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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 language without the express written consent of ELAU AG.Every imaginable measure was taken to guarantee the correctness of this productdocumentation. However, as improvements are continually being made to the hardware and software, ELAU AG cannot guarantee its completeness or correctness.

TrademarkPacDrive is a registered trademark of ELAU AG.All other trademarks named in this documentation are the sole property of their respective manufacturer.

ELAU AGDillberg 1297821 Marktheidenfeld, Germany

Tel.: +49 (0) 9391 / 606 - 0Fax: +49 (0) 9391 / 606-300

E-mail: [email protected]: www.elau.de

Legal notice

Page 2 PacDrive ELAU AG

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Contents

1 About this Manual 51.1 Introduction ............................................................................................................... 5

1.2 Symbols, designator and display format of safety notes .......................................... 7

2 Safety instructions 82.1 Proper use ................................................................................................................ 8

2.2 Selection and qualification of personnel ................................................................... 9

2.3 Residual risks ......................................................................................................... 10

3 Switch Cabinet Planning 173.1 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 244.1 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 335.1 Power Circuit .......................................................................................................... 33

5.2 Control Circuit ......................................................................................................... 34

6 Functional safety - safety connections 366.1 Machine safety ....................................................................................................... 36

6.2 Circuit suggestion for PacDrive system with MC-4 ................................................ 36

6.2.1 Funktionsbeschreibung .......................................................................................... 37

Contents

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6.2.2 Redundant stopping ............................................................................................... 376.2.3 Inverter enable circuit (IE) ...................................................................................... 386.2.4 Level definitions ...................................................................................................... 386.2.5 Impermissible application ....................................................................................... 386.2.6 Switching components ........................................................................................... 396.2.7 PacDrive controller C200 ....................................................................................... 406.2.8 Wiring diagram for PacDrive controllers MAx-4, C400/600 and P600 ................... 426.2.9 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 .......................................................................................... 456.4.2 Circuit suggestion ................................................................................................... 486.4.3 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 888.1 Addresses .............................................................................................................. 88

8.2 Additional Literature ............................................................................................... 89

8.3 Product Training Courses ....................................................................................... 91

8.4 Changes ................................................................................................................. 92

Contents


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1 About this Manual1.1 Introduction

Read this manual before you work on the ELAU component for the first time. Takeparticular note of the safety instructions. As described in section 2.4, only those persons who meet the Selection and qualification of employees are allowed to work onthis unit.

A copy of this manual must always be available for personnel who are entrusted towork on the component.

This manual is intended to help you use the ELAU component and its intended applications 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


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1 About this Manual


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1.2 Symbols, designator and display format of safety notesThis 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 MeaningInformation symbol:After this symbol, you will find instructions and usefultips on using the components.

Marker:After this symbol, you will find references for further information.

Orientation aid:Information serving as an orientation aid regarding thesection's contents follows this symbol..

Keyword If the descriptive text contains technical terms (such as parameters), theyare 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. Followthe 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


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2 Safety instructionsThis section contains general requirements for safe work. Each person who uses or

works on the ELAU component must read and follow these general safety instructions.If activities involve residual risks, a specific note is made at the appropriate points. Thenote details the potential hazard and describes preventative measures to avoid it.

2.1 Proper useThe ELAU component is are intended to be installed in a machine or assembled withother components to form a machine or system. You may only use them in accordancewith the installation and operating conditions described in the documentation. Use onlythe 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 thecomplete 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 maintainedin accordance with the required technical data (performance data and ambient conditions). Commissioning is prohibited until it is guaranteed that the usable machine orsystem in which the component is installed meets all requirements of EC Directive

98/37/EC (machinery directive).

2 Safety instructions


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2.2 Selection and qualification of personnelThis description is geared exclusively toward technically qualified personnel, who havedetailed knowledge in the field of automation technology. Only qualified personnel can

recognize the importance of the safety instructions and implement them consistently.The description is mainly for construction and application engineers from the engineering and electro-technics division as well as service and commissioning engineers.

Professional or training personnelWork on the component may only be carried out by qualified professional or by trainedstaff under the instruction and supervision of a qualified person in accordance withelectrical regulations. Work may only be carried out by qualified professional or bytrained staff under the instruction and supervision of a qualified person in accordancewith 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


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2.3 Residual risksHealth risks arising from of the component have been reduced by means of safetytechnology and design engineering. However a residual risk remains, since the com

ponent works with electrical voltage and electrical currents.Motion Sequence RobotMotion sequences can occur when operating with robot mechanics, which allow operational staff to make misjudgments. Particular attention must be paid to ensuringthat all necessary safety measures are implemented to avert any danger to life andlimb. The safety standards for the country where the equipment is in use, define whichsafety measures are appropriate. Additionally, the System Engineer who is responsible for the integration of the robot mechanics, must evaluate which measures must betaken. Parts of the mechanics can move at very high speeds. In such cases, the weightof the net loading of any additionally installed tools and any shifts in the center of gravityof the parts that are moved, contribute to the total energy of the powers generated.

WARNINGRisk 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.

