line Q tox

TOX® PRESSOTECHNIK GmbH & Co. KG Riedstraße 4 D - 88250 Weingarten Tel. +49 (0) 751/5007-0 Fax +49 (0) 751/52391 www.tox-de.com E-Mail: [email protected]

Operating Manual

Description of the Hardware

EDC Compact

Hardware EDC Compact

EDC_en BA 16.03.05.10 2


EDC_en BA 16.03.05.10 3

Content 1 About this Manual 4

1.1 Introduction 4 1.2 Copyright, warranty 4 1.3 Explanation of the symbols 5 1.4 Abbreviations 6

2 Safety Instruction and Application Advice 7 2.1 General Information 7 2.2 Intended use 8 2.3 Transport and Storage 9 2.4 Installation 9 2.5 Electrical Connection 10 2.6 Operation 11 2.7 Maintenance 11 2.8 Unit Assembly complying EMC 11

3 EDC COMPACT Press – Controller 12 3.1 Hardware Design 12 3.2 Programming 13 3.3 Performance Features of the EDC COMPACT 13 3.4 DATA 14 3.5 Dimension Drawings 16

4 Front Panel 17 4.1 Status Indications FC0 to FC3 (Red Flashing) 18 4.2 Status Indication FC0 to FC3 (Green and Red) 20 STX / SRX / SRR – Status Indication/Error Messages of Bus Systems 21

5 Pin Assignment and Interfaces 22 5.1 General Information 22 5.2 X1 – Connection of First Measuring System (Feedback) 22 5.3 X2 – COM, Connection for Terminal or Programming Device 23 5.4 X3 – ENC0, Encoder Output 23 5.5 Encoder Inputs 24 5.6 X6 – SIO, I/O expansion 25 5.7 Connection of the Bus System 25 5.8 Motor Connector 28 5.9 Power Supply 29 5.10 X 50 / X 51 - Inputs and Outputs of the Logic Signals 30 5.11 X 52 - 24V Supply/Thermal Contact 34

6 Option Modules 35 6.1 Option Module 61.02.0043B 35

7 General Information Regarding the Wiring 42 7.1 General Information 42 7.2 Dangers of Ground Loops 43 7.3 Motor Cables 44 7.4 Cables for the First Measuring System 45 7.5 Cables for the 2./3. Measuring System 45 7.6 Cables for the Connection of the I/O Expansion Modules 46 7.7 Cables for the Terminal Connections 46 7.8 Cables for external ballast resistors 46 7.9 Wiring of 24 V (internal/external) 46


EDC_en BA 16.03.05.10 4

1 About this Manual

1.1 Introduction The Operating Instructions are intended to help you to use the control system for its intended purpose. The Operating Instructions contain important instruc-tions for a safe, appropriate and economical operation of the control system. The observance of these instructions helps to avoid risks, to reduce repair costs and downtimes, and to increase the reliability and the service life of the control system.

All persons charged by the user with the operation, maintenance and repair of the machine, must have read and understood the Operating Instructions, and especially chapter "Safety" before start-up.

Keep the Operating Instructions Keep the Operating Instructions near the machine and always available for the personnel.

Besides the operating instructions and the mandatory regulations valid on site for the prevention of accidents, also the applicable technical regulation for safety and qualified working must be observed.

1.2 Copyright, warranty The present Operating Instructions as well as the enclosed documents are protected by copyright. They are entrusted to our customers and the users of our products.

Copyright: TOX® PRESSOTECHNIK GmbH & Co. KG

These operating instructions are correct at the date of issue. Edition: 30.05.2003 A

Subsequent alterations or conversions to the control system by the user are not covered. These operating instructions are part of the delivery and must be passed on to the new owner in the event of a resale of the control system.

We guarantee the control system according to our conditions of sale and de-livery. The guarantee shall not apply in the event of

− damages caused by improper handling,

− repairs or interventions made by persons not authorized to do so,

− using accessories and spare parts for which our machine is not de-signed,

− not repairing defect parts immediately in order to minimize the extent of the damage and to avoid impairing the safety of the machine (repair obligation).


EDC_en BA 16.03.05.10 5

Damages to the control system Report any failures as soon as they are detected to the competent distribution partner or direct to TOX® PRESSOTECHNIK:

TOX® PRESSOTECHNIK Riedstraße 4 D-88250 Weingarten Tel. +49 (0) 751/5007-0 Fax +49 (0) 751/52391 E-Mail [email protected]

This control system is designed and manufactured according to the state of the art and the applicable German standards and specifications.

The text and the translation of this manual have been worked out very care-fully. However, TOX® PRESSOTECHNIK can accept neither obligation nor le-gal responsibility for incorrect specifications and their consequences.

Any changes to this manual will be to the discretion of TOX® PRESSO-TECHNIK.

We reserve the right to make alterations with a view to technical improve-ments.

1.3 Explanation of the symbols This arrow at the beginning of a paragraph draws attention to the action

steps you must follow.

This hook at the beginning of a paragraph draws attention to a condition to be met before beginning the next step.

Danger notes:

Safety Here you will find instructions for the prevention of dam-ages. These safety notes must be strictly observed by the employer and user of the machine.

Danger Warns of mechanic dangers which can lead to personal injury or risk to life.

Electric voltage Warns of electric dangers which can lead to personal in-jury or risk to life.


EDC_en BA 16.03.05.10 6

Service notes:

Note Informs on work sequences and methods which facilitate the handling of the machine.

Function Explains the functioning of the machine or the sequence of a working process.

Status of the LED display: LED ON LED OFF LED flashes

1.4 Abbreviations -labeling (Communauté Européenne = European Community);

confirms the conformity of products with the relevant EU standards and guidelines

CLK Clock signal

DIN Deutsches Institut für Normung = German Institute for Standards

EMV Electromagnetic compatibility = EMC

EN European standard

IEC International Electrotechnical Commission

VDE Verband Deutscher Elektrotechniker (= Association of German Electricians)

LED Light Emitting Diode

NTC negative temperature coefficient

PTC positive temperature coefficient

VAC Alternating current

VDC Direct current

Product Designations Product names mentioned in this documentation are trademarks or regis-tered trademarks of their respective companies. The appropriate name of the company is characterized by CAPITAL LETTERS.

