Installation Instructions

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Instructions

MC 5004 P STO

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Version:

3rd edition, 5.03.2020 Copyright

by Dr. Fritz Faulhaber GmbH & Co. KG Daimlerstr. 23 / 25 · 71101 Schönaich

No part of this description may be duplicated, reproduced, stored in an information system or processed or

transferred in any other form without prior express written permission of Dr. Fritz Faulhaber GmbH & Co. KG.

This document has been prepared with care.

Dr. Fritz Faulhaber GmbH & Co. KG cannot accept any liability for any errors in this document or for the consequences of such errors. Equally, no liability can be accepted for direct or consequential damages resulting from improper use of the equipment.

The relevant regulations regarding safety engineering and interference suppression as well as the requirements specified in this document are to be noted and followed when using the software.

Subject to change without notice.

The respective current version of this technical manual is available on FAULHABER's internet site:

www.faulhaber.com

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1 About this document ... 5

1.1 Validity of this document ... 5

1.2 Associated documents ... 5

1.3 Using this document ... 5

1.4 List of abbreviations ... 6

1.5 Symbols and designations ... 7

2 Safety ... 8

2.1 Intended use ... 8

2.2 Safety instructions ... 9

2.2.1 Dangers in the event of damages and changes... 9

2.2.2 Correct installation and commissioning ... 10

2.2.3 Heat development ... 10

2.3 Environmental conditions ... 11

2.4 Requirements on the higher-level control ... 11

2.5 EC directives on product safety ... 12

3 Product description ... 13

3.1 General product description ... 13

3.2 Product information ... 15

3.3 Technical data ... 16

3.4 Product variants ... 17

3.4.1 Controller PCBs... 17

3.4.1.1 Standard PCB... 17

3.4.1.2 EtherCAT PCB ... 18

3.4.1.3 State machine and start routine ... 20

3.4.2 Motherboard... 23

4 Installation ... 25

4.1 Mounting ... 25

4.1.1 Mounting instructions ... 25

4.1.2 Installing the Motion Controller PCB on the motherboard ... 26

4.1.3 Installing the Motion Controller PCB in the top-hat-rail housing ... 27

4.2 Electrical connection ... 28

4.2.1 Notes on the electrical connection ... 28

4.2.2 Drive connections... 29

4.2.3 Screening ... 30

4.2.4 Connection of the power supply ... 31

4.2.4.1 Power supply... 31

4.2.5 Connector pin assignment... 32

4.2.5.1 Pin assignment of the X100 connector strip of the Motion Controller ... 32

4.2.5.2 Pin assignment of the motherboard (motor side) ... 34

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4.3 Information on initial commissioning ... 54

5 Maintenance and diagnostics ... 55

5.1 Maintenance tasks ... 55

5.2 Diagnostics ... 55

5.2.1 Standard PCB... 55

5.2.2 EtherCAT PCB ... 56

5.2.3 Self-test... 57

5.3 Troubleshooting ... 57

6 Decommissioning and disposal ... 58

7 Accessories ... 59

8 Warranty ... 60

9 Additional documents ... 61

9.1 Data sheet ... 61

9.2 Declaration of Incorporation ... 63

9.3 Declaration of Conformity ... 64

9.4 EC type-examination certificate ... 67

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1 About this document

1.1 Validity of this document

This document contains the information necessary for the intended use of the MC 5004 P STO series.

This document is intended for use by trained experts authorised to perform installation and electrical connection of the product.

All data in this document relate to the standard versions of the series listed above.

1.2 Associated documents

The following documents are part of these installation instructions. They can be down- loaded in pdf format from the web page www.faulhaber.com/manuals/.

If it is not possible to download the documents, please contact us (see reverse of this document).

You can find the data sheet for Motion Controller series MC 5004 P STO in chap. 9.1, p. 61.

1.3 Using this document

 Read the document carefully before undertaking configuration, in particular chapter

"Safety".

 Retain the document throughout the entire working life of the product.

 Keep the document accessible to the operating and, if necessary, maintenance person- nel at all times.

 Pass the document on to any subsequent owner or user of the product.

Document Description

Motion Manager 6 Operating instructions for FAULHABER Motion Manager PC software

Quick start guide Description of the first steps for commissioning and operation of FAULHABER Motion Controllers

Drive functions Description of the operating modes and functions of the drive Accessories manual Description of the accessories

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1.4 List of abbreviations

Abbreviation Meaning

AC Alternating Current

AES Absolute encoder

AGND Analogue Ground

AnIn Analogue Input

BLDC Brushless DC-motor CAN Controller Area Network

CAN_L CAN-Low

CAN_H CAN-High

CLK Clock

CS Chip Select

DC Direct Current

DigIn Digital input DigOut Digital output DIP Dual In-Line Package EMC Electromagnetic compatibility ESD Electrostatic discharge

ET EtherCAT (Ethernet for Control Automation Technology)

GND Ground

I/O Input/Output

LA Status LED EtherCAT

LM Linear Motor

MC Motion Controller

Mot Motor

n.c. not connected

OSSD Output Signal Switching Device PELV Protective Extra Low Voltage PWM Pulse Width Modulation

RxD Receive data

SGND Signal ground

STO Safe Torque Off

TxD Transmit data

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1.5 Symbols and designations

DANGER! DANGER

Danger with high level of risk: if not avoided, death or serious injury will result.

 Measures for avoidance WARNING! WARNING

Danger with medium level of risk: if not avoided, death or serious injury may result.

 Measures for avoidance CAUTION! CAUTION

Danger with low level of risk: if not avoided, minor or moderate injury may result.

 Measures for avoidance

NOTICE NOTICE

Risk of damage.

