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ITEM
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C 3-Series
ITEM C 3-Series User Manual
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Functional safety technology
Page
66
6.2
Inte
grate
d sa
fety te
chnol
ogy (sc
hema
tic re
prese
ntati
on)
Safety module FSM 2.0
2
6
Mains
L1
L2
L3
Filter + rectifier
DC bus circuit
Inverter
Synchronus machine
Shaft
encoder
Angle
Motor speed
Current
DC bus circuit
voltage
Control signals
Circuit breaker
Signal processing + control
Control module
Communication
Fieldbus
I/Os
digital,
analogue
Parameterisation
Diagnostics
Set values / actual values
Communication
Fig
ure
6
:
Schematic rep
resentation of the
integrated safety technology
65
67
Table of Contents
Default Chapter
4
Table of Contents
4
1 General
15
Documentation
15
Scope of Supply
16
Table 1: Scope of Supply
16
Table 2: Connector Set: POWER Connector
16
Table 3: Connector Set: DSUB Connector
16
Table 4: Connector Set: Shield Connector
16
2 Safety Notes for Electrical Drives and Controllers
17
Symbols
17
General Notes
18
Hazards Resulting from Misuse
20
Safety Instructions
21
General Safety Instructions
21
Safety Notes for Assembly and Maintenance
23
Protection against Contact with Electrical Parts
25
Protection against Electric Shock by Way of Protective Extra-Low Voltage (PELV)26
26
Protection against Dangerous Movements
26
Protection against Contact with Hot Parts
27
Protection During the Handling and Installation of the Devices
28
3 Product Description
29
General
29
Figure 1: Type Key
29
Power Supply
32
Three-Phase AC Power Supply
32
Switch-On Behaviour
32
DC Bus Circuit Linking, DC Supply
32
DC Bus Circuit Linking
32
DC Supply
32
Mains Fuse
32
Brake Chopper
33
Communication Interfaces
33
Serial Interface [X5]
33
USB Interface [X19]
34
UDP Interface [X18]
34
CAN Interface [X4]
34
Technology Module: Profibus
35
Technology Module: Ethercat
35
I/O Functions and Device Control
35
4 Technical Data
36
General Technical Data
36
Table 5: Technical Data: Ambient Conditions and Qualification
36
Table 6: Technical Data: Dimensions and Weight
36
Control Elements and Display Elements
37
Table 7: Technical Data: Cable Specifications
37
Table 8: Technical Data: Motor Temperature Monitoring System
37
Table 9: Display Elements and RESET Button
37
Power Supply [X9]
38
Table 10: Technical Data: Power Data [X9]
38
Table 11: Technical Data: Internal Braking Resistor [X9]
38
Table 12: Technical Data: External Braking Resistor [X9]
38
Motor Connector [X6]
39
Table 13: Technical Data: Motor Connector [X6]
39
Current Derating
40
Table 14: Controller C 3-05: Rated Current Values for a Blocked or Slow-Running Motor
40
Table 15: Controller C 3-05: Rated Current Values for a Rotating Motor
40
Table 16: Controller C 3-10: Rated Current Values for a Blocked or Slow-Running Motor
42
Table 17: Controller C 3-10: Rated Current Values for a Rotating Motor
43
Angle Encoder Connector [X2A] and [X2B]
44
Resolver Connector [X2A]
45
Table 18: Technical Data: Resolver [X2A]
45
Table 19: Technical Data: Resolver Interface [X2A]
45
Encoder Connector [X2B]
46
Table 20: Technical Data: Encoder Evaluation [X2B]
46
Communication Interfaces
48
Rs232 [X5]
48
Usb [X19]
48
Ethernet [X18]
48
CAN Bus [X4]
48
SD/MMC Card
48
Table 21: Technical Data: RS232 [X5]
48
Table 22: Technical Data: USB [X19]
48
Table 23: Technical Data: Ethernet [X18]
48
Table 24: Technical Data: CAN Bus [X4]
48
I/O Interface [X1]
49
Table 26: Technical Data: Digital Inputs and Outputs [X1]
49
Incremental Encoder Input [X10]
50
Table 27: Technical Data: Analogue Inputs and Outputs [X1]
50
Table 28: Technical Data: Incremental Encoder Input [X10]
50
Incremental Encoder Output [X11]
51
Table 29: Technical Data: Incremental Encoder Output [X11]
51
5 Function Overview
52
Motors
52
Synchronous Servomotors
52
Linear Motors
52
Functions of the Item Servo Positioning Controller C 3-Series
53
Compatibility
53
Pulse Width Modulation (PWM)
53
Figure 2: Control Structure of the Item C 3-Series
53
Setpoint Management
54
Torque-Controlled Mode
54
Speed-Controlled Mode
55
Torque-Limited Speed Control
55
