Installation Instructions - FAULHABER Drive Systems€¦ · Follow the instructions for installation and commissioning given in these installation instructions exactly. Only have

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InstallationInstructions

MC 5004 P STO

Original Instructions

EN

Imprint

2

Version: 3rd edition, 5.03.2020

Copyrightby Dr. Fritz Faulhaber GmbH & Co. KGDaimlerstr. 23 / 25 · 71101 Schönaich

All rights reserved, including those to the translation.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 writtenpermission 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 theconsequences of such errors. Equally, no liability can beaccepted for direct or consequential damages resultingfrom improper use of the equipment.

The relevant regulations regarding safety engineeringand interference suppression as well as the requirementsspecified in this document are to be noted and followedwhen using the software.

Subject to change without notice.

The respective current version of this technical manual isavailable on FAULHABER's internet site:www.faulhaber.com

3rd edition, 5.03.2020 7000.05063, 3rd edition, 5.03.20207000.05063

https://www.faulhaber.com

Content

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.................................... 92.2.2 Correct installation and commissioning .............................................. 102.2.3 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...................................................................................... 173.4.1.1 Standard PCB.......................................................................... 173.4.1.2 EtherCAT PCB ......................................................................... 183.4.1.3 State machine and start routine ........................................... 20

3.4.2 Motherboard......................................................................................... 23

4 Installation ...................................................................................................................... 25

4.1 Mounting .............................................................................................................. 25

4.1.1 Mounting instructions .......................................................................... 254.1.2 Installing the Motion Controller PCB on the motherboard ............... 264.1.3 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 ...................................................... 284.2.2 Drive connections.................................................................................. 294.2.3 Screening ............................................................................................... 304.2.4 Connection of the power supply ......................................................... 31

4.2.4.1 Power supply.......................................................................... 314.2.5 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) ............... 344.2.5.3 Pin assignment of the motherboard (supply side)............... 39

4.2.6 Motherboard: connection at the motor side ...................................... 414.2.7 I/O circuit diagrams ............................................................................... 44

4.2.7.1 Inputs...................................................................................... 444.2.7.2 Outputs................................................................................... 47

4.2.8 External circuit diagrams ...................................................................... 49


Content

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......................................................................................... 555.2.2 EtherCAT PCB ........................................................................................ 565.2.3 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


About this document

1 About this document

1.1 Validity of this documentThis 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 documentsThe 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 docu-ment).

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


www.faulhaber.com/manuals/

About this document

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


About this document

1.5 Symbols and designations

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

Measures for avoidance

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


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


NOTICENOTICERisk of damage.


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


Safety

2 Safety

2.1 Intended useThe 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 envi-ronmental conditions.


Safety

2.2 Safety instructionsIn 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 regula-tions 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 cor-rect 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.


Safety

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


Safety

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 controlWhen 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

of the shielding of a shielded cable


Safety

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 indica-tion 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 docu-mented 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 standardsVarious harmonised standards were applied to the products described in these installation instructions; these standards are documented in the EC Declaration of Conformity.

You can find the Declaration of Incorporation for the product and the EC Declaration of Conformity for the safety function in chap. 9.2, p. 63 and chap. 9.3, p. 64.

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).


Product description

3 Product description

3.1 General product descriptionThe 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 commis-sioning by the Motion Manager, the controller can also be operated without any communi-cations interface.

In drive applications, it is often necessary to safely isolate a motor in response to an exter-nal 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.

Fig. 3: Torque shutdown

STO IN1

STO IN2

24V

GND

STO Device

LEDLED 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

STO activation

n

t


Product description

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.


Product description

3.2 Product informationDesignation key

Fig. 4: Designation key

Type plate

Fig. 5: Type plate

1 Identification number 6500.01717 or 6500.017182 Serial number (8 digit): Calendar week (2) and year (2) of manufacture, sequential

number (4)Example: 44170001Manufactured during calendar week 44 of year 2017 with sequential number 1

3 Firmware version FW XXYExample: 03IFirmware 03 in index I

RS: RS232 Serial interfaceCO: 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 …STOMC

6500.10000

FW 03I

SNR 12340002

1

2

3


Product description

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 cur-rent

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 drawingSee 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): PFHD = 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.