 Measures for avoidance

 Pre-requirement for a requested action 1. First step for a requested action

 Result of a step

2. Second step of a requested action

 Result of an action

 Request for a single-step action

Instructions for understanding or optimising the operational procedures

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2 Safety

2.1 Intended use

The Motion Controllers with STO function described here are designed as slaves for control and position tasks in which safe shutdown of the torque is required. When the STO (Safe Torque Off – safe shutdown of the torque) safety function is requested, the outputs for the connected drive are safely switched torque-free.

The Motion Controllers with STO function are suitable for actuating the following motors:

 Linear DC-Servomotors (brushless)

 Brushless DC-Motors

The Motion Controller is not suitable for use in combination with stepper and brushed DC motors.

The Motion Controller is suitable in particular for tasks in the following fields of applica- tion:

 Robotics

 Toolbuilding

 Automation technology

 Industrial equipment and special machine building

 Medical technology

 Laboratory technology

When using the Motion Controllers the following aspects should be observed:

 The Motion Controller contains electronic components and should be handled in accordance with the ESD regulations.

 Do not use the Motion Controller in environments where it will come into contact with water, chemicals and/or dust, nor in explosion hazard areas.

 The Motion Controller should be operated only within the limits specified in these installation instructions.

 Please ask the manufacturer for information about use under individual special environmental conditions.

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2.2 Safety instructions

In addition to the safety risks described in these installation instructions, machine-specific dangers could arise that cannot be foreseen by the manufacturer of the Motion Controller (e.g., risk of injury from driven components). The manufacturer of the machine in which the Motion Controller is installed must perform a risk analysis in accordance with the regulations applicable to the machine and inform the end user of the residual risks.

2.2.1 Dangers in the event of damages and changes

A defect or damage or change to the Motion Controller can impair its safety functions. If safety functions are unavailable, the drive can start up unexpectedly or shutdown of the torque may be ineffective. Depending on the use of the Motion Controller, this can lead to severe or fatal injury.

 Do not start up a machine with a defective or damaged Motion Controller.

 Appropriately mark a defective or damaged Motion Controller.

 Do not replace defective or damaged components of the Motion Controller.

 Make no changes (modifications, repairs) to the Motion Controller.

 Have loose or defective connections immediately replaced by an electrician.

 After replacing a defective or damaged Motion Controller, test and document the correct function of the entire safety circuit.

Electrostatic discharges can damage the electronics.

 Store and transport the Motion Controller in suitable ESD packaging.

 Handle the Motion Controller in compliance with the ESD handling regulations (e.g.

wear an ESD wristband, earth surrounding components).

 During installation, ensure that components in the surroundings cannot be electrostati- cally discharged.

Soiling, foreign bodies, humidity and mechanical influences can damage the electronics.

 Keep foreign bodies away from the electronics.

 Install the Motion Controller in a housing that protects it from mechanical influences and is adapted to the ambient conditions (protection class determination).

Installation and connection work whilst supply voltage is applied at the device can dam- age the electronics.

 Do not insert or withdraw connectors whilst supply voltage is applied at the Motion Controller.

 During all aspects of installation and connection work on the Motion Controller, switch off the power supply.

Incorrect connection of the pins can damage the electronic components.

 Connect the wires as shown in the connection assignment.

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2.2.2 Correct installation and commissioning

Errors during the installation and commissioning of the Motion Controller could impair its safety function. If safety functions are unavailable, the drive can start up unexpectedly or shutdown of the torque may be ineffective. Depending on the use of the Motion Control- ler, this can lead to severe or fatal injury.

 Follow the instructions for installation and commissioning given in these installation instructions exactly.

 Only have work on electrical operating equipment performed by an electrician.

 Do not bypass the safety circuit.

 Do not bypass STO inputs with Performance Level d (PL d) or higher.

 To avoid crosstalk on signal lines, lay the power supply cable separate from the signal cable or take appropriate interference suppression measures.

 During all work on the electrical equipment, observe the 5 safety rules:

a) Disconnect from power

b) Secure against being switched on again c) Check that no voltage is present

d) Ground and short-circuit

e) Cover or block-off adjacent parts that are under voltage

2.2.3 Heat development

Active components may cause the Motion Controller to heat up. If touched, there is a risk of burn- ing.

 Protect the Motion Controller against being touched and cool sufficiently.

 If necessary, affix a suitable warning sign in the immediate vicinity of the controller.

Fig. 1: Suitable warning sign acc. to DIN EN ISO 7010

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2.3 Environmental conditions

 Select the installation location so that clean dry air is available for cooling the Motion Controller.

 Secure the Motion Controller against unauthorised access (e.g., install in a lockable switch cabinet).

 Select the installation location so that the air has unobstructed access to flow around the drive.

 When installed within housings and cabinets take particular care to ensure adequate cooling of the Motion Controller.

 Select a power supply that is within the defined tolerance range.

 Protect the Motion Controller against humidity and wet.

 Protect the Motion Controller against chemical pollutants.

 To store, protect the Motion Controller against dust, humidity and electrostatic charge (e.g., pack in ESD foil).

 Observe technical data (see chap. 3.3, p. 16 and chap. 9.1, p. 61).

2.4 Requirements on the higher-level control

When switching on the Motion Controller, a self-test is performed automatically. The higher-level control must de-energise the Motion Controller and then switch it back on again daily to force the self-test. The internal diagnostics of the Motion Controller monitor the shutdown of the outputs during operation.

To achieve the required safety level SIL 3 acc. to IEC 61800-5-2 / EN 62061, the higher-level control must perform the following diagnostics and tests:

 Evaluate and display the

 error status message

 STO status message

 Monitor the STO signals for

 short-circuit to ground or power supply

 shunt

 line breakage

 hanging (signal/state)

 Interruption

 at the power supply return line

of the functional potential equalization cable

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 Provide indication of a self-test error, e.g., for the following reasons:

 Faulty wiring

 defective cables (cable breakage, loss of contact at the connector, short-circuit, hanging)

If the self-test reports errors, return the Motion Controller to the manufacturer with indication of the error messages.