Examples: TOX PRESSOTECHNIK PHOENIX terminal HEIDENHAIN measurement system


EDC_en BA 16.03.05.10 7

2 Safety Instruction and Application Advice According to Low-Voltage Guideline 73/231/EEC Machine Guideline 89/392/EEC Electromagnetic Compatibility 89/336/EEC

2.1 General Information

Trained staff The complete installation, the initial start up and mainte-nance must only be carried out by trained staff.

Trained staff, according to these fundamental safety in-structions, are persons, familiar with the installation, mounting, initial and operation of the product and are qualified to carry out these tasks The standards DIN VDE 0100 and DIN VDE 0110 and also the legal national rules for prevention of accidents must be paid attention to.

Operation During operation the units may be energized and hot sur-faces may be present according to their protection de-gree.

Subjects can be damaged and persons be injured • when covers are removed illegally • during any improper use • when either the installation or the operation is incorrect

Do not change the machine! Arbitrary conversions or alterations (of mechanics or elec-trics) endanger the safety of personnel, of the whole ma-chine, or of other material assets.

Consult TOX® PRESSOTECHNIK before carrying out any modifications within the unit.

Check all programs before initial operation! Initial programming by TOX PRESSOTECHNIK will still require the user to verify the correctness of programmed values and parameters


EDC_en BA 16.03.05.10 8

2.2 Intended use The TOX® PRESSOTECHNIK servo product is electronic equipment, used for the operation of motors and provided for the installation into machinery, the safety considerations of the Machine Guidelines (89/392/EEC) must be followed.

Before initial operation, make sure that the machine will not post any danger (e.g. uncontrolled moves). The conformity according to the Guideline EN 60204-1 / IEC 204-1 must be established..

The manufacturer of the system or the machine has to meet the require-ments of the Electromagnetic Compatibility (EMC). The TOX® PRESSO-TECHNIK servo units can be operated in industrial areas, provided the at-tached EMC information has been taken into consideration.

TOX PRESSOTECHNIK is testing their products in their own EMC laboratory to meet the respective standards, when they are installed properly. Devia-tions of the construction and the installation, described in the documentation and in the manual, Unit Assembly Complying EMC, require new measure-ments of the system or machine by the machine manufacturer to meet the statutory requirements.

Appropriate proceedings according to the EMC Product Standard (PDS) DIN/EN 61 800-3/IEC 1800-3 ensure the use in industrial areas.

Products, not equipped with an AC supply line filter must be operated with a in series connected mains filter: • Servo amplifiers: TOX® PRESSOTECHNIK mains filter series 011.00.3x

• Servo amplifiers without motor filters need the motor lines to be looped at least 3 times through a ferrite core.

If using the drive systems in residential areas, in business and commercial areas, the user has to take additional and larger filter measures.

TOX® PRESSOTECHNIK products meet the requirements of the Low-Voltage Guideline 73/231/EEC. The coordinated standards of the series DIN EN 60 204 / IEC 204 in combination with DIN EN 60 439-1 / IEC 439-1 and DIN EN 60 947 / IEC 947 are strictly adhered to.

The drive systems must only be operated in enclosed control panels, offering at least the IP54 degree of protection and under the environmental condi-tions, specified in section 2.4.

Technical data and the connection specification can be found in this product document.


EDC_en BA 16.03.05.10 9

2.3 Transport and Storage Make sure, that the unit is correctly used. The following points must espe-cially be taken into consideration:

• Protection against mechanical damage (transport, handling, etc.)! • Protection against dirt and humidity! • Dry and well-ventilated storage area! • No storage outside! • Storage temperature between -25°C to +55°C (13°F to 131°F)!

Short term storage may be at 70°C (158°F). • Protection against contact with electronic components (electrostatic dis-

charge)! • No modification of insulation!

2.4 Installation • The units can be operated to their maximum duty cycle up to a height of

1,000 m M.S.L (3,281 ft M.S.L.) • For operation in areas higher than 1,000 m M.S.L. (3,281 ft M.S.L.) the

duty cycle must be reduced by 15 % per 1,000 m (3,281 ft.) • The ambient air must not contain aggressive, electrically conductive or

flammable substances and should contain minimum amounts of dust. • The maximum relative humidity is approx. 95 % (no condensation). • The admissible ambient temperature during the operation is between

+5°C and +40°C ("41°F and "104°F). • At temperatures higher than +40°C (104°F) the capacity must be reduced

by - 1.5 % per 1°C. Annotation: F = C × 9/5 +32; C = (F : 32) × 5/9 • Make sure that the fans installed in the units have sufficient space to take

in and exhaust the cooling air! • Do not touch electronic components!

Hazard to electrostatic components TOX® PRESSOTECHNIK products contain electrostatic sensitive components that may easily be damaged by im-proper handling.


EDC_en BA 16.03.05.10 10

2.5 Electrical Connection

Electrical voltage The valid rules for prevention of accidents (e.g. VBG 1 and VBG 4) should be paid attention to, when working at current-carrying units.

The electrical installation must be carried out according to the relevant elec-trical codes (e.g. appropriate wire gauges, fuse protection and connections of ground conductors must be considered). Recommendations for the installa-tion according to the EMC (e.g. shields, connection to earth and line installa-tions) can be found in this technical document (only for machine manufactur-ers). The manufacturer of the system or machine has to meet the require-ments of the EMC rules.

• All work at and within the units must only be carried out, when they are turned off and the AC line is disconnected!

• The mains line should only be connected, when the work is completed! • Before turning on the unit the first time, make sure that the connected

machine will not have uncontrolled movement! • After turning off the unit hazardous voltages may still exist for up to

3 minutes in the power supply (due to capacitors). • Capacitive loads must not be connected to the output phases of the servo

amplifiers and frequency converters. • Prevent cable loops. The units must only be connected to earth at the

provided PE connection for the mains supply line and the amplifier only at the provided earth screw.

