Page 1 Product Manual item Servo Positioning Controller C 1-Series designed for Functional Safety item Industrietechnik GmbH Phone: +49-(0)212-6580-0 Friedenstraße 107-109 Telefax: +49-(0)212-6580-310 42699 Solingen E-mail: info@item24.com Germany http://www.item24.com...
Page 2 systems.
Page 3 Revision Information Author: item Industrietechnik GmbH Product Manual „item Servo Positioning Controller C 1-Series“ Manual title: File name: DOK_BEDA_Steuerung-C1-Serie_#SEN_#AQU_#V1.docx Version 5.0 July 2018 Page 3...
Page 4: Table Of Contents
TABLE OF CONTENTS: GENERAL ......................14 Documentation ....................14 Scope of supply ..................... 15 SAFETY NOTES FOR ELECTRICAL DRIVES AND CONTROLLERS ........16 Used symbols ....................16 General notes ....................17 Danger resulting from misuse................19 Safety notes ....................20 2.4.1 General safety notes ................
Page 5 FUNCTION OVERVIEW ..................... 55 Motors ......................55 5.1.1 Synchronous servo motors ..............55 5.1.2 Linear motors ................. 55 Functions of the item servo positioning controller C 1-Series ........56 5.2.1 Compatibility .................. 56 5.2.2 Pulse width modulation (PWM) ............57 5.2.3 Setpoint management ..............
Page 6 FSM 2.0 – STO (Safe Torque Off) ............71 MECHANICAL INSTALLATION ................... 72 Important notes ..................... 72 View of the device ..................74 Mounting ..................... 76 ELECTRICAL INSTALLATION ..................77 Connector configuration .................. 77 item C 1-Series complete system ............... 78 Page 6...
Page 7 Connection: Power supply [X9] ................80 8.3.1 Device side [X9] ................80 8.3.2 Counterplug [X9] ................80 8.3.3 Pin assignment [X9] ................. 81 8.3.4 Cable type and design [X9] ..............81 8.3.5 Connection notes [X9] ..............82 Connection: Motor [X6] ..................83 8.4.1 Device side [X6] ................
Page 8 INITIAL OPERATION ....................108 10.1 General notes on connection ................108 10.2 Tools / material ................... 108 10.3 Connecting the motor ..................108 10.4 Connecting the item servo positioning controller C 1-Series to the power supply ..109 Page 8...
Page 9 10.5 Connecting the PC (serial interface) ..............109 10.6 Connecting the PC (USB interface, alternative) ............ 109 10.7 Checking operability ..................109 SERVICE FUNCTIONS AND ERROR MESSAGES ............110 11.1 Protection and service functions ..............110 11.1.1 Overview ..................110 11.1.2 Overcurrent and short-circuit monitoring ..........
Page 10 12.2.4 Display elements ................152 12.2.5 EtherCAT interface ................ 153 12.3 General installation notes for technology modules ..........154 Page 10...
Page 11 C 1-Series: Mounting plate ............76 Figure 15: Connection to power supply and motor ..................77 Figure 16: Complete setup of the item C 1-Series with motor and PC ............79 Figure 17: Supply [X9] ........................82 Figure 18: Motor connection [X6] ......................85 Figure 19: Connecting a holding brake with high current draw (>...
Page 12 Table of Tables: Table 1: Scope of supply .........................15 Table 2: Connector set: POWER connector ..................15 Table 3: Connector set: DSUB connector .....................15 Table 4: Connector set: Shield connector ....................15 Table 5: Technical data: Ambient conditions and qualification ..............37 Table 6: Technical data: Dimensions and weight ...................37 Table 7: Technical data: Cable specifications ..................38...
Page 13 Table 32: Fieldbus specific assignment of the DIP switches ...............68 Table 33: Pin assignment: [X9] ......................81 Table 34: Pin assignment: [X6] ......................84 Table 35: Pin assignment: I/O communication [X1]..................90 Table 36: Pin assignment: [X2A] ......................92 Table 37: Pin assignment: CAN-Bus [X4] ....................94 Table 38: Pin assignment: RS232 interface [X5] ..................97 Table 39:...
Page 14: General
General Documentation This product manual serves the purpose of a safe use of the item servo positioning controller C 1-Series. It contains safety notes, which must be complied with. Further information can be found in the following manuals of the item C Series product range: Product Manual "item Servo Positioning Controller C 3-Series": Description of the technical data and the device functionality...
Page 15: Scope Of Supply
General Scope of supply The scope of supply includes: Table 1: Scope of supply item Servo Positioning Controller C 1-Series Type C 1-02 C 1-05 C 1-08 item order number 0.0.668.62 0.0.668.63 0.0.668.64 Counterplugs for power are included in standard scope of supply. Counterplugs for controller or shaft encoder connections, as well as for shield connection are not included in the standard scope of supply.
Page 16: Safety Notes For Electrical Drives And Controllers
Safety notes for electrical drives and controllers Safety notes for electrical drives and controllers Used symbols Information Important information and notes. Caution! Nonobservance may result in severe property damages. DANGER! Nonobservance may result in property damages and in personal injuries. Caution! Dangerous voltages.
Page 17: General Notes
Safety notes for electrical drives and controllers General notes In case of damage resulting from non-compliance with the safety notes in this manual, item Industrietechnik GmbH will not assume any liability. Safety notes for electrical drives and controllers Prior to the initial use you must read the starting on page 16 chapter 8.11 Notes on safe and EMC-compliant installation...
Page 18 Safety notes for electrical drives and controllers Professional control process design is a prerequisite for sound functioning of the servo positioning controller! DANGER! Inappropriate handling of the servo positioning controller and non-compliance with the warnings as well as inappropriate intervention in the safety features may result in property damage, personal injuries, electric shock or in extreme cases even death.
Page 19: Danger Resulting From Misuse
Safety notes for electrical drives and controllers Danger resulting from misuse DANGER! High electrical voltages and high load currents! Danger to life or serious personal injury from electrical shock! DANGER! High electrical voltage caused by wrong connections! Danger to life or serious personal injury from electrical shock! DANGER! Surfaces of device housing may be hot! Risk of injury! Risk of burning!
