Imprint 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.
Manufacturer's declaration Manufacturer's declaration According to the EC machine guidelines 98/37/EC ELN 117-02/02.04 page 1/1 The product we delivered: PacDrive C200 Controller is intended for installation in a machine. 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.
Table of contents Table of contents 1 About this manual 1.1 Introduction ............................................................................................................... 6 1.2 Symbols, designator and display format of safety notes .......................................... 7 2 Notes for working safely with the product 2.1 Proper use ................................................................................................................ 8 2.
Table of contents 5.6 Type code ............................................................................................................... 28 6 Technical data 6.1 Ambient conditions ................................................................................................. 29 6.2 Standards and regulations ..................................................................................... 29 6.3 Mechanical and electrical data ............................................................
1 About this manual 1 About this manual 1.1 Introduction Read and observe this manual before you work on the PacDrive Controller for the first time. Take particular note of the safety instructions. As described 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.
1.2 Symbols, designator and display format of safety notes 1.2 Symbols, designator and display format of safety notes This manual divides the safety instructions into four various categories. Hazards and possible results will be categorized using a certain combination of sym‐ bols and signal words. Symbol / Signal word Meaning Indicates an immediate hazardous situation that can lead to death or serious injury if the safety regulations are not observed.
2 Notes for working safely with the product 2 Notes for working safely with the product 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. 2.
2.2 Selection and qualification of personnel 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).
2 Notes for working safely with the product 2.3 Rest dangers 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. If activities involve residual risks, a warning instruction is made at the appropriate points. The note details the potential hazard and its effects and describes preventative measures to avoid it.
2.3 Rest dangers Touching electrical parts DANGER ELECTRIC SHOCK, FIRE OR EXPLOSION CAUSED BY HIGH VOLTAGE • • • • • • • • • • • • • • Observe the general construction and safety regulations for working on highcurrent 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.
2 Notes for working safely with the product 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 Personal safety must be guaranteed by primary equipment monitoring or measures. Don't just rely on the internal monitoring of the drive components.
2.3 Rest dangers "Safe separated extra-low voltage" PELV Protec‐ The signal voltage and control voltage of the PacDriveTM devices are <33 Volts. In this tive Extra-Low range, the specification as a PELV system in accordance with IEC 60364-4-41 in‐ Voltage cludes a protective measure to guard against direct and indirect contact with danger‐ ous voltage through the safe separation of the primary and secondary sides in the system/machine.
3 Indicators, control elements, diagnosis 3 Indicators, control elements, diagnosis The PacDrive™ System supports the user with its comprehensive diagnostic sys‐ tem. The diagnostic messages can be read out with the Automation Toolkit EPAS-4 . The PacDrive™ System contains a powerful message logger in which additional diagnostic information is recorded. Diagnostic messages are usually displayed by a control panel on the machine.
3.1 Indicators on the PacDrive C200 Controller pow (control voltage display) The "pow" LED indicates the state of the control voltage. OFF The control voltage (24 V DC) is not available or too low. ON Normal operation; control voltage in normal range Flashes UPS active wd (watchdog indicator) Watchdog is a hardware module to monitor the controller. OFF Normal operation ON Fatal error; reset required, reboot system A "fatal error" is a serious hardware problem or an unexpected software problem.
3 Indicators, control elements, diagnosis LED yellow: OFF PacDrive Controller not connected LED green: ON 100 MB connection LED green: OFF 10 MB connection After opening the operating cover you have access to the control elements of the Pac‐ Drive Controller: • • • • cf - card CompactFlashTM card slot X21 The CompactFlash™ card slot is the entry for the permanent data memory (CF™ card) of the PacDrive Controller. ▶ ▶ ▶ ▶ Switch off the PacDrive Controller.
3.4 On- /off / reset of the PacDrive Controller ▶ 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.
3 Indicators, control elements, diagnosis 3.5 Diagnosis 3.5.1 Minimal boot of the PacDrive Controller ▶ If a serious boot error occurs as a result of an application error, you have to perform a minimal boot. During a minimal boot the application data (PLC configuration and IEC program) are not loaded. Perform a minimal boot as follows: ▶ ▶ Boot the controller by pressing the [reset] button. ✓ The controller starts and the err - error indicator lights up.
