PD PRJ HW

Legal notice
All rights reserved ELAU AG, even in the case of application for property rights.
No part of this documentation or the related software and firmware may be reproduced,
rewritten, stored on a retrieval system, transmitted, or translated into any other lan
guage without the express written consent of ELAU AG.
Every imaginable measure was taken to guarantee the correctness of this product
documentation. However, as improvements are continually being made to the hard
ware and software, ELAU AG cannot guarantee its completeness or correctness.
Trademark
PacDrive is a registered trademark of ELAU AG.
All other trademarks named in this documentation are the sole property of their re
spective manufacturer.
ELAU AG
Dillberg 12
97821 Marktheidenfeld, Germany
Tel.: +49 (0) 9391 / 606 - 0
Fax: +49 (0) 9391 / 606-300
E-mail: info@elau.de
Internet: www.elau.de
Legal notice
Page 2 PacDrive ELAU AG
Contents
1 About this Manual 5
1.1 Introduction ............................................................................................................... 5
1.2 Symbols, designator and display format of safety notes .......................................... 7
2 Safety instructions 8
2.1 Proper use ................................................................................................................ 8
2.2 Selection and qualification of personnel ................................................................... 9
2.3 Residual risks ......................................................................................................... 10
3 Switch Cabinet Planning 17
3.1 Protection Class ..................................................................................................... 17
3.2 Ambient conditions in the switch cabinet ................................................................ 17
3.3 ESD Protection Measures ...................................................................................... 18
3.4 Assembly Procedure .............................................................................................. 18
3.5 Using Cooling Units ................................................................................................ 22
4 Wiring Notes 24
4.1 General ................................................................................................................... 24
4.2 EMC Rules ............................................................................................................. 26
4.3 PacDrive MC-4 Mains Connection ......................................................................... 28
4.4 PacDrive Controllers and MC-4 Control Voltage Connection ................................. 30
4.5 DC Circuit ............................................................................................................... 31
5 Basic Design and Connection 33
5.1 Power Circuit .......................................................................................................... 33
5.2 Control Circuit ......................................................................................................... 34
6 Functional safety - safety connections 36
6.1 Machine safety ....................................................................................................... 36
6.2 Circuit suggestion for PacDrive system with MC-4 ................................................ 36
6.2.1 Funktionsbeschreibung .......................................................................................... 37
Contents
ELAU AG PacDrive Page 3
6.2.2 Redundant stopping ............................................................................................... 37
6.2.3 Inverter enable circuit (IE) ...................................................................................... 38
6.2.4 Level definitions ...................................................................................................... 38
6.2.5 Impermissible application ....................................................................................... 38
6.2.6 Switching components ........................................................................................... 39
6.2.7 PacDrive controller C200 ....................................................................................... 40
6.2.8 Wiring diagram for PacDrive controllers MAx-4, C400/600 and P600 ................... 42
6.2.9 Wiring diagram for PacDrive controller C200 ......................................................... 43
6.3 Connection of Watchdog and Ready contacts for PacDrive controllers ................. 44
6.4 Extended safety functions for PacDrive MC-4 with SMX Safe PLC ....................... 45
6.4.1 Funktionsbeschreibung .......................................................................................... 45
6.4.2 Circuit suggestion ................................................................................................... 48
6.4.3 Validation example of the SMX12 safety functions ............................................... 58
6.5 Circuit suggestion: PacDrive system with DB-5 and iSH ....................................... 60
6.5.1 Inverter Enable function ......................................................................................... 60
7 Special Conditions 86
8 Appendix 88
8.1 Addresses .............................................................................................................. 88
8.2 Additional Literature ............................................................................................... 89
8.3 Product Training Courses ....................................................................................... 91
8.4 Changes ................................................................................................................. 92
Contents
1 About this Manual
1.1 Introduction
Read this manual before you work on the ELAU component for the first time. Take
particular note of the safety instructions. As described in section 2.4, only those per
sons who meet the Selection and qualification of employees are allowed to work on
this unit.
A copy of this manual must always be available for personnel who are entrusted to
work on the component.
This manual is intended to help you use the ELAU component and its intended appli
cations safely and properly.
Follow the instructions in this manual. Doing so helps avoid hazards, minimize repair
costs and downtime, extend service life and increase reliability.
1.1 Introduction
1 About this Manual
1.2 Symbols, designator and display format of safety notes
This manual divides the safety instructions into four various categories.
Hazards and possible results will be categorized using a certain combination of sym
bols and signal words.
Symbol / Signal word Meaning
Indicates an immediate hazardous situation that can lead to death or
serious bodily injury if the safety regulations are not observed.
Indicates a potentially hazardous situation that can lead to serious injury
or extensive property damage if the safety regulations are not observed.
Indicates a potentially hazardous situation that may result in minor bodily
harm or property damage if the safety regulations are not observed.
Indicates a potentially dangerous situation that may result in property
damage if the safety regulations are not observed.
The following symbols and designators are used in this document:
Symbol/Character Meaning
Information symbol: After this symbol, you will find instructions and useful
tips on using the components.
Marker: After this symbol, you will find references for further information.
Orientation aid: Information serving as an orientation aid regarding the
section's contents follows this symbol..
Keyword
If the descriptive text contains technical terms (such as parameters), they
are highlighted in bold.
Program code is written in a different font.
First level bullet point or the requirement of a instruction
Second level bullet point.
Activity symbol: The text after this symbol contains instructions. Follow
the instructions in sequence from top to bottom.
Result symbol: The text after this symbol contains the result of an action.
1.2 Symbols, designator and display format of safety notes
2 Safety instructions
This section contains general requirements for safe work. Each person who uses or
works on the ELAU component must read and follow these general safety instruc
tions.
If activities involve residual risks, a specific note is made at the appropriate points. The
note details the potential hazard and describes preventative measures to avoid it.
2.1 Proper use
The ELAU component is are intended to be installed in a machine or assembled with
other components to form a machine or system. You may only use them in accordance
with the installation and operating conditions described in the documentation. Use only
the options and add-ons specified in the documentation. You may not use any third-
party devices or components that are not expressly approved by ELAU.
The ELAU components must not be used in the following environments:
in dangerous (explosive) atmospheres
in mobile, movable or floating systems
in life support systems
in domestic appliances
The ELAU component is part of the PacDrive System. The PacDrive System is the
complete control system comprising of
PacDrive Controller of C- or P-Series,
PacDrive Servo amplifier MC-4 and
PacDrive Motor.
For proper use, you must also:
Observe the operating instructions and other documents and
adhere to the inspection and maintenance instructions.
The operating conditions at the installation location must be checked and maintained
in accordance with the required technical data (performance data and ambient condi
tions). Commissioning is prohibited until it is guaranteed that the usable machine or
system in which the component is installed meets all requirements of EC Directive
98/37/EC (machinery directive).
2.2 Selection and qualification of personnel
This description is geared exclusively toward technically qualified personnel, who have
detailed knowledge in the field of automation technology. Only qualified personnel can
recognize the importance of the safety instructions and implement them consistent
ly.
The description is mainly for construction and application engineers from the engi
neering and electro-technics division as well as service and commissioning engineers.
Professional or training personnel
Work on the component may only be carried out by qualified professional or by trained
staff under the instruction and supervision of a qualified person in accordance with
electrical regulations. Work may only be carried out by qualified professional or by
trained staff under the instruction and supervision of a qualified person in accordance
with electrical regulations. Qualified persons are
Evaluate the transferred work,
Recognize possible hazards and
Take appropriate safety measures.
Follow the additional instructions if you use the Inverter Enable Function.
2.2 Selection and qualification of personnel
2.3 Residual risks
Health risks arising from of the component have been reduced by means of safety
technology and design engineering. However a residual risk remains, since the com
ponent works with electrical voltage and electrical currents.
Motion Sequence Robot
Motion sequences can occur when operating with robot mechanics, which allow op
erational staff to make misjudgments. Particular attention must be paid to ensuring
that all necessary safety measures are implemented to avert any danger to life and
limb. The safety standards for the country where the equipment is in use, define which
safety measures are appropriate. Additionally, the System Engineer who is responsi
ble for the integration of the robot mechanics, must evaluate which measures must be
taken. Parts of the mechanics can move at very high speeds. In such cases, the weight
of the net loading of any additionally installed tools and any shifts in the center of gravity
of the parts that are moved, contribute to the total energy of the powers generated.
WARNING
Risk of injury in the working area of the robot.
Risk of bodily harm from crushing, shearing, cutting, and hitting!
All barriers, safety doors, contact mats, light barriers, etc. must be installed cor
rectly and must be activated, as long as the robot mechanics are powered-up.
Define the safety clearance to the working area of the robot such that operational
staff do not have any access to the robot mechanics danger zone.
The configuration of the robot mechanics, the articulation speed, the articulation
direction as well as the additional load have an effect on the total energy, which
can potentially cause damage.
CAUTION
The robot mechanics are not supplied with an emergency stop switch to trigger the brakes.
The constructing engineer must however ensure that if the robot mechanics are no longer
powered up, the robot arms can be moved manually in an emergency. This is particularly
important in the event that operational staff are caught and trapped by the robot mechanics.
Mounting and handling
WARNING
Risk of injury during handling!
Risk of bodily harm from crushing, shearing, cutting, and hitting!
Observe the general construction and safety regulations for handling and mount
ing.
Use suitable mounting and transport equipment correctly and use special tools
if necessary.
Prevent clamping and crushing by taking appropriate precautions.
Wear suitable protective clothing (for example, safety goggles, safety boots, pro
tective gloves).
Do not stand under suspended loads.
Attachments or rebuilds
If different products are transported by the robot mechanics, the seating for the product
must be modified. For this reason, different grippers may be built onto the gripper. In
this respect, it must be ensured that the articulation movement is not restricted and/or
that no motion errors can result from the modifications. It is strictly forbidden to drill
into or modify the articulation arms, to modify the cable loom, to modify access enclo
sures and covers and to modify any of the components of the movable mechanics.
Attachments and rebuilds may not influence the operation of the protective devices in
any way and all emergency stop buttons must be accessible at all times.
Touching electrical parts
If parts have contact with voltages greater than 50 V, it can be a hazard for personnel.
When electrical devices are in operation, certain parts of these devices must neces
sarily carry dangerous voltages.
DANGER
High voltage!
Electric shock, fire or explosion
Observe the general construction and safety regulations for working on high-
current electrical systems.
After installation, check the fixed connection of the ground conductor to all elec
trical units to ensure that connection complies with the connection diagram.
Generally, and also for brief measurements and inspections, operation is only
allowed using a fixed connection from the ground conductor to all electrical com
ponents.
Disconnect the unit from the power supply before working on electrical parts with
a voltage greater than 50 volts. Prevent the unit from being switched back on.
Wait at least 5 minutes after switching off before accessing the components.
Check the voltage with a voltage meter before accessing the unit to be sure that
the voltage is less than 50 volts.
Do not touch the electrical connection points of the components when the unit is
switched on.
Before enabling the device, safely cover the live components to prevent contact.
The following provides protection against indirect contact (DIN EN 50178, Sec
tion 5.3.2).
2.3 Residual risks
High leakage current
DANGER
High leakage current
Risk of death
The leakage current is greater than 3.5 mA. This is why units require a fixed
connection to the power supply network (in accordance to DIN EN 50178 -
Equipping high-current electrical systems).
Touching hot surfaces
The housing temperature of the motor exceeds 70C during nominal operation. As
warning, the symbol shown here is affixed on the motor.
At high tact cycles, the robot mechanics base plate can reach high temperatures. This
warms up the surfaces of the mechanics.
WARNING
Hot surfaces
Risk of burns from surface temperatures up to 100 C.
Wear safety gloves or wait until the surface temperature has cooled to allow safe
contact!
Attach protective cover or touch guard.
Noise protection measures
The noise level of the robot mechanics depends on the tact cycle and the net loading.