Synchronisation with External Clock Signals
55
Load Torque Compensation in the Case of Vertical Axes
55
Positioning and Position Control
55
5.2.10 Synchronisation, Electronic Gear Unit
56
5.2.11 Brake Management
56
Positioning Control
57
Overview
57
Relative Positioning
58
Absolute Positioning
58
Motion Profile Generator
58
Homing
58
Figure 3: Motion Profiles of the Item Servo Positioning Controller C 3-Series
58
Positioning Sequences
59
Figure 4: Path Program
59
Optional Stop Input
60
Contouring Control with Linear Interpolation
60
Figure 5: Linear Interpolation between Two Data Values
60
Time-Synchronised Multi-Axis Positioning
61
6 Functional Safety Technology
62
General
62
DIP Switch
63
Table 31: Overview of the DIP Switch Functionality
63
Assignment of the DIP Switch
64
Table 32: Fieldbus-Specific Assignment of the DIP Switches
65
Integrated Safety Technology (Schematic Representation)
66
Figure 6: Schematic Representation of the Integrated Safety Technology
66
Module Variants
67
FBA Module
67
Figure 7: FBA Module: Front View
67
FSM 2.0 - STO (Safe Torque Off)
68
7 Mechanical Installation
69
Important Notes
69
Figure 8: Item Servo Positioning Controller C 3-Series: Installation Space
70
Device View
71
Figure 9: Item Servo Positioning Controller C 3-10: Front View
71
Figure 10: Item Servo Positioning Controller C 3-05: View from above
72
Figure 11: Item Servo Positioning Controller C 3-05: View from below
72
Installation
73
Figure 12: Item Servo Positioning Controller C 3-Series: Mounting Plate
73
8 Electrical Installation
74
Connector Configuration
74
Figure 13: Connection to the Power Supply and Motor
74
Item C 3-Series - Complete System
75
Figure 14: Complete Set-Up of the Item C 3-Series with a Motor and PC
76
Connector: Power Supply [X9]
77
Configuration on the Device [X9]
77
Mating Connector [X9]
77
Pin Assignment [X9]
78
Cable Type and Configuration [X9]
78
Table 33: Pin Assignment [X9]
78
Connection Notes [X9]
79
Figure 15: Power Supply [X9]
79
Table 34: Pin-And-Socket Connector [X9]: External Braking Resistor
79
Connector: Motor [X6]
80
Configuration on the Device [X6]
80
Mating Connector [X6]
80
Pin Assignment [X6]
80
Table 35: Pin Assignment [X6]
80
Cable Type and Configuration [X6]
81
Connection Notes [X6]
81
Figure 16: Motor Connector [X6]
81
Figure 17: Connecting a Holding Brake with a High Current Demand (> 2 A) to the Device
82
Connector: I/O Communication [X1]
83
Figure 18: Basic Circuit Diagram of Connector [X1]
84
Configuration on the Device [X1]
85
Mating Connector [X1]
85
Pin Assignment [X1]
86
Table 36: Pin Assignment: I/O Communication [X1]
86
Cable Type and Configuration [X1]
87
Connection Notes [X1]
87
Connector: Resolver [X2A]
88
Configuration on the Device [X2A]
88
Mating Connector [X2A]
88
Pin Assignment [X2A]
88
Table 37: Pin Assignment [X2A]
88
Cable Type and Configuration [X2A]
89
Connection Notes [X2A]
89
Figure 19: Pin Assignment: Resolver Connector [X2A]
89
Connector: Encoder [X2B]
90
Configuration on the Device [X2B]
90
Mating Connector [X2B]
90
Pin Assignment [X2B]
91
Table 38: Pin Assignment: Analogue Incremental Encoder - Option [X2B]
91
Table 39: Pin Assignment: Incremental Encoder with a Serial Interface (E.g. Endat, HIPERFACE) - Option [X2B]
92
Cable Type and Configuration [X2B]
93
Table 40: Pin Assignment: Digital Incremental Encoder - Option [X2B]
93
Connection Notes [X2B]
94
Figure 20: Pin Assignment: Analogue Incremental Encoder - Option [X2B]
94
Figure 21: Pin Assignment: Incremental Encoder with a Serial Interface (E.g. Endat, HIPERFACE) - Option [X2B]
94
Figure 22: Pin Assignment: Digital Incremental Encoder - Option [X2B]
95
Connector: Incremental Encoder Input [X10]
96
Configuration on the Device [X10]
96
Mating Connector [X10]
96
Pin Assignment [X10]
96
Table 41: Pin Assignment [X10]: Incremental Encoder Input
96
Cable Type and Configuration [X10]
97
Connection Notes [X10]
97
Figure 23: Pin Assignment [X10]: Incremental Encoder Input
97
Connector: Incremental Encoder Output [X11]
98
Configuration on the Device [X11]
98
Mating Connector [X11]
98
Pin Assignment [X11]
98
Table 42: Pin Assignment [X11]: Incremental Encoder Output
98
Cable Type and Configuration [X11]