2.5 EC directives on product safety

 The following EC directives and standards on product safety must be observed.

 If the Motion Controller is being used outside the EU, international, national and regional directives must be also observed.

Machinery Directive (2006/42/EC)

The products described in these installation instructions are electrical components with integrated safety function according to the Machinery Directive. They are therefore to be considered incomplete machines according to the Machinery Directive. Compliance is documented by the Declaration of Incorporation for the product and by the EC Declaration of the Conformity for the safety function.

EMC Directive (2014/30/EU)

The directive concerning electromagnetic compatibility (EMC) applies to all electrical and electronic devices, installations and systems sold to an end user. In addition, CE marking can be undertaken for built-in components according to the EMC Directive. Conformity with the directive is documented in the Declaration of Conformity.

RoHS Directive (2011/65/EU)

The directive restricts the use of certain hazardous materials in electrical and electronic devices. The products described in these installation instructions fall within the scope of this directive. Conformity with the directive is documented in the EC Declaration of Conformity.

WEEE Directive (2012/19/EU)

The directive on the disposal of electrical and electronic devices prescribes the separate col- lection of old electrical and electronic devices. The products described in these installation instructions fall within the scope of this directive.

Applied standards

Various harmonised standards were applied to the products described in these installation The control of the Motion Controller and the executable functions are described in the manuals for the Motion Manager 6 and the drive functions (see chap. 1.2, p. 5).

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3 Product description

3.1 General product description

The products MC 5004 P STO are variants of the FAULHABER Motion Controllers without housing and control either LM or BL motors. The Motion Controllers are configured here via the FAULHABER Motion Manager software (version 6.3 and higher).

The drives can be incorporated into the network by means of the CANopen or EtherCAT field bus interfaces. In smaller installations networking can be performed using the RS232 interface. The Motion Controller operates within the network principally as a slave. Master functionality for controlling other axes is not provided. Alternatively, after initial commissioning by the Motion Manager, the controller can also be operated without any communications interface.

In drive applications, it is often necessary to safely isolate a motor in response to an external event, if, e.g., a protective door is opened or a light curtain is interrupted.

This safe shutdown is realized via the standardized, integrated STO (Safe Torque Off) safety circuit. Isolation is achieved here via two redundant inputs which, if the enabling voltage is lost, interrupt motor actuation and therefore switch the motor to a torque-free state.

Fig. 2: Functional principle

The connected motor is not actively braked in this situation, but is rather switched to a torqueless state. By means of LEDs and status and error message outputs, the current device state is signalled locally and reported to the higher-level control. The state of the inputs is not signalled.

STO IN1

STO IN2

24V GND

STO Device

LED

LED No-Error STO LED Status STO

24V

24V Status

No-Error

1 2

3 4 1

2

3

4 1

2

3 4 1

2

3 4

n

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The products of the MC 5004 P STO series may only be used in combination with brushless DC motors. Unlike brushed DC motors, these always require actuation. If the control signals are interrupted via the safety circuit, they are thereby safely shut off.

The controllers can be plugged into a motherboard via the 50-pin connector strip. FAUL- HABER offers an appropriately approved motherboard as accessory for this purpose.

With the integrated output stage with optimised current measurement, BL and LM motors from the FAULHABER product line from 12 to 32 mm can be controlled.

The following connections are available on the connector strip:

 Communications interfaces

 Common or separate power supplies between motor and controller (When using the motherboard, only shared power supply possible)

 Various inputs and outputs

 Motor phases

 Feedback components such as:

 Digital/analogue Hall sensors

 Incremental encoders with or without line drivers.

Motion Controllers with RS232, CANopen or EtherCAT interfaces can also be operated independently of the communications interface if a pre-programmed function or sequence program has been programmed without digital command controls.

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3.2 Product information

Designation key

Fig. 4: Designation key Type plate

Fig. 5: Type plate

1 Identification number 6500.01717 or 6500.01718

2 Serial number (8 digit): Calendar week (2) and year (2) of manufacture, sequential number (4)

Example: 44170001

Manufactured during calendar week 44 of year 2017 with sequential number 1 3 Firmware version FW XXY

RS: RS232 Serial interface CO: CANopen interface ET: EtherCAT interface

P: PCB version with pin terminals STO: Safe Torque Off

50: Max. power supply 50 V

MC: Motion Controller

04: Max. continuous output current 4 A 50 04 P STO …

MC

6500.10000

FW 03I

SNR 12340002

1 2

3

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3.3 Technical data

Dimensioning limits

Power supply of the electronics

See chap. 9.1, p. 61 Motor power supply (not if using

the motherboard) PWM switching frequency Electronics efficiency

Maximum continuous output current

Maximum peak output current Standby current of the electronics

Operating and storage conditions

Ambient temperature range See chap. 9.1, p. 61 Relative air humidity 5…93 % (non-condensing) Maximum operating altitude 2000 m above sea level Pollution degree 2, acc. to DIN EN 61010

Dimensions and mass Dimensioned drawing

See chap. 9.1, p. 61 Ground

Safety

Safety integrity level SIL 3, acc. to IEC 61800-5-2 / EN 62061

Performance level PL e (with separate switching of the STO inputs), acc. to EN 13849 Outage rate ^a): PFH_D = 4,57 × 10^-10

a) Assumed as the basis of the calculation of the outage rates was a demand rate of 1 per 8 hours Maximum time between the

request of the safe state and the shutdown of the output signals

5 ms

Overvoltage category III, acc. to DIN EN 60664-1 Decisive voltage class DVC A, acc. to DIN EN 61800-5-1

Adjacent circuits require functional insulation (DVC A), basic insulation (DVC B) or electrical separation (DVC C)

Protection class Housings must be suitable for use in the intended environment.