You should be aware of the fact that noise emissions multiply when several robot
mechanics are in use at the same time. If noise emissions reach a value 85dBA, any
staff affected must wear ear defenders. In this case, the manufacturer of the machine
or the company operating the machine must install the following warning symbol in a
highly visible location on the robot mechanics.
Dangerous Movements
There can be different causes of dangerous movements:
Wiring or cabling errors
Errors in the application program
Component errors
Error in the measured value and signal transmitter
Operation error
Personal safety must be guaranteed by primary equipment monitoring or measures.
Don't just rely on the internal monitoring of the drive components. Monitoring or meas
ures should be implemented based on the specific characteristics of the equipment,
in line with a risk and error analysis. This includes the valid safety regulations for the
equipment. Under no circumstances must the technical safety devices be removed.
Do not make any modifications to a protective device that may put it out of operation.
Protect existing work stations against unauthorized operation. Effectively restrict ac
cess to the control terminals to allow access only to authorized persons.
2.3 Residual risks
DANGER
Dangerous Movements!
Risk of death, serious injury or property damage!
Prevent entry to a danger zone, for example with protective fencing, mesh
guards, protective coverings, or light barriers.
Ensure the protective devices are properly dimensioned.
Position EMERGENCY OFF switches so that they are easily accessible and can
be quickly reached. The functionality of EMERGENCY OFF equipment should
be checked before start-up and during maintenance periods.
Prevent unintentional start-ups by disconnecting the power connection of the
drive using the EMERGENCY OFF circuit or using a safe start-up lock out.
Before accessing or entering the danger zone, safely bring the drives to a stop.
While working on the system, power down the electrical equipment using the
main switch and prevent it from being switched back on.
Avoid operating high-frequency, remote control, and radio devices close to the
unit and system electronics and their feed lines. If the use of such devices cannot
be avoided, the system and the installation must be checked for possible mal
functions in all usage scenarios prior to the initial start-up. Where applicable, it is
necessary to carry out a special EMC check of the system.
"Safe separated extra-low voltage"
PELV Protec
tive Extra-Low
Voltage
The signal voltage and control voltage of the PacDrive
TM
devices are <33 Volts. In this
range, the specification as a PELV system in accordance with IEC 60364-4-41 in
cludes a protective measure to guard against direct and indirect contact with danger
ous voltage through the safe separation of the primary and secondary sides in the
system/machine. ELAU strongly recommends providing the system/machine with safe
isolation.
DANGER
High voltage due to incorrect connection!
Risk of death or serious injury!
Please ensure that only devices, electrical components or lines that have suffi
cient, safe electrical separation from the connected circuits in accordance with
the standards (EN 50178 / 1998 edition - Electronic equipment for use in power
stations) are connected to the signal voltage connectors of this component.
Ensure that the existing electrical separation is maintained throughout the entire
circuit.
FELV Function
al Extra-Low
Voltage
When using ELAU components in systems that do not have safe separation as a pro
tective measure against direct or indirect contact of dangerous voltages, all connec
tions and contacts (e.g. PacDrive controller, Sub-D connector, serial interface) that do
not meet protection class IP2X require a permanent cover. The cover or the device
connection of the connected device must be designed so that it can only be removed
by using a tool. The protective measures have to be adhered on all connected devices.
2.3 Residual risks
Protection against magnetic and electromagnetic fields
Magnetic and electromagnetic fields that are in immediate environments of electrical
conductors and permanent motor magnets represent a serious health hazard to per
sons with heart pacemakers, metal implants and hearing aids.
WARNING
Health risk posed by risk groups in the proximity of electrical equipment.
Do not allow personnel with pacemakers or similar sensitive implants to work on motors!
3 Switch Cabinet Planning
3.1 Protection Class
CAUTION
Metallic dust deposits, oil, moisture, strong electromagnetic interference and ambient
temperature.
May result in damage to components.
Protect them by installing a protection class suitable to the environment in which
they will be used.
3.2 Ambient conditions in the switch cabinet
Climatic ambient conditions
The general climatic conditions defined for the ELAU devices designed for installation
in a switch cabinet are listed in the table below.
In general, class 3K3 according to EN 60721-3-3 applies. Deviations (e.g. higher tem
perature) are allowed, but need to be specified in the technical data.
Environmental parameter Unit Class
3K3
Notes
a Low air temperature max +5
b High air temperature max +40 Higher values (e.g. +55 C, possibly
with derating) can be allowed!
c Low relative humidity % 5
d High relative humidity % 85 95% can be allowed, if precipitation
is ruled out!
e Low absolute humidity g/m
3
1
f High absolute humidity g/m
3
25
g Speed of temperature change C/min 0.5
h Low air pressure kPa 70
i High air pressure kPa 106
j Sunlight W/m
2
700
k Thermal radiaton - - See footnote in the applicable
standard
l Air movement m/s 1.0 See footnote in the applicable
standard
m Condensation - - Not permitted!
n "Wind-driven precipitation (rain, snow,
hail, etc.)"
- -
o Water (except rain) - -
p Icing - -
Table 3-1: Climatic conditions in the switch cabinet
3.1 Protection Class
Mechanical ambient conditions
The general mechanical ambient conditions defined for ELAU devices for installation
in a switch cabinet are listed in the table below.
In general, switch cabinet devices are subject to class 3M3 according to EN 60721-3-3.
Devices designed for direct installation on machines are subject to different classes,
e.g. class 3M7 for the SCL drive or class 3M6 for the iSH drive. See also Technical
data for the drives SH, SCL or iSH.
Environmental parameter Unit Class
3M3
Notes
a Sinus oscillation
Amplitude mm 1.5
in the frequency range Hz 2 ... 9
Acceleration m/s
2
5 9.81 m/s
2
= 1 g
in the frequency range Hz 9 ... 200
b Shock resistance
Total shock-response range Type L
Peak acceleration m/s
2
70
for duration ms 147 m/s
2
= 15 g
Table 3-2: Climatic conditions in the switch cabinet
3.3 ESD Protection Measures
CAUTION
Electrostatic discharge! Damage to component possible!
Touch circuit boards only on edges.
Do not touch any of the circuit points or components.
Before you touch the circuit board, you should discharge any static charge.
When doing so, first touch a grounded metallic surface such as the housing.
Move the circuit board as little as possible to reduce the build-up of electrostatic
charge on clothing, carpet, or furnishings.
3.4 Assembly Procedure
Mount devices horizontally in the 35 mm grid with M6 hexagon socket head cap
screws (Allen screws).
Keep a distance of at least 100 mm above and below the devices (see Fig. "Me
chanical installation").
Do not lay any cables/cable ducts over the PacDrive servo amplifiers or braking
modules.
Avoid "hot spots" in the switch cabinet; install additional fan if necessary.
Do not block the fan air inlet.
Connect only one motor per PacDrive MC-4.
DANGER
High voltage! Risk of death
Disconnect the device from mains or power supply before accessing electrical
parts with voltages greater than 50 Volt.
Prevent the unit from being switched back on.
Wait at least 5 minutes after switching off before accessing the components.
Check the voltage with a voltage meter before accessing the device to be sure
that the voltage is less than 50 Volt.
WARNING
Surfaceson the PacDrive MC-4 and the braking modules (BM-4) are hot!
Risk of burns
Wait until the PacDrive servo amplifier and the braking module have cooled off
or wear protective gloves.
CAUTION
When connecting devices in parallel in the switch cabinet, the most powerful device should
be connected first (in regard to the mains feed) and then the smaller units should be connected
after that. By doing this, the load on the DC circuit connections and the mains connection is
reduced.
air inlet
cooling
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cold
Air
duct
fan switching cabinet
air flow
Schaltschrank_englisch_0798.fh8
mains filter
C200..P600 / MC-4 BM-4
cable duct
wiring level
Figure 3-1: Sample switch cabinet layout with ventilation
CAUTION
Heat dissipation with PacDrive MC-4
Switch cabinet rear wall as an active cooling element
The design of the PacDrive MC-4 allows for a large part of the heat that is generated to be
lead to the surroundings through the switch cabinet rear wall. Under certain circumstances,
this may mean that the use of a cooling unit is unnecessary. For this, the rear wall must be
designed as a cooling element, and the PacDrive MC-4 must be bolted on to the rear wall in
a thermally conductive manner (thermally conductive paste).
No thermal contact with the rear wall
If heat dissipation via the rear wall is undesirable (e.g. if a sub plate is used), spacers should
be used where the MC-4 MotorControllers are screwed onto the rear wall.
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Figure 3-2: Mechanical installation
3.5 Using Cooling Units
CAUTION
Cooling units may cause condensation and condensate!
This may result in damage to electronic components.
Ensure that no condensate can drip out of the cooling unit onto electronic com
ponents.
Risk from condensation
Warm, humid air enters the switch cabinet; upon cooling, it condenses on the sensitive
electronic components located there.
Using cooling units properly:
1. When using cooling units, use only well-sealed switch cabinets so that warm, humid
outside air, which causes condensation, cannot enter the cabinet.
2. If switch cabinets are operated with open doors (commissioning, service, ... ), you
must ensure that the electronic components are at no time cooler than the air in
the switch cabinet after the doors are shut. Otherwise, condensation may occur.
Therefore the cooling unit must continue to operate even when the system is
switched off, so that the temperature of the switch cabinet air and the installed
electronic components remains stable.
3. Set cooling unit with a fixed setting to 40C. Never lower.
4. Set cooling units with temperature monitoring so that the inner temperature of the
switch cabinet does not fall below the external temperature. Set the temperature
limit to 40 C!
switching cabinet
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switching cabinet
air inlet
cooling
aggregate
electronic
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hot
cold
hot
cold
hot
Figure 3-3: Installing a cooling unit
Risk from condensate
If the system is designed adversely, the condensate which continually accrues on
cooling units may drip into the installed electronic components or be sprayed in with
the cooling air flow.
Avoiding dripping and spraying water:
Always configure the cooling unit so that any condensate that can build up cannot
drip onto the installed electronic components. Cooling units on the top of the switch
cabinet require a specially designed switch cabinet.
Design the switch cabinet so that the cooling unit fan cannot spray any accu
mulated condensate onto the electronic components when it restarts after a
pause.
3.5 Using Cooling Units
4 Wiring Notes
4.1 General
The specifications regarding minimum cross sections, shielding and grounding must
be observed when wiring.
The specifications given regarding junctions must be followed when doing this. If, for
example, two parallel conductors are shown as coming from one point, you must not
run one conductor and then branch it off at a later point. This could lead to induction
loops (interference senders and antennae) and interfering ground offset voltages.
CAUTION
As the provider of the system, ELAU provides you with pre-fabricated cables.
CAUTION
Observe minimum bending radius!
Potential cable damage.
Observe the minimum bending radius.
When using ELAU copper cables (motor cables, feedback cables and hybrid cables)
and fiber-optic conductors, observe the properties listed below.
For "permanently flexible" copper and hybrid cables, observe the guidelines for drag
chains.
Property Copper cable Hybrid cable Fiberoptic conduc
tor
Minimum bending radius for stationary
cables
3 x cable diameter iSH: 5 x cable diam
eter
SCL: 5 x cable di
ameter
20 x cable diameter
*
Minimum bending radius for cables in
"permanently flexible" use
12 x cable diameter iSH: 12 x cable di
ameter
SCL: 7.5 x cable di
ameter
-- **
Permissible temperature range for sta
tionary cables (according to DIN VDE)
-50 C ... +90 C -50 C ... +90 C 0 C ... 80 C
Permissible temperature range for mov
able cables (according to DIN VDE)
-40 C ... +90 C -40 C ... +90 C -- **
Number of bending cycles 5 mn cycles *** 5 mn cycles *** -- **
When laying fiber optic conductors, a minimum bending radius of 15 x cable diameter is allowed for a
short period of time.
