Operating manual PacDriveTM PS-4 and PD-8 ELAU On the best machines PD_OperaManPS-4_us Article number: 17130094-001 Edition: 08.
Impressum Imprint No part of this documentation and the related software and firmware may be reproduced, rewritten, stored on a retrieval system, transmitted or translated into any other language or computer language without the express written consent of ELAU AG. All possible measures were taken to ensure the that this product documentation is complete and correct.
Contents PD_OperaManPS-4_usIVZ.fm Korrekturausdruck Contents 1 On this manual 1.1 1.2 Introduction ............................................................................................ 5 Symbols, Signs and Forms of Depiction ................................................ 6 2 General Safety Notes 2.1 2.2 2.3 2.4 2.5 2.5.1 2.5.2 2.5.3 2.5.4 Basics .................................................................................................... 7 Depiction of Safety Notes ................
5.9 5.9.1 5.9.2 Order numbers ..................................................................................... 38 PacDrive PS-4 ...................................................................................... 38 Cables .................................................................................................. 39 6 Project definition 6.1 6.2 6.2.1 6.2.2 6.3 Creation of a PacDrive PS-4/PD-8, SCL055 application ...................... 41 PacDrive PS-4 .....................................
Korrekturausdruck 1.1 Introduction 1 On this manual 1.1 Introduction Before using ELAU components for the first time, you should familiarize yourself with this operating manual. In particular, observe the safety notes described in chapter 2. Only persons who meet the criteria for "Selection and Qualification of Staff" (see chapter 2.4) are allowed to work on ELAU components. One copy of this manual has to be available for staff working on the components with access at any time.
1 On this manual 1.2 Symbols, Signs and Forms of Depiction Depiction Meaning First level enumeration sign. – Second level enumeration sign. Action symbol: The text following this symbol includes an instruction for action. Execute the instruction actions in the given order, from top to bottom. 9 Result symbol: The text following this symbol contains the result of an action.
2.1 Basics Korrekturausdruck 2 General Safety Notes This chapter contains general requirements for working safely. Every person using ELAU components or working on ELAU components has to read and observe these general safety notes. If activities involve a residual risk, you will find a clear note in the respective places. The note describes the risk that may occur and preventive measures to avoid that risk. 2.
2 General Safety Notes 2.2 Depiction of Safety Notes The safety notes in this manual are grouped into different risk categories. The table below shows which risk and possible consequences the symbol (pictograph) and the signal words indicate. Pictograph Signal word Definition DANGER! Indicates an immediately dangerous situation that will result in death or very serious injuries if the safety rules are not observed.
2.3 Use as Directed Korrekturausdruck 2.3 Use as Directed The ELAU components are designed for installation in a machine/ plant or for combination with other components to form a machine/ plant. The components may only be used under the installation and operating conditions described in this documentation. You must use the accessories and ancillary parts (components, cables, etc.) mentioned in the documentation. You must not use any foreign objects or components that are not explicitly approved by ELAU.
2 General Safety Notes 2.4 Selection and Qualification of Staff Only qualified staff can recognize the significance of safety notes and implement them accordingly. This manual is aimed in particular at design and application engineers in the fields of mechanical and electrical engineering, at programmers, service and commissioning engineers.
2.5 Residual Risks 2.5.1 Installation and Handling Korrekturausdruck WARNING! PDM_SicherhMax_us_neu.fm Risk of injury while handling the unit! Risk of injury due to squeezing, cutting or hitting! Observe the universally valid construction and safety rules for handling and installation. Use suitable installation and transport facilities and use them professionally. If necessary, use special tools. Take precautions against squeezing. If necessary, use suitable protective clothing (e.g.
2 General Safety Notes Protection against Touching Electrical Parts Touching parts carrying a voltage of 50 Volts or higher can be dangerous. When electric appliances are operated, certain parts of these appliances inevitably carry a dangerous voltage. DANGER! High voltage! Life hazard! Observe the universally valid construction and safety rules for working on high-voltage units.