CAUTIONThe 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 longerpowered up, the robot arms can be moved manually in an emergency. This is particularlyimportant in the event that operational staff are caught and trapped by the robot mechanics.



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High leakage currentDANGER

High leakage currentRisk 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).



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Touching hot surfacesThe housing temperature of the motor exceeds 70C during nominal operation. Aswarning, the symbol shown here is affixed on the motor.

At high tact cycles, the robot mechanics base plate can reach high temperatures. Thiswarms up the surfaces of the mechanics.

WARNINGHot surfacesRisk 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 measuresThe 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 robotmechanics are in use at the same time. If noise emissions reach a value 85dBA, anystaff affected must wear ear defenders. In this case, the manufacturer of the machineor the company operating the machine must install the following warning symbol in ahighly visible location on the robot mechanics.

Dangerous MovementsThere 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 measures 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 theequipment. 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 access to the control terminals to allow access only to authorized persons.

2.3 Residual risks


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DANGERDangerous MovementsRisk 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 shouldbe checked before start-up and during maintenance periods.

Prevent unintentional start-ups by disconnecting the power connection of thedrive 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 cannotbe avoided, the system and the installation must be checked for possible malfunctions in all usage scenarios prior to the initial start-up. Where applicable, it isnecessary to carry out a special EMC check of the system.



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"Safe separated extra-low voltage"PELV Protec

tive Extra-LowVoltage

The signal voltage and control voltage of the PacDriveTMdevices are

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Protection against magnetic and electromagnetic fieldsMagnetic and electromagnetic fields that are in immediate environments of electricalconductors and permanent motor magnets represent a serious health hazard to persons with heart pacemakers, metal implants and hearing aids.

WARNINGHealth 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



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3 Switch Cabinet Planning3.1 Protection Class

CAUTIONMetallic dust deposits, oil, moisture, strong electromagnetic interference and ambienttemperature.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 cabinetClimatic ambient conditionsThe general climatic conditions defined for the ELAU devices designed for installationin a switch cabinet are listed in the table below.In general, class 3K3 according to EN 60721-3-3 applies. Deviations (e.g. higher temperature) are allowed, but need to be specified in the technical data.

Environmental parameter Unit Class3K3

Notesa Low air temperature max +5

b High air temperature max +40 Higher values (e.g. +55 C, possiblywith 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/m3 1

f High absolute humidity g/m3 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/m2 700

k Thermal radiaton - - See footnote in the applicablestandard

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


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Mechanical ambient conditionsThe general mechanical ambient conditions defined for ELAU devices for installationin 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 Technicaldata for the drives SH, SCL or iSH.

Environmental parameter Unit Class3M3

Notesa Sinus oscillation

Amplitude mm 1.5

in the frequency range Hz 2 ... 9

Acceleration m/s2 5 9.81 m/s2= 1 g

in the frequency range Hz 9 ... 200

b Shock resistance

Total shock-response range Type LPeak acceleration m/s2 70

for duration ms 147 m/s2= 15 g

Table 3-2: Climatic conditions in the switch cabinet

3.3 ESD Protection Measures

CAUTIONElectrostatic 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.

3 Switch Cabinet Planning


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DANGERHigh 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 surethat the voltage is less than 50 Volt.

WARNINGSurfaceson the PacDrive MC-4 and the braking modules (BM-4) are hotRisk of burns Wait until the PacDrive servo amplifier and the braking module have cooled off

or wear protective gloves. CAUTIONWhen connecting devices in parallel in the switch cabinet, the most powerful device shouldbe connected first (in regard to the mains feed) and then the smaller units should be connectedafter that. By doing this, the load on the DC circuit connections and the mains connection isreduced.

Figure 3-1: Sample switch cabinet layout with ventilation

3.4 Assembly Procedure


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CAUTIONHeat dissipation with PacDrive MC-4Switch cabinet rear wall as an active cooling elementThe design of the PacDrive MC-4 allows for a large part of the heat that is generated to belead 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 bedesigned as a cooling element, and the PacDrive MC-4 must be bolted on to the rear wall ina thermally conductive manner (thermally conductive paste).No thermal contact with the rear wallIf heat dissipation via the rear wall is undesirable (e.g. if a sub plate is used), spacers shouldbe used where the MC-4 MotorControllers are screwed onto the rear wall.



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Figure 3-2: Mechanical installation

3.4 Assembly Procedure


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3.5 Using Cooling Units

CAUTIONCooling units may cause condensation and condensateThis may result in damage to electronic components. Ensure that no condensate can drip out of the cooling unit onto electronic com

ponents.

Risk from condensationWarm, humid air enters the switch cabinet; upon cooling, it condenses on the sensitiveelectronic components located there.

Using cooling units properly:

1. When using cooling units, use only well-sealed switch cabinets so that warm, humidoutside air, which causes condensation, cannot enter the cabinet.

2. If switch cabinets are operated with open doors (commissioning, service, ... ), youmust ensure that the electronic components are at no time cooler than the air inthe switch cabinet after the doors are shut. Otherwise, condensation may occur.Therefore the cooling unit must continue to operate even when the system isswitched off, so that the temperature of the switch cabinet air and the installedelectronic 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!