** Fiber-optic conductors must not be used for "permanently flexible" applications.
*** At maximum velocities of 2 m/s and maximum accelerations of 5 m/s
2
Table 4-1: Properties of conductors used by ELAU
PacDrive MC-4 type 1.5 ... 10 A 22 A 50 A
Mains cable in mm 1.5 / 2.5 4 16
4 Wiring Notes
PacDrive MC-4 type 1.5 ... 10 A 22 A 50 A
Ground conductor to CEP in mm (flexible) 10 10 16
Control signals in mm 1 1 1
DC circuit in mm 1.5 / 2.5 4 10
External bleeder in mm 1.5 2.5 6
Table 4-2: Recommended cable cross sections depending on MC-4 type
PacDrive PS-4 Cable cross section
Mains cable in mm 2.5
Ground conductor to CEP in mm (flexible) 10
Control signals in mm 1
DC circuit in mm 2.5 / 4
Table 4-3: Recommended cable cross sections at PS-4 for SCL drives
PacDrive PS-5 Cable cross section
Mains cable in mm 4
Ground conductor to CEP in mm (flexible) 10
Control signals in mm 1
External bleeder in mm 2.5 / 4
Table 4-4: Recommended cable cross section at PD-5 for iSH drives
DANGER
The grounding loosens when the cables are not installed correctly. The housing ground is
broken.
Operating malfunctions and danger of injury from electrical discharge are possible.
Use a ring cable lug for M5 (d = 5.3 mm) for grounding MC-4 1.5-22 A and BM-4
(cross section: 10 mm )
Use a ring cable lug for M6 (d=6.4 mm) for grounding MC-4 50 A (cross section:
16 mm).
Motor type SH-055 SH-070 SH-100 SH-140 SH-205
Motor cable in mm 1 / 1.5 1 / 1.5 1 / 1.5 1.5 / 2.5 / 4 2.5 / 4 / 10
Table 4-5: Cable cross sections depending on motor type
CAUTION
No secure contact.
Cables and terminals may be damaged.
When using cables with a cross section of 2.5 mm, use conductor end sleeves
without plastic collars that have a length of at least 12 mm or conductor end
sleeves with plastic collars that have metal sleeves that are at least 12 mm long.
Connectors Description Stud torque
C200 ... P600
X1 ... X4 Mini Combicon MC 1.5 clamp screw thread M2 0.3 ... 0.4 Nm
4.1 General
Connectors Description Stud torque
MC-4 / 1.5 ... 10 A
X1
X2 ... X4
Mini Combicon MC 1.5 clamp screw thread M2
Front 2.5 H Clamp screw thread M2.5
0.3 ... 0.4 Nm
0.4 ... 0.5 Nm
MC-4 / 22 A
X1
X2 ... X4
Front 4 H Clamp screw thread M3
0.3 ... 0.4 Nm
0.5 ... 0.6 Nm
MC-4 / 50 A
X1
X2 ... X4
HDFK 16 Clamp screw thread M5
0.3 ... 0.4 Nm
2.0 ... 2.5 Nm
Table 4-6: Stud torques for front terminal clamp screws
CAUTION
Wiring error!
Use only ELAU original cables.
Check the wiring once more before turning on.
Common errors The following errors are commonly made when wiring:
No large shielding area
Ground loops
Motor phases interchanged
Encoder connections interchanged
No connection between motors and machine ground
4.2 EMC Rules
The mains voltage is stored by rectification in the DC circuit of the PacDrive MC-4 for
controlling and regulating the motors. This stored power is supplied to the motor by
precise on and off switching using six semi-conductor switches. The steep increase/
decrease in voltage places considerable demands on the dielectric strength of the
motor winding. An important additional aspect to observe is the electromagnetic com
patibility (EMC ) with other system components. The great edge steepness of the
pulsed voltage generates high intensity harmonics even into the high-frequency range.
Observe the following EMC rules:
During installation, select the HF grounding option with the lowest ohm load (e.g.
an uncoated mounting plate on the switching cabinet).
Lay the motor, encoder and serial interface cables apart from each other and
shielded.
Make electrical contact areas as large as possible (skin-effect). Where applicable,
remove any paint or color to make safe, level contact over a large area.
Use a star configuration to ground the switch cabinet from the central grounding
point to the respective connections for the controllers and servo amplifiers. Looping
the grounding is not permitted and can lead to unnecessary influences.
Only use shielded cables.
Only large-area shielding bridges are permitted.
Contacting shields via the PIN contacts of connectors is not permitted.
It is imperative to observe the circuit suggestions.
4 Wiring Notes
Shorten the motor cable to a minimal length.
Do not lay any cable loops in the switching cabinet.
CAUTION
Electromagnetic fields!
Interference or breakdown of system possible!
Observe the following rules during installation to eliminate the consequences of excessive
interference effects as much as possible.
In conjunction with electronic controllers, no inductive loads may be switched
without suitable fault clearance.
Appropriate interference suppression is achieved during direct current operation
by using recovery diodes and by using protector type-based, industry-standard
quenching circuits during alternating current activity.
Only a fault clearance element placed directly at the inductivity serves the pur
pose. It may be possible that in some cases even more interference may occur
as a result of the switching current on the interference suppression lines. It is
much easier to avoid sources of interference than to eliminate the effects of ex
isting interference.
Contacts which switch inductive loads which are not interference-suppressed
may never be located in the same space as the PacDrive MC-4. This also applies
to conductors which carry non-suppressed, switched inductions and those con
ductors which are routed along them in parallel. Insulate the controller from such
interference sources using a Faraday cage (separate partition in the switch cab
inet).
Motor currents Motor cable length
0 - 10 m
Motor cable length
10 - 40 m
Motor cable length
over 40 m
Mains filter (MC-4 1.5 A / 3 A) no FI 07876 Application-specific fil
ters
Mains filter (MC-4 10 A / 22
A)
no FI 07877 Application-specific fil
ters (50m or more)
Mains filter (MC-4 50 A) FI 07878 FI 07878 Application-specific fil
ters
Table 4-7: Mains filter depending on network phase current and motor cable length
CAUTION
When suppression is achieved in groups, the common mains filter should be sized so that
I
Rated
Filter >= sum of the network side phase currents of the PacDrive MC-4.
CAUTION
Wiring error
Keep the cable lengths as short as possible.
When cable lengths are greater than 40 m (in some cases 50 m), special meas
ures which are suited to the individual application may be necessary. Consult
with our application department if this is the case.
4.2 EMC Rules
4.3 PacDrive MC-4 Mains Connection
Using line chokes
Using the PacDrive system requires protective measures on the PacDrive servo am
plifier mains feed. In doing so, the use of a separate choke is required for each mains
contactor group
L1
L2
L3
AnschlussNetzdrossel_de.fh8
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K1.1
MC-4 MC-4
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L2
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db-
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L1
L2
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~
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1 - n
MC-4 MC-4
L1
L2
db+
db-
L3
L1
L2
db+
db-
L3
MC-4 MC-4
L1
L2
db+
db-
L3
L1
L2
db+
db-
L3
NKD XX / X.XX NKD XX / X.XX NKD XX / X.XX
...
1 - n
...
1 - n
Figure 4-1: Block diagram for the use of line chokes
To ensure trouble-free operation, the line chokes should be sized properly. Sizing is
based on the effective current of the corresponding mains contactor group.
Switch-on procedure
When the mains voltage is switched on, the DC circuit capacitors in the PacDrive MC-4
are charged "softly" through the built-in bleeder resistor. The minimum time between
two precharging operations is 15 s.
Grounding conditions of the mains network
Grounded AC
networks
PacDrive MC-4s may be operated without potential separation on AC networks with a
grounded star point.
Non-grounded
three-phase
mains
When operated on ungrounded networks (IT networks), the risk of impermissible over
voltages between external conductors and the PacDrive servo amplifier housing is
increased. Therefore, we specify that an insulating transformer must be used for op
erating on an IT network. Its star point on the output side as well as the PacDrive servo
amplifier's PE connection must be grounded.
Matching the mains voltage
If the mains voltage lies outside of the specified rated voltage, it must be matched using
a transformer according to the system's power requirements.
When used on a grounded network, the voltage is matched using an autotransformer.
When used on a non-grounded network, an isolating transformer is required.
The PacDrive MC-4 is designed for a fixed connection to the power supply network.
4 Wiring Notes
CAUTION
In order to conform to the EMC directive, the MC-4 / 50 requires a line filter, item number
FI07878.
Fusing the mains connection
CAUTION
Overloading the conductors.
May result in damage to the conductors.
In order to protect the system, also use a circuit breaker in the mains connection.
The phase current calculated in ECAM (if there are several devices, the sum of the
phase currents) should be used when sizing and selecting the components for fuses
and mains contactors.
I
RatedProtection
= 1.2 x sum of phase currents
The following components may be used as fusing:
Melting fuses of operating classes gL, gG
Category C circuit brakers
The overload threshold (delayed triggering) can be individually set on circuit breakers.
When turning on, an unintentional triggering is thus avoided because the power circuit
breaker's un-delayed over-current threshold is set a multiple higher. (Caution: take the
unit's increased start-up current into account).
When the mains are connected, the DC circuit capacitors are charged by the internal
braking resistor. Thus a charging current results, consisting of:
The charging circuit is bridged during operation.
CAUTION
Wiring error
Select the cross section of the mains supply system so that it is protected by the
chosen circuit breaker.
Fault current protective gear
Through the integrated line filter, the PacDrive MC-4's operating leakage current is
greater than 3.5 mA AC. If the insulation is damaged, leakage currents with a high
DC portion can occur. This results in incompatibility with general fault current protective
devices.
4.3 PacDrive MC-4 Mains Connection
CAUTION
The MC-4 must not be protected against fault currents using a commercially available FI circuit
breaker with a triggering threshold of 30 mA. The leakage current from the device can trigger
the FI circuit breaker. You can work around this using one of the following options:
In order to provide protection from insulation damage, you can use a universal
current-sensitive fault current circuit breaker (RCD type B) with a higher triggering
threshold (e.g. 300 mA).
According to DIN EN 61800-5-1 (Adjustable speed electrical power drive systems -
Part 5-1: Safety. requirements - Electrical, thermal and energy) devices with an op
erational leakage current greater than 3.5 mA AC or 10 mA DC require a firm con
nection.
Additionally, one of the following procedures is required:
Ground conductor cross section at least 10 mm
2
Cu.
Monitor the ground conductor with a device that automatically shuts off in case of
a fault.
Lay a second conductor using separate terminals, electrically parallel to the ground
conductor. In and of itself, this conductor must meet the requirements of DIN VDE
0100 part 540.
The protective housing provides protection from indirectly touching live parts.
For more information, please see DIN EN 61800-5-1.
Mains contactor
To size the mains contactor, add up the phase currents (see section 4.3) of the con
nected PacDrive MC-4s and select at least the next larger mains contactor (utilization
categories AC2 and AC3).
Recommendation: mains contactor of the type Telemacanique type LC1-Kxxx or LC1-
Dxxx.
4.4 PacDrive Controllers and MC-4 Control Voltage Connection
The control voltage should be PELV.
The 24 V DC for the control voltage may also provide power for other sinks. In this
case, ensure that the tolerances for the 24 V DC control voltage are maintained and
all connected components maintain safe separation from the mains voltage circuits.
This is especially important in applications with inductors (solenoid valves, brakes,
etc.).
CAUTION
Control voltage too low.
If the tolerances for the control voltage are not observed, diagnostic error 036 "External 24 V
power supply too low" or WATCHDOG may arise.
Measure the control voltage with an oscilloscope to detect short-term drops in
the control voltage (e.g. when inductive sinks are switched on).
4 Wiring Notes
CAUTION
The input capacitance of the PacDrive controllers C400 to P600 is 4400 F. Depending on
the 24 V power supply unit used (24 V slew rate, internal resistance of the power supply unit),
an elevated startup current may arise.
CAUTION
Switching off the control voltage
Data loss or flash disk failure can result.
As the control voltage of the PacDrive controller must not be switched off unless
all files are closed, use the UPS option.