2.5 Residual Risks "Safely Separated Low Voltages" PELV Protective-ExtraLow-Voltage Signal voltage and control voltage of the PacDrive units are <33 V. In this range the specification as PELV system according to IEC 364-4-41 includes a protective measure against directly and directly touching dangerous voltages by means of a "safe separation" from the primary to the secondary side in the plant/ machine. ELAU urgently recommends to execute the plant/ machine with safe separation. Korrekturausdruck 2.5.
2 General Safety Notes Potentially Dangerous Movements There can be different causes for potentially dangerous movements: mistakes in wiring or cable connection software errors faulty components errors in measuring value and signal encoders operating mistakes The protection of people must be insured by superior means or monitoring on the plant side. You must not rely on the internal monitoring in the drive components alone.
Hard-copy for correction 3.1 Drive Concepts for Packaging Machines 3 System Overview 3.1 Drive Concepts for Packaging Machines Modern machine concepts in the packaging industry are characterized by the need for high dynamism, flexibility, modularity and efficiency. Packaging machines were traditionally equipped with a main drive and a mechanical main shaft, which coupled all other motion organs in the machine usually with mechanical components with complicated motion functions.
PD_SysUebersSCL_us.fm 3 System Overview Fig.
3.2 Structure of the PacDrive™ Automation System 3.2 Structure of the PacDrive™ Automation System Hard-copy for correction The PackDrive™ automation system offers a technically and economically ideal solution for electronic packaging machines. PacDrive™ consists of an efficient PC-based control, the PacDrive Controller and the digital motor controllers, which include the mains connection unit, the end-stage power and the servo regulator of the individual axes(Fig. 3-2).
3 System Overview Structure PD_SysUebersSCL_us.fm 3.3 Fig.
3.4 Components Hard-copy for correction 3.4 Components Automation Toolkit EPAS-4 EPAS-4 has extensive and proven functions and tools. A key advantage of EPAS-4 is that all components are tuned to each other. For you as a user, this means: Libraries Quick familiarization, easy handling, all tools integrated. Extensive libraries, tailored to the target group, help to save costs and improve the quality of user programs.
3 System Overview PacDrive SCL Motor with The compact size of the PacDrive SCL combines motor and power integrated electronics in the smallest space. The innovative SCL has the MotorController motor, the power output level and the digital servo controller for an axis in one casing, which saves space. Thanks to the compact size with integrated controller, it is perfectly suited for distributed installation.
Hard-copy for correction 4.1 Transportation 4 Transportation, Storage, Unpacking 4.1 Transportation Avoid shocks. Check units for transport damage and immediately inform your transport company, if necessary. 4.2 Storage Store the units in a clean, dry place. Storage conditions: 4.3 Air temperature between -25°C and +70°C Temperature fluctuations max. 30 K per hour. Unpacking Check whether the consignment is complete. Check all units for transport damage.
PS-4/10/16/230/00 POWER SUPPLY 13130258 001000.0010 HW: C00000 SW: 00.14.00 W37 Fig. 4-2: Logistic type plate of a PacDrive PS-4 Article name PS-4/10/16/230/00 POWER SUPPLY Input 1: Input 2: 1AC / 3AC 220V - 240V 20A 50/60Hz DC 24V 13A Output 1: DC 325V 10A / 18A Output 2: DC 24V 13A Fig. 4-3: Technical type plate of a PacDrive PS-4 PD-8 type plate sercos out power out SCL055 7 SCL055 8 SCL055 5 SCL055 6 Vor Inbetriebnahme, Installationshinweise in der Bedienungsanleitung beachten.
4.3 Unpacking Type plate PD-8 / PD-4 board version PD-8 POWER DISTRIBUTOR-UNIT 11130166 591078.0030 HW: 200 Y13 Made in Germany Hard-copy for correction logistic type plate PD_Typenschild_PD8_PL_de.FH8 PD_OpManPS-4_04_us.FM Fig.
PD_OpManPS-4_04_us.
5.1 Spare Parts, Hard-copy for correction 5 Maintenance Recognizing and clearing an error quickly helps to keep the related production loss down to a minimum. The diagnosis messages of the PacDrive™ system, which can be checked using the Automation Toolkit EPAS-4, make it possible to look for errors deliberately and effectively. In case of an error, defective components can easily be exchanged. This ensures that the problem can be solved quickly and operation can be resumed soon.