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3.4 Product variants

The following product variants are possible:

The Motion Controller PCBs can be mounted on a motherboard. The FAULHABER motherboard offers space for a Motion Controller PCB.

3.4.1 Controller PCBs

3.4.1.1 Standard PCB

Fig. 6: Isometric (left) and front view (right) of the standard PCB

Tab. 1: Connector overview

Tab. 2: Device status LEDs

Product variant Identification number (catalog number)

MC 5004 P STO RS/CO 6500.01717

MC 5004 P STO ET 6500.01718

Status LED

STO Status LED

USB (X1) Power LED

No-Error LED

Designation Function

USB (X1) Connection of the USB communication

State LED  Green (continuous light): Device active.

 Green (flashing): Device active. However the state machine has not yet reached the Operation Enabled state.

 Red (continuously flashing): The drive has switched to a fault state. The output stage will be switched off or has already been switched off.

 Red (error code): Booting has failed. Please contact FAULHABER Support.

Power LED  Green: Power supply within the permissible range.

 Off: Power supply out of the permissible range.

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Tab. 3: No-Error LED and STO status LED

3.4.1.2 EtherCAT PCB

Fig. 7: Isometric (left) and front view (right) of the plugged-in EtherCAT PCB Tab. 4: Connector overview

No-Error LED STO status LED For states of the STO state machine, ^a)

a) see chap. 3.4.1.3, p. 20

Motor state

Off Off Powerdown Motor is inactive

Off Yellow Error Motor is inactive

Green Yellow STO On Motor is inactive

Green Off STO Off Motor is active

USB (X1) LA

Run LED

Error LED

OUT IN

STO Status LED No-Error LED

Status LED Power LED

IN/OUT Connection of the EtherCAT communication USB (X1) Connection of the USB communication

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Tab. 5: Device LEDs

Tab. 6: No-Error LED and STO status LED

Designation Interface Function

Status LED all  Green (continuous): Device active.

 Green (flashing): Device active. However the state machine has not yet reached the Operation Enabled state.

 Red (continuously flashing): The drive has switched to a fault state. The output stage will be switched off or has already been switched off.

 Red (Error code): Boot procedure failed. Please contact FAULHABER Support.

Power LED all  Green: Power supply within the permissible range.

 Off: Power supply not within the permissible range.

RUN LED EtherCAT  Green (continuous): Connection available. Device is ready for operation.

 Green (flashing): Device is in the Pre-Operational state.

 Green (single flash): Device is in the Safe-Operational state.

 Off: Device is in the Initialisation state.

ERR LED EtherCAT  Red (flashing): Defective configuration.

 Red (single flash): Local error.

 Red (double flash): Watchdog timeout.

 Off: No connection error

LA LED EtherCAT  Green (continuous): No data transfer. Connection to another participant has been established.

 Green (flashing): Data transfer active.

 Off: No data transfer. No connection to another participant.

No-Error LED STO status LED For states of the STO state machine, ^a)

a) see chap. 3.4.1.3, p. 20

Motor state

Off Off Powerdown Motor is inactive

Off Yellow Error Motor is inactive

Green Yellow STO On Motor is inactive

Green Off STO Off Motor is active

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3.4.1.3 State machine and start routine

Fig. 8: States of the STO state machine Tab. 7: Description of the states

State Description

Powerdown  Voltage supply of the safety function is switched off

 Outputs are switched off

 No torque at motor

Error Fault state

 Internal diagnostics of the STO circuit detected an error

 No torque at motor

STO On  STO shutdown is active

 No torque at motor STO Off  STO shutdown is inactive

 Outputs are switched on

 Torque possible at motor

STO-Reset-Pulse START

Powerdown Motor inactive No-Error:

STO status:

Error Motor inactive No-Error LED:

STO status LED:

No-Error LED:

STO status LED:

No-Error LED:

STO status LED:

STO On Motor inactive

STO Off Motor active

Undervoltage/

overvoltage

Undervoltage/

overvoltage STO IN 1 = low

STO IN 2 = low

yes

yes yes

yes

no

no no

no

yes no Undervoltage/

overvoltage

yes no Undervoltage/

overvoltage AND

STO IN 1 = high STO IN 2 = high

AND

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Fig. 9: Signal diagram

The STO function has a two-channel design. Each channel can perform the shutdown of the output signal, i.e., each STO input can independently initiate a shutdown. Execution of the STO function has priority over all other functions, i.e., triggering an STO signal suffices to switch off the output. The user has to take precautions to protect against automatic restart.

After voltage drops or voltage interruptions, the safety function switches to the fault state.

The fault state must be appropriately evaluated via the two STO outputs. After an error, it is only possible to switch back to the operating state after triggering an STO reset pulse. The fault state remains stored until the STO reset pulse is triggered.

The switch-on sequence must be executed daily (see chap. 2.4, p. 11). During this process, the state machine executes the sequence shown in Fig. 8.

No-Error

STO IN 1

STO IN 2

STO Off

SW H OK

STO

No-Error

No-Error STO Off

STO On

No-Error STO IN 1

STO IN 1 SW L OK

STO IN 1

STO IN 2 BED1BED3 BED2

Reset Pulse

STO On (= not STO Off) = Safe state STO 1 input

STO 2 input

STO Off = Motor released

Plausibility check STO 1

Plausibility checkSTO 2

Self-shutdown

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To activate after switching on again, it is mandatory that the following sequence be executed:

1. Powerdown for at least 1000 ms.

 Error state.