Page 20: Safety Notes
Safety notes for electrical drives and controllers Safety notes 2.4.1 General safety notes The servo positioning controller corresponds to IP20 degree of protection as well as pollution degree 2. Make sure that the environment corresponds to this degree of protection and pollution degree. Only use replacement parts and accessories approved by the manufacturer.
Page 21 Safety notes for electrical drives and controllers Without claiming completeness, the following regulations and others apply: VDE 0100 Erection of power installations with nominal voltages up to 1000 V EN 1037 Safety of maschinery - Prevention of unexpected start-up EN 60204-1 Safety of machinery - Electrical equipment of machines Part 1: General requirements...
Page 22: Safety Notes For Assembly And Maintenance
Safety notes for electrical drives and controllers 2.4.2 Safety notes for assembly and maintenance The appropriate DIN, VDE, EN and IEC regulations as well as all national and local safety regulations and rules for the prevention of accidents apply for the assembly and maintenance of the system. The plant engineer or the operator is responsible for compliance with these regulations: The servo positioning controller must only be operated, maintained and/or repaired by personnel trained and qualified for working on or with electrical devices.
Page 23 “Safe Torque Off” feature in accordance with EN 61800-5-2. This feature can be achieved with the item C 1-Series by integrating the module FSM 2.0 – STO for example. Initial operation must be carried out with idle motors, to prevent mechanical damages for example due to the wrong direction of rotation.
Page 24: Protection Against Contact With Electrical Parts
Safety notes for electrical drives and controllers 2.4.3 Protection against contact with electrical parts This section only concerns devices and drive components carrying voltages exceeding 50 V. Contact with parts carrying voltages of more than 50 V can be dangerous for people and may cause electrical shock. During operation of electrical devices some parts of these devices will inevitably carry dangerous voltages.
Page 25: Protection Against Dangerous Movements
Safety notes for electrical drives and controllers DANGER! High electrical voltages due to wrong connections! Danger to life, risk of injury due to electrical shock! Only devices and electrical components and wires with a protective extra low voltage (PELV) may be connected to connectors and terminals with voltages between 0 to 50 Volts.
Page 26: Protection Against Contact With Hot Parts
Safety notes for electrical drives and controllers 2.4.6 Protection against contact with hot parts DANGER! Housing surfaces may be hot! Risk of injury! Risk of burning! Do not touch housing surfaces in the vicinity of heat sources! Danger of burning! Before accessing devices let them cool down for 10 minutes after switching them off.
Page 27: Protection During Handling And Assembly
Safety notes for electrical drives and controllers 2.4.7 Protection during handling and assembly Handling and assembly of certain parts and components in an unsuitable manner may under adverse conditions cause injuries. DANGER! Risk of injury due to improper handling! Personal injury due to pinching, shearing, cutting, crushing! The following general safety notes apply: Comply with the general setup and safety regulations on handling and assembly.
Page 28: Product Description
Product description General The item servo positioning controller C Series devices are intelligent AC servo inverters with substantial parameterisation possibilities and extension options. They are flexible and can be easily adapted to a number of different applications. These servo positioning controllers are designed for receiving so-called FSM modules (Functional Safety Modules). Thanks to their integrated safety features, external monitoring devices can be omitted for numerous applications.
Page 29 Product description All item Servo Positioning Controller C Series devices have the following features: Space-saving compact design, directly cascadable High quality of control due to extremely high-quality sensor technology, far superior to conventional market standards, and better than average computer resources...
Page 30 Product description ® User-friendly parameterisation with the item Motion Soft software Menu-driven first set up Automatic motor identification Easy coupling to host controller, for example to a PLC via I/O level or fieldbus High-resolution 16-bit analog input Technology slots for extensions such as I/O extension module or PROFIBUS interface.
Page 31: Power Supply
Behaviour during switch-on As soon as the item servo positioning controller C 1-Series is supplied with the input voltage, the DC bus is charged (< 1 s) using the brake resistor as a precharging resistor, the DC link relay deactivated. During this the PFC remains inactive After precharging of the DC bus the relay is energized and the DC bus is coupled hard to the mains power without the precharging resistor.
Page 32: Behaviour During Normal Operation And Control Characteristics
A superimposed digital closed-loop control adjusts the DC bus voltage to an average value close to 380 VDC. To relieve the voltage control that is relatively sluggish, during load changes (acceleration/deceleration of the drive) the output/input power delivered from the item servo positioning controller C 1-Series to the motor is measured and used for the pre-control of the PFC stage 3 phase 100V ...
Page 33: Dc Bus Coupling, Dc Supply
DC bus coupling, DC supply 3.2.2.1 DC bus coupling It is possible to couple multiple servo positioning controllers of the item C 1-Series when they have the same DC bus voltage. For this purpose, the PFC stage has to be deactivated Caution! DC bus coupling is not allowed while the PFC stage is active.
Page 34: Brake Chopper
UDP interface [X18]: Ethernet Fieldbus system [X4]: CANopen I/O interface [X1]: Digital and analog In- and outputs The serial, Ethernet, and USB interface are particularly important for the connection of a PC and for the use of the item Motion ® Soft parameterisation tool.
Page 35: Serial Interface [X5]
The RS232 protocol is mainly intended to be a parameterisation interface, but also allows the control of the item servo positioning controller C Series. 3.4.2 USB interface [X19] This interface, too, was mainly intended as a parameterisation interface, but it can also be used for controlling the item servo positioning controller C Series. 3.4.3 UDP interface [X18] The UDP communication enables the connection of the item servo positioning controller C Series to the Ethernet fieldbus system.
Page 36: Technology Module: Profibus
[X1] The item C Series comprises a target table, in which the positioning targets are stored and from which they can later be retrieved. At least four digital inputs serve the purpose of target selection; one input is used as a start input.
Page 37: Technical Data
Technical data Technical data General Technical data Table 5: Technical data: Ambient conditions and qualification Range Values Admissible temperature ranges Storage temperature: -25 °C to +70 °C Operating temperature: 0 °C to +40 °C +40 °C to +50 °C at reduced power 2,5 %/K Admissible installation height Mounting height maximum 2000 m above msl, above 1000 m above msl with power reduction 1% per 100 m...