5 Maintenance Repair By all means complete the attached error report form when returning defective components. You can also make a photocopy of the error report form and use it as a fax message. CAUTION! Electro static discharge! Components may be damaged! Return electronic components in original or equivalent packaging only. Always use ESD packaging/foil. 5.3 Service Addresses Hard-copy for correction 5.
5.4 Exchanging units 5.4 Exchanging units Hard-copy for correction In addition to the notes below, please observe the information of the machine producer when exchanging the PacDrive PS-4. DANGER! High voltage! Life hazard! High voltage possible with servo motors in generator operation! Before working on electrical units, disconnect from mains supply and lock out. Make sure that the drives are standing still. Do not disconnect connector plugs while they are carrying voltage.
5 Maintenance Open main switch. Lock out main switch. DANGER! High voltage! Life hazard! Disconnect and connect power supply only when the plant is voltage-free! CAUTION! Hot surfaces on the PS-4 casing! Risk of burns! Wear protective gloves or wait until the surface temperature permits touching without risk! Hard-copy for correction Exchanging the PacDrive PS-4 Disconnect PS-4 from power supply. Open screws on the top and bottom of the casing.
5.5 Cleaning Hard-copy for correction Insert the SERCOS in/out cable in the corresponding cable duct, snap the connector into the outlet and fix the strain relief on the cable duct while the cable is relieved. Insert the SCL connections in the corresponding cable duct, snap the connector into the outlet and fix the strain relief on the cable duct while the cable is relieved. Exchanging cables Open main switch. Lock out main switch.
5 Maintenance EMC Rules To control and regulate motors, the mains voltage is stored in the DC-circuit of the PS-4 by means of rectification. This DC-circuit voltage supplies all connected SCL-055s. In the SCL-055, this stored energy is fed to the motor by deliberately activating and deactivating six semiconductor switches. The steep rise and fall of the voltage puts high demands on the insulation strength of the motor winding.
5.7 Commissioning CAUTION! Hard-copy for correction Electromagnetic fields! Disturbances or failure of the system possible! The rules described below must be observed for installation, in order to rule out the consequences of excessive disturbance effects as far as possible. In correlation with electronic controls, no inductive loads must be switched without suitable interference elimination. For DC operation, suitable interference elimination can be achieved by arranging recovery diodes.
Commissioning procedure: Unpacking and Remove packaging. checking Make sure the units are not damaged. Only undamaged units should be put into operation. Check if the consignment is complete. Check the data with the help of the type plate. See also "Unpacking" on page 21. See also "Exchanging units" on page 27. Setting the Set the intended SERCOS address (0-99) with a suitable tool.
5.7 Commissioning Hard-copy for correction Electrical connections of PS-4 Make connections for X1 and X2 according to the wiring diagram. (Wiring examples: See also "Electrical connections" on page 53.) Connect the prefabricated cable (PS-4/PD-8) with X4. Insert the prefabricated SERCOS cable into X8 and snap it on.
5 Maintenance jumper for termination fuse SERCOS cable cap nut cable duct SERCOS connection (SCL) dummy plug SCL_Ansch_us.fh8 Hard-copy for correction power supply connection Fig. 5-4: Wire the PS-4/ connection cable PS-4/PD-8 and fix the strain relief on the cable duct while the cable is relieved. Insert the prefabricated SERCOS cable into the outlet and snap it on. Fix the strain relief on the cable duct while the cable is relieved.
5.8 Configuration / Hard-copy for correction NOTE The two jumpers must be placed in "closed" position over the SERCOS connector only at the connection of the last PacDrive SCL-055, even if several PD-8s are used. This closes the SERCOS ring. The physical order of the SERCOS slaves is different from the numbers on the PD-8 cable ducts. Check safety functions such as the EMERGENCY OFF switch. Continue the plant according to the operating manual of the packaging commissioning. machine producer.