In general, our units can be operated on a Ground Fault Circuit interrupter. Nev-ertheless, like all solid state power electronics, TOX® PRESSOTECHNIK prod-ucts can lead leakage currents via the earth ground. Depending on the sensitiv-ity of the GFCI and the installation type, the operation along with the device may be problematic. The following points should be taken into consideration: • Use shortest motor leads possible. • Do not connect additional consumers to the same residual current oper-

ated device • Use a GFCI device with high response threshold.


EDC_en BA 16.03.05.10 11

2.6 Operation Systems equipped with servo amplifiers and frequency converters generally must be equipped with additional protective devices according to the valid safety guidelines (e.g. safety regulations, rules for prevention of accidents, etc.).

All doors and covers must be closed during the operation.

2.7 Maintenance The unit, especially the fan, must be checked regularly for cleanliness and functionality depending on the ambient environment.

2.8 Unit Assembly complying EMC

EMC Guidelines must be followed! The EC guidelines for the electromagnetic compatibility (EMC) must be taken into consideration for the operation of all TOX® PRESSOTECHNIK units.

The manual "Unit Assembly Complying EMC" is available in German and English and comprises • the EMC guidelines

• Information regarding the professional earth and wiring

• Safety-relevant aspects

• Extracts from the EMC product standard

Availability: • Hard copy version directly from TOX® PRESSOTECHNIK

• PDF file in the Internet under www.tox-de.com (coming soon)


EDC_en BA 16.03.05.10 12

3 EDC COMPACT Press – Controller The EDC COMPACT is a digital controller for high-dynamic press systems, using synchronous and asynchronous AC Motors.

The power and the control components of the EDC COMPACT form a com-pact unit.

The Software of the EDC COMPACT is specifically designed for pressing applications. The controller can process all external sensors directly. The controller can be networked for easier programming and data transfer.

3.1 Hardware Design The EDC COMPACT combines servo and control functions in one module. The hardware comprises the following components:

• digital speed and position controllers with a sample rate of 500 µs

• powerful output stages for various press types and performance ranges

• evaluation of either resolver, Hall effect sensors or optical length measur-ing systems

• standard interface RS232/485

• eight digital inputs and outputs

• additional analog input

• two encoder inputs and one encoder output

• TOX PRESSOTECHNIK IO interface for further 128 digital inputs/outputs

• Integrated Ethernet-Interface

• Integrated Profibus-Interface

• two serial interfaces

• Two load-cell inputs, battery buffered RAM, real time clock

Following option modules are available:

• INTERBUS-Interface

• optional Modlink-Interface

• optional CAN-Bus

All components of the hardware can be accessed due to the digital interface. Possible errors are indicated as error codes via LED’s at the front panel. Evaluated errors are, among others, over voltage, under voltage, limit switch and emergency stop.


EDC_en BA 16.03.05.10 13

3.2 Programming The controller has been programmed and configured by TOX PRES-SOTECHNIK. The user will only need to set the process parameters. Special programming knowledge or programming devices are not required. The commands have a uniform structure and permit compact programming. The software utility to program the servo system is free of charge.

3.3 Performance Features of the EDC COMPACT • Direct supply up to 480VAC –33%/+5%

• Galvanic separation between control and power components

• Integrated protective functions for motor and CNC module (e. g. evalua-tion of the thermal contact, I2t, etc.)

• Output for collective fault messages

• Short-circuit proof (phase to phase, phase to earth)

• Optimized evaluation of the encoder signal

• Constant motion, even at lowest speeds

• High dynamics

• Self-controlled resolver adaptation and adjustment of up to 1,024 angle pulses (version with resolver evaluation)

• Phase shifting for increased drive performance

• Filter for eliminating possible mechanical resonances (e.g. oscillation of coupling)

• Full operation with cables of up to 25 m length between CNC module and motor

• LED’s for diagnostic purposes

• Space and cost-saving solutions due to the compact system design.

The Press controller EDC COMPACT is available in different sizes for differ-ent current requirements.

The press controller EDC Compact is available with safety category 3 ac-cording EN 954-1.


EDC_en BA 16.03.05.10 14

3.4 DATA

EDC Compact Type 20/40 Type 20/80 Width [mm] 123 123 Height [mm] 320 320 Depth [mm] 273,5 273,5 Weight [kg] 5,9 5,9 Degree of Pro-tection

IP20 IP20

Connection Data

EDC Compact Type 20/40 Type 20/80 Supply Power [VAC] 3 x 480 VAC -33%/+5% Frequency [Hz] 47 - 63 47 - 63 Nominal Current [ASS] 20 20 Peak Current [ASS] 40 80 External Fusing [A] 16 20 Efficiency minimum 95% minimum 95% Power Rating [KVA] 6 6 External Ballast [Ohm]

30 Temperature Range 5°C to 60°C at max 95% relative Humidity (no

condensation) 100% Nominal Current up to 40°C

Derating of nominal cur-rent at ambient tempera-tures >40°C at altitudes 1000m

-1,5% pro1°C -15% pro 1000m Erhöhung

EMC Filter Integrated according to DIN-EN 61803


EDC_en BA 16.03.05.10 15

EDC Compact 20/40 and 20/80

Description front panel You can find the description of the front panel on page 17

X 30 X 31

X 40

X 50 X 51 X 52


EDC_en BA 16.03.05.10 16

3.5 Dimension Drawings EDC Compact 20/40 and 20/80

Front view Side view

All dimensions in

mm


EDC_en BA 16.03.05.10 17

4 Front Panel

LED status indications, page 18 ff.

X2 COM, terminal connec-tor/programming device con-nector, page 23

LEDs for status indications of the in-puts and outputs, page 30

X6 SIO, connector for serial input and output modules, page 25

X4, X5 angle pulse inputs, page 24

X3 angle pulse output, page 23

X1 Feedback, connection of the first motor measuring system, page 22

* The front panels of the different option mod-ules

are shown in chapter 6 "Option modules", page 35 ff.