2. STO IN 1 = low.

3. STO IN 2 = low.

 STO reset pulse is triggered via the Motion Controller.

STO On state is reached.

4. STO IN 1 = high.

5. STO IN 2 = high.

 STO Off state is reached.

 Drive can be activated.

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3.4.2 Motherboard

100 72max. 245.33

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Fig. 11: Connector overview of the motherboard Tab. 8: Connector overview of the motherboard

X100 (Motion Controller) Connection of the Motion Controller PCB

M1 (motor) Connection of the motor phases

M2 (sensor) Connection of the Hall sensors

M3 (encoder) Connection of an incremental encoder with or without line driver Alternatively an absolute encoder can be connected with or without line driver

M1_1 (motor + sensor) Combi-connection for motor phases and Hall sensors

X2 (RS232) RS232 interface connection

X2_1 (CAN) CANopen interface connection

X3 (I/O) Inputs or outputs for external circuits X5 (power supply) Voltage supply for motor and controller

X6 (STO) Voltage supply and inputs and outputs for Safe Torque Off

RS232 connector (X2) CAN connector (X2_1)

STO connector (X6)

I/O connector (X3)

Power supply connector (X5)

Motor + Sensor connector (M1_1)

Motor connector (M1) Sensor connector (M2) Encoder connector (M3)

Motion Controller connector (X100)

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4 Installation

4.1 Mounting

4.1.1 Mounting instructions

CAUTION! CAUTION

The Motion Controller can become very hot during operation.

 Place a guard against contact and warning notice in the immediate proximity of the controller (see chap. 2.2.3, p. 10).

DANGER! DANGER

Incorrect handling and installation can damage the Motion Controller.

Damage to the Motion Controller can impair its safety functions. If safety functions are unavailable, the drive can start up unexpectedly or shutdown of the torque may be ineffective.

Depending on the use of the Motion Controller, this can lead to severe or fatal injury.

 Observe the safety information in the chap. 2.2.1, p. 9.

 Use suitable fastening material (see chap. 4.1.3, p. 27).

Visual inspection

 After unpacking the Motion Controller, perform and document a visual inspection:

 Motion Controller is undamaged?

 Sticker with serial number is present?

 Pin contacts are OK (not oxidised, not bent)?

DANGER! DANGER

The safety function of the Motion Controller is not ensured if the visual inspection criteria are not satisfied.

If safety functions are unavailable, the drive can start up unexpectedly or shutdown of the torque may be ineffective. Depending on the use of the Motion Controller, this can lead to severe or fatal injury.

 Do not start up the Motion Controller.

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4.1.2 Installing the Motion Controller PCB on the motherboard

Fig. 12: Installing the Motion Controller PCB on the motherboard

NOTICE NOTICE

Incorrect installation can damage the Motion Controller.

 Note orientation of the Motion Controller PCB acc. to Fig. 12.

Mounting:

 Guide the Motion Controller board (1) into the side guide rails (2) and connect to the motherboard (4) using plug connection X100 (3).

3

4 1

2

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4.1.3 Installing the Motion Controller PCB in the top-hat-rail housing

The test setup in Fig. 13 shows an example for a Motion Controller PCB installed in a top- hat-rail housing.

Fig. 13: Example for installation in a top-hat-rail housing 1 Motion Controller PCB

2 Motherboard 3 Top-hat-rail housing

The following components from Phoenix Contact could, for example, be used as a suitable top-hat-rail housing:

Quan- tity

Component designation Manufacturer number

1 UMK BE 45 2970015

1 UMK BE 22,5 2970028

1 UMK BE 11,25 2971535

2 UMK SE 11,25 2970002

2 UMK FE 2970031

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4.2 Electrical connection

4.2.1 Notes on the electrical connection

DANGER! DANGER

Errors during the installation and commissioning of the Motion Controller could impair its safety function.

If safety functions are unavailable, the drive can start up unexpectedly or shutdown of the torque may be ineffective. Depending on the use of the Motion Controller, this can lead to severe or fatal injury.

 Observe the safety information in the chap. 2.2.2, p. 10.

WARNING! WARNING

Threat to health through high-frequency interference.

The Motion Controller can cause high-frequency interference which can affect the function of electronic implants.

 Take appropriate interference suppression measures, particularly during use in residen- tial environments.

NOTICE NOTICE

Incorrect connection of the wires can damage the electronic components.

 Connect the wires as shown in the connection assignment.

NOTICE NOTICE

Destruction of the controller if voltage is too high.

 When connecting the controller, observe the maximum permissible voltage for the inputs and outputs.

 Do not plug in or unplug the controller while under voltage.

NOTICE NOTICE

A short-term voltage peak during braking can damage the power supply or other connected devices.

 For applications with high load inertia, the FAULHABER Braking Chopper of the BC 5004 series can be used to limit overvoltages and thereby protect the power supply. For more detailed information see the data sheet for the Braking Chopper.

The Motion Controller contains a PWM output stage for controlling the motors. Power losses arising during operation and alternating electrical fields arising due to the pulsed

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 If several electrical devices or controllers are networked by means of RS232 or CAN, make sure that the potential difference between the earth potentials of the various parts of the system is less than 2 V.

 The cross-section of the required potential equalisation conductors between the various parts of the system is specified in VDE 100 and must satisfy the following conditions:

 At least 6 mm²

 Larger than half the cross-section of the supply conductor

Fig. 14: Potential equalisation between electrically connected parts of the system

4.2.2 Drive connections

The maximum length of the cable between the Motion Controller and motor depends on the sensor system used and the electrical and magnetic fields in the environment.

