PD OperaManC200 Us0811
PD OperaManC200 Us0811
PD OperaManC200 Us0811
Legal notice
© All rights reserved to ELAU GmbH, also in case of patent right applications.
No part of this documentation or the accompanying software and firmware may be
reproduced, transferred, paraphrased, saved to a storage medium or translated to
another language or computer language without the written consent of ELAU GmbH.
Any possible measure was taken to ensure that this product documentation is com‐
plete and correct. However, since hardware and software are continuously improved,
ELAU makes no representations or warranties with respect to the contents of this
documentation.
All information on our products in this manual are given purely for the purpose of prod‐
uct description and is not binding. Misprints, errors and modifications -without prior
notice in the course of product development- are reserved. If details contained in this
manual are explicitly a part of an agreement made with ELAU GmbH, then the details
of the agreements in this manual are exclusively to determine the agreed condition of
the object of agreement, on behalf of the § 434 BGB (condition guarantee on behalf
of legal regulations).
Trademark
PacDrive is a registered trademark of ELAU GmbH.
All other trademarks mentioned in this documentation are the exclusive property of
their manufacturers.
ELAU GmbH
Dillberg 12-16
97828 Marktheidenfeld, Germany
Tel.: +49 (0) 9391 / 606 - 0
Fax: +49 (0) 9391 / 606 - 300
E-mail: [email protected]
Internet: www.elau.de
Commissioning is forbidden until it is established that the machine in which this product
is to be installed complies with the provisions of the EC guideline. The manufacturer
guarantees that the product delivered was manufactured in accordance with the ap‐
plied harmonized standards / specifications.
Manufacturer:
ELAU AG
Dillberg 12-16
97828 Marktheidenfeld, Germany
2004-01-09
Günter Locherer
Member of Executive Board
Table of contents
6 Technical data 28
6.1 Ambient conditions ................................................................................................. 28
6.2 Standards and regulations ..................................................................................... 28
6.3 Mechanical and electrical data ............................................................................... 29
6.4 Electrical connections ............................................................................................. 31
6.5 Dimensions ............................................................................................................. 37
7 Appendix 38
7.1 Contact addresses ................................................................................................. 38
7.2 Product training courses ......................................................................................... 38
7.3 Safety tests ............................................................................................................. 39
7.4 Modifications .......................................................................................................... 39
7.5 Fault report form ..................................................................................................... 40
Read and observe this manual before you work on the PacDrive Controller for the first
time. Take particular note of the safety instructions (see 2.3 Rest dangers). As descri‐
bed in section 2.2, only those persons who meet the "Selection and qualification of
employees" are allowed to work on the PacDrive Controller.
A copy of this manual must always be available for personnel who are entrusted to
work on the PacDrive Controller.
This manual is intended to help you use the PacDrive Controller and its intended ap‐
plications safely and properly.
By observing this manual, you will help to
• avoid risks,
• reduce repair costs and down times of the PacDrive Controller,
• increase the life span of the PacDrive Controller
• and increase reliability of the PacDrive Controller.
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 injury if the safety regulations are not observed.
Indicates a potentially hazardous situation that can lead to serious injury
or death if the safety regulations are not observed.
Indicates a potentially hazardous situation that may result in bodily harm
if the safety regulations are not followed.
Indicates a potentially dangerous situation that may result in property
damage if the safety regulations are not observed.
Marker: After this symbol, you will find references for further information.
The PacDrive Controller is state of the art and conform to recognized technical safety
regulations. Nevertheless the use of the PacDrive Controller can present a hazard to
life and limb or cause property damage. The following section contains general re‐
quirements for safe work with the PacDrive Controller. Each person who uses or works
on the PacDrive Controller must read and follow these requirements.
• The regulative, warning and instruction signs on the connected components and
in the switching cabinet
• The warning instructions on the PacDrive Controller on the connected components
and in the switch cabinet
• The inspection and maintenance instructions
• The operating instructions of the other components
• All other documentation
Flawless Operate the PacDrive Controller only when they are in a flawless technical condition.
State Observe the regulations, act with safety and hazards in mind If circumstances occur
that impact safety or cause changes in the operating performance of the PacDrive
Controller, switch the PacDrive Controller off immediately and contact the responsible
service staff.
Only original Use only the options and mounting parts specified in the documentation and no third-
equipment party devices or components that are not expressly approved ELAU recommends. Do
must be used not change the PacDrive Controller inappropriately.
Protection Before installing, provide for appropriate protective devices in compliance with the local
measures and national standards. Do not commission components without accordant protective
provide for devices. After installation, commissioning or repair, test the protective devices used.
