ProjectingNotes US

Projecting
(Translation of the original German Operating Manual)
PacDrive
Projecting Notes
PacDrive System
07.2013
Imprint
The information provided in this documentation contains general descriptions and/or

technical characteristics of the performance of the products contained herein. This
documentation is not intended as a substitute for and is not to be used for determining
suitability or reliability of these products for specific user applications. It is the duty of
any such user or integrator to perform the appropriate and complete risk analysis,
evaluation and testing of the products with respect to the relevant specific application
or use thereof. Neither Schneider Electric nor any of its affiliated or subsidiary com
panies are responsible or liable for a misuse of the information contained herein. If you
have any suggestions for improvements or amendments or have found errors in this
publication, please notify us.
No part of this document may be reproduced in any form or by any means, electronic
or mechanical, including photocopying, without express written permission of Schneid
er Electric.
All pertinent state, regional, and local safety regulations must be observed when in
stalling and using this product. For reasons of safety and to help ensure compliance
with documented system data, only the manufacturer should perform repairs to com
ponents.
When devices are used for applications with technical safety requirements, the rele
vant instructions must be followed.
Failure to use Schneider Electric software or approved software with our hardware
products may result in injury, harm, or improper operating results.
Failure to observe this information can result in injury or equipment damage.
2013 Schneider Electric. All rights reserved.
PacDrive Projecting Notes
Schneider Electric
Contents
Contents
About this manual
1.1
Introduction ............................................................................................................... 5
1.2
Symbols, designator and display format of safety messages .................................. 5
Safety information
2.1
Proper use ................................................................................................................ 7
2.2
Qualification of Personnel ........................................................................................ 8
2.3
Residual risks ........................................................................................................... 8
Control cabinet planning
3.1
Degree of protection ............................................................................................... 12
3.2
Mechanical and climatic environmental conditions in the control cabinet .............. 12
3.3
ESD protection measures ...................................................................................... 12
3.4
3.4.1
3.4.2
3.4.3
3.4.4
3.5
Control cabinet installation of Schneider Electric components ...............................

Heat dissipation PacDrive MC-4 servo amplifier ....................................................
Installing the control cabinet PacDrive MC-4 servo amplifier .................................
Control cabinet installation PacDrive PS-4 Power Supply .....................................
Control cabinet installation PacDrive PS-5 Power Supply .....................................
Using Cooling Units ................................................................................................
Wiring notes
4.1
Bending radii, tightening torques and wire cross sections ..................................... 19
4.2
Electromagnetic compatibility, EMC ....................................................................... 24
4.3
4.3.1
4.3.2
4.3.3
4.3.4
4.3.5
4.3.6
4.3.7
4.4
4.4.1
4.4.2
4.5
Mains connection PacDrive MC-4 servo amplifier ..................................................

Integrated monitoring in the MC-4 ..........................................................................
Servo amplifiers on critical power supplies ............................................................
Switch-on procedure ..............................................................................................
Protective earth ground concept of the mains power supply ..................................
Matching the mains voltage ....................................................................................
Fusing the mains connection ..................................................................................
Residual current operated protective device ..........................................................
Mains connection PacDrive PS-5 power supply .....................................................
Protective earth ground concept of the mains power supply ..................................
Wiring notes ...........................................................................................................
PacDrive Controllers and MC-4 Control Voltage Connection .................................
4.6
DC circuit ................................................................................................................ 37
Schneider Electric
12
13
14
15
16
17
18
19
27
27
28
31
31
31
32
33
34
34
34
37
Contents
Basic Design and Connection
5.1
Load circuit ............................................................................................................. 39
5.2
Control circuit ......................................................................................................... 40
Functional safety - safety connections
6.1
Process minimizing risks associated with the machine .......................................... 42
6.2
6.2.1
6.2.2
6.2.3
6.2.4
6.2.5
6.2.6
6.2.7
6.2.8
6.3
6.3.1
6.3.2
6.3.3
6.4
6.4.1
6.4.2
6.4.3
6.4.4
6.4.5
6.4.6
6.4.7
6.4.8
Circuit suggestion for PacDrive system with MC-4 ................................................

InverterEnable function ..........................................................................................
Setup, installation, and mounting ...........................................................................
Application proposal ...............................................................................................
Commissioning .......................................................................................................
Prevention of reasonably foreseeable misuse .......................................................
Maintenance ...........................................................................................................
Physical environment .............................................................................................
Safety standards ....................................................................................................
Extended safety functions for PacDrive MC-4 with SMX Safe PLC .......................
Functional Description ............................................................................................
Circuit suggestion ...................................................................................................
Validation example of the SMX12 safety functions ...............................................
Circuit suggestion: PacDrive system with DB-5 and iSH .......................................
InverterEnable function ..........................................................................................
Setup, installation, and mounting ...........................................................................
Application proposals .............................................................................................
Commissioning .......................................................................................................
Prevention of reasonably foreseeable misuse .......................................................
Maintenance ...........................................................................................................
Physical environment .............................................................................................
Safety standards ....................................................................................................
Special Conditions
7.1
Increased ambient temperature ............................................................................. 95
7.2
Low air pressure ..................................................................................................... 96
7.3
Long cable .............................................................................................................. 97
39
42
43
43
47
48
55
55
56
56
57
58
59
61
72
74
74
80
82
92
92
93
93
94
95
Schneider Electric
1.1 Introduction
About this manual
1.1
Introduction
Read and understand the material contained in this manual before you work on the
component for the first time. Take particular note of the safety information (see 2.3
Residual risks). As described in section 2.2, only those persons who meet the "Se
lection and qualification of employees" are allowed to work on the component.
A copy of this manual must be available for personnel who work on the component.
This manual is supposed to help you use the capabilities of the component safely and
properly.
Follow the instructions within this manual to:
1.2
avoid risks
reduce repair costs and downtime of the component
increase the service life of of the component,
increase reliability of the component.
Symbols, designator and display format of safety messages

Important Information
NOTE The following special messages may appear throughout this documentation or on the
equipment to warn of potential hazards or to call attention to information that clarifies

or simplifies a procedure.
The addition of this symbol to a Danger or Warning safety label indicates that an electrical
hazard exists, which will result in personal injury if the instructions are not followed.
This is the safety alert symbol. It is used to warn the user of potential personal injury
hazards. Obey all safety messages that follow this symbol to avoid possible injury or
death.
DANGER
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death
or serious injury.
WARNING
WARNING indicates a potentially hazardous situation which, if not avoided, can result in death
or serious injury.
CAUTION
CAUTION indicates a potentially hazardous situation which, if not avoided, can result in minor
or moderate injury.
Schneider Electric
1 About this manual
NOTICE
NOTICE, used without the safety alert symbol, indicates a potentially hazardous situation
which, if not avoided, can result in equipment damage.
The following symbols and designators are used in this document:

Meaning
Symbol/Character
Information Symbol: After this symbol, you will find important information
and useful tips on using the components.
Marker: After this symbol, you will find references for further information.
Prerequisite symbol: This symbol indicates a prerequisite you have to
fulfill before you start to implement an instruction.
Problem symbol: This symbol is followed by a description of the problem
and an instruction how to solve the problem.
Activity symbol: After this symbol, you will find an instruction. Follow the
instructions in sequence from top to bottom.
Result symbol: The text after this symbol contains the result of an action.
(1), (2), (3)
Image numbers in the text always refer to the image numbers in the
referenced figure.
Orientation aid: Information serving as an orientation aid regarding the
section's contents follows this symbol.
bold
lBuffSelect
If the descriptive text contains keywords, such as parameters, they are

highlighted in bold.
Program code is written using a different font.
Schneider Electric
2.1 Proper use
Safety information
This section contains information regarding working with of the component. Qualified
personnel working on the component must read and observe this information. The
component is conform to recognized technical safety regulations.
2.1
Proper use
Provide for Before installing the device, provide for appropriate protective devices in compliance
protective with local and national standards. Do not commission components without suitable
measures protective devices. After installation, commissioning, or repair, test the protective de
vices used.
Perform a risk evaluation concerning the specific use before operating the product and
take appropriate security measures.
If circumstances occur that affect the safety or cause changes to the operating be
havior of the of the component, then immediately shut down the the component and
contact your Schneider Electric contact person.
Use original- Use only the accessories and mounting parts specified in the documentation and no
equipment third-party devices or components that have not been expressly approved by Schneid
only er Electric. Do not change the component inappropriately.
The components must not be used in the following environments:

Forbidden
environments
In hazardous (explosive) atmospheres

In mobile, movable or floating systems
In life support systems
In domestic appliances
underground
Installation Only use the components in accordance with the installation and operating conditions
and operating described in this documentation. The operating conditions at the installation location
conditions must be inspected and maintained in accordance with the required technical data
(performance data and ambient conditions). Commissioning is prohibited until the

usable machine or system in which the component is installed meets all requirements
of EC guidelines 2006/42/EC (machinery directive).
In addition, the following standards, directives and regulations are to be observed:
Schneider Electric
EN ISO 13849-1 Safety of machinery - Safety-related parts of control systems Part 1: General principles for design
EN 60204-1 Safety of machinery - Electrical equipment of machines - Part 1: Gen
eral requirements
EN ISO 12100-1 - Safety of machines - Basic terms, general principles for design
- Part 1: Basic terminology, methodology
EN ISO 12100-2 - Safety of machines - Basic terms, general principles of design
- Part 2: Technical guidelines
EN 50178 - Electronic equipment for use in power installations
EN 61800-3 Adjustable speed electrical power drive systems - Part 3: EMC re

quirements and specific test methods
EN 61800-5-1:2007 Adjustable speed electrical power drive systems - Part 5-1:

Safety requirements - Electrical, thermal and energy
2 Safety information
2.2
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.
Qualification of Personnel
Target audi Electrical equipment must be installed, operated, serviced, and maintained only by
ence qualified personnel. No responsibility is assumed by Schneider Electric for any con
for this manual sequences arising out of the use of this material.
Qualified per A qualified person is one who has skills and knowledge related to the construction and
son operation of electrical equipment and the installation, and has received safety training
to recognize and avoid the hazards involved.
The qualified personnel must be able to detect possible hazards that may arise from
parameterization, changing parameter values and generally from mechanical, electri
cal or electronic equipment. The qualified personnel must be familiar with the stand
ards, provisions and regulations for the prevention of industrial accidents, which they
must observe when working on the drive system.
Inverter Enable Qualified personnel that work with the Inverter Enable function must be trained ac
function cording to the complexity of the machines and the requirements of the EN ISO
13849-1:2008. The training must include the production process and the relation be
tween Inverter Enable function and machine.
Qualification guidelines are available in the following publication: Safety, Competency
and Commitment: Competency Guidelines for Safety-Related System Practitioners.
IEEE Publications, ISBN 0 85296 787 X, 1999.
2.3
Residual risks
Health risks arising from of the component have been reduced. However a residual
risk remains, since the component works with electrical voltage and electrical currents.
If activities involve residual risks, a safety message is made at the appropriate points.
This includes potential hazard(s) that may arise, their possible consequences, and
describes preventive measures to avoid the hazard(s). The following types of warnings
concerning residual risks which cannot be assigned to a specific handling. The struc
ture of a warning instruction is identical to that of a safety label.
Schneider Electric
2.3 Residual risks
Assembly and handling
WARNING
CRUSHING, SHEARING, CUTTING AND HITTING DURING HANDLING
Observe the general construction and safety regulations for handling and as
sembly.
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.
Failure to follow these instructions can result in death or serious injury.
Hanging loads
WARNING
HAZARD FROM HANGING LOADS
Do not stand under hanging loads.
High leakage current
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
Connect devices with leakage current greater than 3.5 mA AC via a fixed con
nection with the power supply network.
In addition, implement one of the measures according to EN 50178:1997, Section
5.3.2.1.
Failure to follow these instructions will result in death or serious injury.
Touching hot surfaces

As warning against housing temperatures of the motor exceeding 70C (158F) during
nominal operation, the symbol shown here is affixed on the motor.
CAUTION
HOT SURFACES OVER 70C (158F)
Wait until the surface temperature has cooled to allow safe contact.
Wear protective gloves.
Attach protective cover or touch guard
Failure to follow these instructions can result in injury.
Schneider Electric
2 Safety information
Touching electrical parts
WARNING
RISK GROUPS IN THE IMMEDIATE VICINITY OF MAGNETIC AND ELECTRO
MAGNETIC FIELDS
Do not allow personnel with pacemakers or similar sensitive implants to work in

the immediate vicinity of live conductors and motor permanent magnets.
Hazardous movements
There can be different causes of hazardous movements:
Missing or incorrect homing of the drive