5 Maintenance C US LISTED i/o ! X1 Instructions see cover side! (INDUSTRIAL CONTROL EQUIPMENT) 72KL reset 24V/in pow err S1 ac-power S2 buserr X2 dc-bus + + X3 - reset reset button control voltage indicator pow err S1 S2 address adjustment SERCOS S1 tens digit S2 units digit buserr X6 S3 SERCOS - bus error indicator sercos X7 SCL-servodrive error indicator X5 diag 230 Volt ! Hard-copy for correction Diagnosis LEDs PS-4 5.8.1 X8 X4 Made in Germany PD_Diagnose_PS-4_LED_us.
5.8 Configuration / Hard-copy for correction The error indicator signals the operating state of the PacDrive PS-4 based on the following states: LED permanent off: no error n f t in sec LED fast flash: general error n f 0 0.26 0.51 1.02 2.05 t in sec 1.02 2.05 t in sec LED slow flash: SERCOS error n f 0 LED permanent on: fatal system error n f Diagnose LED PS4 us fh8 t in sec Fig.
5 Maintenance There is no HardwareEnable input on the SCL. However, the input HardwareEnable, the signal PowerSupplyEnable and error messages of the PS-4 have to lead to reactions in the SCL. Therefore the following signals are sent from the PacDrive PS-4 to the MAx-4: PS-4 is active Class 1 error message from PS-4 Error message with error reaction A from PS-4.
5.9 Order numbers PacDrive PD-8 Hard-copy for correction Order number Article name Explanations 13 13 02 59 - 001 PacDrive PD-8 Plastic (standard) 13 13 02 59 - 002 PacDrive PD-8 Stainless steel 11 13 01 66 PD-8 unit Curcuit board version 11 13 01 67 PD-4 power distributor Curcuit board version Table 5-2: Order numbers for PacDrive PD-8 / PD-4 5.9.2 Cables Connection cables Order number Article name Explanations 15 15 45 02 - XXX E-MO 102 Connection cable PS-4/PD-8 max.
PD_OpManPS-4_05_us.
Hard-copy for correction 6.1 Creation of a PacDrive PS-4/PD-8, SCL055 application 6 Project definition 6.1 Creation of a PacDrive PS-4/PD-8, SCL055 application In addition to their use in normal industrial environments, the units PacDrive PD-8 and PacDrive SCL-055 are also designed for aseptic applications. Aseptic applications have special requirements regarding the surface quality of devices and cables.
6 Project definition If the mains voltage is outside the range indicated in the technical data, a transformer is required to adjust it to the power intake of the plant. In star point grounded networks, the voltage is adjusted by means of an autotransformer. In all other networks, a separating transformer is required.
3 phase power connection with autotransformer (e.g. 3AC 400V) PS-4 Front L1 L2 L3 PE X2 Q1 4 1 23 9 23 1 3 S1 S2 9 2 0 5 1 456 4 +24V 0V PE L1 L2 L3 78 3 0 2 78 1 3~ 24V= 456 X5 5 6 K1 1 phase power connection with (UNetz ¹ 230 V) 3 K1 Q2 3 4 23 1 S1 S2 23 0 5 6 2 456 4 1 9 24V= X2 +24V 0V PE L1 L2 L3 0 2 1 1 9 Q1 ~ PS-4 Front 78 L N PE 78 Q2 456 Hard-copy for correction 6.2 PacDrive PS-4 X5 5 6 PD_Inb_Schalt_1.fh8 Fig.
6 Project definition Transformer dimensioning The following formula can be used for the power of the DC-circuit: 2⋅π P ZK = M eff ⋅ n Mittel ⋅ ---------- ⋅ k ⋅ a ⋅ g 60 PDC = DC-circuit power in W MEFF = effective torque in Nm naverage = average torque in min-1 k = factor for motor and controller efficiency = 1.25 a = number of PacDrive SCL’s g = percentage of PacDrive SCL’s simultaneously in control (min 0.2 ...1) The transformer connection power is calculated as follows: Hard-copy for correction 6.2.