Tab. 9: Guide values for the cable length

Longer cables are generally permissible, but must be validated for the target installation.

Optimisation of the behaviour in respect of transient emission and interference resistance may require additional EMC measures (see chap. 4.2.3, p. 30)

Motion Controller

Neutral point

Drive

Sensor type Unscreened length Screened length ^a)

a) applies to cables separately screened from the motor phase power cables.

Digital Hall sensors 0.5 m 2–5 m

Analogue Hall sensors 0.5 m 2–5 m

Incremental encoders without line driver 0.5 m 2–5 m

Incremental encoders with line driver 2 m 2–5 m

Absolute encoders without line driver 0.3 m 0.5 m

Absolute encoders with line driver 2 m 5 m

(30)

4.2.3 Screening

Fig. 15: MC 50xx connection of a BL servomotor

Fig. 16: MC 50xx connection of a DC motor with encoder

 Connect screen connections for the sensor systems and the motor cables to the Motion Controller to the earthed mounting plate or the screen connection screw on the Motion Controller by the shortest available route.

The best screening effect is achieved if the braiding is laid flat for instance on a screen terminal.

If the installation ensures potential equalisation, the braid can also be attached to an earthed surface on the motor.

Alternatively equalisation currents can also be suppressed by connected the cable screen at the motor end via a capacitor (approx. 1μF … 2μF / 50 V).

Cable Shield

Motor A Phase A

Sensor C Hall Sensor C

Sensor A Hall Sensor A

Motor B Phase B

UDD

Sensor B Hall Sensor B

Motor C Phase C

Brushless DC-Servomotor SGND

Cable Shield

Mot +

Channel A Mot –

Channel B

DC-Motor with Encoder SGND

UDD

Cable Shield

(31)

4.2.4 Connection of the power supply

 Discrete inputs and outputs (for instance for discrete target values preselection or for connection of limit switches / reference switches)

 Communication connections

 Make sure that the connection cables to the connection side are not longer than 3 m.

 Keep the screen connections for connection cables short and flat.

To reduce the effects on the DC power supply network, ferrite sleeves (such as WE 742 700 790) can be fitted on the supply cables.

Fig. 17: EMC protective circuit

4.2.4.1 Power supply

 Connect the Motion Controller to a sufficiently dimensioned PELV power supply unit.

 During acceleration procedures, current peaks with values up to the peak current limit setting of the motor can occur for multiples of 10 ms.

 During braking procedures, energy can be regenerated and fed back into the DC power supply network. If this energy cannot be taken up by other drives, the voltage in the DC power supply network will rise. A limit value for the voltage that can be fed back during regenerative braking can be set in the Motion Controller. Alternatively the overvoltage can be dissipated by an additional external brake chopper, see the data sheet for the brake chopper.

The USB port is a pure configuration connection. A cable length of < 3 m also applies to the USB connection.

L1

D1

GND

Motor Int. Supply

U_P

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4.2.5 Connector pin assignment

4.2.5.1 Pin assignment of the X100 connector strip of the Motion Controller

Motion Controllers have a connector strip by means of which the connection between Motion Controller and motherboard or customer-specific peripherals is established.

Fig. 18: Pin overview of the X100 connector strip

Tab. 10: Pin assignment of the connector strip

For technical data, see motherboard pin assignment.

Pin Designation Meaning

1 Phase A Motor phase A

2 Phase A Motor phase A

3 Phase B Motor phase B

4 Phase B Motor phase B

5 Phase C Motor phase C

6 Phase C Motor phase C

7 U_mot Power supply of the motor

8 U_mot Power supply of the motor

9 GND Ground connection

11 U_p Power supply of the electronics

12 GND Ground connection U_p

13 n.c. –

14 Sens A Hall sensor A

15 Sens B Hall sensor B

1 9

19 29

39 49

2 10

20 30

40 50

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24 Index Index channel (logically inverted signal)

25 n.c. –

26 n.c. –

27 DigOut 1 Digital output

28 DigOut 2 Digital output

29 n.c. –

30 U_DD Power supply for sensors

32 DigIn 1 Digital input

36 STO GND 2 Ground connection for STO input 2

37 STO IN 2 Signal STO 2

38 STO IN 1 Signal STO 1

40 AGND Analogue ground connection

41 AnIn 1 Analogue input

43 STO Out 1 Status STO status message (active/inactive)

44 STO 24V In Supply of the status outputs

45 STO Out 2 No-Error STO error message (ok/nok)

46 CAN-H CAN-High interface

47 CAN-L CAN-Low interface

49 TxD RS232 interface transmit direction

50 RxD RS232 interface receive direction

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4.2.5.2 Pin assignment of the motherboard (motor side) Motor connection (M1)

Tab. 11: Pin assignment of the BL motor connection (M1)

Tab. 12: Electrical data of the motor connection (M1)

Sensor connection (M2)

Tab. 13: Pin assignment of the sensor connection (M2)

Tab. 14: Electrical data of the sensor connection (M2)

1 Motor A Connection of motor, phase A

2 Motor B Connection of motor, phase B

3 Motor C Connection of motor, phase C

Designation Value

Motor power supply 0...U_mot Max. 4/12 A 100 kHz

5 Sens C Hall sensor C

Sensor power supply 5 V

<100 mA

Sensor connection <5 V

(35)

Encoder connection (M3)

The pin assignment of the encoder connector varies depending on the encoder type.

 Incremental encoder with or without line driver

 Absolute encoder with or without line driver.