Page 38: Table 7: Technical Data: Cable Specifications
Technical data Table 7: Technical data: Cable specifications Range Controller C 1- Controller C 1- Controller C 1- Maximum motor cable length for interference emission as per EN 61800-3 for f 10 kHz Category C2 l ≤ 25 m chapter 8.11 Notes on safe and Switch cabinet assembly (see EMC-compliant installation) Category C3...
Page 39: Operating And Display Elements
Technical data Operating and display elements On the front the item Servo Positioning Controller C 1-Series has two LEDs and one seven-segment display to indicate the operating status. Table 9: Display elements and RESET button Element Function Seven segment display...
Page 40: Supply [X9]
Technical data Supply [X9] Table 10: Technical data: Performance data [X9] Type Controller C 1-02 Controller C 1-05 Controller C 1-08 Supply voltage 1 x 100 ... 230 VAC [± 10 %], 50 ... 60 Hz In continuous operation maximum of mains 2,4 A 4,7 A 10 A...
Page 41: Figure 3: Performance Curve Of The Pfc Stage
Technical data Table 13: Performance data of PFC stage Type Controller C 1-02 Controller C 1-05 For a nominal supply voltage of 230 VAC [± 10%]: Continuous power output 500 W 1000 W Peak power output 1000 W 2000 W Below the nominal supply voltage, the power output of the PFC stage is reduced linearly.
Page 42: Motor Connection [X6]
4.4.1 Current derating Differently from the indicated technical motor data the item Servo Positioning Controller C 1-Series have a current derating during nominal operation. The rated current and the time of the maximum allowed peak current of the servo positioning controller depend on different factors.
Page 43 Technical data The last point (electrical rotational frequency) only applies to the C 1-08. For a better clarity, we only distinguish between electrical rotational frequencies less than 2 Hz and those over 3 Hz. For rotational frequencies lying in between these two values, interpolation is required.
Page 44: Table 15: Controller C 1-02: Rated Current For An Ambient Temperature Of ≤ 40 °C
Technical data Table 15: Controller C 1-02: Rated current for an ambient temperature of ≤ 40 °C Parameter Values Power stage clock frequency (kHz) ≤ 12 Output current (A Max. output current (A Max. allowed time (s) Power stage clock frequency (kHz) Output current (A Max.
Page 45: Table 17: Controller C 1-08: Rated Current For Blocked Or Slowly Rotated Servo Motor
Technical data Table 17: Controller C 1-08: Rated current for blocked or slowly rotated servo motor (f ≤ 2 Hz and for an ambient temperature of ≤ 40 °C Parameter Values Power stage clock frequency (kHz) ≤ 10 Output current (A Max.
Page 46: Table 18: Controller C 1-08: Rated Current For Rotated Servo Motor
Technical data Table 18: Controller C 1-08: Rated current for rotated servo motor (f ) ≥ 3 Hz and for an ambient temperature of ≤ 40 °C Parameter Values Power stage clock frequency (kHz) ≤ 10 Output current (A Max. output current (A Max.
Page 47: Motor Feedback Connection [X2A]
Technical data Motor feedback connection [X2A] Different feedback systems can be connected to the item Servo Positioning Controller C 1-Series via the universal encoder interface: Resolver (interface [X2A])  Encoder (interface [X2B])  Incremental encoders with analogue and digital track signals ...
Page 48: Resolver Connection [X2A]
"Motor Data" menu of the item Motion Soft parameterization program so that the item C 1-Series determines the speed correctly. However, the number of pairs of poles can also be identified automatically. The number of pairs of poles of the motor (P...
Page 49 Technical data Standard incremental encoders without commutation signals: This type of encoder is used with low-cost linear motor applications, to save the costs for the provision of the commutation signals (hall sensor). With this type of encoder the ARS 2100 SE series servo drives carry out an automatic pole position determination after power-on.
Page 50 Technical data ISinCoder® encoders like SNS 50 or SNS 60 are no longer supported. Heidenhain encoders: Incremental and absolute encoders by Heidenhain are evaluated. The following series of encoders can be connected: Analog incremental encoders: ROD 400, ERO 1200/1300/1400, ERN 100/400/1100/1300 ...
Page 51: Communication Interfaces
Values Function USB 2.0, Slave–Client, 12 MBaud to 480 MBaud Connector type USB-B, no current consumption from the bus (integrated power supply) Communication protocol item specific (generic device) 4.6.3 Ethernet [X18] Table 23: Technical data: Ethernet [X18] Communication interface Values...
Page 52: Sd/Mmc Card
Technical data 4.6.5 SD/MMC card Table 25: Technical data: SD/MMC card Communication interface Values Card type SD, SDHC and MMC File system FAT12, FAT16 and FAT32 4.6.6 I/O interface [X1] Table 26: Technical data: Digital inputs and outputs [X1] Digital inputs/outputs Values Signal level 24 V (8 V ...
Page 53: Incremental Encoder Input [X10]
Technical data Table 27: Technical data: Analog inputs and outputs [X1] Analog inputs/outputs Values High-resolution ± 10 V input range, 16 Bit, differentially, analog input, AIN 0 < 250 µs delay time Analog input, AIN 1 Optionally, this input can also be ±...
Page 54: Incremental Encoder Output [X11]
Technical data 4.6.8 Incremental encoder output [X11] The output provides incremental encoder signals for processing in superimposed controls. The signals are generated from the encoder’s angle of rotation with a freely programmable number of lines. Besides the encoder signals A and B, the emulation also provides a reset pulse, which goes to high once per rotation (for the programmed number of lines), for the duration of a ¼...
Page 55: Function Overview
5.1.2 Linear motors Besides rotary applications, the item servo positioning controller C 1-Series are also suitable for linear drives. Here also, permanently excited synchronous linear motors are supported. Due to the high signal processing quality, the item C Series is particularly suitable for driving air-core and iron-core synchronous motors with low motor inductances (2 …...