Figure 3-3: Installing a cooling unit



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Risk from condensateIf the system is designed adversely, the condensate which continually accrues oncooling units may drip into the installed electronic components or be sprayed in withthe 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 switchcabinet 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 apause.

3.5 Using Cooling Units


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4 Wiring Notes4.1 General

The specifications regarding minimum cross sections, shielding and grounding mustbe observed when wiring.

The specifications given regarding junctions must be followed when doing this. If, forexample, two parallel conductors are shown as coming from one point, you must notrun one conductor and then branch it off at a later point. This could lead to inductionloops (interference senders and antennae) and interfering ground offset voltages.

CAUTIONAs the provider of the system, ELAU provides you with pre-fabricated cables.

CAUTIONObserve minimum bending radiusPotential 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 dragchains.

Property Copper cable Hybrid cable Fiberoptic conductor

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 stationary 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/s2

Table 4-1: Properties of conductors used by ELAU

PacDrive MC-4 type 1.5 ... 10 A 22 A 50 AMains cable in mm 1.5 / 2.5 4 16

4 Wiring Notes


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PacDrive MC-4 type 1.5 ... 10 A 22 A 50 AGround 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 sectionMains 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 sectionMains 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

DANGERThe grounding loosens when the cables are not installed correctly. The housing ground isbroken.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-205Motor 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

CAUTIONNo 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 endsleeves with plastic collars that have metal sleeves that are at least 12 mm long.

Connectors Description Stud torqueC200 ... P600

X1 ... X4 Mini Combicon MC 1.5 clamp screw thread M2 0.3 ... 0.4 Nm

4.1 General


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Connectors Description Stud torqueMC-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

X1X2 ... X4

Mini Combicon MC 1.5 clamp screw thread M2Front 4 H Clamp screw thread M3

0.3 ... 0.4 Nm0.5 ... 0.6 Nm

MC-4 / 50 A

X1

X2 ... X4

Mini Combicon MC 1.5 clamp screw thread M2

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

CAUTIONWiring errorMay result in damage to components. 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 RulesThe mains voltage is stored by rectification in the DC circuit of the PacDrive MC-4 forcontrolling and regulating the motors. This stored power is supplied to the motor byprecise on and off switching using six semi-conductor switches. The steep increase/decrease in voltage places considerable demands on the dielectric strength of themotor winding. An important additional aspect to observe is the electromagnetic compatibility (EMC ) with other system components. The great edge steepness of thepulsed 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. Loopingthe 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.

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Shorten the motor cable to a minimal length. Do not lay any cable loops in the switching cabinet.

CAUTIONElectromagnetic fieldsInterference or breakdown of system possibleObserve the following rules during installation to eliminate the consequences of excessiveinterference 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-standardquenching 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 occuras a result of the switching current on the interference suppression lines. It ismuch easier to avoid sources of interference than to eliminate the effects of existing interference.

Contacts which switch inductive loads which are not interference-suppressedmay never be located in the same space as the PacDrive MC-4. This also appliesto conductors which carry non-suppressed, switched inductions and those conductors which are routed along them in parallel. Insulate the controller from suchinterference sources using a Faraday cage (separate partition in the switch cabinet).

Motor currents Motor cable length0 - 10 m

Motor cable length10 - 40 m

Motor cable lengthover 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

CAUTIONWhen suppression is achieved in groups, the common mains filter should be sized so thatIRatedFilter >= sum of the network side phase currents of the PacDrive MC-4.

CAUTIONWiring errorMay result in damage to components. 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


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4.3 PacDrive MC-4 Mains ConnectionUsing line chokesUsing the PacDrive system requires protective measures on the PacDrive servo amplifier mains feed. In doing so, the use of a separate choke is required for each mainscontactor group

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 procedureWhen the mains voltage is switched on, the DC circuit capacitors in the PacDrive MC-4are charged "softly" through the built-in bleeder resistor. The minimum time betweentwo precharging operations is 15 s.

Grounding conditions of the mains networkGrounded AC

networksPacDrive MC-4s may be operated without potential separation on AC networks with agrounded star point.

Non-groundedthree-phasemains

When operated on ungrounded networks (IT networks), the risk of impermissible over

voltages between external conductors and the PacDrive servo amplifier housing isincreased. Therefore, we specify that an insulating transformer must be used for operating on an IT network. Its star point on the output side as well as the PacDrive servoamplifier's PE connection must be grounded.

Matching the mains voltageIf the mains voltage lies outside of the specified rated voltage, it must be matched usinga 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.

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CAUTIONIn order to conform to the EMC directive, the MC-4 / 50 requires a line filter, item numberFI07878.Fusing the mains connection CAUTIONOverloading 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 thephase currents) should be used when sizing and selecting the components for fusesand mains contactors.

IRatedProtection= 1.2 x sum of phase currentsThe 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 circuitbreaker's un-delayed over-current threshold is set a multiple higher. (Caution: take theunit'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.

CAUTIONWiring errorMay result in damage to components. Select the cross section of the mains supply system so that it is protected by thechosen circuit breaker.