Wiring or cabling errors
Errors in the application program
Potential component errors
Potential error in the measured value and signal transmitter
Operation error
Protective devices breakdown
Provide for personal safety by primary equipment monitoring or measures. Do not rely
only on the internal monitoring of the drive components. Adapt the monitoring or other
arrangements and measures to the specific conditions of the installation in accordance
with a risk and error analysis carried out by the system manufacturer. For this purpose,
consider the valid safety regulations for the equipment.
DANGER
MISSING PROTECTIVE DEVICE OR INCORRECT PROTECTION
Prevent entry to a hazard area, for example with protective fencing, mesh guards,
protective coverings, or light barriers.
Dimension the protective devices properly and do not remove them.
Do not carry out any changes that can invalidate the protection device.
Before accessing the drives or entering the hazard area, safely bring the drives
to a stop.
Protect existing work stations and operating terminals against unauthorized op
eration.
Position EMERGENCY STOP switches so that they are easily accessible and
can be quickly reached.
Check the functionality of EMERGENCY STOP equipment before start-up and
during maintenance periods.
Prevent unintentional start-up by disconnecting the power connection of the drive
using the EMERGENCY STOP circuit or using an appropriate lock-out tag-out
sequence.
Check the system and installation before the initial start-up for possible glitches
in all general purposes.
Avoid operating high-frequency, remote control, and radio devices close to the
system electronics and their feed lines.
If necessary, perform a special EMC check of the system.
10
Schneider Electric
2.3 Residual risks
PELV circuits
The signal voltage and the control voltage of the devices are <30Vdc and have to be
carried out as PELV circuits. In this range the specification as PELV system, according
to EN 61800-5-1:2007 contains a protective measure against direct and indirect con
tact with dangerous voltage through a implemented safe separation in the system/
machine of the primary and the secondary side. We recommend to design the system/
machine with a safe separation (PELV Protective-Extra-Low-Voltage).
DANGER
HAZARD OF ELECTRIC SHOCK BY INADEQUATE PROTECTIVE SEPARATION
Only connect devices, electrical components or lines to the signal voltage con
nectors of these components that feature a sufficient, protective separation from
the connected circuits in accordance with the standards (EN 50178: 1999 - Elec
tronic equipment for use in power installations - Section 5.2.14.2).
Achieve a safe separation in the entire process of the electric circuit.

To protect from direct contact, always cover connections and contacts which guide
FELV (Functional Extra Low Voltage) voltages.
Avoid using FELV current circuits for safety reasons.
Design the cover or device connection so that it can only be removed by using a
tool.
The protection measures have to be followed on all connected devices.
Examples for connections and contacts of a PacDrive controller to be covered:
Schneider Electric
Sub-D connector
Serial interface
CAN-Bus interface
11
3 Control cabinet planning
Control cabinet planning
3.1
Degree of protection
Install components such that a degree of protection corresponding to the actual

operational environment is set up.
Further information on this can be found in the operating manual of the component.
The following ambient conditions may damage the components:
3.2
Oil
Moisture
Electromagnetic interference
Ambient temperature
Metal dust deposits
Mechanical and climatic environmental conditions in the control

cabinet
Observe the climatic and mechanical ambient conditions.

Further information on the general climatic and mechanical environmental condi
tions according to the EN 60721 Classification of environmental conditions Part
3: Classifications of environmental influence variables and their limits, main sec
tion 1-3 can be found in the operating manual of the components.
3.3
Check the technical data of the device as to whether the permitted deviations (e.g.
higher shock load or higher temperature) are specified.
ESD protection measures
Observe the following instructions for ESD protection in order to avoid any damage
due to electrostatic discharge:
NOTICE
ELECTROSTATIC DISCHARGE
Do not touch any of the electrical connections.

Prevent electrostatic charges; e.g., by wearing appropriate clothing.
Remove existing static charge by touching a grounded, metallic surface, like
for example, a grounded housing.
Failure to follow these instructions can result in equipment damage.
12
Schneider Electric
3.4 Control cabinet installation of Schneider Electric components
3.4
Control cabinet installation of Schneider Electric components

Observe the following points during mounting and control cabinet planning:
DANGER
ELECTRIC SHOCK, FIRE OR EXPLOSION
Observe the general construction and safety regulations for working on highcurrent electrical systems.
Operate electrical components only with a connected protective conductor.
After the installation, verify the fixed connection of the protective conductor
to all electrical devices to ensure that connection complies with the connec
tion diagram.
Make certain that the drives are at a standstill because potentially fatal volt
age can occur on the motor lines in generator operation.
Before enabling the device, safely cover the live components to prevent
contact.
Do not touch the electrical connection points of the components when the
unit is switched on.
Provide protection against indirect contact (DIN EN 50178, Section 5.3.2).
Disconnect/plug in power connector cables only when the system is deacti
vated.
Schneider Electric
Mount devices horizontally in the 35 mm grid with M6 hexagon socket head cap
screws (Allen screws).
Keep a distance of at least 100 mm above and below the devices (see Fig. "Me
chanical installation").
Do not lay any cables/cable channels over the PacDrive servo amplifiers or brak
ing resistor modules.
Avoid "hot spots" in the control cabinet; install additional fan if necessary.
Do not block the fan air inlet.
13
cooling
aggregate
air inlet
switching cabinet
fan
hot
air flow
Air
duct
mains filter
C200..P600 / MC-4
BM-4
wiring level
cable duct
cold
Schaltschrank_englisch_0798.fh8
Figure 3-1: Sample enclosure layout with ventilation
When connecting devices in parallel in the control cabinet, as seen from the mains
feed, the most powerful device should be connected first, followed by the smaller
units. By doing this, the load on the DC circuit connections and the mains con
nection is reduced.
3.4.1
Heat dissipation PacDrive MC-4 servo amplifier
Control
cabinet
rear wall as ac
tive cooling ele
ment
The design of the MC-4 servo amplifier allows for a large part of the heat that is gen
erated to be lead to the surroundings through the control cabinet rear wall. Under
certain circumstances, this may mean that the use of a cooling unit is unnecessary.
For this, the rear wall must be designed as a cooling element, and the MC-4 servo
amplifier must be bolted on to the rear wall in a thermally conductive manner (thermally
conductive paste).
No thermal con If heat dissipation via the rear wall is not desired (e.g. when using a sub plate), screw
tact with the the MC-4 servo amplifier to the rear wall using spacers.
rear wall
14
Schneider Electric
3.4.2
Installing the control cabinet PacDrive MC-4 servo amplifier

1
35
35
35
35
35
35
Made in Germany
battery
77
reset
com1
rs232
com2
rs485
eth
pacnet
pacnet
20
TM
profibus dp
15
X5
13
14
tp/fast
12
profibus dp
max.
torque
0,5Nm
X4
Made in Germany
X8
19
X11
analog in/out
X4
X4
X5
can
diag
feedback
ac-motor
X7
X3
can
phys enc
dc-bus
S3
X3
12
24V/wd/tp in
com2 rs485
eth
digital in
X3
X18
10
X6
C200
X17
PacDrive
X2
S2
X5
cf - card
battery
24V/wd
X1
buserr
X2
X12
enter
Made in Germany
ac-power
296
310
S1
wd
err
bus
err
enter
com1 rs232
reset
pow
err
X1
pow
wd
err
bus
err
digital out
Instructions see cover side!
24V/i
24V/o
X21 cf-card
US
LISTED
(INDUSTRIAL
CONTROL
EQUIPMENT)
72KL
6,5
pow
X21 cf-card
C600
AU
PacDrive
MC-4
35
10
6,5
MC-4
100
75
68
AU
MAx-4
MC-4
100
270
230
~ 260
Figure 3-2: Installing the control cabinet PacDrive MC-4 servo amplifier
1
Distance between fixing holes on the PacDrive MC-4, horizontal
Distance between fixing holes on PacDrive MC-4, vertical
Mounting hole on PacDrive MC-4, top
Mounting hole on PacDrive MC-4, bottom
Install all the other devices in the 35mm raster.
Schneider Electric
15
3.4.3
Control cabinet installation PacDrive PS-4 Power Supply

1
35
35
35
35
35
35
35
3
4
X21 cf-card
battery
X21 cf-card
C600
pow
wd
err
bus
err
enter
24V/wd
PacDrive
35
13
eth
77
X18
10
5
can
phys enc
X3
6,5
296
com1 rs232
X17
com2 rs485
digital out
X2
digital in
296
X1
19
pacnet
tp/fast
X11
12
15
profibus dp
13
14
20
100
~ 270
100
75
X5
Made in Germany
analog in/out
X4
~ 210
~ 230
Figure 3-3: Control cabinet installation PacDrive PS-4 Power Supply
16
Distance between fixing holes on PacDrive PS-4, horizontal
Distance between fixing holes on PacDrive PS-4, vertical
Distance between fixing holes on PacDrive Controller
Mounting hole on PacDrive PS-4, top
Mounting hole on PacDrive PS-4, bottom
Schneider Electric
3.4.4
Control cabinet installation PacDrive PS-5 Power Supply

1
35
35
35
35
35
35
35
reset
pow
err
X1
X21 cf-card
battery
X21 cf-card
C600
4
13
7
enter
S1
X2
X17
com2 rs485
eth
10
can
phys enc
X5
pacnet
12
13
14
15
profibus dp
~
~
X8
X4
Made in Germany
ie
X7
X3
19
X11
tp/fast
X6
analog in/out
X5
slnk
serr
X18
10
X3
sercos
instructions see covber side!
iSH - servodrive
X2
ie/rdy
bleeder
X4
digital in
S3
X1
296
bus
err
com1 rs232
ac-power
x01
digital out
x10
S2
292,2
pow
wd
err
bus
err
78
24V in
24V/wd
PacDrive
PS-5
PacDrive
35
20
100
~ 270
100
75
10
TM
225
~ 250
Figure 3-4: Control cabinet installation PacDrive PS-5 Power Supply

1
Distance between fixing holes on the PacDrive PS-5, horizontal
Distance between fixing holes on the PacDrive PS-5, vertical
Distance between fixing holes on PacDrive Controller
Mounting hole on PacDrive PS-5, top
Mounting hole on PacDrive PS-5, bottom
Schneider Electric
17
3.5
Using Cooling Units

How to proceed when installing a cooling unit:
NOTICE
WATER DAMAGE RESULTING FROM CONDENSATE/CONDENSATION
Ensure proper installation of cooling unit.
Position the cooling units so that no condensate drips out of the cooling unit onto
electronic components or is sprayed by the cooling air flow.
Provide specially designed control cabinets for cooling units on the top of the
control cabinet.
Design the control cabinet so that the cooling unit fan cannot spray any accumu
lated condensate onto the electronic components when it restarts after a pause.
When using cooling units, use only well-sealed control cabinets so that warm,
humid outside air, which causes condensation, does not enter the cabinet.
When operating control cabinets with open doors during commissioning or main
tenance, ensure that the electronic components are at no time cooler than the air
in the control cabinet after the doors are shut, in order to prevent any condensa
tion.
Continue to operate the cooling unit even when the system is switched off, so that
the temperature of the air in the control cabinet and the air in the electronic com
ponents remains the same.
Set cooling unit to a fixed temperature of 40 C / 104 F.
For cooling units with temperature monitoring, set the temperature limit to
40 C / 104 F so that the internal temperature of the control cabinet does not
fall below the external air temperature.
Figure 3-5: Installing a cooling unit
18
Schneider Electric
4.1 Bending radii, tightening torques and wire cross sections
Wiring notes
4.1
Bending radii, tightening torques and wire cross sections

Observe the following critical points when wiring:
1. Observe the minimum cross-sections of the cables.
2. Comply with branch conditions.
3. Check shields.
4. Ensure proper ground.
5. Ensure connection of the motors to the machine ground.
6. Prevent any ground loops.
7. Do not pull plug-in terminals when under load.
8. Use a large shielding area.
9. Do not interchange motor phases.
10. Do not interchange encoder connections.
11. Do not interchange the EMERGENCY STOP circuits. This has to be observed
especially when two different safety circuits are used for axis A and axis B of the
DoubleDrive.
Example:
If, for example, two parallel conductors are shown as coming from one point, you may
not run just one conductor and then branch it off at a later point. If it is wired this way,
induction loops (interference senders and antennas) as well as interfering potential
shifts may occur.
Schneider Electric
19
4 Wiring notes
NOTICE
INCORRECT USE OF COPPER AND HYBRID CABLES
Only use the original, prefabricated Schneider Electric cables.