Also see the SysShutdown() function in Windows Help.
4.5 DC Circuit
The mains voltage is rectified and electrical power is stored in the PacDrive MC-4 in
the "DC circuit". Basically, the DC bus consists of a rectifier and capacitors. The DC
bus voltage is applied to power connector X3 on the PacDrive MC-4.
DANGER
High voltage! (DC bus voltage may be up to 860 V).
Risk of death
Maintain sufficient insulation when routing cables.
Do not ground the DC circuit.
DC circuit voltage limit.
During braking, the servo motor acts as a generator and feeds power into the DC bus
via the motor inverter. The energy is stored in the DC capacitors. This increases the
voltage in the DC bus. When the capacity of the capacitors is not sufficient to absorb
the power, it must be ensured that the DC bus voltage does not increase too much.
The voltage monitoring measures the DC bus voltage and connects the DC bus via a
power transistor to a power resistor (bleeder) when the limit value (approx. 820 V) is
reached. The braking energy is converted to heat. When the DC bus voltage falls below
the lower switching threshold (approx. 800 V), the braking resistor is disconnected
once more.
Jumper in the DC circuit
In multi-axle applications, the DC circuits of the PacDrive MC-4s may be jumpered to
allow for power exchange. In doing this, the total DC circuit capacitance may not ex
ceed 2 mF. This means that e.g. twelve 3 A, six 10 A or two 22 A PacDrive MC-4s may
be jumpered.
The PacDrive MC-4s are coupled using terminals db+ and db-. Additionally, the L1,
L2 and L3 mains feeds must be jumpered, since these are controlled by a common
mains contactor. Each unit has its own braking resistor. These may be supplement by
an additional braking resistor (braking module BM.-4).
4.5 DC Circuit
CAUTION
Wiring error
When jumpering the DC circuits, be sure that the maximum DC circuit capaci
tance of 2 mF is not exceeded.
Wire the mains feed in such a manner that it runs from the device with the most
power (short connection, large cross section) to the device with the least power
(longer connection, smaller cross section.)
When jumpering the DC circuits, be sure that the maximum length of the cables
does not exceed 0.5 m). The cables should have as large a cross section as is
possible and should be twisted.
Note that it is only permissible to jumper the DC circuits on units which are served
by a common mains contactor. Otherwise there is the danger that the inverters
may be overloaded.
4 Wiring Notes
5 Basic Design and Connection
5.1 Power Circuit
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5.1 Power Circuit
5.2 Control Circuit
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5 Basic Design and Connection
Explanations for the sample connection
This sample shows the basic design and the wiring of a PacDrive system without in
cluding safety aspects (e.g. redundant design of auxiliary contactors) in the control
circuit.
Due to EMC considerations, the brakes (PIN 7 bri+ and PIN 8 bri+) should be supplied
by a separate power supply unit. Otherwise, the brake (PIN 7 bri+ and PIN 8 bri+)
should be connected directly to the 24V DC power supply unit.
CAUTION
When using a separate power supply unit, the brake voltage supply may fail without being
noticed.
The stopping brake may be damaged irreparably.
Monitor the separate stopping brake power supply. This monitoring may be car
ried out by the PacDrive Controller, for example, which monitors the voltage ei
ther directly via an input (no potential separation from the brake voltage) or via
an auxiliary relay (floating).
Inverter Enable (safe stop)
When the Inverter Enable relay input is switched off, the PWM signals to the end stage
are interrupted. The motor is immediately switched to a torque-free state. If Inverter
Enable is not used, the input should be set so that it is always 24V.
wd and rdy
wd (PacDrive Controller) and rdy (PacDrive MC-4 and bleeder module BM-4) are relay
outputs that are normally closed. They should be connected in series to the mains
contactor (possibly using an auxiliary contactor), so that, in the event of a serious fault,
the power supply will be switched off.
CAUTION
Wiring error
The PacDrive servo amplifier may be damaged.
Connect the PacDrive servo amplifiers and the PacDrive Controller in such a
manner that, in case of a serious malfunction, the mains feed will be interrupted
via the outputs wd (MAx-4) and rdy (MC-4).
5.2 Control Circuit
6 Functional safety - safety connections
6.1 Machine safety
The goal of designing machines safely is to protect people. The risk associated with
machines with electrically controlled drives comes chiefly from moving machine parts.
EN 954-1:1996 (Safety-related Parts of Control Systems, Part 1: General Design
Guidelines) describes an iterative process for the selection and design of safety-re
lated parts of control systems with the goal of reducing the risk arising from the machine
to a justifiable degree.
In the first step, the machine builder must perform a hazard analysis and a risk
evaluation of the machine (EN 292-1 and EN 1050)
In the next step, the machine builder decides which measures are necessary to
reduce the risk by modifying the design of the machine and/or by providing for
protective devices.
In the third step, the safety requirements for the safety-related parts of the controller
are determined:
Typical characteristics of safety functions, e.g. Emergency stop, Stop function,
Manual override of safety functions
Requirements for accomplishing the safety function
Categories for safety-related parts and combining them
In the fourth step, the safety-related parts are designed and the design is verified
in every phase.
In the fifth step, the safety functions which were achieved are validated. This is
done by analysis as well as by testing the safety-related functions. Instruments
such as FMEA should be used in the analysis. Tests are to ensure that the design
of the safety functions fully corresponds to the specified characteristics in terms of
performance. When testing the categories, performance in the event of an error is
of primary importance. This must occur theoretically, by means of the wiring dia
grams, as well as in actual use on the machine, by simulating error situations. When
doing so, possible ambient conditions, such as temperature, ageing, EMC, etc.,
should be considered. The validation report which is to be created documents the
analyses and tests which were carried out.
6.2 Circuit suggestion for PacDrive system with MC-4
CAUTION
This chapter corresponds to section 7.4 in the user documentation: "Project notes - safety
connections" (Circuit suggestion V1.06 as at 11/04). The German Accident Prevention &
Insurance Association's evaluation report for certificate NG 04110 refers to that same chapter.
The connections presented here are suggestions that show how control of the Pac
Drive system may be accomplished according to EN 954 category 3 and what
options for error detection are available for PacDrive controllers. In the wiring recom
mendations that are given, the SafeStop function is carried out by shutting off the
opto-couple which transmits the PWM signals to the output stage (pulse pattern lock)
using the InverterEnable signal.
The circuit suggestions V1.06b described below were tested by BGN (the responsible
German Accident Prevention & Insurance Association). The test certificate and the
assessment report may be downloaded from the ELAU home page (download area
for PacDrive users / safety). When using Inverter Enable, these documents must be
consulted.
CAUTION
These circuit recommendations are not mandatory for the machine manufacturer. The
machine manufacturer is responsible for the safety of the machine.
6.2.1 Funktionsbeschreibung
After the emergency stop device is actuated, the drive is braked in a controlled manner.
In the process, the DC bus voltage increases until the bleeder resistor is switched on.
In the bleeder resistor, the energy which is fed back from the motor is converted to
heat. The K1 power circuit breaker and/or the InverterEnable signal must remain ener
gized until the drive stops. After the normal braking time at the latest, the IE signal is
switched off by the delayed contacts of K3. After this, the drive is in a safe stop.
6.2.2 Redundant stopping
The emergency stop device is designed with two channels. Braking is triggered and
the drive is brought to a standstill using un-delayed contacts. The K1 power circuit
breaker and/or the InverterEnable signal are switched off using delayed contacts (EN
1 60-204 stop category 1). Shutting off using the off button has the same effect as
using the emergency stop button. Thus, this button is wired in series with the emer
gency stop contacts. When switching off, the drive on PacDrive MC-4, independent of
the PacDrive Controller, can also be brought to a controlled standstill using the MC
en signal. But this function has the disadvantage that, under certain circumstances,
the drives must be re-referenced.
The emergency stop brings the drive to a standstill in a differing manner. The following
errors are thus safely handled:
If the drive is braked in an uncontrolled manner because of an error, the Inverter
Enable signal is switched off after the delay time which is set on the safety switching
unit. (drive coasts to a stop)
If, after braking, the PWM signals are not switched off by the IE relay in the PacDrive
MC-4, the power supply is cut off automatically by switching off K1.
Independent from this measure, most errors are already recognized by the controller,
thus preventing the drive from starting. (K4)
Safety gate
Access to the dangerous areas of a machine may be blocked by means of a safety
gate. In this case, an unexpected startup must be securely prevented if the startup
would cause dangerous movements while access to the dangerous areas is not pre
vented by the safety gate. To achieve this, the safety door contact is wired in series
with the emergency stop switch.
6.2.3 Inverter enable circuit (IE)
The safety circuit with Inverter Enable was developed to reduce wear of the mains
contactor. When the off or the emergency stop button is activated, the mains contact
is not switched off. The safe stop is achieved by disabling the InverterEnable for
the opto-couplers in the final stage. Thus, the PWM signals cannot control the final
stage, so that a startup of the drives is safely prevented (pulse pattern lock). The error
monitoring ensures that the mains contact is switched off when an error occurs. The
error monitoring of the Inverter Enable function in the controller takes place through
an Inverter Enable signal, which is produced in the PacDrive MC-4 and transmitted
to the PacDrive controller via the SERCOS interface. If this signal does not correspond
to the reference state at the PacDrive controller's EmergencyStop input, an error
message is triggered. In order to carry out the "Safe Stop" operating mode via Inverter
Enable, the following boundary conditions should be observed:
The PacDrive MC-4s must be installed in a switch cabinet or housing of at least IP
54.
The PacDrive MC-4s must have the imprint "SL" next to the item name on the type
plate. The MC-4s of this type are provided with a protective coating on the Inverter
Enable circuit part. Beginning with series 11 (MC-4/11/...), all MC-4s are coated as
standard.
These measures prevent a possible error function through conductive dirt build-up or
parts which fall in the device.
6.2.4 Level definitions
Low-Signal or Low-Level is issued when an input is connected or open (not connected)
with L0.
High-Signal or High-Level is issued wen an input is connected with +24 V.
6.2.5 Impermissible application
In the following cases, it is not sufficient to switch off "Inverter Enable":
During maintenance and repair
When the system or the machine is being cleaned.
When operations are interrupted for a long time.
In these cases, the entire system/machine should be shut off using a main switch.
It must be possible to lock the main switch in the "Off" position.
6.2.6 Switching components
When the off button is activated, the mains contact is not switched off. Switching off
"InverterEnable" safely prevents the motor from restarting by switching off the opto-
coupler for the transmission of the PWM signals.
Safety switch
ing unit
The safety switching unit implements the evaluation and control of the on and off or
emergency stop buttons, and, under certain circumstances, the safety contacts. The
safety switching unit must at least be designed according to category 3 of EN 954
External error monitoring of this switching part is thus no longer required. One or two
(see Hardware Enable) undelayed and two delayed contact paths are required. The
safety switching unit delay time (contactor K3) should be only marginally higher than
the braking time needed for safely bringing the drive to a stop in an emergency.
Contactors Safety-related auxiliary contactors must have guided contacts.
Off and
Emergency
Stop
The off and emergency stop buttons have the same function. The circuitry can be
designed with one or two channels (as shown in the circuitry example for the safety
circuit with Inverter Enable / sheet 1 (see 6.2.8 Wiring diagram for PacDrive controllers
MAx-4, C400/600 and P600) and Inverter Enable / sheet 2) (see 6.2.9 Wiring diagram
for PacDrive controller C200). The same function can be achieved through safety gate
contacts (NC contacts), which, accordingly, are connected in one or two channels and
in series with the emergency stop contacts.
When the off or emergency stop button is activated, the outputs of the safety switching
unit K3 switch off, delayed or non-delayed. The PacDrive controller detects the switch
ing off over the non-delayed contact and brings the motors to a controlled standstill.