Fault current protective gearThrough the integrated line filter, the PacDrive MC-4's operating leakage current isgreater than 3.5 mA AC. If the insulation is damaged, leakage currents with a highDC portion can occur. This results in incompatibility with general fault current protectivedevices.

4.3 PacDrive MC-4 Mains Connection


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CAUTIONThe MC-4 must not be protected against fault currents using a commercially available FI circuitbreaker with a triggering threshold of 30 mA. The leakage current from the device can triggerthe 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 triggeringthreshold (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 operational leakage current greater than 3.5 mA AC or 10 mA DC require a firm connection.

Additionally, one of the following procedures is required:

Ground conductor cross section at least 10 mm2Cu. 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 VDE0100 part 540.

The protective housing provides protection from indirectly touching live parts.

For more information, please see DIN EN 61800-5-1.

Mains contactorTo 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 (utilizationcategories 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 ConnectionThe control voltage should be PELV.

The 24 V DC for the control voltage may also provide power for other sinks. In thiscase, 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.).

CAUTIONControl voltage too low.If the tolerances for the control voltage are not observed, diagnostic error 036 "External 24 Vpower 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


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CAUTIONThe input capacitance of the PacDrive controllers C400 to P600 is 4400 F. Depending onthe 24 V power supply unit used (24 V slew rate, internal resistance of the power supply unit),an elevated startup current may arise.

CAUTIONSwitching off the control voltageData 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 CircuitThe mains voltage is rectified and electrical power is stored in the PacDrive MC-4 inthe "DC circuit". Basically, the DC bus consists of a rectifier and capacitors. The DCbus voltage is applied to power connector X3 on the PacDrive MC-4.

DANGERHigh 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 busvia the motor inverter. The energy is stored in the DC capacitors. This increases thevoltage in the DC bus. When the capacity of the capacitors is not sufficient to absorbthe 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 apower transistor to a power resistor (bleeder) when the limit value (approx. 820 V) isreached. The braking energy is converted to heat. When the DC bus voltage falls belowthe lower switching threshold (approx. 800 V), the braking resistor is disconnectedonce more.

Jumper in the DC circuitIn multi-axle applications, the DC circuits of the PacDrive MC-4s may be jumpered toallow for power exchange. In doing this, the total DC circuit capacitance may not exceed 2 mF. This means that e.g. twelve 3 A, six 10 A or two 22 A PacDrive MC-4s maybe 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 commonmains contactor. Each unit has its own braking resistor. These may be supplement byan additional braking resistor (braking module BM.-4).

4.5 DC Circuit


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CAUTIONWiring errorMay result in damage to components. 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 cablesdoes not exceed 0.5 m). The cables should have as large a cross section as ispossible and should be twisted.

Note that it is only permissible to jumper the DC circuits on units which are servedby a commonmains contactor. Otherwise there is the danger that the invertersmay be overloaded.

4 Wiring Notes


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5 Basic Design and Connection5.1 Power Circuit

Figure 5-1: Power circuit sample design

5.1 Power Circuit


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5.2 Control Circuit

Figure 5-2: Control circuit sample design

5 Basic Design and Connection


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Explanations for the sample connectionThis sample shows the basic design and the wiring of a PacDrive system without including safety aspects (e.g. redundant design of auxiliary contactors) in the controlcircuit.

Due to EMC considerations, the brakes (PIN 7 bri+ and PIN 8 bri+) should be suppliedby 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.

CAUTIONWhen using a separate power supply unit, the brake voltage supply may fail without beingnoticed.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 viaan auxiliary relay (floating).

Inverter Enable (safe stop)When the Inverter Enable relay input is switched off, the PWM signals to the end stageare interrupted. The motor is immediately switched to a torque-free state. If InverterEnable is not used, the input should be set so that it is always 24V.

wd and rdywd (PacDrive Controller) and rdy (PacDrive MC-4 and bleeder module BM-4) are relayoutputs that are normally closed. They should be connected in series to the mainscontactor (possibly using an auxiliary contactor), so that, in the event of a serious fault,

the power supply will be switched off.

CAUTIONWiring errorThe 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 interruptedvia the outputs wd (MAx-4) and rdy (MC-4).

5.2 Control Circuit


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6 Functional safety - safety connections6.1 Machine safety

The goal of designing machines safely is to protect people. The risk associated withmachines with electrically controlled drives comes chiefly from moving machine parts.

EN 954-1:1996 (Safety-related Parts of Control Systems, Part 1: General DesignGuidelines) describes an iterative process for the selection and design of safety-related parts of control systems with the goal of reducing the risk arising from the machineto a justifiable degree.

In the first step, the machine builder must perform a hazard analysis and a riskevaluation of the machine (EN 292-1 and EN 1050)

In the next step, the machine builder decides which measures are necessary toreduce the risk by modifying the design of the machine and/or by providing forprotective devices.

In the third step, the safety requirements for the safety-related parts of the controllerare 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 verifiedin every phase.