Installation You may only use them in accordance with the installation and operating conditions
and operating described in the documentation. The operating conditions at the installation location
ambient must be checked and maintained in accordance with the required technical data (per‐
formance data and ambient conditions). Commissioning is prohibited until it is guar‐
anteed that the usable machine or system in which the PacDrive Controller is installed
meets all requirements of EC Directive 98/37/EC (machinery directive).
In addition, the following standards, directives and regulations are to be observed:
• DIN EN 60204 Safety of machinery: Electrical equipment of machines
• DIN EN 292 Part 1 and Part 2 Safety of machinery: Basic Concepts, General Prin‐
ciples for Design
• DIN EN 50178 Electronic equipment for use in high-current electrical systems
• EMC directive 2004/108/EG
• The generally applicable local and national safety and accident prevention regu‐
lations.
• The rules and regulations on accident prevention and environmental protection that
apply in the country where the product is used
• The applicable laws and ordinances
Health risks arising from the PacDrive Controller have been reduced by means of
safety technology and design engineering. However a residual risk remains, since the
PacDrive Controller works with electrical voltage and electrical currents.
WARNING
CRUSHING, SHEARING, CUTTING AND HITTING DURING HANDLING
• 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.
• Cover edges and angles to protect against cutting damage.
• Wear suitable protective clothing (e.g. safety goggles, safety boots, protective
gloves) if necessary.
• Do not stand under suspended loads.
Failure to follow these instructions can result in death or serious injury.
DANGER
ELECTRIC SHOCK, FIRE OR EXPLOSION CAUSED BY HIGH VOLTAGE
• Observe the general construction and safety regulations for working on high-
current electrical systems.
• After installation, check the firm connection of the ground conductor to all elec‐
trical units to ensure that connection complies with the connection diagram.
• Always make sure that the ground conductor is connected when operating elec‐
trical components.
• Before working on electrical equipment with a voltage greater than 50 volts, the
main switch has to be in the "OFF" position and secured, so it cannot be restarted.
• Disconnect devices with a voltage greater than 30 V rms or 42,2 V DC from the
power supply before working on electrical parts.
• Wait at least 5 minutes after switching off before accessing the components.
• Before working on the equipment, discharge the DC bus and use a voltage meter
to make sure that there is no voltage.
• Do not touch the electrical connection points of the components when the device
is switched on.
• Make sure that the drives are at a standstill because potentially fatal voltage can
occur on the motor lines in generator operation.
• Before enabling the device, safely cover the live components to prevent contact.
• Disconnect power connector cables only when the system is deactivated.
• Plug in power connector cables only when the system is deactivated.
• Provide for protection against indirect contact (DIN EN 50178, Section 5.3.2).
• If you are not using prefabricated ELAU cables, check that the assignment of the
new cables complies with the connection diagram of the machine manufacturer.
Failure to follow these instructions will result in death or serious injury.
Dangerous movements
There can be different causes of dangerous movements:
• Missing or faulty homing of the robot mechanics
• Wiring or cabling errors
• Errors in the application program
• Component errors
• Error in the measured value and signal transmitter
• Operation error
DANGER
DANGEROUS MOVEMENTS
• Prevent entry to a danger zone, e.g. by means protective fencing, mesh guards,
protective covers, or light barriers.
• Ensure the protective devices are properly dimensioned.
• 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 op‐
eration.
• Protect existing work stations against unauthorized operation.
• Effectively restrict access to the control terminals to allow access only to author‐
ized persons.
• Position EMERGENCY OFF switches so that they are easily accessible and can
be reached quickly.
• Check the functionality of EMERGENCY OFF equipment before start-up and
during maintenance periods.
• Prevent unintentional start-ups by disconnecting the drives from power supply
using the EMERGENCY OFF circuit or using a safe start-up lock out.
• Before accessing the drives 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.
• Secure the system from being switched back on before working on it.
• Avoid operating high-frequency, remote control, and radio devices close to the
system electronics and their feed lines.
• Prior to the initial start-up, check the system and the installation for possible mal‐
functions in all usage scenarios.
• If necessary, carry out a special EMC check of the system.
Failure to follow these instructions will result in death or serious injury.
DANGER
HIGH ELECTRICAL VOLTAGE DUE TO INCORRECT CONNECTION
• 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.
Failure to follow these instructions will result in death or serious injury.