Optionally, the "MC en" signal can be switched off over the second path using non-
delayed contacts. This triggers an independent standstill in PacDrive MC-4 and the
PWM is switched off. After the maximum stopping time for all drives elapses, the de
layed contacts of the safety switching unit K3 switch off. Through this, the "Inverter
Enable" relay in the PacDrive MC-4 switch off. In the time between when the delayed
contacts of K3 switch off and when the Inverter Enable switching contact ieo closes,
the mains contactor is de-energized. As the decay time of the Inverter Enable relay *
12 ms) is shorter than the decay time of the mains contactor, the mains contactor
remains activated and the power supply remains switched on. By switching off "Inver
terEnable", which switches off the opto-coupler, PWM signals are prevented from be
ing sent to the final stage.
WARNING
High voltage!
Risk of death
Switching off "Inverter Enable" disables the final stage transistors, thus preventing the
formation of a rotating field.
Galvanic isolation from the power supply can only be achieved by switching off the mains
contactor or the main switch.
CAUTION
The mains contactor's dissipation time is also influenced by the design if the quenching circuit.
Measurements have shown that a protective circuit with free-wheeling diodes produces a
sufficiently long dissipation delay. A free-wheeling diode is required.
Notes If desired, the off button (not the EMERGENCY stop button) may be connected to one
of the PacDrive controller's inputs instead of being connected in series to the emer
gency stop button. The level on this input must then be evaluated in the PacDrive
controller and the drives must be brought to a stop. Through this, a flatter braking ramp
can be achieved upon stopping operation, so that, depending on circumstances, wear
during braking can be reduced. No safety function is realized when shutting off using
this circuit. Pressing the off button only achieves EN 60 204-1 stop category 2.
Still, the quickest possible stop is required for an emergency stop.
Unable to find
module identifi
er or field bus
firmware up
date not possi
ble.
If the on button is pressed, and neither the off nor the emergency stop buttons are
pressed, the safety switching unit K3 is turned on. If there is no error in the PacDrive
controller, the K4 contactor is switched on through the Mains Contactor output of the
PacDrive controller. If, in addition, the "WD" contacts of the PacDrive controller and
the "rdy" contact of the PacDrive MC-4 are closed and there is no error in the "Inverter
Enable" circuit, the mains contactor K1 is switched on. The K3 contacts switch on
"Inverter Enable"; thus, the PWM signals of the drives are enabled.
Hardware Ena
ble (MC_en)
The Hardware Enable signal (MC_en) may be connected directly to L0 (+24 V). In this
case, the machine comes to a controlled stop through the PacDrive Controller when
it is switched off. The drives can be stopped synchronously to one another. They need
not be homed when it is switched on again.
If the MC_en signal (as in figure no. EL-810-05-07, sheet 1) is optionally connected
over a non-delayed contact of the safety switching unit K3, the drives are brought to
a standstill using the "best possible stop" in PacDrive MC-4, independent of the posi
tion's setpoint. In some cases, the drives must be homed when they are switched on
again.
The method used depends on the application. Both methods are equally safe.
error
detection
The PacDrive controller monitors the status of the safety switching unit, which controls
the Inverter Enable signal, through the "EmergencyStop" input.
InvEnableActive is uncoupled from the Inverter Enable signal via relay K5. If only the
InverterEnable inputs of the MC-4 are connected to the output (38) of the PNOZ, the
auxiliary relay K5 may be omitted, and the signal may be wired directly to the PacDrive
controller's InvEnableActive input
If the Inverter Enable signal transmitted from the PacDrive servo amplifier via the
SERCOS interface does not correspond to the status of the InvEnableActive signal
(taking into account the delay times), an error is detected. In this case, the mains
contactor K1 is shut off via contactor K4. The system may only be turned on again
after the error is corrected.
The function of the mains contactor is monitored via the "MainsWatch" input. When
the mains contactor "K1" is switched off, the "MainsWatch" auxiliary contactor must
be closed; when the mains contactor is on, the auxiliary contactor must be open.
Further information concerning this theme and the Watch and AxisEnable function
blocks is available from Online help / VarioCam library / Control / Watch The safety
circuit was tested by the responsible German professional association ("Berufsgenos
senschaft"). The test certificate which was issued has the test number NG 04110.
6.2.7 PacDrive controller C200
In addition to the MAx-4 PacDrive controller, PacDrive controllers C400, C600, P600
and C200 may also be used.
The circuits for C400, C600 and P600 are identical to MAx-4 (see 6.2.8 Wiring diagram
for PacDrive controllers MAx-4, C400/600 and P600). C200 is unique in that it has no
integrated IOs. Therefore, the error detection signals (MainsWatch, InvEnableActiive,
EmergencyStop and MainsContactor) are routed via field bus-coupled IO modules.
6.2.8 Wiring diagram for PacDrive controllers MAx-4, C400/600 and P600
+
2
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6.2.9 Wiring diagram for PacDrive controller C200
L
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Figure 6-2: Wiring diagram: Safety circuit with Inverter Enable / sheet 2
6.3 Connection of Watchdog and Ready contacts for PacDrive control
lers
-
K
1
246
135
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Figure 6-3: Wiring diagram: Watchdog and Ready contacts / sheet 3
6.4 Extended safety functions for PacDrive MC-4 with SMX Safe PLC
To implement the safety functions, the MC-4 servo amplifier of the PacDrive system
has the Safe Torque Off as an integrated safety function. An input on the MC-4 (Inverter
Enable) blocks the control signals to the final stage by means of a positively driven
relay. This makes it possible to achieve the safety function described below:
In the case of a safety request (e.g. emergency stop) by the user, the first reaction of
the PacDrive controller is a controlled stop.
Then the safe stop is ensured by means of an external safety switching unit by lifting
the InverterEnable signal (IE).
Figure 6-4: Block diagram: PacDrive MC-4 speed monitoring and external safety
switching unit
The increasing flexibility and complexity of packaging machines also means higher
requirements for the safety functions of a controller. ELAU AG in cooperation with BBH
offers an alternative solution.
The combination of the SMX Save PLC safety switching unit by BBH and an MC-4
servo amplifier makes it possible to implement the following functions:
Safe stop with brake ramp (SS1) in case of safety gate, E stop, jogging, change of
operating mode, i.e. external time control of the brake ramp
Alternatively, additional STO function in case of safety gate, E stop, jogging,
change of operating mode
Several protective circuits (E stop and safety gates work for different drives)
Speed monitoring during setup mode (e.g. jogging while the safety gate is open).
Short reaction time (<20 ms) when the limit speed is exceeded as STO (without
brake ramp).
Stop monitoring (with open safety gate / manual closure of safety gate)
Monitoring of several axes
(with SMX11; monitoring of one axis)
with SMX12; monitoring of up to two axes)
6.4.1 Funktionsbeschreibung
When a project is planned, the use of specific protection mechanisms depends es
sentially on the expected risk potential of the application. The risk potential can be
assessed by means of suitable risk analyses taking into account the relevant ambient
conditions. Different requirements for each operating mode (initial operation, jogging,
etc.) and for each piece of equipment (safety gate, cover, etc.) can be assigned to the
safety functions (STO, SS1, SS2, SDI, SLI, etc.).
The following example will demonstrate the implementation of safety functions with
SMX 12. The example is for an application with 3 drives. Two axes are monitored with
SMX 12. In automatic mode, the 3 axes can be moved freely by the PacDrive controller.
Depending on the operating mode, the individual axes are controlled by the PacDrive
controller. SMX 12 monitors the corresponding safety function via the encoder inter
face and switches the drives to a safe state (STO) in case of an error or emergency
stop. For this purpose, the InverterEnable signal of the PacDrive MC-4 is switched off.
SMX12 will only shut off the mains contactor K1 in case of an internal error of the safety
circuit. This means that the mains contactor K1 remains active in case of an emergency
stop or if the safety gate is open.
No safety relevant information is transmitted to the PacDrive controller via a bus in
terface (IO's, Profibus DP, etc.). Only the information which safety element (emergen
cy stop, safety gate...) was activated is transmitted. This enables the PacDrive con
troller to trigger a controlled stop of the individual axes before SMX 12 puts them into
STO state by means of Inverter Enable. Usually this happens with a delay of several
seconds, so that the PacDrive controller has the opportunity to bring the axes to a
controlled stop.
PacDrive
MC-4
Motor Enc
Encoder
adaptor
X8
X4
SMX11/12
X12 X22
3AC/400V
K1
MainsContactor
DSP
IGBT
output stage
Motor Enc Motor
PacDrive Controller
MAX-4, C200-P600
Fieldbus (CAN, Profibus DP)
InverterEnable
PowerContactor
SERCOS Bus
SinCos SinCos
Enc
Slave-axis with safely
limited speed
Slave-axis with safely
limited speed
Master-axis without safety
monitor
EStop, On, Off,
Reset
Guard Door
DIAGNOSTIC
PacDrive
MC-4
X8
X4
DSP
IGBT
output stage
PacDrive
MC-4
X8
X4
DSP
IGBT
output stage
SERCOS Bus
Safe channels
Signals
SinCos (Hiperface)
Power
Mains
v
Jogging
Encoder
adaptor
Figure 6-5: Block diagram - Application suggestion for two monitored axes
The following table shows the reactions of the individual axes to various stop events,
depending on their operating modes.
Master (axis without speed monitoring):
Automatic mode
Emergency stop, opening of the safety gate SS1 (safe stop plus brake ramp)
Setup mode
Emergency stop SS1 (safe stop plus brake ramp)
Opening the safety gate - no safety function
Slave axis 1, 2 (axes with speed monitoring):
Automatic mode
Emergency stop, opening of the safety gate SS1 (safe stop plus brake ramp)
Setup mode
Emergency stop SS1 (safe stop plus brake ramp)
Open safety gate
- with actuated jog button SLI (incremental position restriction) plus SLS (speed
restriction) (plus SDI (turning direction))
- with unactuated jog button SS2 (standstill monitoring)
6.4.2 Circuit suggestion
Control circuit
Figure 6-6: Circuit suggestion for the control circuit - I/O option
Figure 6-7: Circuit suggestion for the control circuit - PROFIBUS DP option
Power circuit
Figure 6-8: Circuit suggestion for the power circuit
Input / output signals of the SMX
Signal no. Clamp Type Cross circuit
ing test
Description
E.1
E.2
X14:1
X14:2
Emergency stop 1
(2 NC contacts)
Pulse 2
Pulse 1
Triggers emergency stop
E.3 X14:3 Start / Reset
(start element)
OFF Quits errors of SMX and PLC
Enable operating modes
E.4 X14:4 ON OFF
E.5
E.6
X23:1
X23:2
Preselection of setup
mode
Preselection of automat
ic mode (selector switch:
open/close)
Pulse 2
Pulse 2
Selection of setup mode
Selection of automatic mode
E.7 X23:3 Line off (1 NC contact) Pulse 1 Machine off switch
- immediate message to PLC
with "ESTOP PLC"
- time monitoring of brake
ramp
- then STO
- after 5 s switch off mains con
tactor
In addition, there is a mechan
ical main switch
E.8
E.9
X23:4
X24:1
Enable jogging mode
(2 NC contacts, time
monitored)
Pulse 2
Pulse 1
E.10
E.11
X24:2
X24:3
Safety gate
(1 NO contact / 1 NC con
tact; time monitored)
Pulse 2
Pulse 1
E.12 X24:4 IEO_TEST Pulse 2 InverterEnable feedback
E.13 X12:1 MAINSCONTACTOR
(1 NO contact)
OFF PLC message: Enable mains
contacotr when switching on
E.14 X12:2 K1_Test

OFF Feedback from mains contac
tor
Table 6-1: Input signals of the SMX
Symbol Clamp Designation Description
K1.1 X22:1 Wd&rdy
K1.2 X22:2 K1-POWERCONTACTOR
DO0-HI X21:1 InverterEnable (IE)
DO0.1 X13:3 EmergencyStop-message Message to PacDrive controller
Table 6-2: SMX output signals
Configuration of SMX 12
Assignment of inputs/outputs
Figure 6-9: SMX 12 assignment of inputs/outputs
Configuration of inputs
The configuration of the input elements is shown in the figures below. Each input el
ement must be assigned the pulses corresponding to the connections. The configu
ration program checks if pulses were assigned alternately and triggers a warning, if
necessary.