For "permanently flexible" copper and hybrid cables observe the guidelines for
drag chains .
Observe the following restrictions when using Schneider Electric copper- (motor
cables, feedback cables and hybrid cables) as well as optical fiber cables.
Observe the minimum bending radius for wired cable.
Check the wiring once again before turning on.
Non-observance of these instructions can result in damage to the device.
Bending radii of cables

Restrictions
Minimum bending radius
(stationary cables)
Copper cable
3 x cable diameter
Hybrid cable
Optical fiber cable
iSH: 5 x cable diameter

(14.3 mm / 0.56 in )
SCL: 5 x cable diameter
20 x cable diameter *

(cables with an unrestricted range of mo
tion)
iSH: 7.5 x cable diameter

(14,3 mm / 0.56 in)

(permanently flexible cables)
iSH: 12 x cable diameter

(14,3 mm / 0.56 in)
SCL: 7.5 x cable diameter
not permitted
Permissible temperature range

-50 C ... +80 C /
(non stationary cables (according to DIN +122 F ... +176 F
VDE))
-50 C ... +90 C /

+122 F ... +194 F
0 C ... 80 C /
32 F ... +176 F
Permissible temperature range

(stationary cables (according to DIN
VDE))
-40 C ... +80 C /

+104 F ... +176 F
-40 C ... +90 C /

+104 F ... +194 F
-- **
Number of bending cycles
5 million cycles ***
5 million cycles ***
-- **
12 x cable diameter
* When laying fiber optic conductors, a minimum bending radius of 15 x cable diameter is allowed for a short period of
time.
** Fiberoptic conductors may not be laid as "permanently flexible".
*** At maximum velocities of 2 m/s and maximum accelerations of 5 m/s2
Table 4-1: Properties of the cables used by Schneider Electric
Use lower velocities and smaller bend radii to enhance service life of a cable.
20
Schneider Electric
Recommended cable cross sections & tightening torques

max. terminal cross section [mm2]/ [AWG] Tightening torque [Nm / lbf in]
Meaning
Connection
X1
Control voltage
1.5
28-16
0.2 - 0.25 / 1.77 - 2.21
X2
Mains connection
2.5 (MC-4/ 1.5..10 A)
24-12
0.4 - 0.5 / 3.54 - 4.43
4 (MC-4/ 22 A)
22-10
0.5 - 0.6 / 4.93 - 5.31
16 (MC-4/ 50 A)
20-4
2.0 - 2.3 / 17.17 - 20.36
2.5 (MC-4/ 1.5..10 A)
24-12
0.4 - 0.5 / 3.54 - 4.43
4 (MC-4/ 22 A)
22-10
0.5-0,6 /4.43 - 5.32
16 (MC-4/ 50 A)
20-4
2.0 - 2.3 / 17.17 - 20.36
2.5 (MC-4/ 1.5..10 A)
24-12
0.4 - 0.5 / 3.54 - 4.43
4 (MC-4/ 22 A)
22-10
0.5 - 0.6 / 4.93 - 5.31
16 (MC-4/ 50 A)
20-4
2.0 - 2.3 / 17.17 - 20.36
X3
DC circuit
X4
Motor connection
X5
SERCOS LWL IN
0.8 / 7.08
X6
SERCOS LWL OUT
0.8 / 7.08
X7
Diagnostics
0.25
22
X8
Encoder Connection
0.25
22
20-4
Ground conductor connec 10 (1.5 A - 22 A)

tion (flexible)
16 (50 A)
-
Shield guard motor supply For routing motor connection cables with a cross section of maximally 1.5
cable
mm2.
Table 4-2: Connection overview MC-4 servo amplifier
The maximum connection cross section for an external bleeder on the MC-4 is 1.5
mm2 (1.5 A...10 A), 2.5 mm2 (22 A) und 6 mm2 (50 A).
Connection
Meaning
max. terminal cross section [mm2] / [AWG]
max. tightening torque [Nm / lbf in]
X1
Control signals
1.5
16
0.2 - 0.25 / 1.77 - 2.21
X2
Control voltage /
Mains connection
10
0.5 - 0.6 / 4.93 - 5.31
X3
DC circuit
10
0.5 - 0.6 / 4.93 - 5.31
X4
PD-8/SCL connec
tion
4 (22 A)
10
0.5-0,6 / 4.93 - 5.31
X5
LWL IN sercos
0.8 / 7.08
X6
LWL OUT
0.8 / 7.08
X7
Diagnostics
0.25
X8
sercos connection
Shielded connector
10
Table 4-3: Connection overview PacDrive PS-4 Power Supply
Schneider Electric
21
4 Wiring notes
Connection
Meaning
X1
Control voltage/
Mains connection
0.2 - 6
24 - 10
X2
Braking resistor
0.2 - 6
24 - 10
X3
iSH connection
0.2 - 6
24 - 10
X4
sercos LWL IN
0.8 / 7.08
X5
sercos LWL OUT
0.8 / 7.08
X6
sercos connection
X7
Control signals
0.14 - 1.5
X8
Control signals
0.14 - 1.5
Shielded connector
1 / 8.85
Table 4-4: Connection overview - PacDrive Power Supply PS-5
The recommended connection cross section for an external bleeder on the PS-5con
nection cross-section is 2.5 - 4 mm2.
Meaning
Connection
X1
Com 1 (RS232)
0.25
0.4 / 3.54
X2
Com 2 (RS485)
0.25
0.4 / 3.54
X3
Ethernet connection -
X4
Power supply,
watchdog and
Touchprobe inputs
28 - 16
X5
PacNet
X6
Motion bus sercos

input *)
0.8 / 7.08
X7
Motion bus sercos

output *)
0.8 / 7.08
X9
PROFIBUS db
0.25
0.4 / 3.54
X10
CAN
0.25
0.4 / 3.54
X11
Master encoder
0.25
0.4 / 3.54
Shielded connector
1 / 8.85
Table 4-5: Connection overview PacDrive C200 Controller
*) Fiber optic cable
22
Schneider Electric
Connection
Meaning
X1
Control voltage/
Watchdog
1.50
X2
Digital Outputs
1.50
X3
Digital Inputs
1.50
X4
Touchprobe and fast 1.50

digital inputs
28 - 16
X5
Analog inputs/out
puts
X10
Ethernet connection -
X11
Master encoder (Sin 0.25

Cos)
0.4 / 3.54
X11
Master encoder (in 0.25

cremental)
0.4 / 3.54
PacNet
X14
Motion bus sercos

input
0.8 / 7.08
X15
Motion bus sercos

output
0.8 / 7.08
X17
Com 1 (RS232)
0.25
0.4 / 3.54
X18
Com 2 (RS485)
0.25
0.4 / 3.54
X19
CAN
0.25
0.4 / 3.54
X20
PROFIBUS db
0.25
0.4 / 3.54
Shielded connector
1 / 8.85
X12/X13
1.50
Table 4-6: Connection overview PacDrive PacDrive C600 Controller
NOTICE
NO SECURE CONTACT
When using cables with a cross section of 1.5 mm, use conductor end sleeves
with plastic collars and a metal sleeve of 15 mm / 0.59 in.
When using cables with a cross section of 2.5 mm, use conductor end sleeves
with plastic collars and a metal sleeve of 18 mm / 0.71 in.

Motor type
SH-055
Motor cable in mm
1 / 1.5
SH-070
1 / 1.5
SH-100
1 / 1.5
SH-140
1.5 / 2.5 / 4
SH-205
2.5 / 4 / 10
Table 4-7: Cable cross sections depending on motor type
Tightening torques
Connectors
Description
Tightening torque
C200 ... P600 X1 ... X4

Mini Combicon MC 1.5 clamp screw thread M2
0.3 ... 0.4 Nm / 2.66 ... 3.54 lbf

in
Table 4-8: Tightening torques for front terminal clamp screws
Schneider Electric
23
4 Wiring notes
4.2
Electromagnetic compatibility, EMC
WARNING
RISK OF ELECTROMAGNETIC DISTURBANCES OF SIGNALS AND DEVICES
Use proper EMC shielding techniques to help prevent unexpected device oper
ation.

Enclosure The prerequisite for compliance with the specified limit values is an EMC compatible
layout layout. Comply with the following specifications:
EMC measures
Shielded
cables
Target
Use galvanized or chromium-plated sub plates, bond metallic parts

across large surface areas, remove paint layer from contact surfaces.
Good conductivity by surface

area contact
Ground enclosure, door and sub plates by using grounding strips or

grounding cables with a cross-section of 10 mm2 (AWG 6).
Reduce emission.
Supplement switch devices such as contactors, relays or magnetic

valves with interference suppression combinations or spark supressor
elements (e.g. diodes, varistors, RC elements).
Reduces mutual interference
Fit power and control components separately.
EMC measures
Place cable shields on the surface, use cable clamps and grounding
strips.
Target
Reduce emission.
At the control cabinet outfeed, connect the shield of all shielded cables Reduce emission.
via cable clamps to the sub plate across large surface areas.
Ground shields of digital signal cables on both sides across large surface Reduce interference action on
areas or through conducting connector housings.
signal cables, reduce emis
sions.
Ground shield of analog signal cables directly on the device (signal in
put), insulate the shield at the other cable end or ground the same
through a capacitor, such as 10 nF.
Reduce grounding loops by

low frequency interferences.
Use only shielded motor supply cables with a copper braid and at least Specifically discharge interfer
85% cover, ground shield on both sides across a large surface area.
ence currents, reduce emis
sions.
24
Schneider Electric
4.2 Electromagnetic compatibility, EMC
Cable
routing
EMC measures
Target
Do not route fieldbus cables and signal cables together with cabling for Reduces mutual interference
direct and alternating voltages above 60 V in the same cable duct (field
bus cables can be routed together with signal cables and analog cables
in the same duct). Recommendation: Routing in separated cable cuts
with a distance of at least 20 cm (7.84 in.).
Keep the cables as short as possible. Do not install any unnecessary
cable loops, short cable routing from a central grounding point in the
control cabinet to the external grounding connection.
Reduce capacitive and induc

tive interference couplings.
Insert a potential equalization for:
Reduce current on cable

shield, reduce emissions.
large surface installation

different voltage infeeds
networking across buildings
Use fine wire potential equalization conductor.
Discharging of high frequency

interference currents.
If motor and machine are not connected in a conducting fashion, e.g. due Reduce emissions, increase
to an insulated flange or a connection not across a full surface, the motor interference resistance.
must be grounded via a grounding cable > 10 mm2 (AWG 6) or a ground
ing strip.
Use twisted pair for 24 Vdc signals.
Voltage
supply
EMC measures
Reduce interference action on

signal cables, reduce emis
sions.
Target
Operate product on mains with a grounded neutral.
Enable the effect of the inte

grated mains filter.
Protection circuit if there is a risk of overvoltage.
Reduce risk of damage due to

overvoltages.
Motor and From an EMC point of view, motor supply cables and encoder cables are particularly
encoder cables critical. Only use pre-configured cables, or cables with the prescribed properties, and
comply with the following EMC measures.

EMC measures
Do not install switching elements in motor cables or encoder cables.
Target
Reduces interference.
Route motor cable with a distance of at least 20 cm (7.84 in.) to the

signal cables or insert shield plates between the motor supply cable and
the signal cable.
For long cabling, use potential equalization cables.
Reduce current on cable

shield.
Route motor supply cables and encoder cables without any separation Reduces emission.
point. 1)
If a cable must be cut through for installation purposes, the cables must be connected at the point of
separation by means of screen connections and metal housing.
1)
Schneider Electric
25
4 Wiring notes
Additional Depending on the respective application, the following measures may lead to a EMC
measures for compatible layout:
improving the
EMC
EMC measures
Target
Upstream connection of line chokes
Reduction of the harmonic

network oscillations, exten
sion of the service life of the
product.
Upstream connection of external integrated mains filters
Improvement of the EMC limit

values.
Special EMC-suitable layout, e.g. within an enclosed control cabinet

complete with 15 dB attenuation of the interferences emitted
Improvement of the EMC limit

values.
Using mains filters

Select the appropriate version of the mains filter from the table below to comply
with the EMC directive with the respective version of the PacDrive servo amplifier
MC-4.
When an interference suppression in groups takes place the combined mains
filters must be dimensioned,
so that INenn Filter is >= Sum of the network sided phase currents of the PacDrive
MC-4.
Motor currents
Motor cable length

0 - 10 m
Motor cable length

10 - 40 m
Motor cable length

over 40 m
Mains filter (MC-4 1.5 A / 3 A) No
FI 07876
Application-specific fil
ters
Mains filter (MC-4 10 A / 22

A)
No
FI 07877
ters (starting 50 m)
Mains filter (MC-4 50 A)
FI 07878
FI 07878
ters
Table 4-9: Mains filter depending on network phase current and motor cable length
NOTICE
WIRING ERRORS
Keep the cable lengths as short as possible.