Page 56: Functions Of The Item Servo Positioning Controller C 1-Series
Functions of the item servo positioning controller C 1-Series 5.2.1 Compatibility For compatibility reasons, from the user’s point of view, the control structure of the item C 1-Series has mostly the same characteristics, interfaces and parameters as the previous item C Series. Set point management:...
Page 57: Pulse Width Modulation (Pwm)
5.2.2 Pulse width modulation (PWM) The item servo positioning controller C 1-Series is able to vary the clock frequency in the current controller circuit. ® In most cases the settings can be made using the parameterisation software item Motion Soft .
Page 58: Torque-Controlled Mode
The cycle time of the speed control loop for the item servo positioning controller C 1-Series is twice the PWM period duration, thus typically 208,4 µs. However, it can also be set as an integer multiple of the current controller cycle time.
Page 59: Load Torque Compensation For Vertical Axes
The item servo positioning controller C 1-Series allows master-slave operation, which in the following will be called synchronisation. The controller can serve as master or slave. If the item servo positioning controller C 1-Series is the master, it can provide the slave with its current rotor position at the incremental encoder output [X11].
Page 60: Positioning Control
Option: automatic deceleration in case of missing following positioning Different options on the setup of path programs ® The positioning sets can be activated via all bus systems or via the parameterisation software item Motion Soft . The positioning process can be controlled via digital inputs.
Page 61: Relative Positioning
In the case of jerk-limited positioning the acceleration profile is trapezoidal and the velocity profile is therefore of third order. Since the acceleration changes continuously, the drive is extremely gentle on the mechanics. at time optimal jerk limit jerk limit a(t) a(t) a(t) v(t) v(t) v(t) Figure 5: Driving profiles of item servo positioning controller C 1-Series Page 61...
Page 62: Homing
Every positioning control requires a defined zero at start-up, which is determined by means of a homing. The item servo positioning controller C 1-Series can do this homing on its own. As reference signals it evaluates different inputs, for example the end switch inputs.
Page 63: Positioning Sequences
The number of positions in the corresponding positioning sequence is only limited by the number of totally available positions. Every user-defined positioning set (0 to 255) can be used in the path program. For further information, please refer to the software manual “item Servo Positioning Controller C Series”. 5.3.7 Optional stop input The optional stop input can interrupt the ongoing positioning by setting the selected digital input.
Page 64: Time-Synchronized Multi-Axis Positioning
The implementation of the clock synchronisation allows simultaneous movements for multi-axis applications in conjunction with “interpolated positioning mode”. All servo positioning controllers of the item C 1-Series, that is the entire controller cascade, will be synchronized to the external clock signal. Pending positioning values in the case of multiple axes are then taken over and executed simultaneously without jitter.
Page 65: Functional Safety Technology
In their delivery status, the item servo positioning controller C Series are not equipped with integrated features for the safety- relevant monitoring and control of movements but they are equipped with an extension slot for a safety module.
Page 66: Dip Switch
Functional safety technology 6.1.1 DIP switch The FBA module (Fieldbus Activation Module) and all of the integrated functional safety modules (FSM 2.0) are equipped with a DIP switch (8 poles). Under certain conditions, substantial parts of the parameters of the fieldbus communication can be configured with the aid of this DIP switch.
Page 67: Assignment Of The Dip Switch
Setting of the fieldbus address via DIP switch (addition to the basic node number taken from the parameter data set) If the communication is deactivated via the DIP switch, it is optionally possible to reactivate or deactivate it via the item Motion ®...
Page 68: Table 32: Fieldbus Specific Assignment Of The Dip Switches
Motion Soft and can then be saved in the parameter set of the item C Series. The activation of a fieldbus via the DIP switch takes precedence over the activation of the fieldbus based on the parameter data set.
Page 69: Integrated Safety Technology (Schematic Representation)
Functional safety technology Integrated safety technology (schematic representation) Filter + Rectifier Intermediate circuit Power inverter Synchronus machine Mains Intermediate circuit voltage Control signals Power switch Set values / Actual values Communication Control module Field bus I/Os Parameterisation Current Signal processing + Control digital, Diagnostics analogue...
Page 70: Module Variants
Functional safety technology Module variants 6.3.1 FBA module As a standard, the basic device comes supplied with a so-called “FBA module” (Fieldbus Activation Module) that has a DIP switch (8 poles) on its front panel. Under certain conditions, substantial parts of the parameters of the fieldbus communication can be configured with the aid of this DIP switch.
Page 71: Fsm 2.0 - Sto (Safe Torque Off)
Functional safety technology 6.3.2 FSM 2.0 – STO (Safe Torque Off) Please refer to the Original instructions “FSM 2.0 – STO” for further information. Page 71...
Page 72: Mechanical Installation
Please note that excessive heat may cause premature aging and/or damaging of the device. In case the item servo positioning controller C 1-Series are subject to high thermal stress, a space of...
Page 73: Figure 10: Item Servo Positioning Controller C 1-Series: Installation Space
Mechanical installation Figure 10: item servo positioning controller C 1-Series: Installation space Page 73...
Page 74: View Of The Device
Mechanical installation View of the device Figure 11: item servo positioning controller C 1-02: Front view Page 74...
Page 75: Figure 12: Item Servo Positioning Controller C 1-02: Top View
Mechanical installation [X11] OUT [X10] IN [X1] I/O [X9] Figure 12: item servo positioning controller C 1-02: Top view [X2B] ENCODER [X2A] RESOLVER [X6] Figure 13: item servo positioning controller C 1-02: Bottom view Page 75...
Page 76: Mounting
Mounting The item servo positioning controller C 1-Series has attachment lugs on the top and the bottom of the device. These lugs are used to mount the servo positioning controller vertically to a control cabinet plate. The lugs are part of the cooling body profile.
Page 77: Electrical Installation
Electrical installation Electrical installation Connector configuration The item servo positioning controller C 1-Series is connected to the supply voltage, the motor, the brake resistor and the holding brakes as shown in Figure 15 100VAC ... 230 VAC main fuse Power Supply [X9]...