6.2 PacDrive PS-4 Hard-copy for correction In addition, you can use the tool ECAM-4 version V2.3 or higher for the calculation. This makes it possible to take almost any possible combination into account. Selection table for autotransformers by Block (third-party products) Type DSP 400/1,5 DSP 400/3 Output current 3 x 1.
6 Project definition Electricity Supply via Slip Ring For applications where the PacDrive PD-8 and PacDrive SCL-055 are installed on a turning machine rack (rotary), it is possible to use a slip ring to supply electricity to the components on the rotary rack. The following connection proposal shows the connection plan for the power cable and data cable.
Hard-copy for correction 7.1 PacDrive PS-4 7 Technical Data 7.1 PacDrive PS-4 7.1.1 General PacDrive PS-4/10/16/230 Parameter Article name PS-4 / 10 / 16 / 230 Order number 13 13 02 58 Supply - rated connected voltage - mains frequency - control voltage/current rotary current 3 AC / 1 AC 220V (-10%) to 240V (+10%) 48 .. 62 Hz DC 24 V (-15%..+25%) / max 13 A own consumption max.
7 Technical Data In case of ambient temperatures >45 °C, ensure additional circulation of the cooling air in the switching cabinet (external fan). C US LISTED X1 Instructions see cover side! (INDUSTRIAL CONTROL EQUIPMENT) 72KL ! i/o control signals X1 PS-4 Electrical connections PacDrive 7.1.
7.1 PacDrive PS-4 Hard-copy for correction X1 - Control signals 1 5 Pin Designation 4 8 Meaning Hardware enable Range DC24V (pursuant to IEC61131-2 type I) max. cross section 1.5 mm2 1 HW enable 2 0V 3 DC dis 4 0V 5 *) RDY + Ready contact (opens DC 20...30 V / 2 A in case of an error) 1.5 mm2 6 *) RDY - Ready contact 1.5 mm2 7 NC not connected 1.5 mm2 8 NC not connected 1.5 mm2 1.5 mm2 DC-circuit discharge DC24V (pursuant to IEC61131-2 type I) 1.5 mm2 1.5 mm2 DC 20...
7 Technical Data DC+ DC+ DCDC- Pin Designation Meaning Range max. cross section 1 DC+ DC-circuit + DC 270..370 V 4 mm2 2 DC + DC-circuit + DC 270..370 V 4 mm2 3 DC - DC-circuit - DC 270..370 V 4 mm2 4 DC - DC-circuit - DC 270..
7.1 PacDrive PS-4 X8 - SERCOS Hard-copy for correction 1 8 Pin Designatio n 1 SEROUT+ SERCOS Out + 2 SEROUT- SERCOS Out - 3 SERIN+ SERCOS In + 4 NC not connected 5 NC not connected 6 SERIN- SERCOS In - 7 NC not connected 8 NC not connected Meaning max. cross section Range Table 7-7: Connection X8 - SERCOS connection 7.1.
7.2 PacDrive PD-8 7.2.1 General Parameter Value Article name PacDrive PD-8 Order number 13 13 02 59 - 001/002 Supply - DC-circuit voltage/current - control voltage/current DC 270V..370V / 16 A DC 24 V (-15%..+25%) / max 13 A Power supply SCL DC-circuit permanent current 5A Control voltage SCL - permanent current (24V) 1A Weight 0.
7.2 PacDrive PD-8 Electrical connections Hard-copy for correction 7.2.2 control voltage IN control voltage OUT SERCOS connection IN SERCOS connection OUT SERCOS-/control voltage SCL label field terminator SCL SERCOS IN SCL 1 SCL 2 SCL 3 SCL 4 SCL 5 SCL 6 SCL 7 SCL 8 0V 24V POWER IN SERCOS OUT 24V 0V POWER IN DCDC+ PE DCDC+ PE power supply connection SCL power supply connection IN power supply connection OUT shield connection IN shield connection OUT PD-8_Ansicht_de_0308.fh8 Fig.