If cable lengths are greater than 40 m (or 50 m), contact our application depart
ment because special measures, suited to the individual application, may be
necessary.
26
Schneider Electric
4.3 Mains connection PacDrive MC-4 servo amplifier
4.3
Mains connection PacDrive MC-4 servo amplifier
4.3.1
Integrated monitoring in the MC-4

There are 5 methods for protecting the IGBT power stage and the motor integrated
into the MC-4:
(1) The power stage is monitored for over currents. Any exceeding of the peak current
specified in the device is calculated using the following formula:
IOutSC = IMC4_cont 2.5 2 1.2 (Example: MC4 /10A, IOutSC = 42 A.)

The reaction time for the over-current detection < 125s (1 PWM cycle).
(2) A very quick short-circuit protection (reaction time < 5s) monitors the maximum per
missible output currents of the IGBT power stage. If these currents are exceeded, the
power stage switches off.
(3) It monitoring protects the IGBT power stage from thermal destruction through over
loading on the motor phases.
For more information see the Diagnosis section in the PacDrive Controller operating
instructions.
(4) The motor It calculation is performed continuously and protects the motor from over
load.
There is no protection of the DC bus in the MC-4. You must cover this using the input
mains protection.
For more information see the Diagnosis section in the PacDrive Controller operating
instructions.
(5) Phase monitoring for detection during failure of network phases.
Schneider Electric
27
4 Wiring notes
4.3.2
Servo amplifiers on critical power supplies

The worldwide use of the PacDrive system in different mains power supply systems
requires protection measures by the network supply of the servo amplifier MC-4, be
cause critical network conditions might cause an increased wear, up to the point of
where it can lead to a damage of the power input connection of the MC-4. Integrated
mains filters and mains chokes provide effective protection in this case.
Mains filters avoid that interferences caused by the servo amplifiers are retroactive on
the mains power supply systems. However mains chokes are used for the current
limiting, to suppress circuit feedbacks and to protect against commutation notches.
They compensate the current peaks in the mains power supply systems and thereby
protect the servo amplifier MC-4 effectively from transient overvoltage.
Critical mains power supply conditions are present if the following ascertainments are
made when testing the system:
The asymmetry of the power supply is more than 3 %

The maximum power output of the power supply is higher than ten times the rated
power of the motor controller
Sudden interference with the power supply is to be expected
Cause of critical voltage curves

Critical voltage curves occur:
When Thyristor systems (e.g. Thyristor direct current drives) and servo amplifiers
are operated using the same power supply
When power factor compensations are switched on or off
when large inductances (induction ovens etc.) are switched on
when the mains power supply of the servo amplifier is switched on or off frequently
when, in the case of in-house power generation, the output voltage deviates sig
nificantly from the ideal sine curve
as a result of lightning striking the mains power supply
Effects of critical voltage curves

Such unfavorable operating conditions result in
28
damage to the network input rectifier of the servo amplifier MC-4 and in
increased wear or defects on the mains protection contacts.
Schneider Electric
Switching circuit for critical mains power supply systems

To avoid that circuit feedbacks form the mains power supply system "penetrate" the
power input connection of the MC-4 " or interferences caused by the MC-4 reach the
mains power supply system, it is recommended to use the switching of a load circuit
with mains choke and mains filter, as shown in the following figure.
Figure 4-1: Load circuit with mains choke and integrated mains filter
Schneider Electric
29
4 Wiring notes
Mains choke Observe the following steps when using mains chokes:
Provide for protective measures on the PacDrive servo amplifier mains feed when
using the PacDrive system.
Provide for a separate choke for each mains contactor group.
The mains choke depends on the effective current of the respective mains con
tactor group to ensure smooth operation.
~
~
~
L1
L2
L3
Q1
FI
NKD XX / X.XX
K1.1
NKD XX / X.XX
K1.2
NKD XX / X.XX
K1.3
L1
L2
L3
L1
L2
L3
L1
L2
L3
L1
L2
L3
L1
L2
L3
L1
L2
L3
db+
db-
db+
db-
db+
db-
db+
db-
db+
db-
db+
db-
MC-4 ... MC-4

1-n
MC-4 ... MC-4

1-n
MC-4 ... MC-4

1-n
AnschlussNetzdrossel_de.fh8
Figure 4-2: Block diagram for the use of mains chokes
30
Schneider Electric
4.3.3
Switch-on procedure
When the mains voltage is switched on, the DC circuit capacitors in the PacDrive MC-4
are pre-charged "softly" using the built-in braking resistor resistor. The minimum time
between two precharging operations is 15 s.
4.3.4
Grounded AC
networks
Non-grounded
three-phase
supply systems
Protective earth ground concept of the mains power supply
The PacDrive MC-4 servo amplifier can be operated without a potential separation
on three-phase supply systems with a grounded star point.
Use an insulating transformer when operating on an ungrounded network. The

star point on the output side as well as the servo amplifier's PE connection must
be grounded.
WARNING
ELECTRIC SHOCK WITH UNGROUNDED NETWORKS
Use an insulating transformer when operating on an ungrounded network. The

star point on the output side as well as the servo amplifier's PE connection must
be grounded.
Otherwise only operate on grounded networks to avoid non-permitted excess
voltages between the outer conductors and the housing.
4.3.5
Matching the mains voltage

This is how to match the mains voltage using a transformer according to the system's
power requirements if the mains voltage lies outside of the rated voltage specified in
the technical data:
Use an autotransformer for grounded networks.
For non-grounded networks, use an isolating transformer.
The PacDrive MC-4 is designed for a fixed connection to the mains power supply
system.
Schneider Electric
31
4 Wiring notes
4.3.6
Fusing the mains connection
NOTICE
OVERLOADING THE LINES
In order to protect the system, also use a circuit breaker in the mains connection.
Provide for an external power protection for the mains supply and the power
connector.
Configure the mains contactor to ensure that insulation is maintained in the event
of a short circuit.
Use one of the following components as protection:

Melting fuses of operating classes gG (e.g. Telemechanique DF2-CNxx).
Power protection switch, characteristic C (e.g. Telemechanique GV2 MExx).
Cover all short circuit conditions between the mains supply and the IGBT jumper
with the mains contactor.
Select and size the mains contactor or other components for protection as follows:
Consult the phase current calculated in ECAM for calculation.
When several devices are involved, add up the phase currents and select at least
the next larger mains contactor (utilization categories AC2 and AC3). Recom
mendation: Mains contactor of the type Telemecanique LC1-Kxxx or LC1-Dxxx.
Calculate the mains contactor as follows:
IRated protection = 1.2 sum of phase currents
Calculate the short-circuit mains contactor as follows:
ISC_fuse = 5...10 sum of phase currents
The overload threshold (delayed triggering) can be individually set on circuit breakers.
Consider the increased inrush current of the devices. A unintentional triggering when
switching on is thereby avoided because the un-delayed over-current threshold of the
circuit breakers is much higher.
When the mains are connected, the DC circuit capacitors are charged by the internal
braking resistor. Thereby the charging current is:
I = (UN 2) / RBleeder
The charging circuit is bridged during operation.
NOTICE
WIRING ERRORS
Select the cross section of the mains supply system so that it is protected by the
chosen circuit breaker.
32
Schneider Electric
4.3.7
Residual current operated protective device
DANGER
HAZARD OF ELECTRIC SHOCK CAUSED BY HIGH TOUCH VOLTAGE
Connect devices with a leakage current of 3.5 mAac or more through a fixed
connection to the power supply network.
In addition, implement one of the measures according to EN 50178:1997, Section
5.3.2.1.
Observe the following when using fault current protective devices:

If an additional protection measure against indirect or direct (by rated fault current
< 30 mA) contact comes into operation, then an upstream fault current circuitbreaker with 30 mA response threshold can be also triggered in normal operation
through the device leakage current of the MC-4.
An insulation fault or a direct contact can cause a current with a direct current
component in the ground conductor. Thereby the sensitivity of fault current circuitbreakers of the type A or AC is reduced and therewith also the ability to protect
other accessories in the system.
Therefore, only use the MC-4 with a universal current sensitive fault current circuitbreaker of the type B with a triggering threshold over 30mA (for example,
300 mA, as a protection measure against a fire outbreak through insulation
breakdown).
If on the line side of this electronic equipment a fault current protective device is used
to protect against direct or indirect contact, then only type B is permitted. Otherwise
another protection measure has to be used, like separating the electronic equipment
from the environment through double or reinforced insulation or from the line by a
transformer.
Handle the fault current protective circuit-breakers of the type B for the design and
mounting of electronic system carefully. All the fault current circuit breakers that are
upstream to a fault current circuit breaker of the type B up to the supply transfomer
have to be of the type B.
According to DIN EN 61800-5-1 Adjustable speed electrical power drive systems, Part
5-1: Safety requirements - Electrical, thermal and energy - are required on devices
with an operational current greater than 3,5 mAac or 10 mAdc.
Additionally, one of the following procedures is required:
1. Use a ground conductor cross section with at least 10 mm2 (AWG 6) Cu.
2. Monitor the ground conductor with a equipment that automatically shuts off in case
of a potential error.
3. Install the second conductor electric parallel to the protective conductor by using
separate terminals. In and of itself, this conductor must meet the requirements of
DIN VDE 0100 part 540.
The protective housing provides protection from indirectly touching live parts.
Schneider Electric
33
4 Wiring notes
4.4
Mains connection PacDrive PS-5 power supply
4.4.1
Protective earth ground concept of the mains power supply
grounded PacDrive PS-5 may be operated without potential separation on AC networks with a
grounded star point.
ungrounded Operating on ungrounded mains (IT networks) or mains without a grounded neutral
point increases the hazard of impermissible overvoltage between external conductors

and the PacDrive servo amplifier housing. For this reason, use an isolating transformer
when operating on such networks. The star point on the output side as well as the
PacDrive PS-5 PE connection must be grounded.
Meet UL conformity as follows:
Use a fuse (Type: maximum 40 A, 600 Vac) in the feed line.
Operate the power supply only on a circuit capable of delivering not more than
5000 rms symmetrical amperes.
For 24 V supply, use a fuse with max. 15 A.
4.4.2
Wiring notes
Cable bushing at control cabinet
PS-5 / DB-5
PacDrive
PS-5
PacDrive
DB-5
E-MO-117
E-MO-118
E-MO-119
E-MO-120
E-MO-124
E-MO-125
E-MO-126
PacDrive
iSH
2
E-MO-118
control cabinet
Connection cable to another DB-5
Table 4-10: PS-5/DB-5 cable gland
34
Schneider Electric
4.4 Mains connection PacDrive PS-5 power supply
DB-5 / DB-5 This enables cable bushing from DB-5 to DB-5
through a cable channel or pipe.
DANGER
ELECTRIC SHOCK, FIRE OR EXPLOSION
Observe the general construction and safety regulations for working on highcurrent electrical systems.
Operate electrical components only with a connected protective conductor.
After the installation, verify the fixed connection of the protective conductor
to all electrical devices to ensure that connection complies with the connec
tion diagram.
Make certain that the drives are at a standstill because potentially fatal volt
age can occur on the motor lines in generator operation.
Before enabling the device, safely cover the live components to prevent
contact.
Do not touch the electrical connection points of the components when the
unit is switched on.
Provide protection against indirect contact (DIN EN 50178, Section 5.3.2).
Disconnect/plug in power connector cables only when the system is deacti
vated.
WARNING
LOSS OF INVERTERENABLE SAFETY FUNCTION
Do not confuse ie+ and ie-.