Page 78: Item C 1-Series Complete System
The item servo positioning controller C 1-Series must be connected to ground with its PE connection. The item C 1-Series must be completely wired first. Only then the operating voltages for the DC bus and the electronics may be switched on. In the case of inversed wiring of the operating voltage connections, excessive operating voltage or in the case of confusing the connections for operating voltage and motor the servo positioning controller will be damaged.
Page 79: Figure 16: Complete Setup Of The Item C 1-Series With Motor And Pc
Electrical installation Figure 16: Complete setup of the item C 1-Series with motor and PC Page 79...
Page 80: Connection: Power Supply [X9]
Electrical installation Connection: Power supply [X9] The item servo positioning controller C 1-Series receives its 24 VDC power supply for the control electronics via connector [X9]. The mains voltage supply is single-phase. As an alternative to AC feed or for the purpose of DC bus coupling a direct DC supply for the DC bus is possible.
Page 81: Pin Assignment [X9]
Electrical installation 8.3.3 Pin assignment [X9] Table 33: Pin assignment: [X9] Pin No. Denomination Values Specification 100 ... 230 VAC [± 10 %], Phase conductor 50 ... 60 Hz Neutral conductor < 440 VDC Pos. DC bus voltage GND_ZK Neg. DC bus voltage BR-INT <...
Page 82: Connection Notes [X9]
C 1-08: PHOENIX COMBICON MSTB 2,5/9-ST-5,08 BK The item servo positioning controller C 1-Series has an internal brake chopper with brake resistor. For more brake power it is possible to connect an external brake resistor to the connector [X9]. If no external brake resistor is used, a bridge must be connected between PIN 5 and PIN 6 so that the DC bus precharge, when the mains power supply is “ON”, and the DC bus rapid discharge can function properly!
Page 83: Connection: Motor [X6]
Electrical installation Connection: Motor [X6] 8.4.1 Device side [X6] C 1-02 and C 1-05 PHOENIX MINI-COMBICON MC1.5/9-G-5.08 BK C 1-08 PHOENIX COMBICON MSTBA 2,5/9-G-5.08 BK 8.4.2 Counterplug [X6] C 1-02 and C 1-05 PHOENIX MINI-COMBICON MC1.5/9-ST-5.08 BK C 1-08 PHOENIX COMBICON MSTB 2,5/9-ST-5,08 BK C 1-02 and C 1-05 PHOENIX MINI-COMBICON connector housing 12-pole, KGG-MC1,5/12 BK...
Page 84: Pin Assignment [X6]
Electrical installation 8.4.3 Pin assignment [X6] Table 34: Pin assignment: [X6] Pin No. Denomination Values Specification 0 V brake Holding brake (motor), signal level dependent on switch status, high side / low 24 V brake side switch Connection for inner shield (holding brake + temperature sensor) Motor temperature sensor , N.C.
Page 85: Connection Notes [X6]
Connect total shield on motor side flat to connector or motor housing; maximum length 40 mm. Via terminals ZK+ and ZK- the DC buses of several item servo positioning controller C 1-Series can be interconnected. The coupling of the DC bus is interesting for applications with high brake energies or if movements have to be carried out even in the case of power failure.
Page 86: Figure 19: Connecting A Holding Brake With High Current Draw (> 1A) To The Device
Electrical installation Resistor and capacitor item C 1-Series for spark extinguishing Free-wheeling diode Motor with holding brake Figure 19: Connecting a holding brake with high current draw (> 1A) to the device The switching of inductive direct current via relay produces strong currents and sparking. For interference suppression we recommend integrated RC suppressor elements, for example by Evox RIFA, denomination: PMR205AC6470M022 (RC element with 22 Ω...
Page 87: Connection: I/O Communication [X1]
The item servo positioning controller C 1-Series is shown on the right hand side, the control system connection on the left. The cable design is also visible. The item servo positioning controller C 1-Series features two potential ranges: Analog inputs and outputs: All analog inputs and outputs refer to AGND.
Page 88: Figure 20: Basic Circuit Diagram Connector [X1]
If the control comprises single-ended outputs, the output is connected to AIN 0 and #AIN 0 is put on the reference potential of the control. If the control has differential outputs, they are to be connected 1:1 to the differential inputs of the item servo positioning controller C 1-Series.
Page 89: Device Side [X1]
+ 10 V. These outputs can be led to the superimposed control, the reference potential AGND must be carried along. If the control has differential inputs, the "+"-input of the control is connected to the output of the item servo positioning controller C 1-Series and "-"-input of the control with AGND.
Page 90: Pin Assignment [X1]
Electrical installation 8.5.3 Pin assignment [X1] Table 35: Pin assignment: I/O communication [X1] Pin No. Denomination Values Specification AGND Shield for analog signals, AGND AGND Reference potential for analog signals AIN 0 = ± 10 V Setpoint input 0, differential, max. 30 V input voltage ≥...
Page 91: Cable Type And Design [X1]
For optimal interference suppression on the analog signals the cores for the analog signals are to be shielded together and separate from others. This internal cable shield is connected to AGND (Pin 1 or 14) on one side of the item C 1-Series. It can be connected on both sides in order to establish a connection between the reference potentials of the control and the item servo positioning controller C 1-Series.
Page 92: Connection: Resolver [X2A]
Electrical installation Connection: Resolver [X2A] 8.6.1 Device side [X2A] 1 D-SUB connector, 9-pole, female 8.6.2 Counterplug [X2A] D-SUB connector, 9-pole, male Housing for 9-pole D-SUB connector with bolting screws 4/40 UNC 8.6.3 Pin assignment [X2A] Table 36: Pin assignment: [X2A] Pin No.
Page 93: Cable Type And Design [X2A]
Pin assignment: Resolver connection [X2A] The outer shield is always connected to PE (connector housing) on the controller side. The three inner shields are connected on one side of the item servo positioning controller C 1-Series to PIN3 of [X2A]. Page 93...
Page 94: Connection: Can-Bus [X4]
*) External terminating resistor 120 Ω required on both ends of the bus. If the bus ends are not formed by item C 1-Series servo positioning controllers with integrated terminating resistors, we recommend using metal film resistors with a 1 % tolerance of type 0207, for example made by BCC, order no.: 232215621201.