In the fifth step, the safety functions which were achieved are validated. This isdone by analysis as well as by testing the safety-related functions. Instrumentssuch as FMEA should be used in the analysis. Tests are to ensure that the designof the safety functions fully corresponds to the specified characteristics in terms ofperformance. When testing the categories, performance in the event of an error isof primary importance. This must occur theoretically, by means of the wiring diagrams, as well as in actual use on the machine, by simulating error situations. Whendoing 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

CAUTIONThis chapter corresponds to section 7.4 in the user documentation: "Project notes - safetyconnections" (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 PacDrive system may be accomplished according to EN 954 category 3 and what

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options for error detection are available for PacDrive controllers. In the wiring recommendations that are given, the SafeStop function is carried out by shutting off theopto-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 responsibleGerman Accident Prevention & Insurance Association). The test certificate and theassessment report may be downloaded from the ELAU home page (download areafor PacDrive users / safety). When using Inverter Enable, these documents must beconsulted.

CAUTIONThese circuit recommendations are not mandatory for the machine manufacturer. Themachine manufacturer is responsible for the safety of the machine.

6.2.1 FunktionsbeschreibungAfter 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 toheat. The K1 power circuit breaker and/or the InverterEnable signal must remain energized until the drive stops. After the normal braking time at the latest, the IE signal isswitched 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 andthe drive is brought to a standstill using un-delayed contacts. The K1 power circuitbreaker and/or the InverterEnable signal are switched off using delayed contacts (EN1 60-204 stop category 1). Shutting off using the off button has the same effect asusing the emergency stop button. Thus, this button is wired in series with the emergency stop contacts. When switching off, the drive on PacDrive MC-4, independent ofthe PacDrive Controller, can also be brought to a controlled standstill using the MCen 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 followingerrors are thus safely handled:

If the drive is braked in an uncontrolled manner because of an error, the InverterEnable signal is switched off after the delay time which is set on the safety switchingunit. (drive coasts to a stop)

If, after braking, the PWM signals are not switched off by the IE relay in the PacDriveMC-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 gateAccess 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 startupwould cause dangerous movements while access to the dangerous areas is not pre



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vented by the safety gate. To achieve this, the safety door contact is wired in serieswith the emergency stop switch.

6.2.3 Inverter enable circuit (IE)The safety circuit with Inverter Enable was developed to reduce wear of the mainscontactor. When the off or the emergency stop button is activated, the mains contactis not switched off. The safe stop is achieved by disabling the InverterEnable forthe opto-couplers in the final stage. Thus, the PWM signals cannot control the finalstage, so that a startup of the drives is safely prevented (pulse pattern lock). The errormonitoring ensures that the mains contact is switched off when an error occurs. Theerror monitoring of the Inverter Enable function in the controller takes place throughan Inverter Enable signal, which is produced in the PacDrive MC-4 and transmittedto the PacDrive controller via the SERCOS interface. If this signal does not correspondto the reference state at the PacDrive controller's EmergencyStop input, an errormessage 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 typeplate. The MC-4s of this type are provided with a protective coating on the InverterEnable circuit part. Beginning with series 11 (MC-4/11/...), all MC-4s are coated asstandard.

These measures prevent a possible error function through conductive dirt build-up orparts which fall in the device.

6.2.4 Level definitionsLow-Signalor Low-Levelis issued when an input is connected or open (not connected)with L0.

High-Signalor High-Levelis 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.



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6.2.6 Switching componentsWhen 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 switching unit

The safety switching unit implements the evaluation and control of the on and off oremergency stop buttons, and, under certain circumstances, the safety contacts. Thesafety switching unit must at least be designed according to category 3 of EN 954External 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. Thesafety switching unit delay time (contactor K3) should be only marginally higher thanthe 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

EmergencyStop

The off and emergency stop buttons have the same function. The circuitry can bedesigned 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 controllersMAx-4, C400/600 and P600) and Inverter Enable / sheet 2) (see 6.2.9 Wiring diagramfor PacDrive controller C200). The same function can be achieved through safety gatecontacts (NC contacts), which, accordingly, are connected in one or two channels andin series with the emergency stop contacts.

When the off or emergency stop button is activated, the outputs of the safety switchingunit K3 switch off, delayed or non-delayed. The PacDrive controller detects the switching 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 thePWM 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 "InverterEnable" relay in the PacDrive MC-4 switch off. In the time between when the delayedcontacts 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 contactorremains activated and the power supply remains switched on. By switching off "InverterEnable", which switches off the opto-coupler, PWM signals are prevented from being sent to the final stage.

WARNINGHigh voltageRisk of deathSwitching off "Inverter Enable" disables the final stage transistors, thus preventing theformation of a rotating field.Galvanic isolation from the power supply can only be achieved by switching off the mainscontactor or the main switch.

CAUTIONThe 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 asufficiently long dissipation delay. A free-wheeling diode is required.

Notes If desired, the off button (not the EMERGENCY stop button) may be connected to oneof the PacDrive controller's inputs instead of being connected in series to the emer



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gency stop button. The level on this input must then be evaluated in the PacDrivecontroller and the drives must be brought to a stop. Through this, a flatter braking rampcan be achieved upon stopping operation, so that, depending on circumstances, wearduring braking can be reduced. No safety function is realized when shutting off usingthis 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 findmodu le identifi

er or field busfirmware up

date not possible.