Deviation of unit layout with option modules Depending on the configuration of the model, the connec-tors and the assignment on the slot of the option module can vary! The configuration of the option module must be specified when ordering the module. A later upgrading of the individual option modules is not possible.

Module Slot – Option Module (Example)*


EDC_en BA 16.03.05.10 18

4.1 Status Indications FC0 to FC3 (Red Flashing) FC0 FC1 FC2 FC3

• LED is continuously red: permanent error, e. g. emergency stop

• LED is flashing red: error occurred and must be reset via the software

LEDs Code*

Error Reaction Possible Cause of Error

0 no error no

129 active monitoring of

travel area ref. Position = actual position ref. speed = 0

130 14 V not provided ref. speed = 0 and

regulator off1

131 -14 V not provided ref. speed = 0 and

regulator off1

logic voltage is not provided

132 short circuit ref. speed = 0 and

regulator off1 double peak current flows via the measuring shunt into the output stage

133 reserved no

134 Over voltage /

under voltage ref. speed = 0 and regulator off1,2

Over voltage:

– 325 VDC method = cut-off threshold 385 V

– 560 VDC method = cut-off threshold 810 V

under voltage: < 42 V

24 V are not provided – 24 V internal:

over voltage protection has re-sponded

– 24 V external: 24 V are not provided

135 error of first meas-

uring system ref. speed = 0 and regulator off1

136 motor temperature ref. speed = 0 and

regulator off1 NTC/PTC characteristic is adjustable. Check the adjustment

137 heat sink tempera-

ture ref. speed = 0 and regulator off1

heat sink is too hot

138 I²t computer ref. speed = 0 and

regulator off1 Rated current has been exceeded or the motor became too hot.

140 emergency stop deceleration with the parame-ter “quick delay”


EDC_en BA 16.03.05.10 19

LEDs Code*

Error Reaction Possible Cause of Error

141 positive limit switch ref. position = actual position

ref. speed = 0

142 negative limit

switch ref. position = actual position ref. speed = 0

143 power fail deceleration with the parame-

ter “quick delay” and the ref. speed = 0 and regulator off1

main supply is not provided

144 tracking error deceleration with the parame-

ter “quick delay” and then ref. speed = 0 or regulator off1

acc. to the settings in the parameter file)

* error variable in the software 1 The output stage is released and the motor coasts. 2 This message is also generated, if

a) the EDC Compact module is operated with internal 24 volts and the over volt-age protection (on the processor card of the EDC Compact) has responded, or

b) the EDC Compact module is to be supplied with external 24 volts, but this volt-age is not applied. Reason: the internal or external 24 volts are used for the generation of the mes-sage/signal lines of the power module. This means, that if this voltage is not pro-vided, 0 volts are applied to the signal lines and the EDC Compact interprets this as over voltage / under voltage!


EDC_en BA 16.03.05.10 20

4.2 Status Indication FC0 to FC3 (Green and Red)

FC0 FC1 FC2 FC3

LEDs Status Cause

FC0 lights green PI LIMIT and Regula-tor ON are active

FC0 to FC3 alter-nately light red and green

no operating system (firmware) is pro-vided

RIO – Malfunction Indication

RIO Meaning

no error of regula-tor

error of regulator

RON – Status of Regulator

RON Meaning

regulator ON

regulator OFF

CNC – Operation Indication

CNC Meaning

CNC operation

REMOTE operation

REM – Indication “Remote Control“

REM Meaning

CNC operation

REMOTE operation


EDC_en BA 16.03.05.10 21

STX / SRX / SRR – Status Indication/Error Messages of Bus Systems Bus System MODLINK

LED Meaning

transmission signal is provided STX green

no transmission signal

receive signal is provided SRX green

no receive signal

transmission failure SRR or-ange no fault

* or-ange

no meaning

* LED has no designation Bus System Ethernet

LED Meaning

STX green no meaning

connection with the Ethernet has been established

input data

SRX green

no connection to the Ethernet (or wrong Firmware)

SRR or-ange no meaning

* or-ange no meaning


EDC_en BA 16.03.05.10 22

5 Pin Assignment and Interfaces

5.1 General Information • RJ 45 connection with 8pole female connector

For the connection a shielded and twisted-pair high quality CAT5 cable should be used.

Danger of short circuit Wires, which are not used, must be isolated when fabri-cating the cable. Otherwise a short circuit can occur.

5.2 X1 – Connection of First Measuring System (Feedback)

• 15- pole female Sub D-connector

The shield must be connected to the metal housing of the 15 pole D-Sub con-nector and if possible to the housing of the motor connector.

Resolver Evaluation

0V1 S1 sine

0V1 S4 cosine

0V1 R3 rotor

thermal contact2 0V1

1 is connected to earth by the servo amplifier 2 If the thermal contact is not connected, the Pins 15 and 7 must be

strapped.

Use a shielded cable with three pairs of wires, each of which being twisted (e. g. LIY- CY 3 × 2 × 0.14). Twist mode: sine/sine; cosine/cosine; rotor/rotor. If the thermal contact is evaluated, a shielded cable with four twisted pairs of wires must be used.

S3 sine 0V1 S4 cosine

0V1 R1 rotor

0V1 thermal contact

(24V)


EDC_en BA 16.03.05.10 23

5.3 X2 – COM, Connection for Terminal or Programming Device • RJ45 female connector

The signals RxD, TxD, CTS and RTS conform to the RS232 specification.

Pin Designa-tion

Function

1 TxD Transmit Data 2 RxD Receive Data 3 CTS Clear to Send 4 D+ 5 D-

RS 485-Data bus

6 RTS Request to Send 7 VCC Supply for terminating resistors

8 GND Ground

5.4 X3 – ENC0, Encoder Output • RJ45 female connector

The module provides an output of the encoder pulses of the first measuring system.

Pin Designa-tion

Function

1 UA0+ 2 UA0-

First differential signal pair

3 UB0+ In combination with UBO- sec-ond differential signal pair shifted by 90°

4 UN0+ 5 UN0-

Zero pulse

6 UB0- In combination with UBO+ second differential signal pair shifted by 90°

7 NC Not connected

8 GND Ground


EDC_en BA 16.03.05.10 24

5.5 Encoder Inputs The module permits to connect two incremental encoders (2./3. measuring system) to the EDC COMPACT. Incremental encoders with 5 V output level can be used. For the 2./3. measuring system an external supply is required.