FELV Function‐ When using ELAU Components in systems that do not have safe separation as a
al Extra-Low protective measure against direct or indirect contact of dangerous voltages, all con‐
Voltage nections 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.
battery
pow
cf - card
wd
pow X11
err battery - +
wd bus
X12
X12 cf
err !
reset
enter
com2 rs485
com1 rs232
C200
1 2
C200
1 2
battery
cf - card
- +
PacDrive
X12
PacDrive
!
reset
safety instructions.
eth
X3
X3
24V/wd/tp in
24V/wd/tp in
X4
X4
pacnet
pacnet
X5
X5
6
6
7
7
C US
LISTED C US
(INDUSTRIAL
CONTROL LISTED
EQUIPMENT) (INDUSTRIAL
profibus dp
72KL CONTROL
EQUIPMENT)
profibus dp
72KL
can
Made in Germany 9 10
can
Made in Germany 9 10
If the cover of the PacDrive Controller is closed, you will see four vertically arranged
pow indicators, which signal different operating- or error conditions.
wd • pow (control voltage indicator)
err • wd (watchdog indicator)
• err (error display)
bus
err • bus err (SERCOS real-time bus error indicator)
V00.24.23
10.128.2111.103
In addition to the LED displays, you will receive further information about the operating
0406-0117.0601 status of the PacDrive Controller via the 2-line LCD display.
The horizontal arranged buttons have no function on the PacDrive Controller currently.
wd (watchdog indicator)
Watchdog is a hardware module to monitor the controller.
OFF Normal operation
ON Fatal error; reset required, reboot system
The err-LED is switched on following "Power on". Once the operating system, user
configuration, user parameters and the IEC program have been loaded and the IEC
program has been started successfully the err LED will switch off again. The boot
procedure is now complete.
bus err (SERCOS real-time bus error indicator)
OFF Normal operation
ON Bus error (problem with fiber-optic cable connection, e.g. transmitting
power is too low or too high, cable break, etc.)
The innovative iSH combines motor, final stages and the digital servo regulator for one
axis in a space-saving housing. The sending power (fiber optic cable intensity) is set
in the PLC configuration by the PacDrive Controller.
X10
LED yellow: ON PacDrive Controller connected
LED yellow: flashing/flickering Current network traffic
After opening the operating cover you have access to the control elements of the Pac‐
Drive Controller:
• CompactFlashTM card slot
• Battery compartment
• [on / off] button
• [reset] button
The CompactFlash™ card slot is the entry for the permanent data memory (CF™ card)
of the PacDrive Controller.
top side here
cf - card
▶ Hold the CF™ card with your thumb and forefinger and pull it out of the slot.
▶ To insert, carefully place the CF™ card on the guide rail and push it into the device.
▶ Push lightly until the card clicks in.
3.3 Battery compartment
The battery of the PacDrive Controller buffers controller data (Bios, NVRAM, time,
etc.).
battery
Maintenance- The battery should be replaced every 6 years. After this period of time the battery must
interval be replaced. If the device (with battery inserted) is not used for an extended period of
time, you should check/replace the battery.
Measurement This is how you measure the battery:
▶ Replace battery and continue with the manual measurement
or
▶ observe the diagnostic message "037 Battery down“ in the IEC program and dis‐
play it on an HMI (panel), if necessary.
▶ Replace battery three days after the first diagnostic message at the latest.
This is how you replace the battery:
▪ You can exchange the battery while the controller is on or off. There is no data
loss if it is performed while the controller is on. When the controller is switched off,
the time period of the data buffering without a battery is approx. 5 minutes.
WARNING
THERE IS A RISK OF EXPLOSION/FIRE IF THE WRONG BATTERY IS USED
• Only use the type of battery with the following data: 3V Lithium Renata Type
2450N.
Failure to follow these instructions can result in death or serious injury.
▶ Use insulated pliers to lightly pull the old battery out of its slot.
CAUTION
DANGER OF EXPLOSION WHEN REMOVING/REPLACING BATTERY
• Use a pair of suitable, insulated pliers.
• When replacing the battery use tools which contain no current conducting
material on the contact points.
• In general, be careful not to short circuit the battery poles.
• Do not recharge, dismantle or place battery in fire.
A non-observance of these instructions can cause bodily injury or damage the equipment.
▶ Carefully place the new battery on the guide and lightly push it into the device.
For ordering information (see 5.6 Type code).
[reset] button
▶ Press this button to reset the controller and reboot it.
reset
3.5 Diagnosis
You can connect the (Service)-PC (EPAS-4) with the PacDrive Controller in two dif‐
ferent ways:
1. Serial connecting cable
2. Ethernet connection 10/100 Base-T
If the Windows computer being used in the service case or for commissioning has a
functioning TCP/IP installation, the PacDrive Controller net management tool can be
used to establish a connection. Further information on working with the PacDrive Con‐
troller Net Manage commissioning tool can be found on the PacDrive EPAS-4 CD.