Check the wiring after installation.
Connect iSH-HCN1 either between PS-5 and DB-5 or between DB-5 and DB-5.
Depending on the configuration, use different cable variations.
The degree of protection of the iSH-HCN1 is IP20. However, due to the "Inverter
Enable" safety function, a minimum of IP54 is required.
Schneider Electric
Install iSH-HCN1 into a housing or a control cabinet to attain a minimum of degree

of protection IP54.
35
4 Wiring notes
Possible positions of the iSH-HCN1:
PacDrive
PS-5
iSH-HCN1
E-MO-118
E-MO-119
iSH-HCN1
PacDrive
DB-5
E-MO-117
E-MO-127
PacDrive
DB-5
E-MO-121
E-MO-117
E-MO-120
E-MO-124
E-MO-125
E-MO-126
PacDrive
iSH
E-MO-118
E-MO-118
1
2
control cabinet
Connection cable to another DB-5
Table 4-11: Cable gland DB-5 -> DB-5
E-MO-121
iSH-HCN1
ie1 ie2
ie1 ie2
E-MO-117
Figure 4-3: iSH-HCN1 wiring
36
Schneider Electric
4.5 PacDrive Controllers and MC-4 Control Voltage Connection
4.5
PacDrive Controllers and MC-4 Control Voltage Connection

Observe the following instructions for the control voltage connection of PacDrive Con
troller and MC-4:
Design control voltage as PELV (protected extra-low voltage).
When supplying several consumers via the 24 V DC for the control voltage ensure
that the tolerances for the 24 V DC control voltage are maintained and all con
nected components maintain safe separation from the mains voltage circuits. This
is especially important in applications with inductors (solenoid valves, brakes,
etc.).
Measure the control voltage with an oscilloscope to recognize short-term drops in
the control voltage (e.g. when inductive sinks are turned on). If the tolerances for
the control voltage are not observed, diagnostic error 036 "External 24 VDC too
low" or WATCHDOG may arise.
NOTICE
DATA LOSS OR FLASH DISK FAILURE.
Because the control voltage of the controller may only be shut off when all
files are closed, use the UPS option for the controllers.
The input capacitance of the PacDrive controllers C400 and C600 is 4400 F. De
pending on the 24 V power supply unit used (24 V slew rate, internal resistance of the
power supply unit), an elevated startup current may arise.
4.6
DC circuit
The rectified mains voltage is stored in the "DC bus" in the PacDrive MC-4. Basically,
the DC bus consists of a rectifier and capacitors. The DC bus voltage is applied to
power connector X3 on the PacDrive MC-4.
DC circuit voltage limit.
During braking, the servo motor acts as a generator and feeds power into the DC bus
via the motor inverter. The energy is stored in the DC capacitors. This increases the
voltage in the DC bus. When the capacity of the capacitors is not sufficient to absorb
the power, it must be ensured that the DC bus voltage does not increase too much.
DANGER
ELECTRIC SHOCK CAUSED BY HIGH VOLTAGE
Maintain sufficient insulation when routing cables.

Do not ground DC bus (DC bus voltage may be up to 860 V).
The voltage monitoring measures the DC bus voltage and connects the DC bus via a
power transistor to a power resistor (braking resistor) when the limit value (approx.
820 V) is reached. The braking energy is converted to heat When the DC bus voltage
falls below the lower switching threshold (approx. 800 V), the braking resistor is dis
connected once more.
Schneider Electric
37
4 Wiring notes
Connection of the DC circuits

In multi-axle applications, the DC circuits of the PacDrive MC-4s may be connected to
allow for power exchange. In doing this, the total DC circuit capacitance may not ex
ceed 2 mF. This means that e.g. twelve 3 A, six 10 A or two 22 A PacDrive MC-4s may
be connected.
Connect the DC buses as follows:
NOTICE
WIRING ERRORS
Do not exceed the maximum DC circuit capacitance of 2 mF when connect

ing the DC circuits.
Wire the mains feed in such a manner that it runs from the device with the
most power (short connection, large cross section) to the device with the
least power (longer connection, smaller cross section.)
Ensure that the maximum length of the cables does not exceed 0.5 m when
connecting the DC circuits.
Use a twisted cable with the largest possible cross section.
Note that it is only permissible to connect the DC circuits on units which are
served by a common mains contactor. Otherwise there is the danger that the
inverters may be overloaded.
38
Couple the PacDrive MC-4 servo amplifier using terminals db+ and db-.
In addition, connect the L1, L2 and L3 mains feeds since these are controlled by
a common mains contactor.
If desired, support the device's own braking resistors with an additional braking
resistor (braking resistor module BM-4).
Schneider Electric
Schneider Electric
F2

X9 encoder
24V
0V
X1
MAx-4
mains
contactor
mains
choke
TX
TX
machine
earthing
decreasing capacity
machine
earthing
Load circuit
M
3~
too
more
MC-4
5.1
M
3~
X4
U V W PE
U V W PE
X3
X8 encoder
db+
db-
X2
X4
X3
L1
L2
L3
PE
X1
5/6
24V
0V
MC-4
X8 encoder
db+
db-
L1
L2
L3
PE
X2
5/6
24V
0V
X1
MC-4
Basic Design and Connection
TX master
encoder
earthing line in
switching cabinet
F1
power circuit
breaker
Aufbaubeispiel_Lastkreis_englisch_0798.fh8
>= 10 mm
(flexible)
L1
3AC 50-60Hz L2
L3
380-480V
N
PE
main switch
5.1 Load circuit
Figure 5-1: Load circuit sample design
39
40
mains
contactor
power on
power off
K1
DC 0 V
K2
K1
Enable
X1
1
2
3
4
5
6
7
8
OUT
OUT
IN
IN
auxiliary
contactor
24V
0V
+UL
L0
24V
0V
WD
WD
MAx-4
K2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
brake
(optional)
X1
24V IN
0V IN
ie
en
motor temp.
motor temp.
bri +
bri 24V OUT
0V OUT
ieo
ieo
rdy
rdy
bro+ <- 7 bri+
bro- <- 8 bri-
MC-4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
24V IN
0V IN
ie
en
motor temp.
motor temp.
bri +
bri 24V OUT
0V OUT
ieo
ieo
rdy
rdy
bro+ <- 7 bri+
bro- <- 8 bri-
Aufbaubeispiel_Steuerkreis_englisch_0798.fh8
brake
(optional)
X1
MC-4
5.2
limit switch
DC 24 V
5 Basic Design and Connection
Control circuit
Figure 5-2: Control circuit sample design
Schneider Electric
5.2 Control circuit
Explanations for the control circuit sample design

This sample shows the basic design and the wiring of a PacDrive system without in
cluding safety aspects (e.g. redundant design of auxiliary contactors) in the control
circuit.
Due to EMC considerations, the brakes (PIN 7 bri+ and PIN 8 bri+) should be supplied
by a separate power supply unit. Otherwise, the brake (PIN 7 bri+ and PIN 8 bri+)
should be connected directly to the 24V DC power supply unit.
WARNING
DAMAGING THE HOLDING BRAKE
Monitor the separate holding brake power supply. This monitoring may be carried
out by the PacDrive Controller, for example, which monitors the voltage either
directly via an input (no potential separation from the brake voltage) or via an
auxiliary relay (floating).

InverterEnable When the InverterEnable relay input is switched off, the PWM signals to the end stage
(safe stop) are interrupted. The motor is immediately switched to a torque-free state. If Inverter
Enable is not used, the input should be set so that it is always 24V.
wd and rdy
wd (PacDrive Controller) and rdy (PacDrive MC-4 and braking resistor module BM-4)
are relay outputs that are closed during the correct operation. They should be con
nected in series to the mains contactor (possibly using an auxiliary contactor), so that,
in the event of a serious fault, the power supply will be switched off.
NOTICE
WIRING ERRORS
Wire the PacDrive servo amplifier and the PacDrive Controller in such a manner
that, in case of a serious malfunction via the output wd (MAx-4, C200, C400,
C600, P600) and rdy (MC-4), the mains feed will be interrupted.
Schneider Electric
41
6 Functional safety - safety connections
Functional safety - safety connections
6.1
Process minimizing risks associated with the machine

The goal of designing machines safely is to protect people. The risk associated with
machines with electrically controlled drives comes chiefly from moving machine parts.
Hazard and risk analysis
On the basis of the system configuration and utilization, a hazard and risk analysis can
be carried out for the system (for example, according to EN ISO 14121 or EN ISO
13849-1:2006). The results of this analysis must be considered when using the In
verter Enable safety function. The circuit resulting from this analysis may deviate from
the application examples. For example, additional safety components may be re
quired. In principle, the results from the hazard and risk analysis have priority.
The EN ISO 13849-1 Safety of machinery - Safety-related parts of control systems Part 1: General principles for design describes an iterative process for the selection
and design of safety-related parts of controllers to reduce the risk to the machine to a
reasonable degree:
This is how you perform risk assessment and risk minimization according to EN ISO
14121:
1. Define the boundary of the machine.
2. Identifying risks associated with the machine.
3. Assessing risks.
4. Evaluating risks.
5. Minimizing risks by:
- intrinsically safe design
- protective devices
- user information (see EN ISO 12100-1:2003, Figure 4)
6. Designing safety-related controller parts (SRP/CS, Safety-Related Parts of the
Control System) in an interactive process.
This is how you design the safety-related controller parts in an interactive process:
Identifying necessary safety functions that are executed via SRP/CS (Safety-Re
lated Parts of the Control System).
Determining required properties for each safety function.
Determining the required performance level PLr.
Identifying safety-related parts executing the safety function.
Determining the performance level PL of the afore-mentioned safety-related parts.
Verifying performance level PL for the safety function (PL PLr).
Checking, if all requirements have been met (validation).
Additional information ist available on www.schneider-electric.com.
42
Schneider Electric
6.2 Circuit suggestion for PacDrive system with MC-4
6.2
Circuit suggestion for PacDrive system with MC-4
6.2.1
InverterEnable function
Functional Description
With the Inverter Enable function (IE) you can bring drives to a safe stop. This Inverter
Enable function relates to the components
MC-4
The Inverter Enable function requires further components, e.g. emergency stop, safety
switching unit (optional) and connections. The following chapter describes the correct
use of the Inverter Enable function.
The Inverter Enable function must be used correctly to enable proper operation. Nev
ertheless, the accidental loss of the Inverter Enable function cannot be ruled out. Such
losses are only restricted to the upper limit required by the relevant safety standards.
(see 6.2.8 Safety standards) This is expressed by the following characteristic values:
MTTF_d and DC_avg according to EN ISO 13849-1
In the sense of the relevant standards, the requirements of the stop category 0 (Safe
Torque Off, STO) and stop category 1 (Safe Stop 1, SS1) can be met. Both categories
lead to a torque-free motor while SS1 takes this state after a predefined time. As a
result of the hazard and risk analysis, it may be necessary to choose an additional
brake as a safety option (e.g. for hanging loads).
Scope of operation (designated safety function)
In the circuit suggestions given, the "Safe Torque OFF, STO" safety function is carried
out by switching off the trigger signals of the power stage. They transmit the PWM
signals to the power stage (pulse pattern lock) using the "InverterEnable" signal.
Schneider Electric
After the emergency stop device is activated, a controlled ramp down takes place
for the drive.
In the process, the DC bus voltage increases until the braking resistor resistor is
switched on.
In the braking resistor, the energy which is fed back from the motor is converted to
heat.
The K1 power circuit breaker and/or the Inverter Enable signal must remain ener
gized until the drive stops.
At the latest after the normal ramp down time, the Inverter Enable signal is switched
off by the delayed contacts of K3.
After this, the drive is in a safe stop.
43
3 Phase AC
Channel B
Channel A
Figure 6-1: MC-4 InverterEnable block diagram

Operating prin The Inverter Enable function safely switches off the motor torque. It is sufficient to set
ciple a logical zero at the function input. There is no need to interrupt the power supply.
Standstill, however, is not monitored.
Safe InverterEnable is synonymous with "Safe Torque Off (STO)" according to IEC
state 61800-5-2. This torque-free state is automatically entered when potential errors are
detected and is therefore the safe state of the drive.
Mode of opera The safety circuit with InverterEnable was developed to minimize wear on the mains
tion contactor. When the stop or the emergency stop button is activated, the mains con
tactor is not switched off. The safe stop is achieved by removing the InverterEnable
for the opto-couple in the power stage. Thus, the PWM signals cannot control the
power stage, so that a startup of the drives is safely prevented (pulse pattern lock).
The error monitoring ensures that the mains contact is switched off when an error
occurs. The error monitoring of the InverterEnable function in the controller takes
place through an InverterEnable signal, which is produced in the PacDrive MC-4 and
transmitted to the PacDrive controller via the sercos interface. If this signal does not
correspond to the reference state at the PacDrive controller's EmergencyStop input,
an diagnostic message is triggered.
Stop In the application proposal, the emergency stop device is designed with two channels.
category 1 The ramp down is triggered and the drive is brought to a standstill using un-delayed
contacts. The K1 power circuit breaker and/or the Inverter Enable signal are switched
off using delayed contacts (EN 60-204-1 stop category 1). Shutting off using the off
button has the same effect as using the emergency stop button. Thus, this button is
wired in series with the emergency stop contacts. When switching off, the drive on
PacDrive MC-4, independent of the PacDrive Controller, can also be brought to a
controlled standstill using the "MC en" signal. But this function has the disadvantage
that, under certain circumstances, the drives must be re-referenced. The emergency
stop triggers a redundant shutdown of the drives. The following errors are thereby
safely controlled:
44
If the ramp down phase of a drive is uncontrolled because of an error, the Inver
terEnable signal is switched off after the deceleration time, which is set on the
safety switching device (drive is moving to a stop).
Schneider Electric
If, after the ramp down the PWM signals are not switched off by the IE relay in the
PacDrive MC-4, the power supply is cut off automatically by switching off mains
contactor K1.
Independent of these measures, the errors that do not affect the safety function are
recognized by the controller and a start of the drives is prevented. Contactor K4 pre
vents the mains contactor from being switched on.
Execute Proceed as follows to deactivate the InverterEnable function:
muting
WARNING
UNCONTROLLED AXIS MOVEMENT
Ensure that no-one has access to the hazard area as long as the DC bus still
has residual charge.
Supply the IE input permanently with 24 V to deactivate the InverterEnable func

tion.
Validity of the safety case

The safety case for the InverterEnable function of the MC-4 system applies for the
following hardware codes:
Device
Item no.
Hardware code:
MC4 1A
(MC-4/11/01/400)
from 27.06.2006
VDM01U15xxxx
(e.g. VDM01U15AA00)
xxMxxx, xxNxxx, xxOxxx,

xxPxxx, xxQxxx, xxRxxx
MC4 3A
(MC-4/11/03/400)
from 27.06.2006
VDM01U30xxxx
(e.g. VDM01U30AA00)