If the on button is pressed, and neither the off nor the emergency stop buttons arepressed, the safety switching unit K3 is turned on. If there is no error in the PacDrivecontroller, the K4 contactor is switched on through the Mains Contactor output of thePacDrive controller. If, in addition, the "WD" contacts of the PacDrive controller andthe "rdy" contact of the PacDrive MC-4 are closed and there is no error in the "InverterEnable" 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 Enable MC_en)

The Hardware Enable signal (MC_en) may be connected directly to L0 (+24 V). In thiscase, the machine comes to a controlled stop through the PacDrive Controller whenit is switched off. The drives can be stopped synchronously to one another. They neednot 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 connectedover a non-delayed contact of the safety switching unit K3, the drives are brought toa standstill using the "best possible stop" in PacDrive MC-4, independent of the position's setpoint. In some cases, the drives must be homed when they are switched onagain.

The method used depends on the application. Both methods are equally safe.

errordetection

The PacDrive controller monitors the status of the safety switching unit, which controlsthe Inverter Enable signal, through the "EmergencyStop" input.

InvEnableActive is uncoupled from the Inverter Enable signal via relay K5. If only theInverterEnable inputs of the MC-4 are connected to the output (38) of the PNOZ, theauxiliary relay K5 may be omitted, and the signal may be wired directly to the PacDrivecontroller's InvEnableActive input

If the Inverter Enable signal transmitted from the PacDrive servo amplifier via theSERCOS 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 mainscontactor K1 is shut off via contactor K4. The system may only be turned on againafter the error is corrected.

The function of the mains contactor is monitored via the "MainsWatch" input. Whenthe 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 functionblocks is available from Online help / VarioCam library / Control / Watch The safetycircuit was tested by the responsible German professional association ("Berufsgenossenschaft"). The test certificate which was issued has the test number NG 04110.

6.2.7 PacDrive controller C200In addition to the MAx-4 PacDrive controller, PacDrive controllers C400, C600, P600and C200 may also be used.

The circuits for C400, C600 and P600 are identical to MAx-4 (see 6.2.8 Wiring diagramfor PacDrive controllers MAx-4, C400/600 and P600). C200 is unique in that it has no



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integrated IOs. Therefore, the error detection signals (MainsWatch, InvEnableActiive,EmergencyStop and MainsContactor) are routed via field bus-coupled IO modules.



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6.2.8 Wiring diagram for PacDrive controllers MAx-4, C400/600 and P600

Figure 6-1: Wiring diagram: Safety circuit with Inverter Enable / sheet 1



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6.2.9 Wiring diagram for PacDrive controller C200

Figure 6-2: Wiring diagram: Safety circuit with Inverter Enable / sheet 2



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6.3 Connection of Watchdog and Ready contacts for PacDrive controllers

Figure 6-3: Wiring diagram: Watchdog and Ready contacts / sheet 3



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6.4 Extended safety functions for PacDrive MC-4 with SMX Safe PLCTo implement the safety functions, the MC-4 servo amplifier of the PacDrive systemhas the Safe Torque Off as an integrated safety function. An input on the MC-4 (InverterEnable) blocks the control signals to the final stage by means of a positively drivenrelay. 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 ofthe PacDrive controller is a controlled stop.

Then the safe stop is ensured by means of an external safety switching unit by liftingthe InverterEnable signal (IE).

Figure 6-4: Block diagram: PacDrive MC-4 speed monitoring and external safetyswitching unit

The increasing flexibility and complexity of packaging machines also means higherrequirements 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-4servo amplifier makes it possible to implement the following functions:

Safe stop with brake ramp (SS1) in case of safety gate, E stop, jogging, change ofoperating 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 (

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etc.) and for each piece of equipment (safety gate, cover, etc.) can be assigned to thesafety functions (STO, SS1, SS2, SDI, SLI, etc.).

The following example will demonstrate the implementation of safety functions withSMX 12. The example is for an application with 3 drives. Two axes are monitored withSMX 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 PacDrivecontroller. SMX 12 monitors the corresponding safety function via the encoder interface and switches the drives to a safe state (STO) in case of an error or emergencystop. 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 safetycircuit. This means that the mains contactor K1 remains active in case of an emergencystop or if the safety gate is open.

No safety relevant information is transmitted to the PacDrive controller via a bus interface (IO's, Profibus DP, etc.). Only the information which safety element (emergency stop, safety gate...) was activated is transmitted. This enables the PacDrive controller to trigger a controlled stop of the individual axes before SMX 12 puts them intoSTO state by means of Inverter Enable. Usually this happens with a delay of severalseconds, so that the PacDrive controller has the opportunity to bring the axes to acontrolled stop.