Product description

3.4 Product variantsThe following product variants are possible:

The Motion Controller PCBs can be mounted on a motherboard. The FAULHABER mother-board 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.


Product description

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 LEDPower LED


IN/OUT Connection of the EtherCAT communication

USB (X1) Connection of the USB communication


Product description

Tab. 5: Device LEDs


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.


a) see chap. 3.4.1.3, p. 20

Motor state






Product description

3.4.1.3 State machine and start routine

Fig. 8: States of the STO state machine

Tab. 7: Description of the statesState 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 Outputs are switched off No torque at motor

STO On STO shutdown is active Outputs are switched off No torque at motor

STO Off STO shutdown is inactive Outputs are switched on Torque possible at motor

STO-Reset-Pulse

START

PowerdownMotor inactiveNo-Error:STO status:

ErrorMotor inactive

No-Error LED:STO status LED:



STO OnMotor inactive

STO OffMotor active

Undervoltage/overvoltage

Undervoltage/overvoltage

STO IN 1 = low

STO IN 2 = low

yes

yes

yes

yes

yes

no

nono

no

no

yesno Undervoltage/overvoltage

yesno Undervoltage/overvoltage

AND

STO IN 1 = high

STO IN 2 = highAND


Product description

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-ErrorSTO Off

STO On

No-Error

STO IN 1

STO IN 1SW L OK

STO IN 1

STO IN 2

BED

1

BED

2

BED

3

ResetPulse

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


Product description

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

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.


Product description

3.4.2 Motherboard

Fig. 10: Side view (top), top view (middle) and isometric view (bottom) of the mother-board (dimensions in mm)

On delivery, there are rubber pads in the outer and centre holes of the motherboard. These holes are marked in blue in Fig. 10.

100

72m

ax. 2

45.

33


Product description

Fig. 11: Connector overview of the motherboard

Tab. 8: Connector overview of the motherboardDesignation Function

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 supplyconnector (X5)

Motor + Sensorconnector (M1_1)

Motor connector (M1)

Sensor connector (M2)

Encoder connector (M3)

Motion Controllerconnector (X100)


Installation

4 Installation

4.1 Mounting

4.1.1 Mounting instructions

CAUTIONCAUTION!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).

DANGERDANGER!Incorrect handling and installation can damage the Motion Controller.

Damage to the Motion Controller can impair its safety functions. If safety functions are un-available, 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)?

DANGERDANGER!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 thetorque may be ineffective. Depending on the use of the Motion Controller, this can lead tosevere or fatal injury.

Do not start up the Motion Controller.


Installation

4.1.2 Installing the Motion Controller PCB on the motherboard

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

NOTICENOTICEIncorrect 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


Installation

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 PCB2 Motherboard3 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


Installation

4.2 Electrical connection

4.2.1 Notes on the electrical connection

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



WARNINGWARNING!Threat to health through high-frequency interference.

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

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

NOTICENOTICEIncorrect connection of the wires can damage the electronic components.

Connect the wires as shown in the connection assignment.

NOTICENOTICEDestruction 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.

NOTICENOTICEA short-term voltage peak during braking can damage the power supply or other connec-ted 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 control of the motors, must be dissipated and damped by appropriate installation.

Connect the Motion Controller to a grounding system. This should be done preferably by mounting it on an earthed baseplate, or alternatively by connecting it to an earthed mounting rail.

Make sure that potential equalisation is present between all coupled parts of the sys-tem. This applies even if the Motion Controller and motor are mounted separately.