Page 95: Cable Type And Design [X4]
(see On both ends of the CAN bus cable must be exactly one terminating resistor of 120 Ω +/- 5 %. The item servo positioning controller C 1-Series is equipped with an integrated terminating resistor that can be activated/deactivated with the aid of the...
Page 96: Figure 23: Integrated Can Terminating Resistor
The shield of the cable is led to the CAN shield connections for all nodes chapter 8.7.4 Cable type and design [X4] For suitable and item-recommended cables please refer to We advise against the use of plug adaptors for CAN bus cabling. Should this be necessary nonetheless, make sure to use...
Page 97: Connection: Rs232/Com [X5]
Electrical installation Connection: RS232/COM [X5] 8.8.1 Device side [X5] D-SUB connector, 9-pole, male 8.8.2 Counterplug [X5] D-SUB connector, 9-pole, female Housing for 9-pole D-SUB connector with bolting screws 4/40 UNC 8.8.3 Pin assignment [X5] Table 38: Pin assignment: RS232 interface [X5] Pin No.
Page 98: Cable Type And Design [X5]
Electrical installation 8.8.4 Cable type and design [X5] Interface cable for serial interface (null modem), 3-core. 8.8.5 Connection notes [X5] D-SUB connector at X5 Female Female Connector housing Connector housing Figure 24: Pin assignment: RS232 null modem cable [X5] Page 98...
Page 99: Connection: Usb [X19]
Electrical installation Connection: USB [X19] 8.9.1 Device side [X19] USB female, type B 8.9.2 Counterplug [X19] USB male, type B 8.9.3 Pin assignment [X19] Table 39: Pin assignment: USB interface [X19] Pin No. Denomination Values Specification + 5 VDC Data - Data + Figure 25: Pin assignment: USB interface [X19], front view...
Page 100: Sd/Mmc Card
Electrical installation 8.10 SD/MMC card 8.10.1 Supported card types SDHC 8.10.2 Supported functions Load a parameter set (DCO file) Save the current parameter set (DCO file) Load a firmware file 8.10.3 Supported file systems FAT12 FAT16 FAT32 8.10.4 File names Only file and directory names according to the 8.3 standard are supported.
Page 101: Pin Assignment Sd/Mmc Card
Electrical installation 8.10.5 Pin assignment SD/MMC card Table 40: Pin assignment: SD card Pin No Denomination SD Mode SPI Mode DATA3/CS Data Line 3 (Bit 3) Chip Select CMD/DI Command/Response Host to Card Commands and Data Vss1 Supply Voltage Ground Supply Voltage Ground Supply Voltage Supply Voltage...
Page 102: Boot-Dip-Switch
Electrical installation Figure 26: Pin assignment: SC/MMC card 8.10.6 BOOT-DIP-Switch During a restart/reset, the BOOT-DIP-Switch is used to determine whether to perform a firmware download from the SD/MMC card or not. BOOT-DIP-Switch in position “ON”  firmware download requested BOOT-DIP-Switch in position “OFF” ...
Page 103: Notes On Safe And Emc-Compliant Installation
Execution and type of wiring Superimposed control In order to increase interference immunity and to decrease interference emissions the item servo positioning controller C 1- Series already comprises output chokes and mains filters, so that it can be operated without additional shielding and filtering devices in most applications.
Page 104: Emc Areas: First And Second Environment
The following must be considered for an EMC-compliant setup of the drive system (see also page 77 In order to keep the leakage currents and the losses in the motor connection cable as small as possible, the item servo chapter 8.11.5...
Page 105: Operation With Long Motor Cables
Electrical installation DANGER! For safety reasons, all PE ground conductors must be connected prior to initial operation. The EN 61800-5-1 regulations for protective earthing must be complied with during installation! 8.11.5 Operation with long motor cables Compliance with the EMC standard EN 61800-3 is only guaranteed for motor cable lengths of up to 25 m. For cable lengths beyond this a new measurement of the interference emission may possibly be required.
Page 106: Esd Protection
To prevent such discharge, protective caps are available (for example Spoerle). The item servo positioning controller C 1-Series has been designed to provide high interference immunity. For that reason, some individual functional blocks are electrically isolated. Inside the device the signals are transmitted via optocouplers.
Page 107: Additional Requirements For The Servo Drives Concerning The Ul Approval
Additional requirements for the servo drives concerning the UL approval Additional requirements for the servo drives concerning the UL approval This chapter gives further information concerning the UL approval of the C 1-02, C 1-05 and C 1-08. Circuit protection In case of a required UL-certification the following data for the main fuse are to be considered: Listed Circuit Breaker according to UL 489, rated 277 Vac, 16 A, SCR 10 kA Wiring and environment regards...
Page 108: Initial Operation
Initial operation Initial operation 10.1 General notes on connection Since the laying of the connection cables is very important in terms of EMC, make sure to comply with the chapter 8.11.4 EMC-compliant cabling (page 104) previous DANGER! chapter Safety notes for electrical drives and (page 16) Noncompliance with controllers...
Page 109: Connecting The Item Servo Positioning Controller C 1-Series To The Power Supply
Plug the plug A of the USB interface cable into the socket for the USB interface of the PC Plug the plug A of the USB interface cable into the socket [X19] USB of the item servo positioning controller C 1-Series Check all of the plug-and-socket connections once more 10.7...
Page 110: Service Functions And Error Messages
11.1.1 Overview The item servo positioning controller C 1-Series has a powerful sensor analysis, which monitors the proper functioning of the controller, power output stage, motor and communication with the outside world. All occurring errors are stored in an internal error memory.
Page 111: Overvoltage Monitoring For The Dc Bus
I²t monitoring The item servo positioning controller C 1-Series comprises an I²t monitoring to limit the average power loss in the power output stage and in the motor. Since the occurring power loss in the power electronics and in the motor in the worst case increases square with the current, the squared current value is assumed as the measure for the power loss.
Page 112: Power Monitoring For The Brake Chopper
Servo positioning controllers, which are sent to item for service, will be equipped with a different firmware and other parameters for testing purposes. Before the next initial operation at the customer the item servo positioning controller C 1-Series must be parameterized again. ®...