PacDrive

MC-4

Motor Enc

Encoder

adaptorX8

X4

SMX11/12

X12 X22

3AC/400V

K1MainsContactor

DSP

IGBToutput stage

Motor Enc Motor

PacDrive Controller

MAX-4, C200-P600

Fieldbus (CAN, Profibus DP)

InverterEnable

PowerContactor

SERCOS Bus

SinCos SinCos

Enc

Slave-axis with safelylimited speed

Slave-axis with safelylimited speed

Master-axis without safetymonitor

EStop, On, Off,Reset

Guard Door

DIAGNOSTIC

PacDrive

MC-4

X8

X4

DSP

IGBToutput stage

PacDrive

MC-4

X8

X4

DSP

IGBToutput 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



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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 (speedrestriction) (plus SDI (turning direction))- with unactuated jog button SS2 (standstill monitoring)

6.4 Extended safety functions for PacDrive MC-4 with SMX Safe PLC


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6.4.2 Circuit suggestionControl circuit

Figure 6-6: Circuit suggestion for the control circuit - I/O option



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Figure 6-7: Circuit suggestion for the control circuit - PROFIBUS DP option



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Power circuit

Figure 6-8: Circuit suggestion for the power circuit



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Input / output signals of the SMXSignal no. Clamp Type Cross circuit

ing testDescription

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 brakeramp

- 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 contact; 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 DescriptionK1.1 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



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Configuration of SMX 12Assignment of inputs/outputs

Figure 6-9: SMX 12 assignment of inputs/outputs

Configuration of inputsThe configuration of the input elements is shown in the figures below. Each input element must be assigned the pulses corresponding to the connections. The configuration program checks if pulses were assigned alternately and triggers a warning, ifnecessary.



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Figure 6-10: Input configuration

Configuration of outputsThree 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 fieldbus.

Figure 6-11: Output configuration

Motor encoder interfaceThe encoder interface (SIN/COS) must be configured depending on the encoder typeused in the motor. If there is only one encoder for each axis, sensor 2 is not used.



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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 automaticoperation, an E stop message is immediately sent to the PacDrive controller. Then thetwo timers monitor the stop time. Normally, the ESS functions are used to monitor thebrake ramp. However, two effects must be taken into account:



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1. The latent time cannot be set longer than 100 ms, which is too short for the MC-4to lift "ControllerEnable" and the brake to engage.

2. Depending on the motion profile of the drive, it may happen that the drive has toaccelerate again. However, the ESS block generates a dynamic brake ramp depending 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 inputinformation needs not additionally be connected to the PacDrive controller.

The figure below "function block diagram (FBD) for jogging in setup mode" shows themonitoring 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 thatany operation that may be in progress can be stopped when the operating mode ischanged. 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.



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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 drivenIEO 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.



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Figure 6-16: Function block diagram (FBD) for switching off the InverterEnable signal



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6.4.3 Validation example of the SMX12 safety functions

CAUTIONThe following tests only check the correct monitoring limits and the call up of the correct safetyfunctions.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/comment1 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 functionImmediate 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 Press the ON button and/or let

the machine run

Emergency stop function

OK

3 Test of the safety gate functionImmediate EmergencyStop message

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.

Switch on as described under 1 Open safety gate Lift safety gate Press reset Press the ON button and/or let

the machine run

safety gate function OK

4 Test of the OFF functionImmediate EmergencyStop message

from SMX to PLC.


After a delay, IE must disengage.The mains contactor should drop after 5 s.

Switch on as described under 1 Press OFF button

Switch on as described under 1

OFF function OK

5 Test activation of the setup modeImmediate EmergencyStop message

from SMX to PLC.


When jogging, move at reduced velocity.

Switch on as described under 1 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



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No. Setting Test procedure Result/commentWhen 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.Safety gate may be open orclosed (test both options)

Press JOG button.(let drives run at 10% excess velocity)

Velocity monitoring OK

7 Test of safety functions "JSS (jogging skip supervision)" in setup modeIf the relative maximum path/angle is ex

ceeded, the InverterEnable signal must

disengage immediately.


engage as a following error.

Error can be quitted.

Select setup mode.Safety gate may be open orclosed (test both options)

Press JOG button.(Let drives move beyond the position range at rated speed)

Position area OK

8 Test of safety functions "ZSC (Zero Speed Control)" in setup modeIf the relative maximum path/angle is exceeded, the InverterEnable signal must

disengage immediately.


engage as a following error.

Error can be quitted.

Select setup mode.Safety gate may be open orclosed. (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" signalfrom SMX12 (simulates a stuckmains contactor)

Repeatedly press ON and Resetbuttons.

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 automaticmode as described under 1.

Move drives. Remove the "ieo-Signal" from

the SMX12 (simulates a stuck IneverterEnable relay)

Activate emergency stop or safety gate

IE relay diagnosis OK

Table 6-3: Function block diagram (FBD) for switching off the Inverter Enable signal



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6.5 Circuit suggestion: PacDrive system with DB-5 and iSH

6.5.1 Inverter Enable functionIntroductionWith the Inverter Enable function (IE) you can bring drives to a safe stop. This functionincludes the components PS-5, DB-5and iSH. The Inverter Enable function requiresfurther components, e.g. emergency stop, safety switching unit (optional) and connections. The following chapter describes the correct use of the Inverter Enable function.