MC4 5A (230V)
(MC-4/11/05/230)
from 27.06.2006
VDM01U50xxxx
(e.g. VDM01U50AA00)

MC4 10A
(MC-4/11/10/400)
from 27.06.2006
VDM01D10xxxx
(e.g. VDM01D10AA00)

MC4 22A
(MC-4/11/22/400)
from 24.10.2007
VDM01D22xxxx
(e.g. VDM01D22AA00)
xxxxBx, xxxxCx, xxxxDx
MC4 50A
(MC-4/10/50/400)
from 24.10.2001*
VDM01D50xxxx
(e.g. VDM01D50AA00)
x21xxx, x31xxx
MC4 50A LIB (soft n/a

ware)*
V00.16.00
A safety case for higher hardware codes is also planned.

* The function block FB_MC50AIEDiag from the library PD_MC450A_V001600.lib has to be used for the
diagnostic by the MC4 50A (MC-4/10/50/400).
For questions on this, please contact your Schneider Electric partner.
Schneider Electric
45
Interface and control

The operation of the InverterEnable function takes place via the InverterEnable input
(IE Pin 3) and via the positively driven output contact (IEO Pin 11 and Pin 12).
Low-Signal or Low-Level is issued when an input is connected or open (not connected)
with L0.
High-Signal or High-Level is issued when an input is connected with +24 V.
Response time
WARNING
UNCONTROLLED MOVEMENT OF THE SYSTEM
Should a response time be required because of the risk assessment of the ma

chine, the total response time of the machine has to be considered.
All components related to the safety functions from the sensor to the drive shaft
or the driven mechanics have to be considered.

Response time The maximum response time until switch off with the Inverter Enable function is 12ms.
with InverterEn This is the time from the corresponding change of the "InverterEnable" input on the
able function MC-4 to the torque-free SH motor (safe torque off, STO). If the relay is not working
correctly, then the time for the mains contactor K1 and the discharge time of the DC
bus have to be considered. The times depend on the application.
Muting re The Muting response time for switching off (i.e. without the Inverter Enable function)
sponse time depends on the load on the machine and has to be determined from the application.
The axes without Inverter Enable function become torque-free via the mains contactor
and come to a stop.
46
Schneider Electric
6.2.2
Setup, installation, and mounting

Prevent possible functional disorder
The following measures prevent a possible functional disorder through conductive
pollution or parts falling into the device:
DANGER
LOSS OF THE ELECTRICAL SAFETY
Install the MC-4 in a control cabinet or a housing with at least IP 54.

Compliance with the clearances and creepage distances according to EN 50178
Failure to follow this instruction will result in death or serious injury.
Avoid overvoltages
To avoid overvoltages in the system, proceed as follows:
DANGER
Only operate the MC-4 with certified power supply units as power supply
according to EN 60950 or EN 50178 (so-called "Safe voltage outputs").
These power supply units do not deliver an overvoltage over 120 Vdc for
more than 120ms or no permanent overvoltage over 60 Vdc.
Only operate the drive system with approved, specified cables, accessories- and
spare parts by Schneider Electric.
Avoid unintentional restart
DANGER
UNINTENTIONAL RESTART OF THE MOTOR
Ensure that the restart of the motor (e.g. when the power supply returns after an
outage or after a safety requirement has been removed) to reach the stop cate
gory is only possible after receipt of an enable signal.
Ensure that the enable signal meets the specified safety criteria.
Schneider Electric
47
6.2.3
Application proposal
Safety switch The safety switching unit implements the evaluation and control of the on and off or
ing unit emergency stop buttons, and, under certain circumstances, the safety gate contacts.
Contactors
The safety switching unit must fulfill at least the requirements for the PLr.
Ensure that 1 or 2 (see Hardware-Enable) undelayed and 2 delayed contact paths
are available.
The safety switching unit delay time (contactor K3) should be only marginally
higher than the braking time needed for safely bringing the drive to a stop in an
emergency.
Secure the safety switching unit according to the documentation.
Check, if the safety involved auxiliary contactors have positively driven contacts.
Dimension and secure the contactors according to the utilization category.
Off or The off and emergency stop buttons have the same function. The circuitry can be
emergency designed with one or two channels (as shown in the circuitry example for the safety
stop circuit with InverterEnable / sheet 1 (see 6.2.3 Application proposal) and InverterEn
able / sheet 2) (see 6.2.3.2 Wiring diagram for PacDrive controller C200). The same
function can also be achieved through safety door contacts (NC contact), which, ac
cordingly, are wired in one or two channels and in series with the emergency stop
contacts.
When the off or emergency stop button is activated, the outputs of the safety switching
unit K3 switch off, delayed or non-delayed. The PacDrive controller detects the switch
ing off over the non-delayed contact and brings the motors to a controlled standstill.
Optionally, the "MC en" signal can be switched off over the second path using nondelayed contacts. This triggers an independent standstill in PacDrive MC-4 and the
PWM is switched off. After the maximum stopping time for all drives elapses, the de
layed contacts of the safety switching unit K3 switch off. The time until stop depends
on the application. Select as short a time as possible. Through this, the "InverterEna
ble" relay in the PacDrive MC-4 switch off. In the time between when the delayed
contacts of K3 switch off and when the InverterEnable switching contact ieo closes,
the mains contactor is de-energized. Since the decay time of the InverterEnable relay
is 12 ms lower than the decay time of the mains contactor, the mains contactor re
mains energized and thereby the power supply switched on. The mains contactor's
decay time is also influenced by the design of the quenching circuit. When using a
free-wheeling diode as a quenching circuit, a sufficient long dropout delay is provided.
By switching off the "InverterEnable" the PWM control signals of the power stage are
switched off. This prevents an arising of the rotating field. The galvanic isolation from
the power supply can only be achieved by switching off the mains contactor or main
switch.
Off button If desired, the off button (not the emergency stop button) may be connected to one of
with stop- the PacDrive controller's inputs instead of being connected in series to the emergency
category 2 stop button. The level on this input must then be evaluated in the PacDrive controller
and the drives must be brought to a stop. Through this, a flatter braking ramp can be
achieved upon stopping operation, so that, depending on circumstances, wear during
braking can be reduced. No safety function is realized when switching off using this
circuit. Pressing the off button only achieves EN 60 204-1 stop category 2. This is no
safety function.
A safe stop is still required for an emergency stop.
on If the "On" button is pressed, and neither the off or the emergency stop buttons are
pressed, the safety switching unit K3 is switched on. If there is no error in the PacDrive
controller, the K4 contactor is switched on via the mains contactor output of the Pac
Drive controller. If, in addition, the "WD" contacts of the PacDrive controller and the
"rdy" contact of the PacDrive MC-4 are closed and there is no error in the "Inverter
48
Schneider Electric
Enable" circuit, the mains contactor K1 is switched on. The K3 contacts switch on the
"InverterEnable" and thereby the PWM signals of the drives are enabled.
Notes concerning the application proposal:
Hardware Ena The Hardware Enable signal (MC_en) may be connected directly to L0 (+24 V). In this
ble (MC_en) case, the machine comes to a controlled stop through the PacDrive Controller when
it is switched off. The drives can be stopped synchronously to one another. They need
not be homed when it is switched on again.
If the MC_en signal (as in figure no. EL-810-05-08, sheet 1) is optionally connected
over a non-delayed contact of the safety switching unit K3, the drives are brought to
a standstill using the "Best possible stop" in PacDrive MC-4, independent of the posi
tion's setpoint. In some cases, the drives must be homed when they are switched on
again. The MC_en signal is no safety function.
Which method for the standstill is used depends on the application. In interaction with
the safety function Safe stop both methods are equal.
Error The PacDrive controller monitors the status of the safety switching unit, which controls
detection the InverterEnable signal, of the "EmergencyStop" input.
The InvEnableActive signal is decoupled via the relay K5 from the signal InverterEn
able. If only the "Inverter Enable" inputs of the MC-4 are connected to output (38) of
the safety switching unit K3, then the signal can be connected directly to the PacDrive
controller input InvEnableActive. When using the iSH the InverterEnable signal has to
be decoupled.
WARNING
LOSS OF THE SAFETY FUNCTION
Decouple the InverterEnable signal from the controller if you are controlling the
iSH- and MC system with the same shut-off signal as the safety function.
All devices: If the internal positively driven relay in the MC-4 is not opened, then the
mains contactor will open in the application. This has to be indicated to the user as an
error, so that appropriate measures can be carried out for the error elimination or a
start of the machine through the PacDrive Cx00 Controller is prevented.
When using the MC-4/50A device an additional comparison between the "InvEnActive"
input on the PacDrive Cx00 Controller and the "InverterEnable" sercos drive parameter
from the MC-4/50A is necessary. If the InverterEnable signal transmitted from the
PacDrive servo amplifier via the sercos interface does not correspond to the status of
the InvEnableActive signal (taking the delay times into account), an error is detected
and the mains contactor K1 is shut off via the contactor K4. The system can only be
turned on again after the error is corrected.
The certified diagnostic function block "FB_MC450AIEDiag" can be found in the
"PD_MC450A_V001600.lib" library. This library will be provided by your Schneider
Electric contact partner.
Further information for the implementation can be found in the online help.
The function of the mains contactor is monitored via the "MainsWatch" input. When
the mains contactor "K1" is switched off, the "MainsWatch" auxiliary contactor must
be closed; when the mains contactor is on, the auxiliary contactor must be open.
Schneider Electric
49
Further information concerning this theme and the Watch and AxisEnable function
blocks is available from Online help / VarioCam library / Control / Watch.
Connect the InverterEnable relay if the InverterEnable function is not being used and
the InverterEnable input is permanently on 24V.
50
Schneider Electric
Schneider Electric
Datum
10.01.06
10.11.09
Name
SE
SE
L0
S32
22
-S3
On
S34
14
13
S33
S12 Y40
S11 Y39
-K3
PREVENTA XPS-AV 1113Z002
or PNOZ XV2
S22
12
21
22
21
S31
nderung
Preventa XPS-AV
Marked functial safety part
Erstellt:
Geprft:
Freigabe:
Verteilt:
SE
VM
WR
10.11.09
16.11.09
17.11.09
* If more circuit parts should be

connected to the output (38) of the
PNOZ, then the input ie "Inverter
Enable" of the MC-4 and the input
"InvEnableActive" of the PacDrive
Controller, a auxiliary relay must be
used to uncouple the signal paths.
Off
-S2
-S1
Emergency 12
Stop
11
11
S21
Part of functional safety
+24V
14
13
38
37
-K5
48
47
97828 MARKTHEIDENFELD
A2
A1
-K4
14
13
-K1
A2
A1
22
21
Inverter Enable-Beschaltung MC-4

bei Verwendung der PacDrive Controller MAx-4, C400, C600, P600
MC en
optional
(see sheet 3)
24
23
Schneider Electric
A2
A1
Z. Art:
mains
-K1
+24V
L0
A2
A1
Z. Nr.:
3 ie
Sicherheitsbeschaltung PacDrive-Familie
mit Inverter Enable / Version V1.07
mit Sicherheitsschaltgert
MainsContactor
EmergencyStop
InvEnableActive
MainsWatch
WD
MAx-4/ C400
C600/ P600
-A1
PacDrive Controller
Vcc_ie 12 ieo
Vcc 11 ieo
EL-810-05-08
Vcc_ie 12 ieo
Vcc 11 ieo
-A3 MC-4 Inverter Enable
3 ie
BLATT 1
von 3
14
13
WD
& rdy
-K4
(see sheet 3)
Figure 6-2: Wiring diagram: Safety circuit with InverterEnable / sheet 1
51
Validation of the safety function

The InverterEnable function has to be validated according to the requirements of the
risk evalutation. The following tests are necessary to check the diagnostic functions
and the InverterEnable function.
No.
1
Setting
Test procedure
Safety function test of SS1
Press emergency stop

When pressing the "Emergency stop" the
The drives have to be tor
machine must execute the safety function The drives have to be stopped synchronously que-free.
(MCen asynchron) by the PacDrive Control
SS1.
ler. After the set deceleration in the safety
switching device the InverterEnable has to
dropout and the drive must be torque-free.
Test of the mains contactor monitoring (Function block "Watch3()")
The machine must not start if the mains
contactor is not working correctly.
Switch off the machine

Remove the "MainsWatch" signal on the
PacDrive Controller.
Press the "On" button and "Reset/Dia
gQuit" several times.
It must not be possible to

switch on the mains con
tactor or that the machine
starts.
Test of the positively driven "IEO" signal (Function block "Watch3()")

The machine must not start if the "Inver
terEnable" function is not working correct
ly.
Result/comment
Switch off the machine.