If a connection between EPAS-4 and the controller is not possible, the following causes
may be the problem:
TCP/IP
▶ Check the IP_Address in EPAS-4 under ONLINE > communication parameters.
- Is the channel (umbrella term for connection parameters) set correctly?
connection
- Is the TCP/IP_Address set correctly?
- Is the port set to "5000"?
- Is the Motorola byte order set to "No"?
▶ Check TCP/IP settings in the PLC configuration of the project.
- Is the parameter IP_SubNetMask correctly filled out?
- Is the parameter IP_Address entered correctly and does it match the setting
under ONLINE > communication parameters in EPAS-4?
- Is the parameter IP_Gateway address entered correctly?
▶ Establish a serial connection to the PacDrive Controller.
- Enter settings for a serial connection under ONLINE > communication parame‐
ters (Port = "5000"(depending on the computer); Baud rate = "38400"; Parity =
"No"; Stop bits = "1"; Motorola byte order = "No").
- Establish serial connection.
▶ Check the settings in the PLC configuration of the PacDrive Controller.
- Is the IP_SubNetMask entered correctly?
- Is the parameter IP_Address correct and does it match the setting under ONLINE
> communication parameters in EPAS-4?
- Is the address IP_Gateway entered correctly?
4.2 Storage
▶ Store devices in a clean, dry room.
▶ Make sure that the air temperature at the storage location is between - 25 °C and
+70 °C.
▶ Make sure that the temperature variations at the storage location are a not more
than maximum 30 K per hour.
For further information (see 6.1 Ambient conditions).
4.3 Unpacking
▶ Remove the packaging.
▶ Check that delivery is complete.
▶ Check the delivered goods for transport damage.
Made in
German
y
518939.0010 U04 SW: 00.16.20
HW: B43276
PacDrive C200 / 10 / 1 / 1 / 1 / 00
2
13130260-001
For warranty reasons, we strongly recommend that you contact ELAU personnel for
initial start-up. The ELAU personnel
• will check the equipment,
• determine the optimal configuration
• and instruct the operating staff.
WARNING
DANGEROUS MOVEMENTS
• Ensure that no one is in the danger zone.
• Remove all tools, loose parts and other working aids not belonging to the
axis/machine/system from the area of movement. (Ensure machine is in op‐
erating state!)
• ELAU recommends waiting to engage the engine until after the function tests
have been successfully performed!
Failure to follow these instructions can result in death or serious injury.
The PacDrive™ System is adapted to your task using the EPAS-4 Automation Toolkit.
The system will be configured and programmed according to IEC 61131-3 in EPAS-4.
CAUTION
FAULTY PROGRAM CHANGES
• Program changes may only be carried out by trained personnel with detailed
knowledge of the system.
• Changes may only be carried out by your machine supplier or by ELAU employ‐
ees.
• ELAU GmbH is not liable for damages caused by unauthorized program
changes.
Failure to follow these instructions can result in equipment damage.
To control and regulate the motors, the mains voltage is stored by rectification in the
DC bus of the servo amplifier. This stored energy is supplied to the motor by targeted
switching on and off using six semiconductor 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 compatibility (EMC)
with other system components. The high rate of change of the clocked voltage gen‐
erates harmonics of great intensity up into the high frequency range.
CAUTION
SYSTEM FAULTS OR FAILURES DUE TO ELECTROMAGNETIC FIELDS
• During installation, select the HF grounding option with the lowest ohm load (e.g.
an uncoated mounting plate on the switching cabinet).
• Ensure largest possible contact surface area (skin effect).
• If necessary remove any existing paint to ensure contact.
• Lay the grounding in a star configuration from the Central-Earthing-Point.
• Current loops of earthing are prohibited and can cause unnecessary interference.
• Only use shielded cables.
• Supply large-area shielding bridges.
• Do not connect shields via the PIN contacts of connectors.
• Observe the circuit suggestions.
• Shorten the motor cables to a minimal length.
• Do not lay any cable loops in the switching cabinet.
• In conjunction with electronic controllers, do not switch inductive loads without
suitable interference suppression.
• Provide for suitable interference suppression. For direct current operation, this is
achieved by using recovery diodes and protector type-based, industry-standard
quenching circuits during alternating current activity.
• Arrange the interference suppression immediately at the point of inductivity, as
otherwise even more interference may be generated by the shock of the switch‐
ing current on the interference suppression lines.
• Avoid sources of interference instead of eliminating the effects of existing inter‐
ference.