Installation

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)

MotionController

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


Installation

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 ShieldMotor 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

BrushlessDC-ServomotorSGND

Cable Shield

Mot +

Channel A

Mot –

Channel B

DC-Motor

with EncoderSGNDUDD

Cable Shield

Cable Shield


Installation

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 dur-ing regenerative braking can be set in the Motion Controller. Alternatively the overvolt-age 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

MotorInt. Supply

UP


Installation

4.2.5 Connector pin assignment

4.2.5.1 Pin assignment of the X100 connector strip of the Motion ControllerMotion 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 Umot Power supply of the motor

8 Umot Power supply of the motor

9 GND Ground connection


11 Up Power supply of the electronics

12 GND Ground connection Up

13 n.c. –

14 Sens A Hall sensor A

15 Sens B Hall sensor B

16 Sens C Hall sensor C

17 UDD Supply connection for sensors


19 Channel A Encoder channel A

20 Channel A Encoder channel A (logically inverted signal)

21 Channel B Encoder channel B

22 Channel B Encoder channel B (logically inverted signal)

23 Index Index channel

1919293949

21020304050


Installation

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 UDD 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



Installation

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...Umot

Max. 4/12 A

100 kHz







Designation Value

Sensor power supply 5 V

<100 mA

Sensor connection <5 V


Installation

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 UDD Power supply for incremental encoder


3 Channel A Encoder channel A (logically inverted sig-nal)


5 Channel B Encoder channel B (logically inverted sig-nal)


7 Index Encoder index (logically inverted signal)

8 Index Encoder index

Designation Value

Power supply for incremental encoder

5 V

<100 mA

Connection of the incremental encoder

<5 V

<2 MHz

5 kΩ


1 UDD Power supply for incremental encoder


3 Channel A n.c.


5 Channel B n.c.


7 Index n.c.

8 Index Encoder index


Installation

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)

Designation Value

Power supply for incremental encoder

5 V

<100 mA

Connection of the incremental encoder

<5 V

<2 MHz

5 kΩ


1 UDD 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

Designation Value

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 UDD Power supply for absolute encoder


3 CS n.c.

4 CS Chip Select for AES

5 Data n.c.

6 Data Data for AES

7 CLK n.c.

8 CLK Clock for AES


Installation

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)

Designation Value

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






Designation Value

Motor power supply 0...Umot

Max. 4/12 A

100 kHz

Sensor power supply 5 V

<100 mA

Sensor connection <5 V


Installation

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


Installation

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 UDD 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

Designation Value

Power supply for external consumer load

5 V

<100 mA

DigOut low = GND

high = high resistance

47 kΩmax. 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


Installation

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)

Tab. 32: Electrical data for the voltage supply (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


6 STO In 2 Signal STO 2


8 STO In 1 Signal STO 1

Designation Value

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 UB Power supply of the motor + controller

Designation Value

Supply of the motor + controller 12…50 V, max. 4 A continuous current

8 6 4 2

7 5 3 1


Installation

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

3 421 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 SupplyDDU

Motor Phase A

Motor Phase B

Motor Phase C

M1_1


Installation

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

3 421 5


Motor B

Motor C

GND GND




Motor Phase A

Motor Phase B

Motor Phase C

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

U +5 V Encoder SupplyDD

GND GND

M1_1


Installation

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

3 421 5


Motor B

Motor C

GND GND




Motor Phase A

Motor Phase B

Motor Phase C

1

2

3

4

5

6

7

8

M3

1 3 5 7

2 4 6 8

CLK CLK

CLK CLK

Data Data

Data Data

CS CS

CS CS

U +5 V Power SupplyDD

GND GND

M1_1


Installation

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 configured for the following purposes (see the Drive Functions):

Digital input for reference and limit switches

Connection of an external encoder

PWM (Pulse Width Modulation) set value specification for current, speed and position

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


Installation

STO inputs

DANGERDANGER!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.

WARNINGWARNING!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 arisk 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


Installation

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


Installation

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)

A digital output can be assigned to an error output. It can be configured for the following purposes:

Pulse output

Digital output (freely programmable)

I (mA)1 2 3 4002468

1012141618202224262830

U (V DC)

DigOut

33k

UP

DigOut


Installation

STO outputs

DANGERDANGER!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).

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

Controllable components: The outputs are intended for controlling inputs of type 3 acc. to DIN EN 61131-2. They cannot control loads.