Remove the "IEO" signals on every Pac
Drive MC-4.
Press the "On" button and "Reset/Dia
gQuit" several times.
The mains contactor

drops out and it must not
be possible to switch it on
or that the machine starts.
Extended diagnostic only when using the MC-4 50A device

The machine must not start if the "Inver
terEnable" function is not working correct
ly.
Switch off the machine.

Disconnect the "IEI" signals on every
PacDrive MC-4 50A and connect to 24V.
Additionally bypass the "IEO" signal.
Press emergency stop.
The mains contactor

drops out over K4 and it
must not be possible to
switch it on or that the ma
chine starts. The error has
to be detected through the
comparison of the param
eters "InverterEnable"
and the "InvEnableAc
tive" input signal in the
PacDrive Controller.
Table 6-1: Test plan for the diagnostic- and InverterEnable function
Wiring diagram for PacDrive controller C200

The C200 does not have built in IOs, which is why the error detection signals (Mains
Watch, InvEnableActiive, EmergencyStop and MainsContactor) are routed via field
bus-coupled IO modules.
52
Schneider Electric
Schneider Electric
Datum
10.01.06
10.11.09
SE
SE
Name
L0
S32
-S3
Ein
S34
14
13
S33
S12 Y40
S11 Y39
-K3
PREVENTA XPS-AV 1113Z002
or PNOZ XV2
S22
22
21
11
12
22
12
21
S31
Preventa XPS-AV
nderung
Erstellt:
Geprft:
Freigabe:
Verteilt:
SE
VM
WR
10.11.09
16.11.09
17.11.09
* If more circuit parts should be

connected to the output (38) of the
PNOZ, then the input ie "Inverter
Enable" of the MC-4 and the input
"InvEnableActive" of the PacDrive
Controller, a auxiliary relay must be
used to uncouple the signal paths.
-S2
Off
-S1
Emergency
Stop
11
S21
+24V
14
13
38
37
-K5
48
47
MC en
optional
(see sheet 3)
24
23
Schneider Electric
A2
A1
-K4
14
13
A2
A1
22
Inverter Enable-Beschaltung MC-4

bei Verwendung des PacDrive Controllers C200
A2
A1
-K1
21
+24V
L0
Z. Art:
Z. Nr.:
-MainsWatch
-InvEnableActive
-EmergencyStop
-MainsContactor
Fieldbus
WD
C200
Vcc 11 ieo
EL-810-05-08
-K1
mains
+24V
L0
Vcc_ie 12 ieo
-A1
PacDrive Controller
3 ie
available fieldbuses:
- CAN-Bus
- DeviceNet
- PacNet
- Profibus DP
MainsContactor
Outputs
EmergencyStop
InvEnableActive
MainsWatch
Inputs
Fieldbus
Node
-A4
Vcc_ie 12 ieo
Vcc 11 ieo
3 ie
BLATT 2
von 3
A2
A1
14
13
WD
& rdy
-K4
(see sheet 3)
Figure 6-3: Wiring diagram: Safety circuit with InverterEnable / sheet 2
53
54
Datum
10.01.06
10.11.09
Name
SE
SE
nderung
Preventa XPS-AV
Erstellt:
Geprft:
Freigabe:
Verteilt:
SE
VM
WR
WD &
rdy
10.11.09
16.11.09
17.11.09
4
6
3
5
4
6
Schneider Electric
WD
MainsWatch
InvEnableActive
EmergencyStop
MainsContactor
MAx-4/ C200
C400 / C600
P600
rdy
4 en
3 ie
MC-4
-A2
ac-power
Netzeinspeisung MC-4 /
Beschaltung Watchdogund Ready-Kontakte
MC en
+24V
L0
-K1
-L1
Line Reactor
-A1
PacDrive Controller
I>
+24V
L0
I>
L3
I>
3 x 400VAC L2
L1
-Q1
Z. Art:
rdy
4 en
3 ie
MC-4
MC en
+24V
L0
-A3
ac-power
Z. Nr.:
EL-810-05-08
BLATT 3
von 3
Connection of Watchdog and Ready contacts for PacDrive controllers
Figure 6-4: Wiring diagram: Watchdog and Ready contacts / sheet 3
Schneider Electric
6.2.4
Commissioning
6.2.5
Carry out a functional test of the STO function for all drives that need the safety
function.
Especially check the correct application of the axes without Inverter Enable func
tion.
Complete installation in accordance with the EMC regulations and further speci
fications in the device operating manuals.
Then commission the drive systems.
Prevention of reasonably foreseeable misuse
WARNING
STAYING IN THE HAZARD AREA
At plant start-up, the connected drives are normally outside the range of vision
of the plant personnel and cannot be monitored directly.
Only start the plant if there are no persons within the working area of moving plant
components and when the plant can be operated safely.
Checkplug
connections
Check all the terminal units, connectors and other connections for a correct and
secure fit.
Only use robust connectors and secure fixings.
Check the protective earth ground 24Vdc PELV supply.
Check the wiring of the safety functions to the axes to avoid an interchange of the
IE input with the 24V supply.
Use coded connectors and perform a commissioning test.
Use only suitable transport packaging to forward or return individual devices.
Acting of The safe state of the motor is the torque-free output shaft. If external forces act upon
external the output shaft, it will not necessarily maintain its position. Take additional precautions
forces if this is one of the safety targets of the hazard and risk analysis.
Hanging &
pulling
loads
WARNING
UNCONTROLLED MOVEMENT OF THE AXES
Do not use the internal holding brake as a safety function.

Only use specified external brakes as safety function.
If a safe blocking from hanging / pulling loads is the safety target of the machine,
then you are only able to perform this by adding an appropriate brake as a safety
function.
The device does not provide its own safe output to connect an external safety brake.
Schneider Electric
55
6.2.6
Maintenance
As the Inverter Enable function has been designed for a defined lifetime (see 6.2.8
Safety standards), no routine checks are necessary to maintain or verify functional
safety. After this lifetime has elapsed a statement about the Inverter Enable function
cannot be made due to the aging of the component. If you want to ensure the func
tionality in terms of safety standards and product liability after this period, you need to
replace the device that includes the safety function.
Subject the device to a complete function test after replacement.
Keep a logbook for tracing the maintenance history of the machine and note the re
placed components (as per EN 62061:2005).
Further information can be found in the "Operating instructions PacDrive MC-4 servo
amplifier".
6.2.7
Physical environment
The system is not protected against physical or chemical sources of danger by any
design features. Possible sources of danger include:
toxic,
explosive,
corrosive,
highly reactive, or
inflammable types.
WARNING
LOSS OF THE INVERTER ENABLE FUNCTION
Observe the ambient, storage and transport temperatures of the individual com
ponents indicated in the operating manuals of the components.
Please prevent the formation of moisture during the operation, storage and trans
port of individual components.
Please adhere to the vibration and shock requirements specified in the operating
manuals for the components when operating, storing and transporting system
components.
In principle, all plugs and plug-in connectors which include InverterEnable must be
designed according to IP54 or higher. Control cabinet devices such as a MC-4 (for
example) do not have this high protection class and are therefore not designed for the
use in an environment according to IP54 or higher (for example, control cabinets).
56
Schneider Electric
6.2.8
Safety standards
The InverterEnable function was developed and tested according to the following
standards for the functional safety:
EN ISO 13849-1:2008
Certification was performed by TV NORD SysTec GmbH & Co. KG (86150 Augsburg,
Germany).
The components that include the InverterEnable function are generally tested accord
ing to
CE
According to the above listed standards, the figures for the devices are as follows:
Standard characteristics
MC-4/
1,5A, 3A, 5A, 10A, 22A
MC-4/50A
PL (cat) (EN ISO 13849-1)

Performance Level (Category)
d (3)
d (3)
MTTFd (EN ISO 13849-1)

Mean Time to Dangerous Failure
4807 years
4035 years
DC (EN ISO 13849-1)