3.5 Diagnosis ▶ serial connection over COM1 ▶ ▶ ▶ > communication parameters in EPAS-4? - Is the address IP_Gateway entered correctly? Adjust parameter to detect an error. - Take over the parameter with ONLINE > Parameter. - Activate the parameter with ONLINE > reset controller. Check serial cable if jumpers are available.
4 Transport, storage, unpacking 4 Transport, storage, unpacking 4.1 Transport ▶ ▶ 4.2 Avoid heavy shocks and/or vibrations during transport. Check the units for visible transport damage and inform the shipping company immediately if necessary. 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.
4.4 Type Plate 4.4 Type Plate 1 13130260-001 HW: B43276 518939.0010 U04 SW: 00.16.20 German y PacDrive C200 / 10 / 1 / 1 / 1 / 00 Made in 2 Figure 4-1: PacDrive Controller C200 with type plate 1 Technical type plate 2 Logistic type plate Figure 4-2: Logistic type plate of the PacDrive Controller C200 PacDrive C200/C400/C600... Item name ELAU GmbH 1313026X Item no. 888067.
4 Transport, storage, unpacking Figure 4-3: Technical type plate of the PacDrive Controller C200 Page 22 PacDrive C200/...
5.1 Initial start-up 5 Installation and maintenance When carrying out the following steps, make sure to exercise with the necessary ac‐ curacy and make arrangements to avoid • • • • injuries and material damage, incorrect installation and programming of components, the incorrect operation of components and the use of not authorized cables or modified components. For warranty reasons, we strongly recommend that you contact ELAU personnel for initial start-up. The ELAU personnel • • • 5.
5 Installation and maintenance ˗ buserr: OFF ˗ wd: OFF How to finish the initial start-up: ▶ Check safety functions such as the EMERGENCY OFF switch. This is how you connect the mains voltage: ▶ ▶ ▶ ▶ Activate EMERGENCY STOP switch. Connect mains voltage. Check status displays for proper function. Release EMERGENCY OFF switch and activate ON switch.
5.2 Configuration, homing and programming 5.2 Configuration, homing and programming 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.
5 Installation and maintenance 5.3 EMC Rules 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.
5.4 Maintenance, repair, cleaning 5.4 Maintenance, repair, cleaning 5.4.1 Repair Proceed as follows in case of repair: ▶ ▶ ▶ 5.4.2 Fill in the fault report form in the attachment (can also be sent per Fax). When possible, replace defective parts. Send the defective part back to ELAU. Cleaning How to remove dust and foreign objects from the drive: ▶ ▶ De-energize PacDrive Controller. Remove PacDrive Controller.
5 Installation and maintenance 5.
6.1 Ambient conditions 6 Technical data 6.1 Ambient conditions Procedure Parameters Operation Class 3K3 Transport Ambient temperature +5°C...+45°C Condensation Prohibited Icing Prohibited Another water Prohibited Relative humidity 5% ... 85% IEC/EN 60721-3-2 Ambient temperature -25°C...+70°C Condensation Prohibited Icing Prohibited Another water Prohibited Relative humidity 5% ... 95% Class 1K4 IEC/EN 60721-3-1 Ambient temperature -25°C...
6 Technical data 6.
6.3 Mechanical and electrical data Category Parameters Value Actuator power C200: 4 servo axes: SERCOS cycle time 2 ms C200: 8 servo axes: SERCOS cycle time 4 ms Output C200 / A2: 2 servo axes: SERCOS cycle time 2 ms C200 / A2: 2 servo axes: SERCOS cycle time 4 ms Max.
6 Technical data Electrical connections wd cf - card pow battery 6.4 err reset X12 bus err com2 rs485 1 2 X2 PacDrive eth X3 X3 24V/wd/tp in X1 com1 rs232 C200 enter X4 pacnet X4 X5 6 X6 7 X7 X9 X10 can profibus dp Made in Germany X5 10 9 X11 11 Connection Meaning max. terminal cross-section [mm2]/ [AWG] X1 Com 1 (RS232) 0.25 mm2 - X2 Com 2 (RS485) 0.
6.