Connection of multiple modules: When connecting multiple modules, it must be ensured that the total current of the output is not exceeded, as the switching threshold cannot otherwise be achieved due to the voltage drop.

Current-voltage characteristics: see Fig. 29

Status 24 V /No-Error 24 V

STO Status /STO No-Error


Installation

Fig. 29: Output characteristic curve for STO Out Status

4.2.8 External circuit diagrams

Bipolar analogue set value specification via potentiometer

Fig. 30: Bipolar analogue set value specification via potentiometer

I (mA)2 4002468

1012141618202224262830

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

UP

GND

GND

UP

10 V


Installation

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

Fig. 32: Connection of reference and limit switches

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

–+10k

Motion Controller

AnIn

AGND

Interface

Ref

UP

GND

GND

UP

UDD

1k 1k

InterfaceLimit Switch

Motion Controller

DigIn X

DigIn Y

GND

GND

GND

UP

UP


Installation

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 resis-tors. No internal pull-up resistors are incorporated in the Motion Controller.

2,7k

Interface

QuadratureCounter

AA

B

IndexB

Index

DigIn2

DigIn3

Encoder

UDD

GND

UP

DigIn1

PC orHigh Level Control

Node 1

TxD

RxD

RxD

TxD

GN

D

GN

D

(D-S

ub

9 Pi

n 2

)

(D-S

ub

9 Pi

n 3

)

(D-S

ub

9 Pi

n 5

)


Installation

Wiring with several Motion Control Systems in RS232 network operation

Fig. 35: Wiring with several Motion Control Systems in RS232 network operation

Connection to the CANopen network

Fig. 36: Connection to the CANopen network

Depending on the number of networked controllers a smaller value may be necessary for the pull-down resistor.

If the CAN wiring is not laid in a straight line it may be necessary to individually opti-mise the amount and location of the terminating resistors. For instance in a star net-work a central 60 Ohm terminating resistor may be more suitable. When the optimum arrangement of terminating resistors is fitted, no accumulation of error frames should be evident.

PC orHigh Level Control

4,7k

Node 1 Node n

TxD

TxD

RxD

RxD

RxD

TxD

GN

D

GN

D

GN

D

(D-S

ub

9 Pi

n 2

)

(D-S

ub

9 Pi

n 3

)

(D-S

ub

9 Pi

n 5

)

Node 1

CAN Bus Line

Node n

GND

CAN_H

CAN_L

120 120


Installation

Connection of the STO safety control

Fig. 37: Connection of the STO safety control

Safety Control Node 1 Node n

STO

IN 1

STO

IN 2

STO OUT 2 ErrorSTO OUT 1 StatusST

O 2

4 V

IN


Installation

4.3 Information on initial commissioningDuring the initial commissioning, the correct function of the entire safety circuit must be tested and documented.

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



Prior to the initial commissioning, also take the following measures:

Ensure that all operating materials within the safety circuit are professionally installed and functional.

Check all electrical connections.

Visually inspect all safety-relevant components.

If necessary, take additional safety measures to protect persons from danger during the initial commissioning which could arise from incorrect function of the safety circuit.

When started, the Motion Controller performs an automatic self-test. An error message is output if the self-test fails.

When starting the Motion Controller, pay attention for error and STO status messages.

Do not commission a Motion Controller whose self-test has failed.

Perform a self-test daily (see chap. 2.4, p. 11).

During commissioning, check whether the following results are achieved (see chap. 3.4.1.3, p. 20):

D

The configuration and commissioning of the Motion Controller are described in the manuals for the Motion Manager 6 and the drive functions (see chap. 1.2, p. 5).

Test criterion Test result

STO In 1 = high, STO In 2 = high STO Off

STO In 1 = high, STO In 2 = low STO On

STO In 1 = low, STO In 2 = high STO On

STO In 1= low, STO In 2 = low STO On

Switch-off time via STO In 1 <10 ms

Switch-off time via STO In 2 <10 ms

Power consumption during STO On <1500 mW


Maintenance and diagnostics

5 Maintenance and diagnostics

5.1 Maintenance tasksThe drive is generally maintenance-free. Where the device is mounted in a cabinet, depend-ing on the deposition of dust the air filter should be regularly checked and cleaned if neces-sary.