99
Connection Notes [X11]
99
Figure 24: Pin Assignment [X11]: Incremental Encoder Output
99
Connector: CAN Bus [X4]
100
Configuration on the Device [X4]
100
Mating Connector [X4]
100
Pin Assignment [X4]
100
Table 43: Pin Assignment CAN Bus [X4]
100
Cable Type and Configuration [X4]
101
Connection Notes [X4]
101
Figure 25: CAN Bus Cabling Example
101
Figure 26: Integrated CAN Terminating Resistor
102
Connector: RS232/COM [X5]
103
Configuration on the Device [X5]
103
Mating Connector [X5]
103
Pin Assignment [X5]
103
Table 44: Pin Assignment RS232 Interface [X5]
103
Cable Type and Configuration [X5]
104
Connection Notes [X5]
104
Figure 27: Pin Assignment RS232 Null Modem Cable [X5]
104
Connector: USB [X19]
105
Configuration on the Device [X19]
105
Mating Connector [X19]
105
Usb [X19]
105
Cable Type and Configuration [X19]
105
Figure 28: Pin Assignment USB Interface [X19], Front View
105
Table 45: Pin Assignment USB Interface [X19]
105
SD/MMC Card
106
8.13.1 Supported Card Types
106
8.13.2 Supported Functions
106
8.13.3 Supported File Systems
106
8.13.4 File Names
106
8.13.5 Pin Assignment SD/MMC Card
107
Figure 29: Pin Assignment: SD/MMC Card
107
Table 46: Pin Assignment: SD Card
107
Table 47: Pin Assignment: MMC Card
107
8.13.6 BOOT-DIP Switch
108
Notes Concerning the Safe and EMC-Compliant Installation
109
8.14.1 Definitions and Terms
109
8.14.2 General Information on EMC
109
8.14.3 EMC Areas: First and Second Environment
109
8.14.4 EMC-Compliant Cabling
110
Table 48: EMC Requirements: First and Second Environment
110
8.14.5 Operation with Long Motor Cables
111
8.14.6 ESD Protection
112
9 Additional Requirements to be Fulfilled by the Servo Positioning Controllers for UL Approval
113
Mains Fuse
113
Wiring Requirements and Environmental Conditions
113
Motor Temperature Sensor
113
10 Start-Up
114
General Connection Notes
114
Tools/Material
114
Connecting the Motor
114
Connecting the Item Servo Positioning Controller C 3-Series to the Power Supply
115
Connecting the PC (Serial Interface)
115
Connecting the PC (USB Interface, Alternative)
115
Operability Check
115
11 Service Functions and Error Messages
116
Protection and Service Functions
116
11.1.1 Overview
116
11.1.2 Phase and Mains Power Failure Detection
116
11.1.3 Overcurrent and Short-Circuit Monitoring
117
11.1.4 Overvoltage Monitoring of the DC Bus Circuit
117
11.1.5 Temperature Monitoring of the Heat Sink
117
11.1.6 Monitoring of the Motor
117
11.1.7 I²T Monitoring
117
11.1.8 Power Monitoring of the Brake Chopper
118
11.1.9 Start-Up Status
118
11.1.10 Rapid Discharge of the DC Bus Circuit
118
11.1.11 Operating Hours Counter
118
Operating Mode and Error Messages
119
11.2.1 Operating Mode and Error Indication
119
Table 49: Operating Mode and Error Indication
119
11.2.2 Error Messages
120
Table 50: Error Messages
120
12 Technology Modules
153
PROFIBUS-DP Interface
153
Product Description
153
Technical Data
153
Table 51: Technical Data: PROFIBUS-DP Interface: Ambient Conditions, Dimensions, and Weight
153
Figure 30: PROFIBUS-DP Interface: Front View
154
Table 52: Technical Data: PROFIBUS-DP Interface: Interfaces and Communication
154
Pin Assignment and Cable Specifications
155
Pin Assignment
155
Mating Connector
155
Cable Type and Configuration
155
Table 53: Pin Assignment: PROFIBUS-DP Interface
155
Termination and Bus Terminating Resistors
156
Figure 31: PROFIBUS-DP Interface: Connection with External Terminating Resistors
156
Ethercat
157
Product Description
157
Characteristics of the Ethercat Technology Module
157
Technical Data
158
Display Elements
158
Figure 32: Ethercat Module: Front View
158
Table 54: Technical Data: Ethercat Module: Ambient Conditions, Dimensions, and Weight
158
Table 55: Display Elements
158
Ethercat Interface
159
Table 56: Signal Level and Differential Voltage
159
General Installation Notes for Technology Modules
160
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ITEM C 3-Series Specifications
General
Brand
ITEM
Model
C 3-Series
Category
Controller
Language
English
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ITEM C 1-Series
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