downloads.

8.14 Notes concerning the safe and EMC-compliant installation

Guidelines for safe and EMC-compliant installation of the system.

8.14.1 Definitions and terms

Definitions of electromagnetic compatibility (EMC) and interference.

8.14.2 General information on EMC

Overview of factors affecting EMC performance in drive systems.

8.14.3 EMC areas: first and second environment

Classification of EMC environments and related requirements.

8.14.4 EMC-compliant cabling

Guidelines for setting up EMC-compliant drive system cabling.

8.14.5 Operation with long motor cables

Recommendations for operating with long motor cables and filters.

8.14.6 ESD protection

Measures to prevent damage from electrostatic discharge (ESD).

9 Additional requirements to be fulfilled by the servo positioning controllers for UL approval

9.1 Mains fuse

UL approval requirements for the mains fuse.

9.2 Wiring requirements and environmental conditions

UL approval requirements for wiring and environment.

9.3 Motor temperature sensor

UL approval requirements for motor temperature sensors.

10 Start-up

10.1 General connection notes

Essential EMC-compliant notes for connecting cables.

10.2 Tools/material

List of necessary tools and materials for setup.

10.3 Connecting the motor

Step-by-step instructions for connecting the motor.

10.4 Connecting the item Servo Positioning Controller C 3-Series to the power supply

Instructions for connecting the device to the main power supply.

10.5 Connecting the PC (serial interface)

Steps for connecting the PC using the serial interface.

10.6 Connecting the PC (USB interface, alternative)

Steps for connecting the PC using the USB interface.

10.7 Operability check

Procedure for checking the device's operability after installation.

11 Service functions and error messages

11.1 Protection and service functions

Overview of the controller's protection and service functions.

11.1.1 Overview

Overview of the controller's sensor system and monitoring functions.

11.1.2 Phase and mains power failure detection

Detection of phase and mains power failures in three-phase operation.

11.1.3 Overcurrent and short-circuit monitoring

Monitoring for overcurrent and short circuits to protect the output stage.

11.1.4 Overvoltage monitoring of the DC bus circuit

Monitoring for overvoltage in the DC bus circuit and power output stage shutdown.

11.1.5 Temperature monitoring of the heat sink

Monitoring the temperature of the power output stage heat sink.

11.1.6 Monitoring of the motor

Protective functions for monitoring the motor and shaft encoder.

11.1.7 I²t monitoring

System for limiting power loss in the output stage and motor.

11.1.8 Power monitoring of the brake chopper

Power monitoring system for the internal braking resistor.

11.1.9 Start-up status

Information on device status and parameterization requirements.

11.1.10 Rapid discharge of the DC bus circuit

Procedure for rapid discharge of the DC bus circuit upon power failure.

11.1.11 Operating hours counter

Functionality and display of the integrated operating hours counter.

11.2 Operating mode and error messages

Information on operating modes and error indications.

11.2.1 Operating mode and error indication

Description of seven-segment display indications for operating modes and errors.

11.2.2 Error messages

Overview of error messages, their codes, and corresponding measures.

12 Technology modules

12.1 PROFIBUS-DP interface

Description and technical data of the PROFIBUS-DP interface module.

12.1.1 Product description

Introduction to the PROFIBUS-DP interface for fieldbus connection.

12.1.2 Technical data

Technical specifications for the PROFIBUS-DP interface module.

12.1.3 Pin assignment and cable specifications

Pin assignment and cable details for the PROFIBUS-DP interface.

12.1.3.1 Pin assignment

Pin assignment details for the PROFIBUS-DP interface connector.

12.1.3.2 Mating connector

Details of the mating connector for the PROFIBUS-DP interface.

12.1.3.3 Cable type and configuration

Recommended cable types and configurations for PROFIBUS-DP.

12.1.4 Termination and bus terminating resistors

Information on bus termination and required resistors for PROFIBUS.

12.2 EtherCAT

Description and technical data of the EtherCAT technology module.

12.2.1 Product description

Introduction to the EtherCAT technology module for fieldbus communication.

12.2.2 Characteristics of the EtherCAT technology module

Key features and characteristics of the EtherCAT module.

12.2.3 Technical data

Technical specifications for the EtherCAT module.

12.2.4 Display elements

Description of the LEDs used for indicating operating states.

12.2.5 EtherCAT interface

Details on the EtherCAT interface signal levels.

12.3 General installation notes for technology modules

General safety and installation guidelines for technology modules.

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