5.2 Diagnostics

5.2.1 Standard PCB

Standard PCB

Fig. 38: Isometric view of the standard PCB

Tab. 33: Device status LEDsDesignation Function

Status LED 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 Green: Power supply within the permissible range. Off: Power supply not within the permissible range.

Status LED

Power LED

STO Status LED

No-Error LED




5.2.2 EtherCAT PCB

Fig. 39: Isometric view of the plugged-in EtherCAT PCB

Tab. 35: LED overview


a) see chap. 3.4.1.3, p. 20

Motor state





Status LED

Power LED

STO Status LED

No-Error LED

Run LED

Error LED

LA

LA


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 out of the permissible range.

RUN LED EtherCAT Green (continuous light): Connection present. Device is ready for use. 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.




5.2.3 Self-test

When switching on the Motion Controller, a self-test is performed automatically. The fol-lowing causes could result in an error message here:

If the error had other causes, return the Motion Controller to the manufacturer with indica-tion of the error messages.

5.3 TroubleshootingIf faults occur during operation, check the following components:

Power supply unit (voltage range, standby current)

Wiring (detachment, damage, short circuit)

If faults continue to occur, please contact your support partner.

ERR LED EtherCAT Red (flashing): Faulty configuration. Red (single flash): Local error. Red (double flash): Watchdog timeout. Off: No connection error

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

Green (flashing): Data transfer active. Off: No data transfer. No connection to another participant.


a) see chap. 3.4.1.3, p. 20

Motor state






Cause Remedy

Faulty wiring Check wiring and correct or replace if necessary

Defective cable (cable breakage, loss of contact at the connector, short-circuit, hanging)

Repair or replace cable



Decommissioning and disposal

58

6 Decommissioning and disposal1. Switch off the power.

2. Disconnect the Motion Controller from the power supply unit.

3. Dispose of the Motion Controller at a suitable disposal centre in accordance with the local regulations.


Accessories

59

7 AccessoriesDetails of the following accessory parts can be found in the Accessories Manual:

Connection cables

Connectors

Connector sets

Additional equipment

Permissible motors (see page 2 of the data sheet, chap. 9.1, p. 61)


Warranty

60

8 WarrantyProducts of the company Dr. Fritz Faulhaber GmbH & Co. KG are produced using the most modern production methods and are subject to strict quality inspections. All sales and deliv-eries are performed exclusively on the basis of our General Conditions of Sale and Delivery which can be viewed on the FAULHABER home page www.faulhaber.com/gtc and down-loaded from it.

https://www.faulhaber.com/en/contact/gtc/

Additional documents

9 Additional documents

9.1 Data sheet

Edition 2018 Apr. 11

MC 5004 P STO

Motion ControllersV3.0, 4-Quadrant PWMwith RS232, CANopen or EtherCAT interface

MC 5004 P STOValues at 22°C MC 5004 P STOPower supply electronic UP 12 ... 50 V DCPower supply motor 1) Umot 0 ... 50 V DCPWM switching frequency fPWM 100 kHzEfficiency electronic η 95 %Max. continuous output current Icont 4 AMax. peak output current 2) Imax 12 AStandby current for electronic (at UP =24V) lel RS / CO: 0,06 ET: 0,07 APermissible ambient temperature (operation) -5 ... 40 °CPermissible ambient temperature (storage) -40 ... 85 °CMass RS / CO: 28 ET: 52 g

Interfaces MC 5004 P STO RS/CO MC 5004 P STO ETConfiguration from Motion Manager 6.3 RS232 / USB RS232 / USBFieldbus RS232 / CANopen EtherCAT

Basic features

Control of brushless and linear motors

Supported sensor systems: absolute encoders (AES or SSI), incremental encoders (optical or magnetic), Hall sensors (digital or analog), tachometers

Position resolution when using analog Hall sensors as position encoders: 4096 increments per revolution

4 digital inputs, 2 digital outputs, 2 analog inputs, flexible configuration

Setpoint specification via fieldbus, quadrature signal, pulse and direction or analog inputs

Optional stand-alone operation via application programs in all interface versions

Safe deactivation of torque via standardized integrated safe torque off circuit. Use up to security level SIL 3 according to IEC 61800-5-2 und PL e according to EN ISO 13849-1.