X4 – ENC1, Encoder Input • RJ45 female connector

Pin Designa-tion

Function

1 UA2+ 2 UA2-


3 UB2+ In combination with UB1- sec-ond differential signal pair shifted by 90°

4 UN2+ 5 UN2-

Zero pulse

6 UB2 In combination with UB1+ sec-ond differential signal pair shifted by 90°

7 NC Not connected

8 GND Ground X5 – ENC2, Encoder Input • RJ45 female connector

Pin Designa-tion

Function

1 UA2+ 2 UA2-


3 UB2+ In combination with UB2- sec-ond differential signal pair shifted by 90°

4 UN2+ 5 UN2-

Zero pulse

6 UB2 In combination with UB1+ sec-ond differential signal pair shifted by 90°

7 NC Not connected

8 GND Ground


EDC_en BA 16.03.05.10 25

5.6 X6 – SIO, I/O expansion • RJ45 female connector

The module provides an I/O expansion of additional 128 inputs and outputs. The I/O expansion interface only establishes the connection to the following basic module 44.20.012 or to the I/O system 50.06. Input modules 44.20.014 and output modules 44.20.013 can be connected to the mentioned modules in any order providing 16 inputs or 16 outputs, respectively.

Pin Designa-tion

Function

1 DO+ Data Out+ = positive data out-put signal

2 DO- Data Out- = negative data output signal

3 CLK+ Clock+ = positive clock signal 4 LD+ Load Data+ 5 LD- Load Date- 6 CLK- Clock- = negative clock signal

7 DI+ Data In+ = positive data input signal

8 DI- Data In- = negative data input signal

5.7 Connection of the Bus System

The connectors for the connection of the bus system are on the bottom side of the module (see figure below). These connectors provide different connec-tion possibilities (double assignment) e.g. CAN Bus, MODLINK, Ethernet etc.

Connec-tor Possible Connections

X7 MODLINK, Ethernet, CAN

X8 MODLINK, CAN

X9 CAN, analog input

Bottom view

No later upgrading The required bus system must be specified when order-ing the option module, since a later upgrading of the op-tion module is not possible.


EDC_en BA 16.03.05.10 26

X7 - MODLINK, Ethernet, CAN • RJ45 female connector

Pin Designation Function 1 Ethernet_Tx+ 2 Ethernet_Tx-

Ethernet transmission signal

3 Ethernet_Rx+

Positive Ethernet receiving signal

4 CAN+ 5 CAN-

Data signal

6 Ethernet_Rx- Negative Ethernet receiving signal

7 MODLINKIn+

8 MODLINKIn- MODLINK input signal

X8 - MODLINK, CAN • RJ45 female connector

Pin Designation Function 1 NC Not connected

2 VCC_EXT Voltage supply for terminating resistors

3 GND_EXT Ground 4 CAN+ Positive data signal 5 CAN- Negative data signal 6 NC Not connected 7 MOD-

LINKOut+

8 MOD-LINKOut-

MODLINK output signal

X9 - CAN, Analog Input • RJ45 female connector

Pin Designation Function

1 VCC_EXT Voltage supply for terminating resistors

2 NC Not connected

3 AnalogIN+ Positive analog input data signal

4 CAN+ 5 CAN-

Data signal

6 AnalogIN- Negative analog input signal


EDC_en BA 16.03.05.10 27

7 NC Not connected

8 GND_EXT Ground


EDC_en BA 16.03.05.10 28

5.8 Motor Connector • 4- pole Power COMBICON

Pin assignment of the motor connector

Pin Designation

1 Motor phase U

2 Motor phase V

3 Motor phase W

4 PE

Bottom view

Cable clamps Shield bar


EDC_en BA 16.03.05.10 29

5.9 Power Supply • Power CombiCon connection 2 x 6 pole for 20/40 and 20/80

Intermediate circuit voltage Please consider that an intermediate circuit voltage of up to 600 VDC may result.

If necessary, use an autotransformer For devices, which are designed for a high power but low intermediate circuit voltage, an autotransformer is re-quired in order to reduce the supply voltage.

Pin Designation

1 L1 2 L2 3 L3

Main voltage supply. The intermediate circuit volt-age depends on the input voltage. E.g.: 3 × 480 VAC

+/- 10 % results in an intermediate circuit voltage of 560 V. Please check, if your device is designed for

this voltage range! 4 PE Earth connector 5 LL1

X 30

6 LL2 Logic voltage supply. The logic voltage supply must always be connected.

The phase position must coincide with the phase position of the main voltage supply !

1 -UB 2 -UB

Intermediate circuit voltage -

High DC. voltages are generated

3 +UB 4 +UB

Intermediate circuit voltage +

High DC. voltages are generated

5 REX 1) REX External ballast resistor. This must not be lower than 30 Ohm. If required, the external ballast resistor is connected between +UB and RE.

X 31

6 RB 1) Jumper to Rex if no external ballast is used 1) If an external ballast is used the jumper between the terminals X31/5 and X31/6

must be removed. The external ballast will be connected to +UB und REX termi-nals.


EDC_en BA 16.03.05.10 30

X 40 – Category 3 Safety circuit • 1 x 6 pole Mini CombiCon connection

Pin Designation Pin Designation 1 – Input K2/3 4 – + 24 V K2 2 – Output K2/3 5 – 0 V K3 3 – 0 V K2 6 – + 24 V K3

Control Relay Inputs NN1 und LL1 must always be connected. The Posi-tion Feedback and Error messages will be stored in the event of an E-Stop situation. All three phases have to be disconnected at the same time in the event of power down and therefore an appropriate control relay has to be se-lected.

5.10 X 50 / X 51 - Inputs and Outputs of the Logic Signals

• PHOENIX Mini CombiCon

All inputs and outputs work with a level of 24 V. The total load of all outputs must not exceed 350 mA.