DANGERLoss of the Inverter Enable function due to incorrect useRisk of death, serious injury, property or environmental damageDrive 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 required by the relevant safety standards. This is expressed by the characteristics PFHand 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 atorque-free motor while SS1 takes this state after a predefined time. As a result of thehazard and risk analysis, it may be necessary to choose an additional brake as a safetyoption (e.g. for pending loads).

The function is selected via a signal (pair) at the input of PS-5(2), which is forwardedto all drives (7)of this PS-5group. The supply voltage (AC)needs not be interrupted(see figure below).

1

2

4

5

6

7IE

AC

3

Figure 6-17: Implementation of "Emergency stop with Inverter Enable"

1 switch cabinet2 PacDrive Power Supply PS-53 Contactor4 Emergency stop switch



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5 Safety switching device (e.g. Preventa XPS AV)6 PacDrive Distribution Box DB-57 Intelligent Servo Module iSH

If only some of the drives attached to a PS-5(1) should be put in the safe state, thiscan be achieved by the configuration of the drives. This is interesting e.g. for cleaningmodes (6). If an optional module iSH-DIS1(9)has been set, the IE signal will be ignored. To implement the emergency stop, the power supply on the PS-5must beinterrupted; see illustration below.

1

2

3

6

7

8

5

9

IE

4AC

Figure 6-18: Implementation of "Emergency off" and "Cleaning mode iwith InverterEnable" in two protective circuits

1 PacDrive Power Supply PS-52 switch cabinet3 Emergency stop switch4 Contactor5 Safety switching device (e.g. Preventa XPS AV)6 Switch: Operating mode (normal/cleaning)7 PacDrive Distribution Box DB-58 Intelligent Servo Module iSH (without iSH-DIS1)9 Intelligent Servo Module iSH (with iSH-DIS1)

iSH Cleaning Emergency stop Parameter InverterEnableMode

iSH without iSH-DIS1 (8) Torque-free motor Torque-free motor Standard/1iSH with iSH-DIS1 (9) - Torque-free motor Off/0

DANGERRemaining charge of the DC bus for iSH with iSH-DIS1Risk 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.



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Qualification of personnelOperators of the iSHsystem and/or the Inverter Enable function must be trained according to the complexity of the machine and the safety integrity level of the InverterEnable function (SIL2). The training must include the production process and the relation between Inverter Enable function and machine.

The specialists must be able to detect possible hazards that may arise from parameterization, changing parameter values and generally from mechanical, electrical orelectronic equipment.. The specialists must be able to assess the jobs that are assigned to them on the basis of their technical expertise, knowledge and know-how.

The specialists must be familiar with the relevant standards, provisions and regulationsfor the prevention of industrial accidents, which they must observe when working onthe drive system.

Qualification guidelines can be found in the following publication, for example: Safety,Competency and Commitment: Competency Guidelines for Safety-Related SystemPractitioners. IEE Publications, ISBN 0 85296 787 X, 1999, http://www.iee.org/Pub

lish/Books/EPD/



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Preparatory measures taken by the machine manufacturerHazard and risk analysisBased on the plant configuration and utilization, a hazard and risk analysis can becarried 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. Thecircuit resulting from this analysis may deviate from the application examples. For example, additional safety components may be required. In principle, the results fromthe hazard and risk analysis have priority.

Using additional safety equipmentIn 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.

DANGERAccidental use of the brake as a safety functionRisk of death or serious injury when operating pending loads Do not use the optional brake available for iSHas a safety function. Use an external safety brake.

If the hazard and risk analysis based on this fact should lead to physical injuries orproperty damage that cannot be eliminated by design, suitable additional safety measures (e.g. preventing a stay in the danger zone or additional safety equipment such asa brake) must be provided within the machine. The machine concept must guaranteepersonal safety.

This applies when the machine is in operation as well as when maintenance or commissioning work is carried out on the machine and drives.

Always observe the valid rules for safety and accident prevention (e.g. for the US, seeNEMA ICS1.1 and NEMA ICS7.1) and observe the specified ambient conditions, giventechnical data etc.



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Functional descriptionScope of operation (designated safety function)The Inverter Enable function relates to PS-5, DB-5and iSH, hereinafter referred to as"iSH ystem".

1

2

4

5

6

7IE

AC

3

Figure 6-19: iSH system with emergency stop

1 switch cabinet2 PacDrive Power Supply PS-53 Contactor4 Emergency stop switch5 Safety switching device (e.g. Preventa XPS AV)6 PacDrive Distribution Box DB-57 Intelligent Servo Module iSH

Operating principle

The InverterEnable function safely switches off the motor torque. It is sufficient to seta 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.

SafeState

This torque-free state is automatically assumed when errors are detected in the system. Therefore it is the safe state of the drive.

Mode of operation:

By setting a logical one for the "InverterEnable" input on the PS-5, the output stagecontrol of all iSH-drives connected to this PS-5become possible (necessary condition).If, on the other hand, this input is set to a logical zero, the power supply at the InverterEnable 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-5generates DC voltage that is fed into the hybrid cable). The failure of one of the two

channels already results inthe logical zero. When the power supply is cut off, the finalstage becomes de-energized, and an error message is generated. The motor can nolonger generate torque and stops unbraked.

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