Figure 6-10: Input configuration
Configuration of outputs
Three different types of outputs are used:
1. Relay output:
Addresses the mains contactor.
2. Safe HiLo-output:
InverterEnable; only the positively switching output is used.
3. Message output:
Emergency messge to the PLC; this signal can also be transmitted via the field
bus.
Figure 6-11: Output configuration
Motor encoder interface
The encoder interface (SIN/COS) must be configured depending on the encoder type
used in the motor. If there is only one encoder for each axis, sensor 2 is not used.
Resolution, SH motor:
Stegmann encoder SKS/SKM 36 with 128 sine/cosine periods
Resolution, SM motor:
Stegmann encoder SRS/SRM 50 with 1024 sine/cosine periods
The monitoring of the supply voltage for the MC-4 is set to 10 V.
Figure 6-12: Configuration of the encoder interface
Logic connections in the function block diagram
Figure 6-13: Function block diagram (FBD) for E-stop and safety gate circuit
In the case of switching off, emergency stop and opening the safety gate in automatic
operation, an E stop message is immediately sent to the PacDrive controller. Then the
two timers monitor the stop time. Normally, the ESS functions are used to monitor the
brake ramp. However, two effects must be taken into account:
1. The latent time cannot be set longer than 100 ms, which is too short for the MC-4
to lift "ControllerEnable" and the brake to engage.
2. Depending on the motion profile of the drive, it may happen that the drive has to
accelerate again. However, the ESS block generates a dynamic brake ramp de
pending on the current velocity.
For this reason, time monitoring of the brake ramp is preferred in our example.
If a CAN/Profibus DP module is used, wiring requirements can be reduced, as the input
information needs not additionally be connected to the PacDrive controller.
The figure below "function block diagram (FBD) for jogging in setup mode" shows the
monitoring for setup mode.
There are two monitoring paths that can be activated / deactivated with the JOG button.
When changing into setup mode, a delay time for a brake ramp is monitored, so that
any operation that may be in progress can be stopped when the operating mode is
changed. If the safety gate was already open, the drive is already standing.
Figure 6-14: Function block diagram (FBD) for jogging in setup mode
In this case, the OFF button has an immediate effect on the EmergencyStop signal.
After a set time (e.g. 5 s) the mains contactor is disengaged.
Figure 6-15: Function block diagram (FBD) for switching off the mains contactor
All conditions for the activation of InverterEnable are combined. If a signal is missing,
the STO of the connected MC-4 drives is triggered immediately. The positively driven
IEO contacts are monitored by the output function block itself. If an error is detected,
an alarm is triggered in SMX12, which results in the switch-off of all outputs and thus
the disengagement of the mains contactor K1.
Figure 6-16: Function block diagram (FBD) for switching off the InverterEnable signal
6.4.3 Validation example of the SMX12 safety functions
CAUTION
The following tests only check the correct monitoring limits and the call up of the correct safety
functions.
The safety functions for the specific application depend on the outcome of the risk analysis.
Validation of the safety functions used in the example
No. Setting Test procedure Result/comment
1 Test of automatic mode
It must be possible to drive axes 1-3 in
automatic mode
Switch on the machine
Select automatic mode
Close safety gate
Quit error(s)
Press the ON button and/or let
the machine run
Automatic mode OK
2 Test of emergency stop function
Immediate EmergencyStop message
from SMX to PLC.
PLC must be able to stop the drive.
After a delay (1 s) the IE must disen
gage.
After reset, IE is on again.
The mains contactor must not disengage.
Switch on as described under 1
Press emergency stop
Lift emergency stop
Press reset
the machine run
Emergency stop function
OK
3 Test of the safety gate function
from SMX to PLC.
After a delay, IE must disengage. (alter
natively, an SOS should be executed)
After reset, IE is on again.
The mains contactor must not disengage.
Open safety gate
Lift safety gate
Press reset
the machine run
safety gate function OK
4 Test of the OFF function
from SMX to PLC.
After a delay, IE must disengage.
The mains contactor should drop after 5 s.
Press OFF button
OFF function OK
5 Test activation of the setup mode
from SMX to PLC.
When jogging, move at reduced velocity.
Let drives run
Select setup mode
Safety gate may be open or
closed (test both options)
Press JOG button (let drives run)
Jogging mode OK
6 Test of safety functions "safely reduced velocity" in setup mode
No. Setting Test procedure Result/comment
When jogging at excessive velocity, the
InverterEnable signal must disengage im
mediately.
In addition, the mains contactor may dis
engage as a following error.
The error can be quitted when the velocity
has been reduced.
Select setup mode.
Press JOG button.
(let drives run at 10% excess ve
locity)
Velocity monitoring OK
7 Test of safety functions "JSS (jogging skip supervision)" in setup mode
If the relative maximum path/angle is ex
ceeded, the InverterEnable signal must
disengage immediately.
Error can be quitted.
Select setup mode.
Press JOG button.
(Let drives move beyond the po
sition range at rated speed)
Position area OK
8 Test of safety functions "ZSC (Zero Speed Control)" in setup mode
If the relative maximum path/angle is ex
ceeded, the InverterEnable signal must
disengage immediately.
Error can be quitted.
Select setup mode.
closed. (test both options)
Do not press JOG button.
Move drive "manually".
Zero speed control OK
9 Test of mains contactor monitoring "K1 Test"
Mains contactor must not engage.
Switch off the machine.
Remove the "K1-Test" signal
from SMX12 (simulates a stuck
mains contactor)
Repeatedly press ON and Reset
buttons.
Mains contactor diagno
sis OK
10 Test of the InverterEnable relay "ieo-Signal"
When the InverterEnable relay disengag
es, the mains contactor must disengage
as well.
Switch the machine to automatic
mode as described under 1.
Move drives.
Remove the "ieo-Signal" from
the SMX12 (simulates a stuck In
everterEnable relay)
Activate emergency stop or safe
ty gate
IE relay diagnosis OK
Table 6-3: Function block diagram (FBD) for switching off the Inverter Enable signal
6.5 Circuit suggestion: PacDrive system with DB-5 and iSH
6.5.1 Inverter Enable function
Introduction
With the Inverter Enable function (IE) you can bring drives to a safe stop. This function
includes the components PS-5, DB-5 and iSH. The Inverter Enable function requires
further components, e.g. emergency stop, safety switching unit (optional) and con
nections. The following chapter describes the correct use of the Inverter Enable func
tion.
DANGER
Loss of the Inverter Enable function due to incorrect use
Risk of death, serious injury, property or environmental damage
Drive cannot be put into the safe state.
Machine functionalities are not as required.
Observe all requirements for the correct functioning of the Inverter Enable func
tions as described in the following sections.
The correct use of the Inverter Enable function is a prerequisite for correct functioning.
Nevertheless, the accidental loss of the Inverter Enable function cannot be ruled out.
Such losses of the Inverter Enable function are only restricted to the upper limit re
quired by the relevant safety standards. This is expressed by the characteristics PFH
and SFF.
In the sense of those standards, the requirements of stop category 0 (Safe Torque Off,
STO) and stop category 1 (Safe Stop 1, SS1) can be met. Both categories lead to a
torque-free motor while SS1 takes this state after a predefined time. As a result of the
hazard and risk analysis, it may be necessary to choose an additional brake as a safety
option (e.g. for pending loads).
The function is selected via a signal (pair) at the input of PS-5 (2), which is forwarded
to all drives (7) of this PS-5 group. The supply voltage (AC) needs not be interrupted
(see figure below).
1
2
4
5
6
7
IE
AC
3
Figure 6-17: Implementation of "Emergency stop with Inverter Enable"
1 switch cabinet
2 PacDrive Power Supply PS-5
3 Contactor
4 Emergency stop switch
5 Safety switching device (e.g. Preventa XPS AV)
6 PacDrive Distribution Box DB-5
7 Intelligent Servo Module iSH
If only some of the drives attached to a PS-5 (1) should be put in the safe state, this
can be achieved by the configuration of the drives. This is interesting e.g. for cleaning
modes (6). If an optional module iSH-DIS1 (9) has been set, the IE signal will be ig
nored. To implement the emergency stop, the power supply on the PS-5 must be
interrupted; see illustration below.
1
2
3
6
7
8
5
9
IE
4
AC
Figure 6-18: Implementation of "Emergency off" and "Cleaning mode iwith Inverter
Enable" in two protective circuits
2 switch cabinet
4 Contactor
6 Switch: Operating mode (normal/cleaning)
8 Intelligent Servo Module iSH (without iSH-DIS1)
9 Intelligent Servo Module iSH (with iSH-DIS1)
iSH Cleaning Emergency stop Parameter InverterEna
bleMode
iSH without iSH-DIS1 (8) Torque-free motor Torque-free motor Standard/1
iSH with iSH-DIS1 (9) - Torque-free motor Off/0
DANGER
Remaining charge of the DC bus for iSH with iSH-DIS1
Risk of injury due to uncontrolled axis movement
Make sure that nobody has access to the danger zone as long as there is any
charge remaining in the DC bus.
Qualification of personnel
Operators of the iSH system and/or the Inverter Enable function must be trained ac
cording to the complexity of the machine and the safety integrity level of the Inverter
Enable function (SIL2). The training must include the production process and the re
lation between Inverter Enable function and machine.
The specialists must be able to detect possible hazards that may arise from parame
terization, changing parameter values and generally from mechanical, electrical or
electronic equipment.. The specialists must be able to assess the jobs that are as
signed to them on the basis of their technical expertise, knowledge and know-how.
The specialists must be familiar with the relevant standards, provisions and regulations
for the prevention of industrial accidents, which they must observe when working on
the drive system.
Qualification guidelines can be found in the following publication, for example: Safety,
Competency and Commitment: Competency Guidelines for Safety-Related System
Practitioners. IEE Publications, ISBN 0 85296 787 X, 1999, http://www.iee.org/Pub
lish/Books/EPD/
Preparatory measures taken by the machine manufacturer
Hazard and risk analysis
Based on the plant configuration and utilization, a hazard and risk analysis can be
carried our for the plant (e.g. according to EN1050 or ISO13849:2006). The results of
this analysis must be considered when using the Inverter Enable safety function. The
circuit resulting from this analysis may deviate from the application examples. For ex
ample, additional safety components may be required. In principle, the results from
the hazard and risk analysis have priority.
Using additional safety equipment
In its final state, the Inverter Enable function provides a torque-free drive. Therefore,
unexpected or non-braked motions cannot be ruled out due to external loads.
DANGER
Accidental use of the brake as a safety function
Risk of death or serious injury when operating pending loads
Do not use the optional brake available for iSH as a safety function.
Use an external safety brake.
If the hazard and risk analysis based on this fact should lead to physical injuries or
property damage that cannot be eliminated by design, suitable additional safety meas
ures (e.g. preventing a stay in the danger zone or additional safety equipment such as
a brake) must be provided within the machine. The machine concept must guarantee
personal safety.
This applies when the machine is in operation as well as when maintenance or com
missioning work is carried out on the machine and drives.
Always observe the valid rules for safety and accident prevention (e.g. for the US, see
NEMA ICS1.1 and NEMA ICS7.1) and observe the specified ambient conditions, given
technical data etc.
Functional description
Scope of operation (designated safety function)
The Inverter Enable function relates to PS-5, DB-5 and iSH, hereinafter referred to as
"iSH ystem".
1
2
4
5
6
7
IE
AC
3
Figure 6-19: iSH system with emergency stop
1 switch cabinet
3 Contactor
7 Intelligent Servo Module iSH
Operating prin
ciple
The InverterEnable function safely switches off the motor torque. It is sufficient to set
a logical zero at the function input. There is no need to interrupt the power supply.