Allocation of inputs version TOX Standard • 10-pole PHOENIX Mini COMBICON

Pin Designation Function * 1 24 V 2 0 V 3 IN7 Program bit 3 4 IN6 Program bit 2 5 IN5 Program bit 1 6 IN4 Program bit 0 7 IN3 Sensor reference 8 IN2 free 9 IN1 Start signal

Pin 3 is coded

10 IN0 E - STOP * valid for TOX® standard software


EDC_en BA 16.03.05.10 31

Allocation of inputs version TOX cat.4 Press without PLC • 10-pole PHOENIX Mini COMBICON

Pin Designation Function * 1 24 V 2 0 V 3 IN7 YB2 disengaged 4 IN6 YB1 disengaged 5 IN5 Hand / Jog 6 IN4 2-Hand-Auto 7 IN3 Sensor reference 8 IN2 E - STOP 9 IN1 Start signal

Pin 3 is coded

10 IN0 E - STOP Allocation of inputs version TOX cat. 4 with PLC • 10-pole PHOENIX Mini COMBICON

Pin Designation Function * 1 24 V 2 0 V 3 IN7 YB2 disengaged 4 IN6 YB1 disengaged 5 IN5 free 6 IN4 free 7 IN3 Sensor reference 8 IN2 free 9 IN1 Start signal

Pin 3 is coded

10 IN0 E - STOP


EDC_en BA 16.03.05.10 32

Input Functions Caution, all functions can be changed and edited in the program.

Function Description Comment E - STOP Stops the axis within the config-

ured decel ramp. Cannot be changed by user

Start bit Starting the press sequence, must be set high during the entire press cycle

Configurable with Wait for start contact.

Program bit 0 Program bit 1 Program bit 2 Program bit 3

Binary Inputs to select the press program. Caution: Program = binary code + 1

Sensor reference Input for reference switch. In Func-tion “ referencing“ Select Method 1

YB1 disengaged YB2 disengaged

Gives the state of the brakes 1 = brake is in open position

Hand / Jog Select function 1 = function is selec-ted

2-Hand-Auto Select function 1 = function is selec-ted

Allocation of outputs version TOX Standard • 10-pole PHOENIX Mini COMBICON

Pin Designation Function * 11 OUT7 free 12 OUT6 free 13 OUT5 free 14 OUT4 Press Ready 15 OUT3 NOK 16 OUT2 OK 17 OUT1 Ready 18 OUT0 Amplifier ON 19 RIO -

Pin 18 is coded

20 RIO + * valid for TOX® standard software


EDC_en BA 16.03.05.10 33

Allocation of outputs version TOX cat.4 Press without PLC • 10-pole PHOENIX Mini COMBICON

Pin Designation Function * 11 OUT7 Br. Test2 I1 12 OUT6 Br. Test1 I0 13 OUT5 Supervision on 14 OUT4 Press Ready 15 OUT3 NOK 16 OUT2 OK 17 OUT1 Ready 18 OUT0 Amplifier ON 19 RIO -

Pin 18 is coded

20 RIO +

Allocation of outputs version TOX cat. 4 with PLC • 10-pole PHOENIX Mini COMBICON

Pin Designation Function * 11 OUT7 Br. Test2 I1 12 OUT6 Br. Test1 I0 13 OUT5 Supervision on 14 OUT4 Press Ready 15 OUT3 NOK 16 OUT2 OK 17 OUT1 Ready 18 OUT0 Amplifier ON 19 RIO -

Pin 18 is coded

20 RIO +

Output Functions

Function Description Comment Amplifier ON Indicates that the Amplifier is on Cannot be

changed by user Ready No System Faults present. Indicator will

go off, if new data is transmitted to the amp or saved to the Flash EPROM

OK Signal for correct press cycle, will be reset with new start bit


EDC_en BA 16.03.05.10 34

Function Description Comment NOK Signal for faulty press cycle, will be reset

with new start bit

Press Ready Ready for pressing, meaning Press is referenced and a press program is se-lected. Will be off while process is ac-tive

Supervision ON Supervision on

Br. Test Brake tested, I.O.

5.11 X 52 - 24V Supply/Thermal Contact

• 4-pole PHOENIX Mini COMBICON

Pin Designation 21 Thermal con-

tact 22 24 V internal* 23 24 V external

24 0 V *only auxiliary voltage to supply for example, the thermal contact

Connect pin 22 and pin 23.

The CNC module generates an internal voltage of 24 V, which can be used for small loads (max. 350 mA).

24 V external Apply a voltage of 24 V to Pin 23 and Pin 24 by connecting an external

power supply. Pin 22 must not be used/assigned.

A diagram showing the wiring of the 24 V (internal/external) can be found in the chapter "Wiring of 24 V (internal/external)", page 46.


EDC_en BA 16.03.05.10 35

6 Field bus modules

6.1 Field bus module 61.02.0043B (Profibus) The module 61.02.0043B adds the following functionalities:

• two additional RS232 interfaces with one RS232/RS485 interface

• PROFIBUS Interface

• two independent transducer inputs for passive transducers (350/700 S; 1 mV/V to 4 mV/V)

• 128 kByte battery-buffered RAM and real-time clock

On the front panel of the option module only features the connections re-quired for the respective option type.

2 LED

X14, X13

Connections for two active / passive trans-ducers, page 38

COM3, COM2

Serial interfaces, page ???

X10 Profibus interface, page 37


EDC_en BA 16.03.05.10 36

Two RS232/RS485 interfaces • RJ45 connector

Two additional serial interfaces with RS232/RS485 specification to connect printers, bar code scanners etc., which can be initiated by the application program.

Pin Designation Function 1 TxD2 Transmit data 2 RxD2 Receive data 3 CTS2 Clear to send 4 RS 485+ 5 RS 485-

RS 485 data bus for COM2

6 RTS2 Request to send

7 VCC Voltage supply for the terminat-ing resistors

COM2

8 GND Ground

Pin Designation Function 1 TxD3 Transmit data 2 RxD3 Receive data 3 CTS3 S Clear to send 4 RS 485+ 5 RS 485-

RS 485 data bus for COM3

6 RTS3 Request to send 7 VCC Voltage supply for the terminat-

ing resistors

COM3

8 GND Ground Software Access In the application software the interfaces can be operated via the commands ARD, AWL, AWR and Atxt (COM2) as well as BRD, BWL, BWR and Btxt (COM3).