• Do not arrange contacts with unsuppressed inductive loads in one room with
PacDrive Components. The same applies for connection lines that do not lead
suppressed, switched inductances and lines that run parallel to them.
• Isolate the controller from such interference sources using a Faraday cage (sep‐
arately partitioned switching cabinet).
• Mains filters and motor filters may by used depending on the combination of the
servo amplifier/motor and the cable length.
Failure to follow these instructions can result in equipment damage.
5.4.1 Repair
CAUTION
IMPROPER CLEANING
• Use cleaning processes appropriate to the protection class .
• Do not use any alkaline detergent because the polycarbonate can loose its
stability if you have contact with it.
• Do not use any cleaning fluid, as this will damage the motor's aluminum
housing.
Failure to follow these instructions can result in equipment damage.
▶ Then blow out with dry pressurized air (max. 1 bar).
Keep a stock of the most important components to ensure that the equipment is func‐
tioning and ready for operation at all times.
You may only exchange units with the same hardware configuration and the same
software version.
You will find this information on the type plate and in the controller configuration of the
PacDrive System.
HW-Variant
Processor
1 = ST-PC VEGA
RAM
1 = 128 MB
Flash memory
1 = 32 MB
Optional functions
6 Technical data
6.1 Ambient conditions
battery
cf - card
pow
wd
err X12
reset
bus
err
enter
rs232
rs485
com1
com2
C200
1 2
X1 X2
PacDrive
X3
eth
X3
24V/wd/tp in
X4
X4
pacnet
X5
X5
6 X6
7 X7
Made in Germany
X9
profibus dp
X10
can
9 10
11 X11
X1 - Com 1 (RS232)
- Ethernet
CAUTION
SWITCHING OFF THE CONTROL VOLTAGE.
• Use a UPS to avoid loss of data or damage to flash disk.
• Switch off PacDrive Controller control voltage only when all files are closed.
Failure to follow these instructions can result in equipment damage.
X5 - PacNet
X9 - profibus dp
1
2
3
X10 - CAN
CAUTION
MALFUNCTION AND DAMAGE TO FIELD BUS COMPONENTS ON SYNCHRO‐
NOUS OPERATION OF MULTIPLE FIELD BUSES
• Use only X9 or X10. The field bus connections X9/X10 are not electrically sep‐
arated!
• Do not operate more than one field bus at a time.
Failure to follow these instructions can result in equipment damage.
CAUTION
PLUGGING IN/UNPLUGGING THE MASTER ENCODER PLUG WHEN SWITCHED
ON
• Only unplug or plug in master encoder plug when off-circuit.
• Disconnect controller from the 24 V supply voltage.
Failure to follow these instructions can result in equipment damage.
6.5 Dimensions
12 (0.47)
24.5 (0.96)
7 (0.28)
6.5 (0.26)
7 (0.28)
battery
cf - card
pow
wd
err X12
reset
bus
err
enter
rs232
rs485
com1
com2
C200
1 2
PacDrive
239.5 (9.43)
310 (12.2)
296 (10.6)
eth
X3
24V/wd/tp in
X4
pacnet
X5
Made in Germany
profibus dp
can
9 10
46 (1.81)
7 (0.28)
12.5 (0.49)
ca. 235 (9.25) 47.5 (1.87)
60 (2.36)
ca. 260 (10.23) max. depth incl. connectors!
7 Appendix
7.1 Contact addresses
See the ELAU Homepage (www.elau.de) for further information and our current sem‐
inar schedule.
The following safety checks for the PacDrive Controller are performed in the production
in accordance to EN 50178 / EN 60204-1:
Check for end-to-end connection of grounding conductor
with 30 A
Insulating resistance check
with U = 500 V DC
Withstand voltage check
with U = 2500 V DC
for a time period of 1 min.
7.4 Modifications
The latest product documentation, application notes and the change service are al‐
ways available on the ELAU Homepage.
06 / 2004
• New edition of the operating manual
02 / 2007
• Various error eliminations and additions
• Layout of document revised
• Diagnostic messages expanded
• PROFIBUS connector added
• Chapter on hardware/software compatibility list added
11 / 2008
• Update document structure
Return address:
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Additional information:
C
Certifications 28
Configuration 24
Contact addresses 38
D
Diagnosis 14
Diagnosis message 19
E
EMC Rules 25
H
Homepage 2, 38
I
Imprint 2
O
Order numbers 0
P
Proper use 8
Q
Qualification of personnel 9
R
Risk classification 7
S
Seminars 38
Service addresses 38
Storage 20
Symbols 7
T
Trademark 2