Standstill, however, is not monitored.
Inverter Enable is equivalent to safe torque off (STO) according to IEC 61800-5-2.
Safe
State
This torque-free state is automatically assumed when errors are detected in the sys
tem. Therefore it is the safe state of the drive.
Mode of opera
tion:
By setting a logical one for the "InverterEnable" input on the PS-5, the output stage
control of all iSH-drives connected to this PS-5 become possible (necessary condition).
If, on the other hand, this input is set to a logical zero, the power supply at the Inver
terEnable input is interrupted and no torque can be built up in the connected iSH-
drives.
This InverterEnable-input has a redundant design (AC voltage from which the PS-5
generates DC voltage that is fed into the hybrid cable). The failure of one of the two
channels already results in the logical zero. When the power supply is cut off, the final
stage becomes de-energized, and an error message is generated. The motor can no
longer generate torque and stops unbraked.
You can use the Inverter Enable function to implement the control function "Stopping
in case of emergency" (EN 60204-1) for stop categories 0 and 1. Use a suitable ex
ternal safety circuit to prevent the unexpected restart of the drive after a stop, as re
quired in the machine directive (see application suggestion).
Stop
Category 0
In stop category 0 (Safe Torque Off, STO) the drive stops in an uncontrolled way.. If
this means a hazard in your machine. You must take suitable measures (see hazard
and risk analysis (see 6.5.1.3 Preparatory measures taken by the machine manufac
turer)).
Stop
Category 1
For stops of category 1 (Safe Stop 1, SS1) you can request a controlled stop via the
PacController. The controlled stop by the PacController is not safe, not monitored and
not guaranteed to work in case of power outage or an error. Final switch off in the safe
state is ensured by switching off the InverterEnable-input on the PS-5. This has to be
implemented by means of an external safety switching device with safe delay (see
application suggestion).
Muting
Execute
You can mute the Inverter Enable function by using the optional module iSH-
DIS1.
The safe state can only be achieved if the power supply is switched off.
To avoid misconfigurations, you now have to define the configuration to be used
with the parameter "InverterEnableMode" of the iSH in the PLC configuration.
If the set mode does not match the real configuration of the iSH, error message 123
"Inverter Enable error" with the extended diagnostic message "Wrong Mode: xx" is
triggered. "xx" is the mode which the iSH currently has. The drive doesn't switch to
control mode as long as the configuration is wrong. The error can only be acknowl
edged if the InverterEnableMode setting corresponds to the real configuration. This
can be used to divide the drives on one PS-5 into two groups, if it is technically im
possible to use two PS-5 for the two groups in the existing machines.
Validity of the safety proof
The Inverter Enable function relates to PS-5, DB-5, iSH-HCN1, iSH-DIS1 and iSH,
hereinafter referred to as "iSH system", and is valid for the following hardware codes:
device Item no. Hardware code:
iSH 070/xx
iSH 100/xx
6601 2xxx-xxx
6601 3xxx-xxx
xx401xxx oder
xx402xxx oder xx502xxx
iSH DIS1 5113 0325 1
PS-5 1313 0265 xx4xxx oder xx5xxx
DB-5 1313 0266-1 2xxx
Hybrid cable 1515 4513-xxx,1515 4514-xxx,
1515 4515-xxx,1515 4516-xxx,
1515 4517-xxx
not existing
iSH HCN1 1515 4417 1
Safety proof for higher hardware codes is also planned.
For questions on this issue, please contact your ELAU partner.
Firmware version 00.24.20 or higher is required in the controllers and the iSH system.
Interface
The Inverter Enable function is operated via the switching thresholds of the Inverter
Enable-input (IE1 on Pin1, IE2 on Pin2) of the PS-5.
Technical data of the input:
Max. test pulse width: none
Max. switching frequency of input signal: 10 Hz
For technical dara and information on electrical connections of the PS-5, please see
the operating manual "Power Supply PS-5 and Distribution Box DB-5".
For more technical data and information on the electical connections of the iSH system.
There must be a description of or reference to the connector assignment with input
and output clamps of the Inverter Enable-clamps on the PS-5.
Lifetime and response time
The Inverter Enable function is designed for a maximum of 15 years of operation. After
this time, flawless functionality can no longer be guaranteed. The expiry date of the
device is the date given on the type plate plus +15 years. Please include this date in
the maintenance schedule of the plant.
Response time with Inverter Enable function
The response time until switch off with Inverter Enable function (without using the iSH-
DIS1) is not more than 20 ms. This is the time from the corresponding change of the
Inverter Enable input on the PS-5 to the torque-free iSH motor (safe torque off, STO).
Response time with iSH-DIS1
The response time to switch off when the iSH-DIS1 (without the Inverter Enable func
tion) is used depends on the load on the PS-5 (i.e. on the machine) and has to be
determined from the application. Axes with iSH-DIS1 become torque free via the mains
contactor and come to a stop.
Setup, installation, and maintenance
The drive system must only be operated with specific cables, accessories and spare
parts approved by ELAU.
DANGER
Loss of electrical safety due to operation of the PS-5 with uncertified power supply units
Risk of death or serious injury!
PS-5 must only be operated with power supply units certified according to EN
60950 or EN 50178 (so-called "safe voltage outputs").
These power supplies supply no excess voltage above DC 120 V for more than
120 ms and no permanent excess voltage above DC 60 V.
CAUTION
To use the Inverter Enable function, the given maximum configurations (number of devices,
network structure and cable length) must be observed; otherwise the system will always be
in safe state (power drop of the Inverter Enable signal over the length of the cables).
The system must not include more than 4 PS-5, 40 DB-5 and 95 iSH-motors.
CAUTION
Do not use pulsed semiconductor outputs with external safety switch devices.
Application proposals
There are three application suggestions to implement the safe stop of category 1
(SS1):
EL-1054-05-xx: Inverter Enable circuit iSH/PS-5 using the PacDrive Controller
Cx00 with safety switch device for two protective circuits
EL-1055-05-xx: Inverter Enable circuit iSH/PS-5 and MC-4 using the PacDrive
Controller Cx00 with safety switch device for two protective circuits
EL-1056-05-xx: Inverter Enable circuit iSH/PS-5 and iSH-DIS1 using the PacDrive
Controller Cx00 with safety switch device
Notes on application suggestions
General
All application suggestions provide for a protected IE+/IE- wiring (switch cabinet
IP54) from the safety switch device to the PS-5, as faults need to be ruled out.
All application suggestions are designed with two protective circuits (emergency
stop and safety gate). As required, one of those can be removed.
Protection against automatic restart is ensured by the external safety switch device.
Notes on
EL-1054
The mains contactor K1 in this circuit proposal is not necessary for functional safety
purposes. It is, however, used in the application suggestion for the device protection
of PS-5/iSHs.
Notes on
EL-1055
To monitor the mains contactor, the positively driven contacts of the mains contactor
K1 must be monitored by the PacDrive Controller when switching it on. This can be
accomplished by using the ContactorControl software component either separately
or integrated into the template.
Notes on
EL-1056
To monitor the mains contactors, the positively driven contacts of the mains contactors
K1 and K2 must be monitored by the PacDrive Controller when switching them on.
This can be accomplished by using the ContactorControl software component either
separately or integrated into the template.
DANGER
Dangerous motion due to residual energy!
Risk of death, serious injury or property damage!
No DC bus discharge is planned in this application. Therefore you need to make
sure that the residual energy saved in the drives equipped with iSH-DIS1 cannot
cause any dangerous motion in case of an error.
Figure 6-20: EL-1054-05-xx Sheet 1
Operating states
DANGER
Unintentional restart of the motor!
Risk of death, serious injury, property or environmental damage!
The restart of the motor (e.g. when the power supply returns after an outage or
after a safety requirement has been removed) to reach the stop category must
only be possible after receipt of an enable signal .
This enable signal must meet the given safety criteria.
Mode selection
In principle, you can choose between the functions STO and SS1. You can deactivate/
mute the chosen function as you please using the iSH-DIS1. This can be regarded as
a mode selection, but is already covered by the application suggestions above.
DANGER
Use of an inadequate external safety device
Safety function as a whole is not executed according to the standards
Insufficient error detection
High probability of dangerous failures
Implement the safety related time for the SS1 function with an external safety
switch device
The mode selection between STO and SS1 is made by an external safety switch de
vice. If SS1 is selected, this external device will select STO after a certain safe time.
The user will be warned (diagnostic message 123 "Inverter Enable error") if the mode
set in the parameter InverterEnableMode does not match the real devices. That means
if InverterEnableMode = "Off / 0", then the iSH-DIS1 must be plugged in on the iSH.
Optional module iSH-DIS1
DANGER
High voltage!
Electric shock, fire or explosion!
Before working on electrical equipment, always put the main switch in the "OFF"
position and secure it against being switched back on.
Make sure that the drives are at a standstill because potentially fatal voltage can
occur on the motor lines in generator operation.
Disconnect the plug-in connectors that are not live.
Disconnect and plug in power connector cables only when the system is deacti
vated.
Before working on the unit, discharge the DC bus and use a voltage meter to
make sure that there is no voltage.
If you are using prefabricated cables not manufactured by ELAU, check that the
assignment of the new cables complies with the connection diagram of the ma
chine manufacturer.
CAUTION
Electrostatic discharge!
Damage to component possible!
Touch circuit boards only on edges.
Do not touch any of the circuit points or components.
Discharge any present static charge by touching a grounded metallic surface
such as a grounded housing.
Prevent electrostatic charges; e.g., by wearing appropriate clothing.
How to install the iSH-DIS1 optional module.
Installation
Open main switch.
Prevent main switch from being switched back on.
Remove green, transparent cover plate on the motor.
Remove plugged in jumpers J1 and J2 (see figure).
J1
J2
J3
J4
J5
Plug optional module iSH-DIS1 onto contact pins, as shown in the following dia
gram.
The following figure shows the correctly plugged module.
Place green, transparent cover plate onto the motor and tighten the screws.
How to disassemble the optional module iSH-DIS1:
Disassembly
Open main switch.
Prevent main switch from being switched back on.
Remove green, transparent cover plate on the motor.
Remove optional module iSH-DIS1.
Plug in jumpers J1 and J2 (see figure).
J1
J2
J3
J4
J5
Place green, transparent cover plate onto the motor and tighten the screws.
Commissioning
Carry out a functional test of the STO function for all drives that need the safety
function.
In particular, check that the iSH-DIS1 jumper is placed correctly.
CAUTION
Do not put the drive systems into operation until you have completed the installation in
accordance with the EMC regulations and further specifications in the device operating
manuals.
Prevention of reasonably foreseeable misuse
Plug-in
connections
for wear
Check explicitly for iSH and DB-5 if all connectors are placed correctly.
Use only robust connectors and safe fixtures.
Check clamping points and make sure that connections are firmly seated on the
PS-5 (see PS-5 operating manual, commissioning and electrical connections).
Transport
packaging
Use only suitable transport packaging to forward individual devices or return them
to ELAU.
Effects
of external
forces
The safe state of the iSH-motor is the torque-free output shaft. If external forces act
upon the output shaft, it will not necessarily maintain its position. However, if this is
one of the protection goals of the hazard and risk analysis, you need to take additional
safety measures.
Pending and
pulling
loads
If it is a protection goal for the machine to safely block pending or pulling loads,
you need to ensure this by means of an additional, suitable brake which is de
signed as a safety function.
DANGER
Accidental use of the brake as a safety function
Risk of death or serious injury when operating pending loads
Do not use the optional brake available for iSH as a safety function.
Use an external safety brake.
The iSH-motor has no safe output to connect such a brake.
Hybrid connec
tion
The maximum number of bending cycles of the cable must not be exceeded.
Observe wiring instructions and maintenance cycles (see "Project planning notes
for the PacDrive System")
The maximum permissible lifetime of the hybrid cable may not be exceeded.
CAUTION
Persons in the operating range of moving components of a complex plant
Risk of injury!