Page 113: Display Of Operating Mode And Error Messages
A warning is displayed at least twice on the seven-segment-display. The numbers are successively indicated. Option “STO” (Safe Torque-Off) active for the item servo positioning controller C Series. (seven-segment display = “H”, blinking with a frequency of 2 Hz) Page 113...
Page 114: Error Messages
Error messages If an error occurs, the item servo positioning controller C Series will cyclically show an error message in its seven-segment display. The error message is comprised of an E (for Error), a main index (xx) and a sub index (y), for example: E 0 1 0.
Page 115: Table 44: Error Messages
Service functions and error messages Table 44: Error messages Error message Meaning of the error message Measures Main Sub index index Invalid error Information: Only for connected service module. An invalid (corrupted) entry in the error buffer has been marked by this error number.
Page 116 Service functions and error messages Error message Meaning of the error message Measures Main Sub index index Undervoltage of the DC bus circuit Error priority set too high? Check the power supply. Check (measure) the DC bus circuit voltage. Check the response threshold of the DC bus circuit monitoring system.
Page 117 Service functions and error messages Error message Meaning of the error message Measures Main Sub index index X10, X11 and RS232 supply voltage Check the pin assignment of the connected peripheral failure equipment. Check the connected peripheral equipment for short-circuits. Safety module internal voltage failure Safety module defective? Replace the safety module.
Page 118 Service functions and error messages Error message Meaning of the error message Measures Main Sub index index Internal angle encoder error The internal monitoring system of the angle encoder at [X2B] has detected an error. Communication error? If necessary, contact the Technical Support. Encoder at [X2B] not supported Please contact the Technical Support.
Page 119 Service functions and error messages Error message Meaning of the error message Measures Main Sub index index Homing: timeout The maximum time that has been parameterised for homing has been reached before the homing run could be completed. Check the parameterisation of the time. Homing: wrong/invalid limit switch The associated limit switch is not connected.
Page 120 Service functions and error messages Error message Meaning of the error message Measures Main Sub index index CAN: Align the cycle time of the remote frames with the PLC or node Guarding failure of the PLC. Signals disturbed? CAN: Check the configuration. RPDO too short CAN: Check the command syntax of the control (record the data...
Page 121 Service functions and error messages Error message Meaning of the error message Measures Main Sub index index Invalid number of pole pairs The calculated number of pole pairs is beyond the parameterisation range. Check the data sheet of the motor. If necessary, contact the Technical Support.
Page 122 Service functions and error messages Error message Meaning of the error message Measures Main Sub index index PROFIBUS: Check the slave address. communication error Check the bus terminators. Check the cabling. PROFIBUS: Incorrect slave address. Please select another slave address. invalid slave address PROFIBUS: error in value range Mathematical error during the conversion of physical units.
Page 123 Service functions and error messages Error message Meaning of the error message Measures Main Sub index index Error in data tables (CAM) Load the default parameter set and perform a start-up procedure. If necessary, reload the parameter set. If necessary, contact the Technical Support. Following error warning threshold Check the parameterisation of the following error.
Page 124 Service functions and error messages Error message Meaning of the error message Measures Main Sub index index DC bus circuit discharge time exceeded Bridge for the internal brake resistor installed? Check the connection of the external braking resistor. If necessary, contact the Technical Support. No power supply for the controller No DC bus circuit voltage? enable signal...
Page 125 Service functions and error messages Error message Meaning of the error message Measures Main Sub index index Positioning: no follow-up position: stop The positioning target cannot be reached with the current positioning options or boundary conditions. Positioning: reversal of rotation not Check the positioning parameters.
Page 126 Service functions and error messages Error message Meaning of the error message Measures Main Sub index index SDO error occurred Please contact the Technical Support. No or unknown FSM module or faulty Cause: Internal voltage error of the safety module or of driver supply the fieldbus activation module.
Page 127 Service functions and error messages Error message Meaning of the error message Measures Main Sub index index FSM: Fault in SSIO communication Cause: Error in the internal communication connection between the basic device and the safety module. Action: Identify interfering radiators in the environment of the servo drive.
Page 128 Service functions and error messages Error message Meaning of the error message Measures Main Sub index index with active PWM activation Action: The safe status was requested with power output stage enabled. Check integration into the safety- orientated interface. FSM: Rotational speed limits in basic Cause: Basic device reports error if the currently device overlap...
Page 129 Service functions and error messages Error message Meaning of the error message Measures Main Sub index index Action: See USF0, error 53-0. USF2: Safety condition violated Cause: Violation of monitored speed limits of the SSF2 in operation / when USF2 / SSF2 requested. Action: See USF0, error 53-0.
Page 130 Service functions and error messages Error message Meaning of the error message Measures Main Sub index index Action: Check when the violation of the safety condition occurs: During dynamic braking to zero. After the drive has reached zero speed. With a) Check of braking ramp – record measuring data - can the drive follow the ramp? Change parameters for the slowdown ramp or start time / delay times for monitoring.
Page 131 Service functions and error messages Error message Meaning of the error message Measures Main Sub index index Action: Check when the violation of the safety condition occurs: During dynamic braking to zero. After the drive has reached zero speed. With a) Check of braking ramp – record measuring data - can the drive follow the ramp? Change parameters for the slowdown ramp or start time / delay times for monitoring.
Page 132 Service functions and error messages Error message Meaning of the error message Measures Main Sub index index Action: Check whether the error can be acknowledged and whether it occurs again upon a new STO request – if yes: Basic device is presumably faulty.
Page 133 Service functions and error messages Error message Meaning of the error message Measures Main Sub index index Action: Error may occur with SIN/COS and Hiperface encoders. Check the position encoder. Check the connection wiring (broken wire, short between two signals or signal / screening). Check the supply voltage for the position encoder.
Page 134 Service functions and error messages Error message Meaning of the error message Measures Main Sub index index Action: Check the position encoder at X2B. Check the connection wiring (broken wire, short between two signals or signal / screening). Check the supply voltage for the ENDAT encoder. Check the motor cable / screening on motor and drive side –...