7 Technical Data 4 3 2 1 Pin Designation Meaning max. cross section Range 1 PE protective conductor 1 mm² 2 PE shield 1 mm² 3 DC- DC-circuit - DC 270V-370V 1 mm² 4 DC+ DC-circuit + DC 270V-370V 1 mm² Table 7-12: Connection - power supply SCL SERCOS Connection SCL 8 5 4 1 Pin Designation Meaning max. cross section Range 1 24 V 2 SERCOS Out + SERCOS Transmit + 24V control voltage -15%..+25% 0.5 mm² 0.5 mm² 3 shield shield SERCOS Out 0.
174 190 196 190 298 238 87,8 116 106 Hard-copy for correction 7.2 PacDrive PD-8 PD-8_AS_Massblatt.FH8 Fig. 7-5: Dimensions of the PacDrive PD-8 (aseptic version) 226 130 230 110 12 31 76 67,5 87,5 14 10 PD_OpManPS-4_07_us.fm 23,5 12 41,5 198,5 228 240 PD-8_PL_Massblatt.FH8 Fig.
7 Technical Data 167,5 Hard-copy for correction 163,75 123 41 79,5 20,5 31 87,5 3,75 23,5 PD-4_PL_Massblatt.FH8 PD_OpManPS-4_07_us.fm Fig.
7.3 Declaration by the manufacturer Korrekturausdruck 7.3 Declaration by the manufacturer Herstellererklärung / EC-Declaration by the manufacturer / CE-Déclaration du fabricant ELN 122-00/08.
Appendix 7.4 Modifications 08 / 2003 Operating manual newly written 04 / 2005 Aseptic variant, PD-8 connectors and cables updated Various error Corrections and supplements Document structure updated Product names, definitions and layout updated NOTE PD_OpManPS-4Aen_us.FM The latest documentation of the modification service for this product can be found on ELAU's homepage (http://www.elau.de).
Korrekturausdruck 8.1 Contact 8 Appendix 8.1 Contact For repair Please send the components to be repaired or checked, along with the error report, to this address: ELAU AG Abt.
8 Appendix 8.2 Further Literature ELAU can provide you with these manuals and instructions on the PacDrive™ System:1 Korrekturausdruck Project Manual Art.No. 17 13 00 58 - 00x (DE, EN, FR) Programming Manual Art.No. 17 13 00 61 - 00x (DE, EN) Operating Manual MC-4 MotorController Art.No. 17 13 00 62 - 00x (DE, EN, IT, FR) Operating Manual CAN L2 Art.No. 17 13 00 66 - 00x (DE, EN) Operating Manual PROFIBUS-DP Art.No. 17 13 00 67 - 00x (DE, EN) Operating Manual SM Motor Art.No.
8.2 Further Literature Operating Manual BusTerminal BT-4/DIO1 Art.No. 17 13 00 83 - 00x (DE, EN) Operating Manual TTS Korrekturausdruck Art.No. 17 13 00 88 - 00x (DE) User Manual Automatic Controller Optimization Art.No. 17 13 00 89 - 00x (DE, EN) Operating Manual PacDrive SCL Art.No. 17 13 00 93 - 00x (DE, EN) Operating Manual PacDrive PS-4 und PacDrive PD-8 Art.No. 17 13 00 94 - 00x (DE, EN) Operating Manual Evaluation Kit Art.No.
8 Appendix 8.3 Product Training Our experienced seminar leaders will enable you to make optimum use of the vast possibilities of the PacDrive™ system. NOTE PDM_AnhangStd_us.FM Please contact us for further information or to order our seminar program. See also our homepage (www.elau.de). Korrekturausdruck We offer practical workshops and seminars.
Index 8.
Index Korrekturausdruck trademarks 2 training 62 Transportation 21 Type plate 21, 22 PD_OperaManPS-4_usSIX.
8.5 Form for Error Report 8.5 Form for Error Report This error report is absoluteley necessary in order to enable efficient processing. Korrekturausdruck Send the error report to your ELAU representative or to: ELAU AG, Abt. Kundendienst Dillberg 12, D-97828 Marktheidenfeld Fax: +49 (0) 93 91 / 606 - 340 Sender: Company: City: Date: Department: Name: Phone: Details on the defective product Product name: ..................................................................................
8.5 Form for Error Report Description of the problem: .......................................................................................................... ..........................................................................................................