6 Technical data X3 - Ethernet Pin 8 1 Designation Meaning 1 Tx+ OutputTransmitData+ 2 Tx- OutputTransmitData- 3 Rx+ InputReceiveData+ 4 - (PE) 5 - (PE) 6 Rx- InputReceiveData- 7 - (PE) 8 - (PE) Table 6-7: Connection X3 Range Depending on the application, you will need different cables to connect the controller via the RJ-45 outlet.
6.4 Electrical connections X5 - PacNet Pin 8 1 Designation Meaning 1 TxD+ OutputTransmit Data+ 2 TxD- OutputTransmit Data- 3 RxD+ InputReceive Data+ 4 TxC- OutputTransmit Clock- 5 TxC+ OutputTransmit Clock+ 6 RxD- InputReceive Data- 7 RxC+ InputReceive Clock+ 8 RxC- InputReceive Clock- Table 6-9: Connection X5 Range Use only approved PacNet cables at the PacNet connection to avoid malfunction.
6 Technical data 1 2 3 4 Figure 6-2: Position of the bus terminal resistors 1 Last bus slave 2 Nth bus slave 3 First bus slave 4 Bus terminator X10 - CAN Pin 6 9 1 5 Designation Meaning 1 - Reserved 2 CAN_L CAN bus line (low) 3 GND Ground 4 - Reserved 5 - Reserved 6 GND Ground 7 CAN_H CAN bus line (high) 8 - Reserved 9 - Reserved Table 6-11: Connection X10 Range CAUTION MALFUNCTION AND DAMAGE TO FIELD BUS COMPONENTS ON SYNCHRO‐ NOUS OPERATION OF MULTIPLE FIELD B
6.
6 Technical data Dimensions 7 (0.28) 12 (0.47) 7 (0.28) 6.5 (0.26) wd cf - card pow battery 24.5 (0.96) 6.5 err reset X12 bus err com2 rs485 2 eth 24V/wd/tp in X3 296 (10.6) com1 rs232 1 PacDrive 239.5 (9.43) 310 (12.2) C200 enter pacnet X4 X5 6 ca. 235 (9.25) ca. 260 (10.23) max. depth incl. connectors! 10 7 (0.28) 46 (1.81) 9 can profibus dp Made in Germany 7 12.5 (0.49) 47.5 (1.87) 60 (2.
7.1 Contact addresses 7 Appendix 7.1 Contact addresses ELAU GmbH Deutschland Dillberg 12 - 16 97828 Marktheidenfeld, Germany Tel.: +49 (0) 9391 / 606 - 0 Fax: 09391/606-300 E-mail: info@elau.de Internet: www.elau.de ELAU GmbH Customer Service Post office box 1255 97821 Marktheidenfeld, Germany Tel.: +49 (0) 9391 / 606 - 142 Fax: +49 (0) 9391 / 606 - 340 E-mail: info@elau.de Internet: www.elau.de See the ELAU Homepage (www.elau.de) for additional contact addresses. 7.
7 Appendix 7.3 Safety tests 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.
7.5 Fault report form 7.5 Fault report form This fault report is required without fail to enable efficient processing. Send the fault report to your ELAU GmbH-representative or to: ELAU GmbH Customer Service Department Dillberg 12 97828 Marktheidenfeld Fax: +49 (0) 93 91 / 606 - 340 Return address: Company: City: Date: Department: Name: Phone: Specifications regarding product in question Item name: ........................................................................ Item no.: ..................
7 Appendix [ ] occurs after approx. hours [ ] occurs by concussion [ ] depends on the temperature [ ] foreign objects in the device [ ] moisture in device [ ] defect encoder [ ] motor failure [ ] broken cable [ ] insufficient ventilation Is there an air conditioner in the switch cabinet? Y / N [ ] Have there been similar errors in the same axis previously? How often: .............................. Did the errors always occur on certain days or at certain times of day? ...................................
Index Index Training courses 39 C Certifications 29 Configuration 25 Contact addresses 39 D Diagnosis 14 Diagnosis message 19 E EMC Rules 26 H Homepage 2, 39 I Imprint 2 O Order numbers 0 P Proper use 8 Q Qualification of personnel 9 R Risk classification 7 S Seminars 39 Service addresses 39 Storage 20 Symbols 7 T Trademark 2 ELAU GmbH PacDrive Controller C200 Page 43