Page 135 Service functions and error messages Error message Meaning of the error message Measures Main Sub index index Action: Check the connected position encoder: If further error messages occur in conjunction with the encoders, then eliminate their cause first. Check the motor and encoder cable / screening on motor and drive side.
Page 136 Service functions and error messages Error message Meaning of the error message Measures Main Sub index index Error, cross-comparison of encoder Cause: Cross-comparison between µC1 and µC2 has analysis detected an angle difference or rotational speed difference or difference in capture times for the position encoders.
Page 137 Service functions and error messages Error message Meaning of the error message Measures Main Sub index index Action: Check the connection wiring for the digital outputs DOUT40 ... DOUT42 (short circuit, cross circuit, etc.). Check the connection wiring for the brake (short circuit, cross circuit, etc.).
Page 138 Service functions and error messages Error message Meaning of the error message Measures Main Sub index index Action: Check the external active and passive sensors – do they switch on two channels and simultaneously (within the parameterised discrepancy time). Two-handed control device: Check how the device is operated by the user –...
Page 139 - this may overload the communication connection. Check whether the firmware versions of the safety module and basic device and the versions of the item Motion Soft® and SafetyTool are compatible. Communication module - basic device Cause: Packet counter error during transmission µC1 µC2...
Page 140 Action: Internal malfunction in the servo drive. Check whether the firmware versions of the safety module and basic device and the versions ® of the item Motion Soft and SafetyTool are compatible. Error in cross-comparison for Cause: Timeout during cross-comparison (no data) or processors 1 - 2 cross-comparison faulty (data for µC1 and µC2...
Page 141 Service functions and error messages Error message Meaning of the error message Measures Main Sub index index Action: This is an internal error in the module that should not occur during operation. Check the operating conditions (temperature, air humidity, condensation). Check the EMC wiring as specified and screening design;...
Page 142 Clarify: What is the status of the installed safety module - does it contain a valid parameter set? Read out and analyse the permanent event memory of the basic device via item Motion Soft® Eliminate error causes step by step.
Page 143 Service functions and error messages Error message Meaning of the error message Measures Main Sub index index Action: Check the firmware version of the basic device and the version of the safety module – update available? Safety module faulty; replace. Ethernet user-specific (1) Please contact the Technical Support.
Page 144 Service functions and error messages Error message Meaning of the error message Measures Main Sub index index DeviceNet: overflow of transmit buffer Reduce the number of message per time unit that are to be transmitted. DeviceNet: IO send error Please contact the Technical Support. DeviceNet: bus Off Check the DeviceNet wiring.
Page 145 Service functions and error messages Error message Meaning of the error message Measures Main Sub index index IRQ: speed controller overflow IRQ: position controller overflow IRQ: interpolator overflow IRQ: Please contact the Technical Support. low-level overflow IRQ: MDC overflow Sequence control: general For information only, no measures required.
Page 146 Service functions and error messages Error message Meaning of the error message Measures Main Sub index index IRQ 0 (current controller): trigger error CAN controller not available Device parameters checksum error DEBUG-Firmware loaded Internal initialisation error Please contact the Technical Support. Memory error Controller/power stage code read error Internal software initialization error...
Page 147: Technology Modules
The PROFIBUS-DP interface provides an additional field bus connection. All functions and parameters can be addressed directly, for example from a Simatic S7 control system. The interface is plugged into the technology slot TECH 2 of the item servo positioning controller C Series.
Page 148: Figure 27: Profibus-Dp Interface: Front View
Technology modules Table 46: Technical data: PROFIBUS-DP interface: Interfaces and communication Communication interface PROFIBUS module Controller PROFIBUS controller VPC3+, 12 Mbaud max. Protocol PROFIBUS-DP, 32-byte telegrams with operating-mode-depending configuration Interface Floating, D-SUB 9-pin, integrated bus terminating resistors (can be activated by DIP switches) Special functions Support of diagnosis data, RTS signal led out, fail-safe mode, sync/freeze The following elements can be found on the front plate of the PROFIBUS-DP interface (see...
Page 149: Pin Assignments And Cable Specifications
Technology modules 12.1.3 Pin assignments and cable specifications 12.1.3.1 Pin assignment 9-pin DSUB connector, female Table 47: Pin assignment: PROFIBUS-DP interface Pin no. Denomination Values Specification Shield Cable shield +5 V +5V output (floating) Not used Not used RxD / TxD-P B-line transmission / reception data RxD / TxD-N A-line transmission / reception data...
Page 150: Termination And Bus Terminating Resistors
Technology modules 12.1.4 Termination and bus terminating resistors Every bus segment of a PROFIBUS network has to be equipped with bus terminating resistors to minimise line reflections and to adjust a defined rest potential on the line. The bus termination has to be provided at the beginning and at the end of every bus segment.
Page 151: Ethercat
EtherCAT 12.2.1 Product description The EtherCAT technology module enables the connection of the item servo positioning controller C Series to the EtherCAT fieldbus system. The communication via the EtherCAT interface (IEEE-802.3u) is realised with the aid of standard EtherCAT cabling.
Page 152: Technical Data
Technology modules Figure 29: EtherCAT module: Front view 12.2.3 Technical data Table 48: Technical data: EhterCAT module: Ambient conditions, dimensions and weight Range Values Storage temperature range -25°C to +75°C Operating temperature range 0°C to 50°C Atmospheric humidity 0..90%, non-condensing Altitude up to 2000 m above msl External dimensions (LxWxH):...
Page 153: Table 50: Signal Level And Differential Voltage
Technology modules Element Function LED 1 Run (green), link/activity EtherCAT port 1 (red), Two-colour-LED (green/red) EtherCAT active (yellow) LED 2 (red) Link/activity EtherCAT port 2 12.2.5 EtherCAT interface Table 50: Signal level and differential voltage Signal level 0 ... 2.5 VDC Differential voltage 1.9 ...
Page 154: Figure 30: Servo Positioning Controller With Integrated Technology Module
Make sure that ESD protection measures are taken when handling technology modules. To insert a technology module into the item servo positioning controller C 1-Series, please proceed as follows: Remove the front plate of the technology slot (TECH 1 or TECH 2) of the servo positioning controller with a suitable Phillips screwdriver.

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