EDC_en BA 16.03.05.10 37

Profibus (X10) The Profibus interface establishes the connection to Profibus. It is electrically isolated from the bus and can be operated with a maximum of 12 Mbaud. The linking with the software, which is independent of the bus system, is real-ized in the firmware, and is available to the user in the application program. Further information can be found in the manual "Communication Protocol DNC 61.00 for Bus Connections". The status of the bus is displayed via a LED at the front panel of the option module:

LED Meaning PB green Profibus active

Shield

RxD/TxD-P

Reference ground for the bus

termination

possible supply voltage for the bus termination

RxD/TxD-N

Bus Termination The Profibus must be terminated according to specifications in order to elimi-nate interferences. For this reason each bus participant provides the possibil-ity of a .passive. termination (see figure below). Usually, this termination is included in the connector of the cable for the Profibus and must be provided at both sides of the bus.

Bus termination Bus termination

Connector for the bus termination


EDC_en BA 16.03.05.10 38

Assignment of the Module Numbers In the Profibus bus system the modules are counted as follows:

The master module receives the number 1, the first slave module starts with number 3, i.e. there is an offset of 3 in the address assignment (address in type plate) in the S&M components prepared for bus systems.

Software Further information about the software can be found in the manual "Commu-nication Protocol DNC 61.00 for Bus Connections ".

Two Passive Transducers (X13/X14) This option provides two passive transducer inputs independent of each other (measuring bridges for measuring torques/forces). The option module provides the supply voltage for the measuring bridge (± 5 volts, max. 400 mA for both transducers) and includes a measuring amplifier for the arriving ana-log signals, as well as a 12 bit AD converter for the data transmission.

Transducer 1/2 passive (X13) • 9-pole female D-Sub connector

transducer input 1+ transducer input 2+

supply voltage for the transducer + 5 V

NC NC

– transducer input 1- – transducer input 2- – supply voltage for the

transducer - 5 V – GND

Address in Profibus 1

Address in Profibus 4 Address in module 1




EDC_en BA 16.03.05.10 39

Transducer 2 passive (X14) • 9-pole female D-Sub connector

transducer input 2+ NC

supply voltage for the transducer + 5 V

NC NC

– transducer input 2- – NC – supply voltage for the

transducer - 5 V – GND

Battery-buffered RAM and Real-Time Clock The module provides the user with a RAM of 128 Kbytes that may be used for the user-specific management. This area is battery-buffered, which means the data are not lost after turning off the supply voltage. Additionally, this option comprises a real-time clock that of course keeps running after turning off the supply voltage.

T_Offset [-2048..2047], T_Offset2 [-2048..2047]

The parameters define the offsets for both passive transducers. A deviation to the zero point of the transducer can be compensated by entering the actual converter value (T_ACTx of the unloaded transducers) into this parameter.

6.2 Fieldbus modul 61.02.0045B (Interbus) The fieldbus module 61.02.0045B incorporates following functionalities:

• two additional RS232 Interfaces; one of them RS485 capable

• Interbus-Interface

• Two independant transducer inputs for passive Transducer (350/700 S, 1 mV/V to 4 mV/V)

• 128 kByte battery buffered RAM and real time clock


EDC_en BA 16.03.05.10 40

LED

X14, X13

Connection for two active / passive Transducer, Page 38

COM3, COM2

Serial interface (2), Seite Fehler! Textmarke nicht definiert.

X11, X12

Interbus Connection, page

Interbus (X11/X12) The Interbus-Interface will enable the EDC Compact as a RemoteBus mod-ule on the Interbus. The EDC occupies 4 words (64 Bits) on the bus and is configured as ID=3 (Identification). The bus status is displayed with the means of three LED’s :

LED Bezeichnung Bedeutung CC green Remotebus Check Input connector ok BA green

Bus aktiv Bus is active

RD red

Error Modul Error/ Master not acti-ve

Interbus-Input (X12)

9-pin D-Sub connector ( male )

DO 1+ DI 1+ GND

DO 1-

DI 1-

5V


EDC_en BA 16.03.05.10 41

Interbus-Ausgang (X11)

9-pin D-Sub connector ( female )

DO 2+ DI 2+ GND

5V

DO 2-

DI 2-

RBST

• Pin 5 will feed a signal to Pin 9; as recognition, if more bus modules will follow.

• Pin 5 and Pin 9 not connected = no further Modules;

• Pin 5 und Pin 9 verbunden = further Modules

Meaning of ID-Code The ID-Code of an Interbus-Module will give functional information to the bus master.

Beispiele:

ID-Code Bedeutung ID=3 digital I/O-Modul ID=127 Analog- I/O-Module ID=227 DRIVECOM-Modul with PCP-

Channel

two passive Transducer (X13/X14) Function and pinout same as Fieldbus modul 61.02.0043B

two serial interfaces RS232/RS485 Function and pinout same as Fieldbus modul 61.02.0043B

battery buffered Ram and real time Clock Function same as Fieldbus modul 61.02.0043B


EDC_en BA 16.03.05.10 42

7 General Information Regarding the Wiring

24 V supply voltages The 24 V supply voltages of the connectors for the internal inputs and outputs must only be used for thermal contacts, LEDs, switches, or similar components.

Never connect the 24 V lines of the separate axes.

7.1 General Information The cables, described in this section correspond to the requirements, TOX® PRESSOTECHNIK demands for correct functionality of the cable connec-tions. If cables are exposed to mechanical strain within the machine, for ex-ample in trailing chains or similar, the machine manufacturer must take care for only using appropriate cables. In general, the following points apply for the cables (see also 'Installation Guidance to Meet Compliance With Elec-tromagnetic Compatibility (EMC)', as attached):

• Motor and signal cables must not be wired in the same conduit!