Tab. 15: Pin assignment for incremental encoder with line driver (M3)

Tab. 16: Electrical data for incremental encoder with line driver (M3)

Tab. 17: Pin assignment for incremental encoder without line driver (M3)

1 U_DD Power supply for incremental encoder

3 Channel A Encoder channel A (logically inverted signal)

4 Channel A Encoder channel A

5 Channel B Encoder channel B (logically inverted signal)

6 Channel B Encoder channel B

7 Index Encoder index (logically inverted signal)

8 Index Encoder index

Power supply for incremental encoder

5 V

<100 mA Connection of the incremental

encoder

<5 V

<2 MHz 5 kΩ

1 U_DD Power supply for incremental encoder

3 Channel A n.c.

4 Channel A Encoder channel A

5 Channel B n.c.

6 Channel B Encoder channel B

7 Index n.c.

8 Index Encoder index

(36)

Tab. 18: Electrical data for incremental encoder without line driver (M3)

Tab. 19: Pin assignment for absolute encoder with line driver (M3)

Tab. 20: Electrical data for absolute encoder with line driver (M3)

Tab. 21: Pin assignment for absolute encoder without line driver (M3)

Power supply for incremental encoder

5 V

<100 mA Connection of the incremental

encoder

<5 V

<2 MHz 5 kΩ

1 U_DD Power supply for absolute encoder

3 CS Chip Select for absolute encoder (logically inverted signal)

4 CS Chip Select for absolute encoder

5 Data Data for absolute encoder (logically inverted signal)

6 Data Data for absolute encoder

7 CLK Clock for absolute encoder (logically inverted signal)

8 CLK Clock for absolute encoder

Absolute encoder power supply 5 V

<100 mA Connection Chip Select 5 V

Connection data <5 V

5 kΩ

Connection clock 5 V

1 MHz

1 U_DD Power supply for absolute encoder

3 CS n.c.

(37)

Tab. 22: Electrical data for absolute encoder without line driver (M3)

Motor + sensor connection (M1_1)

Tab. 23: Pin assignment of motor + sensor combination connector (M1_1)

Tab. 24: Electrical data of motor + sensor connection (M1_1)

Absolute encoder power supply 5 V

<100 mA Connection Chip Select 5 V

Connection data <5 V

5 kΩ

Connection clock 5 V

1 MHz

1 Motor C Connection of motor, phase C

2 Motor B Connection of motor, phase B

3 Motor A Connection of motor, phase A

6 Sens C Hall sensor C

Motor power supply 0...U_mot Max. 4/12 A 100 kHz

Sensor power supply 5 V

<100 mA

Sensor connection <5 V

(38)

COM port (X2)

The pin assignment at the COM port differs according to the type of communication. The distinction is made between the following types of communication:

 RS232

 CANopen

Tab. 25: Pin assignment of the COM port (X2) for RS232

Tab. 26: Pin assignment of CAN (X2_1) with CANopen

1 TxD RS232 interface transmit direction

2 RxD RS232 interface receive direction

3 GND Ground

1 CAN-H CAN-High interface

2 CAN-L CAN-Low interface

3 GND Ground

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4.2.5.3 Pin assignment of the motherboard (supply side) I/O connection (X3)

Tab. 27: Pin assignment of the I/O connection (X3)

Tab. 28: Electrical data for the I/O connection (X3)

1 U_DD Power supply for external consumer loads

3 DigOut 1 Digital output (open collector) 4 DigOut 2 Digital output (open collector)

12 AGND Ground connection for analogue inputs

Power supply for external consumer load

5 V

<100 mA

DigOut low = GND

high = high resistance 47 kΩ

max. 0.7 A

TTL level: low < 0.5 V, high > 3.5 V PLC level: low < 7 V, high > 11.5 V

DigIn <50 V

47 kΩ

<1 MHz

AnIn ±10 V

AGND

12 10 8 6 4 2

11 9 7 5 3 1

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STO connection (X6)

Tab. 29: Pin assignment of the STO connection (X6)

Tab. 30: Electrical data for the STO connection (X6)

Voltage supply of the motor + controller (X5)

Tab. 31: Pin assignment of the voltage supply of the motor + controller (X5)

1 STO Out 2 Error STO error message (ok/nok) 2 STO Out 1 Status STO status message (active/inactive) 3 STO GND Ground connection for STO output 4 STO 24V In Supply of the STO outputs 5 STO GND 2 Ground connection for STO input 2

6 STO In 2 Signal STO 2

8 STO In 1 Signal STO 1

STO 24V In 24 V, max. 50 mA

STO Out1 Status

low <7 V high > 11.5 V STO Out2 Error

STO GND 1 STO GND 2 STO In 1 STO In 2

2 U_B Power supply of the motor + controller

8 6 4 2

7 5 3 1

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4.2.6 Motherboard: connection at the motor side

Fig. 19: BL/LM motor with Hall sensors

Connection M1_1 can be used as an alternative to the combination of connections M1 and M2.

1 2 3 1 2 3 4 5 PIN

M1

1 2 3

BL-Motor Motor A

M2 3 4 2

1 5

Sens A Hall Sensor A Motor B

Motor C

GND GND

Sens B Hall Sensor B Sens C Hall Sensor C

+5 V Power Supply UDD

Motor Phase A Motor Phase B Motor Phase C

M1_1

(42)

Fig. 20: BL motor with Hall sensors and incremental encoders 1

2 3 1 2 3 4 5 PIN

M1

1 2 3

BL-Motor Motor A

M2 3 4 2

1 5

Motor C

GND GND

1 2 3 4 5 6 7 8 M3

1 3 5 7

2 4 6 8

Index Encoder Index Index Encoder Index Channel B Encoder Channel B Channel B Encoder Channel B Channel A Encoder Channel A Channel A Encoder Channel A

Encoder UDD +5 V Encoder Supply

GND GND

M1_1

(43)

Fig. 21: BL motor with Hall sensors and absolute encoders 1

2 3 1 2 3 4 5 PIN

M1

1 2 3

BL-Motor Motor A

M2 3 4 2

1 5

Motor C

GND GND

1 2 3 4 5 6 7 8 M3

1 3 5 7

2 4 6 8

CLK CLK

Data Data

CS CS

UDD +5 V Power Supply

GND GND

M1_1

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4.2.7 I/O circuit diagrams

4.2.7.1 Inputs

Analogue input

Fig. 22: Analogue input circuit diagram (internal)

The analogue inputs are executed as differential inputs. Both inputs use the same reference input.