At plant start-up, the connected drives are normally outside the range of vision
of the plant personnel and cannot be monitored directly.
Only start the plant if there are no persons within the action area of moving plant
components and when the plant can be operated safely.
Maintenance
As the Inverter Enable function has been designed for a lifetime of 15 years, no routine
checks are necessary to maintain or verify functional safety. Due to the aging of com
ponents and the related failure rate, it is impossible to make any statement about the
Inverter Enable function after those 15 years. If you wish to ensure the functionality in
the sense of safety standards and product liability after this period, you need to ex
change the iSH.
CAUTION
After exchanging a iSH servo module, the iSH-DIS1 module must be explicitly checked and
the corresponding drive must be subjected to a functional test.
Keep a logbook for recording the maintenance history of the machine and note in it
the components replaced (as per IEC62061, 7.2.k) 1)).
For more information on initial installation and maintenance.
Physical environment
The iSH Inverter Enable system is not protected by design against physical or chemical
sources of danger. Possible sources of danger include:
toxic,
explosive,
corrosive,
highly reactive, or
inflammable types.
CAUTION
Harmful ambient, storage and transport temperature
Loss of the InverterEnable function
Check the ambient, storage and transport temperature of the individual compo
nents as indicated in the respective manuals.
CAUTION
Moisture during operation, storage and transport of components
Please make sure that there is no moisture during the operation, storage and
transport of individual components, as described in the corresponding manuals.
In principle, all plugs and plug-in connectors which include Inverter Enable must be
designed according to IP54 or higher. For iSH and DB-5, this is ensured by the design
according to IP65. All other components (PS-5, plug-in connections in the hybrid cable)
do not have this high protection class and therefore are only intended for use in an
environment according to IP54 or higher (e.g. switch cabinet).
CAUTION
Vibration and shock during operation, storage and transport of components
Please note the vibration and shock requirements for components during oper
ation, storage and transport, as described in the corresponding operating man
uals.
Safety standards
The Inverter Enable function was developed and tested according to the following
standards for functional safety:
IEC 61800-5-2:2007; Safe Torque Off, STO und Safe Stop 1, SS1, SIL2-ena
bled
IEC 61508; Part 1:1998 + Corrigendum 1999
EN 61508; Part 2:2000; Safe Torque Off, STO and Safe Stop 1, SS1, SIL 2-
enabled
EN ISO 13849-1:2006; PL d, EN 954-1:1996; Category 3
IEC 62061:2005; SILCL 2
Certification was handled by TV NORD SysTec GmbH & Co. KG (Augsburg, Ger
many) (certificate no. SAS1736/08).
Those components that include the IE function are generally tested according to
CE
cUL
The Inverter Enable function achieves the following safety integrity:
Safety Integrity Level (SIL) 2, according to IEC61508:1998.
Performance level (PL) d, category 3 according to ISO13849:2007
The probability of dangerous failures per hour (PFH) and the safe failure fraction (SFF)
according to IEC61508-2:2000 and the diagnostic coverage (DC) according to
ISO13849:2006 for the devices are as follows:
PS-5: PFH: 3.66*10
-9
/h, SFF: 99.9%, DC: 98.7%
DB-5: included in PS-5 and iSH calculations
iSH: PFH: 0, SFF: 100%, DC: 100%
A system with maximum configuration (consisting of 4xPS-5, 40xDB-5, 95xiSH) results
in the following values:
PFH: 1.46*10
-8
/h, SFF: 100%, DC: 98.7%
Figures for other configurations within the machine can be requested from ELAU AG.
7 Special Conditions
Power reduction at increased ambient temperature
The permissible ambient temperature for the PacDrive MC-4 is 45 C. At higher am
bient temperatures up to 55 C, the rated current is reduced by 2 % per C.
35
1
0,8
0,6
0,4
0,2
0
ambient temperature in C
L
o
a
d
f
a
c
t
o
r
P_Umgebungstemp_englisch.fh8
40 45 50 55
Figure 7-1: Power reduction at increased ambient temperature
The maximum allowable ambient temperature is 55C for the PacDrive Controller.
Power reduction at low air pressure
Below an altitude of 1000 m above sea level, no power reduction is necessary. Above
an altitude of 1000 m, the maximum rated current should be reduced as shown in the
diagram below.
0
1
0,8
0,6
0,4
0,2
height above sea level in m
L
o
a
d
f
a
c
t
o
r
P_Hoehe_englisch.cdr
1000 2000 3000 4000 5000
Figure 7-2: Power reduction at low air pressure
7 Special Conditions
Power reduction with long motor cables
The load on the end stage increases because of increasing cable capacitance when
long motor cables are used. This causes additional heating in the end stage. For cables
> 15 m, the rated current may need to be reduced. With PacDrives MC-4 / 1.5 A ; 3 A;
5 A, for example, the rated current has to be reduced to 75 % for a 40 m long cable
(see table below).
1
0,8
0,6
0,4
0,2
0
motor cable length in m
L
o
a
d
f
a
c
t
o
r
P_Motorkabel_us0001.fh8
10 20 30 40
MC-4 / 22 A
MC-4 / 10 A
MC-4 / 1.5 A;3 A;5 A
Figure 7-3: Power reduction with long motor cables
Servo Drives Power reduction with motor cables longer than 15 m
PacDrive MC-4 / 1.5 A ; 3 A; 5 A -1 % / m
PacDrive MC-4 / 10 A -0.6 % / m
PacDrive MC-4 / 22 A -0.5 % / m
Table 7-1: Power reduction dependant on motor cable length
CAUTION
If a power reduction is required for several reasons, the corresonding load factors must be
multiplied.
8 Appendix
8.1 Addresses
ELAU AG
Customer Services
Postfach 1255
Tel.: +49 (0) 9391 / 606 - 142
Fax: +49 (0) 9391 / 606 - 340
Street address:
Dillberg 12
ELAU AG
Dillberg 12
Tel.: +49 (0) 9391 / 606 - 0
Fax: 09391/606-300
ELAU, Inc.
165 E. Commerce Drive
Schaumburg, IL 60173, USA
E-mail: info@elau.com
Internet: www.elau.com
Tel.: +1 847490 4270
Fax: +1 847 490 4206
ELAU Systems Italia S.r.l.
Via Speranza, 48/A
40068 San Lazzaro di Savena (BO), Italy
Tel.: +39 051 / 62 76 711
Fax: +39 051 / 62 72 702
E-mail: info@elau.it
Internet: www.elau.it
CAUTION
See the ELAU homepage (www.elau.de) for additional contact addresses.
8 Appendix
8.2 Additional Literature
The following manuals and guides for the PacDrive system are available from ELAU:
Programming Manual
Item No. 17 13 00 61 - 00x (DE, EN)
PacDrive System Projecting Notes
Item No. 17 13 00 58 - 00x (DE, EN)
PacDrive MC-4 Operating Manual
Item No. 17 13 00 62 - 00x (DE, EN, IT, FR)
CAN L2 Operating Manual
Item No. 17 13 00 66 - 00x (DE, EN)
PROFIBUS DP Operating Manual
Item No. 17 13 00 67 - 00x (DE, EN)
SM Motor Operating Manual
EPAS-4 Operating Manual
Item No. 17 13 00 70 - 00x (DE, EN)
PacDrive Controller MAx-4 Operating Manual
OPC Server User Manual
Item No. 17 13 00 73 - 00x (DE, EN)
Device Net Operating Manual
Item No. 17 13 00 76 - 00x (DE, EN)
HMI Libraries Operating Manual
Item No. 17 13 00 77 - 00x (DE, EN)
INC-4 Incremental Encoder Module Operating Manual
Item No. 17 13 00 78 - 00x (DE, EN)
CANopen Operating Manual
Item No. 17 13 00 79 - 00x (DE, EN)
ECAM-4 Motion Toolkit Operating Manual
Item No. 17 13 00 80 - 00x (DE, EN)
PacNet Module PN-4 Operating Manual
Item No. 17 13 00 81 - 00x (DE, EN)
SR Motor Operating Manual
Item No. 17 13 00 82 - 00x (DE, EN)
BT-4 Bus Terminal Operating Manual
Item No. 17 13 00 83 - 00x (DE, EN)
TTS Training and Test System Operating Manual
Item No. 17 13 00 88 - 00x (DE)
Automatic Controller Optimization User Manual
Item No. 17 13 00 89 - 00x (DE, EN)
PacDrive SCL Operating Manual
Item No. 17 13 00 93 - 00x (DE, EN)
8.2 Additional Literature
PacDrive PS-4 and PacDrive PD-8 Operating Manual
Item No. 17 13 00 94 - 00x (DE, EN)
Evaluation Kit User Manual
Item No. 17 13 00 95 - 00x (DE)
PacDrive Controller P600 Operating Manual
Art. Nr. 17 13 00 96 - 00x (DE, EN, IT, FR)
PacDrive Controller C200 Operating Manual
PacDrive PC Panel PCP Operating Manual
Item No. 17 13 01 02 - 00x (DE)
SH Motor Operating Manual
Item No. 17 13 01 05 - 00x (DE, EN)
iSH Intelligent Servo Module Operating Manual
Item No. 17 13 01 13 - 00x (DE, EN)
PS-5 Power Supply and DB-5 Distribution Box Operating Manual
Item No. 17 13 01 15 - 00x (DE, EN)
PacDrive P3 Robot Operating Manual
Item No. 17 13 02 19 - 00x (DE)
Item No.-000 DEutsch -001 ENglish-002 ITalian -003 FRench
8 Appendix
8.3 Product Training Courses
We offer a range of training courses about our products.
Our experienced instructors teach you to get the most out of the comprehensive func
tions of the PacDrive
TM
system.
CAUTION
See the ELAU homepage (www.elau.de) for further information and our current seminar
schedule.
8.3 Product Training Courses
8.4 Changes
12/2006
User manual newly written
08/2008
Functional Safety chapter written
CAUTION
The updated documentation, application notes and the updating to the products are available
on the ELAU Homepage.
8 Appendix
Index
A
Additional Literature 89
Air pressure 86
Ambient temperature 86
B
Braking 31
C
Changes 92
Climatic 17
Condensate 22, 23
Condensation 22
Contact addresses 88
Contactors 39
Control circuit 34
Cooling units 22
D
Dragchains 24
E
ELAU AG 2
Electromagnetic fields 27
Electrostatic discharge. 18
Emergency stop 64
Error Number 78
F
Fault currents 29
Fiber-optic conductors 24
Function block diagram 54
H
Hazard analysis 36
Hazard and risk analysis 63, 82
Heat dissipation 20
High voltage! 19
Homepage 2, 88
Hot spot 18
Hot surfaces 19
Hybrid cable 24
I
Input capacitance 31
Input elements 52
Installation 67
Internet 88
Inverter Enable 35, 38
InverterEnable 38
InverterEnable input 64, 66
iSH 68
L
Legal notice 2
Line chokes 28
Long motor cables 87
M
Machine grounding 26
Mains contactor 30
Mains contactor group 28
Mains filter 27
Mains networks 28
Manuals 89
Maximum constellation 67
MC-4 42
Mechanical 18
Minimum bending radius 24
Minimum cross sections 24
Misuse 82
Muting 65
O
Operating manual 89
P
Plan odravanja 66
Power circuit 33
Power reduction 86
Proper use 8
Protection class 17
Q
Qualification of personnel 9, 62
R
Ready contact 35
Index
response time 66
Risk classification 7
Risk evaluation 36
S
Safe state 64
Safe stop 35, 60
Safety function 64
Safety switching unit 39
Seminars 91
Service addresses 88
Skin effect 26
Specialist 62
SS1 78
Standards 85
STO 78
Stop category 0 60, 64
Stop category 1 60, 64
Symbols 7
T
Temperature limit 22
Three-phase mains 28
Trademark 2
Training 62
Training courses 91
V
Voltage monitoring 31
W
Watchdog 35
Wiring 26
Wiring error 26
Index

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