Failure value PFHD = 4,57 · 10-10, at a request rate of 1 per 8h. Activation via two redundant inputs, separate outputs for status and error indication.

Range of functions

Operating modes PP, PV, PT, CSP, CSV, CST and homing acc. to IEC 61800-7-201 or IEC 61800-7-301 as well as position-, speed- and torque control via analog setpoint or voltage controller

Speed range for brushless motors 0 min-1 … 30 000 min-1 with sinusoidal commutation (optionally to 60 000 min-1 with block commutation)

Application programs Max. 8 application programs (BASIC), one of which is an autostart function

Additional functions Touch-probe input, connection of a second incremental encoder, control of a holding brake

Indicator LEDs for displaying the operating state Trace as recorder (scope function) or logger

Motor types BL- and linear motors

1) Separate power supply not available in combination with Motherboard MB1 MC 5004 P STO2) S2 mode for max. 1s

For notes on technical data and lifetime performance refer to “Technical Information”.

© DR. FRITZ FAULHABER GMBH & CO. KGSpecifications subject to change without notice.



Edition 2018 Apr. 11

Dimensional drawing

MC 5004 P STO RS/CO MC 5004 P STO ET

±0,3

±0,5

(3x) ø3,270

max.6,5max.5,7

76

±0,547

±0,335

±0,52,2

±0,56,1

±0,550 ±0,551,1

X1

X2 0,64

max.21max.5,7

±0,543,4

IN OUT

Scale reduced

Grid 2,54

Options and connection information

FC

MC 5004 P STO ET FC

Option Type Description

DescriptionName FunctionConnection

Example product designation:

X1 USB configuration interface USB

X2 Pin Header Analog and digital input/output, motor and eletronic power supply, fieldbus, motor phases, sensors

IN Fieldbus EtherCAT INOUT Fieldbus EtherCAT OUT

Note: For details on the connection assignment, see device manual for the MC 5004 STO.

Interface connector DIN, for use in combination with flat cables (see chapter “accessories”)

EtherCAT IN/OUT

Product combination

Brushless DC-Motors

Linear DC-Servomotors

1218 ... B LM 0830 ... 011226 ... B LM 1247 ... 111628 ... B LM 1483 ... 111660 ... BHT LM 2070 ... 112036 ... B2057 ... B2057 ... BHS2232 ... BX42250 ... BX42250 ... BX4 S2444 ... B3056 ... B3242 ... BX43268 ... BX4

Cables / Accessories

An extensive range of accessories is available for the products of the MC 5004 STO controller series.

A motherboard is available that can be used to operate one controller in one-axis operation (slave).

Furthermore, connection cables are available for controller and motor supply, sensors and interfaces as well as connector sets for the motor and supply side.

To view our large range of accessory parts, please refer to the „Accessories“ chapter.

For notes on technical data and lifetime performance refer to “Technical Information”.

© DR. FRITZ FAULHABER GMBH & CO. KGSpecifications subject to change without notice.



9.2 Declaration of Incorporation



9.3 Declaration of Conformity







9.4 EC type-examination certificate






7000.05063, 3rd edition, 5.03.2020© Dr. Fritz Faulhaber GmbH & Co. KG

DR. FRITZ FAULHABER GMBH & CO. KGAntriebssysteme

Daimlerstraße 23 / 2571101 Schönaich • GermanyTel. +49(0)7031/638-0Fax +49(0)7031/[email protected]

https://www.faulhaber.com

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Installation Instructions - FAULHABER Drive Systems€¦ · Follow the instructions for installation and commissioning given in these installation instructions exactly. Only have