The analogue inputs can be used flexibly:

 Specification of set values for current, speed or position

 Connection of actual value encoders for speed or position

 Use as a free measurement input (queried via the interface) Digital input

Fig. 23: Digital input circuit diagram (internal)

The digital inputs are switchable from the input level (PLC/TTL). The digital inputs can be So that the voltage drop on the supply side does not affect the speed specification value, connect the analogue input ground (AGND) to the power supply ground (GND).

AnIn

AGND –

+

A D

In Dig-In

(45)

STO inputs DANGER! DANGER

The safety function of the Motion Controller is not ensured if connected incorrectly.

 Observe the safety information in chap. 4.2.1, p. 28 and chap. 2.2.2, p. 10.

WARNING! WARNING

Unexpected startup of the drive or shutdown of the torque.

Because there is no redundancy when the circuit of the two STO inputs is bridged, there is a risk of serious injury or death.

 Bridged circuit (see Fig. 24) is only to be used for applications up to Performance Level c (PL a, PL b, PL c).

 For applications with Performance Level d or higher (PL d, PL e) that use redundant cir- cuitry (see Fig. 25).

Fig. 24: Circuit diagram of bridged STO inputs 1 and 2 STO In

STO 1

STO 2 STO GND

PL a, PL b, PL c

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Fig. 25: Circuit diagram of redundantly connected STO inputs 1 and 2

The following properties must be taken into account when connecting the STO inputs:

 Input type: Type 3 acc. to DIN EN 61131-2

 Protective separation: The inputs are electrically isolated from each other and from other circuits

 Isolation voltage: Max. 110 V DC

 Typical standby current per channel: 3 mA

 Delay when changing from low to high and from high to low: <5 ms (typically 1 ms)

 Evaluation of the input signals: Static evaluation. A change has immediate effect.

 Design for test pulses: OSSD test pulses with a maximum test pulse duration of 400 μs and a maximum test pulse cycle of 100 ms

 Current-voltage characteristics: see Fig. 26 STO In 1

STO GND 1 STO In 2

STO GND 2

PL a, PL b, PL c, PL d, PL e

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Fig. 26: Input characteristic curve for STO In

4.2.7.2 Outputs Digital output

Fig. 27: Digital output circuit diagram (internal) The digital output has the following properties:

 Open collector switch to ground

 Monitored output current (switch opens in the event of an error)

I (mA)

1 2 3 4

0 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 U (V DC)

DigOut 33k

U_P

DigOut

(48)

STO outputs DANGER! DANGER

The safety function of the Motion Controller is not ensured if connected incorrectly.

 Observe the safety information in chap. 4.2.1, p. 28 and chap. 2.2.2, p. 10.

Fig. 28: Circuit diagram for the Status and No-Error STO outputs The STO outputs are redundantly linked via the LED:

 LED illuminates: Low-impedance state of the outputs with 24 V as reference

 LED does not illuminate: High-impedance state of the outputs with 24 V as reference The following properties must be taken into account when connecting the STO outputs:

 Protective separation:

 The outputs are not electrically isolated from one another. The inputs and the remaining electronics are galvanically isolated from earth.

 An external suppressor circuit for the outputs is not necessary.

 Power supply:

 Common voltage supply with 24 V via the STO 24V In connection.

 The supply line of the outputs must be protected against overcurrent. The provided plug connectors must be taken into account for the dimensioning.

 Isolation voltage: The outputs are designed according to overvoltage category III for an isolation voltage of 800 V.

 Output current:

 The output current for both channels is <50 ma (short-circuit current STO Out Status and STO Out Error).

 Each channel is limited to approx. 20 mA (<25 mA).

Status 24 V / No-Error 24 V

STO Status / STO No-Error

(49)

Fig. 29: Output characteristic curve for STO Out Status

4.2.8 External circuit diagrams

Bipolar analogue set value specification via potentiometer

I (mA)

2 4

0 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 U (V DC)

6 8 10 12 14 16 18 20 22 24 26

– + 20 V

10k

4,7k

1k

Motion Controller

AnIn AGND

Interface

Ref

U_P

GND U_P

10 V

(50)

Analogue set value specification via potentiometer with internally set offset and scaling

Fig. 31: Analogue set value specification via potentiometer with internally set offset and scaling

Connection of reference and limit switches

– 10k +

Motion Controller

AnIn AGND

Interface

Ref U_P

GND GND

U_P UDD

1k 1k

Interface Limit Switch

Motion Controller

DigIn X DigIn Y GND

GND GND

U_P

(51)

Connection of an external incremental encoder

Fig. 33: Connection of an external incremental encoder

Wiring between PC/control and a drive during RS232 operation

Fig. 34: Wiring between PC/control and a drive during RS232 operation

Depending on the type of encoder it may be necessary to use additional pull-up resistors. No internal pull-up resistors are incorporated in the Motion Controller.

2,7k

Interface

Quadrature Counter A

A B

Index B

Index

DigIn2

DigIn3 Encoder

UDD

GND U_P

DigIn1

PC or High Level Control

Node 1

TxD

RxD RxDTxD GNDGND(D-Sub9 Pin 2) (D-Sub9 Pin 3) (D-Sub9 Pin 5)