• Motor cables must be shielded. They must be wired separate from signal lines.

• Signal lines must be shielded. Differential signal lines should only be transmitted in twisted pair. They must be wired separate from motor ca-bles.

• The cable shields must be connected to the shell in the connectors. In-side the controls panel they should be connected to an earth ground bus.

• Cable shields, not ending in a connector within the controls panel, such as motor cables, must be connected on the respective bar.

• Both ends of shields are generally to be connected to the shell.

The conductor cross sections should be selected carefully to prevent an ex-ceeding of the maximum admissible current at maximum ambient tempera-ture (the max. ambient temperature of the EDC Compact module is 60°C). DIN 60204-1 defines the admissible values for the separate cross sections, which must absolutely be considered.


EDC_en BA 16.03.05.10 43

The following table shows the current carrying capacity in combination with the conductor cross-section of copper leads, isolated with polyvinyl chloride or cables according to DIN/EN 60204-1 for wiring type B2 and an ambient temperature of +40°C:

Conductor Cross-Section A [mm²]

Admissible Current I [A]

0,75 7,60 1,00 9,60 1,50 12,20 2,50 16,50 4,00 23,00 6,00 29,00

10,00 40,00 16,00 53,00 25,00 67,00 35,00 83,00

The following correction factors are provided for deviating ambient tempera-tures:

Ambient Tempera-ture T [°C]

Correction Factor

30 1,15 35 1,08 40 1,00 45 0,91 50 0,82 55 0,71 60 0,58

7.2 Dangers of Ground Loops Even if all ground points seem to have an identical potential, the potentials in the ground system may result from r.f. capacitances in a particular area of the machine (e.g. r.f. clocked motor lines). The resulting magnetic fields may cause malfunctions in the machine or controller (e.g. initiation of count pulses).

Connection Information The main requirements for an efficient grounding according to DIN/EN 60 204-1 (electrical equipment of machines) are:

Only one PE point The complete system must have only one PE point. All earth connections are connected tree-shaped to the PE point


EDC_en BA 16.03.05.10 44

Connecting example of a machine and the connected CNC with connection to earth according to the EMC guidance

Particular notes: • The PE point usually is the connecting

point of the PE conductor of the volt-age supply or the earth connection of a separate earth arrangement of the complete system.

• If several points within the system are marked with PE, all marks should be provided with the earth character, ex-cept for one.

• Motors must be connected with least impedance to the earth points. Earth connections to the outputs of the servo amplifiers must not be made!

• Motors, mounted on an insulated machine part (e.g. linear motors, handheld nut setting unit, etc.) must be connected to earth with largest surface.

• Earth connections must always be made with largest surface. Earth straps, con-sisting of many thin wires offer a larger surface than only one fixed core with thick cross-section. Earth connectors should be shortest possible.

7.3 Motor Cables Use shielded conductors and shielded D-Sub connectors for the wiring of the different measuring systems. At the side of the EDC COMPACT module the shield must be put with one end to the D-Sub connectors and at the side of the measuring system on its housing.

connect with best conduc-tivity and with largest sur-face to both cabinet sides!

shield connection, e.g. Better-mann mounting clip

shield bar

cable clamp bar shield also from unit side


EDC_en BA 16.03.05.10 45

7.4 Cables for the First Measuring System Use shielded conductors and shielded D-Sub connectors for the wiring of the different measuring systems. At the side of the EDC COMPACT module the shield must be put with one end to the D-Sub connectors and at the side of the measuring system on its housing.

Examples for the usage of conductors: • Motors with resolver

LIYCY 3 × 2 × 0.14 or 4 × 2 × 0.14 for motors with integrated thermal contact. Shielded, paired, twisted conductors. Twist mode: sine/sine, co-sine/cosine, rotor/rotor and, if necessary, thermal contact/thermal contact. We recommend to additionally shield the separate pairs for delicate ap-plications.

7.5 Cables for the 2./3. Measuring System For the connection of the 2./3. measuring system a shielded conductor with a shielded D-Sub Connector must be used, like for example LIYCY 4 × 0.14. At the side of the EDC COMPACT module the shield must be put with one end to the shell of the RJ45 connector and on the housing of the 2./3. measuring sys-tem. We recommend using twisted-pair conductors, possibly with an additional shield of the separate pairs for delicate applications. Twist mode: A+/A–; B+/B–.

INFORMATION As at all fast-clocked devices of the power electronics also the EDC COMPACT module can deliver high-frequency perturbing radiation into the feeding mains and leakage current can occur.

Specific measures in the circuitry of the devices already provide an effective protection against possible interfer-ences (high frequency screening unit). However, due to the integration of the modules into plants with their result-ing physical operating parameters the admissible values according to VDE 0875 can be exceeded. Therefore, the user should take additional steps, if necessary. Interfer-ences can considerably be reduced with specific trans-formers or filter sections and by appropriate wiring.


EDC_en BA 16.03.05.10 46

7.6 Cables for the Connection of the I/O Expansion Modules Use a shielded conductor with shielded D-Sub connector, like for example LIYCY 4 × 2 × 0.14, for the wiring of the I/O Expansion Modules. Put the shield on the D-Sub shell at the side of the EDC COMPACT module. We recommend using paired twisted conductors, possibly with an additional shield of the separate pairs for delicate applications. The cable can be or-dered at TOX® PRESSOTECHNIK.

7.7 Cables for the Terminal Connections Use a shielded conductor with shielded D-Sub connectors, like for example LIYCY 4 × 0.14, for the wiring of the Terminal Connections. Put the shields on the D-Sub connector at the sides of the EDC Compact module and the PC. The cable can be ordered at TOX PRESSOTECHNIK.

7.8 Cables for external ballast resistors The cables for external ballast resistor of REX and +UB must be twisted. If the cable is longer than 20 cm, a shielded cable must be used.

7.9 Wiring of 24 V (internal/external)

Date post:	16-May-2023
Category:	Documents
Upload:	independent
View:	2 times
Download:	0 times

line Q tox

Documents