Diagnostic Coverage
77%
56%
Lifetime
15 years
15 years
Note:
The values specified are rounded individually and are therefore not a result of a conversion by e.g. PFH
in MTTFd or the comparative tables from EN ISO13849-1:2008.
Table 6-2: Standard characteristics
Schneider Electric
57
6.3
Extended safety functions for PacDrive MC-4 with SMX Safe PLC
To implement the safety functions, the MC-4 servo amplifier of the PacDrive System
has the "Safe stop" (Save Torque Off) as an integrated safety function. An input on
the MC-4 (InverterEnable) blocks the control signals to the power stage by means of
a positively driven relay. This makes it possible to achieve the safety function described
below:
In the case of a safety request (e.g. emergency stop) by the user, the first reaction of
the controller is a controlled stop.
Then the safe stop is ensured by means of an external safety switching unit by lifting
the Inverter Enable signal (IE).
Controller
MC-4
sercos
SH
SinCos (Hyperface)
IE
Profibus DP, CAN
Figure 6-5: Block diagram: MC-4 servo amplifier speed monitoring and external safety switching
unit
1
Emergency stop switch
Safety switching unit (e.g. BBH SMX12)
The increasing flexibility and complexity of packaging machines also means higher
requirements for the safety functions of a controller. In cooperation with the company
BBH, Schneider Electric offers an alternative solution.
The combination of the SMX Save PLC safety switching unit by BBH and an MC-4
servo amplifier makes it possible to implement the following functions:
58
Safe stop with brake ramp (SS1) in case of safety gate, E stop, jogging, change of
operating mode, i.e. external time control of the brake ramp
Alternatively, additional STO function in case of safety gate, E stop, jogging,
change of operating mode
Several protective circuits (E stop and safety gates work for different drives)
Speed monitoring during setup mode (e.g. jogging while the safety gate is open).
Short reaction time (<20 ms) when the limit speed is exceeded as STO (without
brake ramp).
Stop monitoring (with open safety gate / manual closure of safety gate)
Monitoring of several axes
(with SMX11; Monitoring of one axis)
(with SMX12; Monitoring of up to two axes)
Schneider Electric
6.3 Extended safety functions for PacDrive MC-4 with SMX Safe PLC
6.3.1
When a project is planned, the use of specific protection mechanisms depends es
sentially on the expected risk potential of the application. The risk potential can be
assessed by means of suitable risk analyses taking into account the relevant ambient
conditions. Different requirements for each operating mode (initial operation, jogging,
etc.) and for each piece of equipment (safety gate, cover, etc.) can be assigned to the
safety functions (STO, SS1, SS2, SDI, SLI, etc.).
The following example will demonstrate the implementation of safety functions with
SMX 12. The example is for an application with three drives. Two axes are monitored
with SMX 12. In automatic mode, the three axes can be moved freely by the PacDrive
controller. Depending on the operating mode, the individual axes are controlled by the
PacDrive controller. SMX 12 monitors the corresponding safety function via the en
coder interface and switches the drives to a safe state (STO) in case of an error or
emergency stop. For this purpose, the Inverter Enable signal of the PacDrive MC-4 is
switched off.
SMX12 will only shut off the mains contactor K1 in case of an internal error of the safety
circuit. This means that the mains contactor K1 remains active in case of an emergency
stop or if the safety gate is open.
No safety relevant information is transmitted to the PacDrive controller via a bus in
terface (IOs, Profibus DP, etc.). Only the information concerning which safety element
(emergency stop, safety gate...) was activated is transmitted. This enables the Pac
Drive controller to trigger a controlled stop of the individual axes before SMX 12 puts
them into STO state by means of Inverter Enable. Usually this happens with a delay
of several seconds, so that the PacDrive controller has the opportunity to bring the
axes to a controlled stop.
Figure 6-6: Block diagram - Application proposal for two monitored axes
Schneider Electric
59
The following table shows the reactions of the individual axes to various stop events,
depending on their operating modes.
Master (axis without speed monitoring):
Automatic mode
Emergency stop, opening of the safety gate SS1 (safe stop + brake ramp)
Setup mode
Emergency stop SS1 (safe stop + brake ramp)
Opening the safety gate - no safety function
Slave axis 1, 2 (axes with speed monitoring):
60
Automatic mode
Emergency stop, opening of the safety gate SS1 (safe stop + brake ramp)
Setup mode
Emergency stop SS1 (safe stop + brake ramp)
open safety gate
- with activated JOG button SLI (incremental position restriction) plus SLS
(speed restriction) (plus SDI (direction of rotation))
- for not activated JOG button SS2 (stop monitoring)
Schneider Electric
L0
-S5
open
GuardDoor
-S4
-F1
PE
14 22
13 21
22
21
On
-S6
13
manual
13
23 21
autom.
Mode 14 24 22
-S3
11 21
Off 12 22
-S7
23 13
Jogging 14 24 14
14
-S8
13
Reset
-S2
23
14 24
13
11 21
-K1
X32 ENC2
X31 ENC1
GuardDoor
Jogging
Manual
Off
Reset
On
C400/ C600
P600
L0
+24V
C400-P600 Betrieb
-A1
Axis 2
Axis 1
SMX12
A1
K1-Test
22
-K1
P1
P2
DI01
DI02
DI03
DI04
DI05
DI06
DI07
DI08
DI09
DI10
DI11
DI12
DI13
DI14
X12.3
X12.4
X14.1
X14.2
X14.3
X14.4
X23.1
X23.2
X23.3
X23.4
X24.1
X24.2
X24.3
ieo-Test
X24.4
MainsContactor X12.1
K1-Test
X12.2
E-Stop 12 22
-S1
TP2
TP1
21
X11.1
X11.2
X13.1
X15.1
U24 ext
U24 ext
U_ENC_1
U_ENC_2
ext
ext
ENC_1
ENC_2
Schneider Electric
GND
GND
GND
GND
MC-4
-A3
Vcc_ie
Vcc
MC-4
ieo
ieo
iei
-A4
Vcc_ie
Vcc
ieo
ieo
Inverter Enable
iei
Inverter Enable
-A2
-A1
MainsWatch
InvEnableActive
EmergencyStop
MainsContactor
C400-C600
P600
L0
+24V
PacDrive Controller
PowerA2
Contactor
-K1
A1
WD
& rdy
TP2
MC-4
Inverter Enable
X21.1
iei Vcc
ieo
X21.2
X21.3
X21.4
ieo ieo-Test
X22.1
Vcc_ie
X22.2
X22.3
X22.4
X13.3 EmergencyStop
X13.4
MainsWatch
InverterEnable
EmergencyStop
MainsContactor
DO0-HI
DO0-LO
DO1-HI
DO1-LO
K1.1
K1.2
K2.1
K2.2
DO 0.1
DO 0.2
MainsWatch
14
13
Inverter
Enable
6.3.2
X11.3
X11.4
X13.2
X15.2
24V
Circuit suggestion
Figure 6-7: Circuit suggestion for the control circuit - I/O option
61
L0
-S5
open
GuardDoor
-S4
-F1
PE
14
13
22
21
On
-S8
13
23
Jogging 14 24
-S6
14
13
Off
-S7
22
21
manual
Mode 14 22
-S3
autom.
13 21
Reset
-S2
14
13
Axis 2
Axis 1
X31 ENC1
X32 ENC2
SMX12
-A6
Inverter
Enable
MC-4
-A3
Vcc_ie
Vcc
ieo
ieo
iei
-A4
Vcc_ie
Vcc
ieo
ieo
Inverter Enable
iei
Inverter Enable
MC-4
-A2
TP2
MainsContactor
Profibus DP
PB DP
-A7
SMX52
-A1
MainsContactor
Profibus DP
C400-C600
P600
L0
+24V
PacDrive Controller
PowerA2
Contactor
-K1
A1
WD
& rdy
MC-4
Inverter Enable
X21.1
iei Vcc
ieo
X21.2
X21.3
X21.4
ieo ieo-Test
X22.1
Vcc_ie
X22.2
X22.3
X22.4
X13.3 EmergencyStop
X13.4
K1-Test
22
21
DO0-HI
DO0-LO
DO1-HI
DO1-LO
K1.1
K1.2
K2.1
K2.2
DO 0.1
DO 0.2
-K1
P1
P2
DI01
DI02
DI03
DI04
DI05
DI06
DI07
DI08
DI09
DI10
DI11
DI12
DI13
DI14
X12.3
X12.4
X14.1
X14.2
X14.3
X14.4
X23.1
X23.2
X23.3
X23.4
X24.1
X24.2
X24.3
ieo-Test
X24.4
MainsContactor X12.1
K1-Test
X12.2
E-Stop 12 22
-S1
11 21
TP2
TP1
X11.1
X11.2
X13.1
X15.1
U24 ext
U24 ext
U_ENC_1
U_ENC_2
ext
ext
ENC_1
ENC_2
GND
GND
GND
GND
62
X11.3
X11.4
X13.2
X15.2
24V
Figure 6-8: Circuit suggestion for the control circuit - PROFIBUS DP option
Schneider Electric
Schneider Electric
L1
L2
L3
WD &
rdy
I >I >I >
-Q1
WD
MainsWatch
InvEnableActive
EmergencyStop
MainsContactor
C400-C600
P600
+24V
L0
PacDrive Controller
-A1
Line Reactor
-L1
-K1
rdy
en
iei
ac-power
MC-4
-A2
+24V
L0
rdy
en
iei
ac-power
MC-4
-A3
+24V
L0
rdy
en
iei
ac-power
MC-4
-A4
+24V
L0
Figure 6-9: Circuit suggestion for the power circuit
63
Input / output signals of the SMX

Signal no.
Clamp
Type
Cross circuit
ing test
Description
E.1
E.2
X14.1
X14.2
Emergency stop 1
(2 NC contacts)
Pulse 2
Pulse 1
Triggers emergency stop
E.3
X14.3
Start / Reset
(start element)
OFF
Quits errors of SMX and PLC

Enable operating modes
E.4
X14.4
On
OFF
E.5
E.6
X23.1
X23.2
Preselection of setup
Pulse 2
mode
Pulse 2
Preselection of automat
ic mode (selector switch:
open/close)
Selection of setup mode

Selection of automatic mode
E.7
X23.3
Line off (1 NC contact)
Pulse 1
Machine off switch

- immediate message to PLC
via "ESTOP-PLC"
- Brake ramp time monitored
- then STO
- switch off the mains connec
tor after 5s
In addition, there is a mechan
ical main switch
E.8
E.9
X23.4
X24.1
Enable jogging mode

(2 NC contacts, time
monitored)
Pulse 2
Pulse 1
E.10
E.11
X24.2
X24.3
Safety gate
Pulse 2
(1 NO contact / 1 NC con Pulse 1
tact; time monitored)
E.12
X24.4
IEO_TEST
Pulse 2
Inverter Enable feedback
E.13
X12.1
MAINSCONTACTOR
(1 NO contact)
OFF
PLC message: Enable mains

contacotr when switching on
E.14
X12.2
K1_Test
OFF
Feedback from mains contac

tor
Table 6-3: Input signals of the SMX

Symbol
Clamp
Designation
K1.1
X22.1
Wd&rdy
K1.2
X22.2
K1-POWERCONTACTOR
DO0-HI
X21.1
Inverter Enable (IE)
DO0.1
X13.3
EmergencyStop-message
Description
Message to PacDrive controller
Table 6-4: SMX output signals
64
Schneider Electric
Symbol
Clamp
Designation
Description
U24_ext
X11.1
24 V
24 V supply voltage SMX12
U24_ext
X11.2
24 V
GND_ext
X11.3
L0
GND_ext
X11.4
L0
U_ENC_1
X13.1
n.c.
Do not assign, because encoder supply

from MC-4
GND_ENC_1 X13.2
L0
0 V supply voltage encoder
U_ENC_2
n.c.
Do not assign, because encoder supply

from MC-4
L0
0 V supply voltage encoder
X15.1
GND_ENC_2 X15.2
Table 6-5: Supply voltage for the SMX and the encoder of the MC-4
MC-4 ENC
0&
6XE'PDOH0
;
0RWRU
(QFRGHU
,QSXW
Hiperface Encoder
6XE'IHPDOH0
3LQ5HIVLQ
3LQ6LQ
3LQ5HIFRV
3LQ&RV
(QFRGHU&DEOH
&RQQHFWRU
0RWRU
(QFRGHU
2XWSXW
3LQ99HUVRUJXQJ
3LQ56
3LQ56
3LQ6&B6(/
3LQ*1'

60;
SMX11/12
Sub-D 9 male (M3)
(1&
(1&
3LQQF
;;
3LQ*1'
PD[P
3LQQF
3LQ5HIFRV
3LQ6LQ
3LQ5HIVLQ
3LQQF
3LQ&RV
3LQ9&&
Figure 6-10: Encoder adapter cable for MC-4 with SMX

*)
Combined connector housing
**)
Encoder cable
The knurled-head screws of the D-Sub plug-in connectors on the MC-4, SMX11/12
and the encoder have a M3 thread (no UNC).
Schneider Electric
65
Configuration of SMX 12
Assignment of inputs/outputs
Figure 6-11: SMX 12 assignment of inputs/outputs
Configuration of inputs
The configuration of the input elements is shown in the figures below. Each input el
ement must be assigned the pulses corresponding to the connections. The configu
ration program checks if pulses were assigned alternately and triggers a warning, if
necessary.
66
Schneider Electric
Figure 6-12: Input configuration
Configuration of outputs
Three different types of outputs are used:
1. Relay output:
Addresses the mains contactor.
2. Safe HiLo output:
InverterEnable; only the positively switching output is used.
3. Message output:
Emergency message to the PLC; this signal can also be transmitted via the field
bus.
Figure 6-13: Output configuration
Motor encoder interface

The encoder interface (SINCOS) must be configured depending on the encoder type
used in the motor. If there is only one encoder for each axis, sensor 2 is not used.
Schneider Electric
67
Release SH motor:
Stegmann encoder SKS/SKM 36 with 128 sine/cosine periods
Release SM motor:
Stegmann encoder SRS/SRM 50 with 1024 sine/cosine periods
The monitoring of the supply voltage for the MC-4 is set to 10 V.
Figure 6-14: Configuration of the encoder interface
Logic connections in the function block diagram
Figure 6-15: Function block diagram (FBD) for E-stop and safety gate circuit
In the case of switching off, emergency stop and opening the safety gate in automatic
mode, an E-stop message is immediately sent to the PacDrive controller. Then the
two timers monitor the stop time. Normally, the ESS functions are used to monitor the
brake ramp. However, two effects must be taken into account:
1. The latent time cannot be set longer than 100 ms, which is too short for the MC-4
to lift "ControllerEnable" and the brake to engage.
2. Depending on the motion profile of the drive, the drive may have to accelerate
again. However, the ESS block generates a dynamic brake ramp depending on
68
Schneider Electric
the current velocity. Accordingly, the maximum monitored velocity, during activa
tion of the ESS monitoring module, depends on the current velocity.
For this reason, time monitoring of the brake ramp is preferred in our example.
If a CAN/PROFIBUS DP module is used, wiring requirements can be reduced as the
input information does not need to be connected for the PacDrive controller as well.
The figure below illustrates the monitoring for the setup mode.
There are two monitoring paths that can be activated / deactivated with the JOG button.
When changing into setup mode, a delay time for a brake ramp is monitored, so that
any operation that may be in progress can be stopped when the operating mode is
changed. If the safety gate was already open, the drive is already standing.
Figure 6-16: Function block diagram (FBD) for jogging in setup mode
In this case, the OFF button has an immediate effect on the EmergencyStop signal.
After a set time (e.g. 5 s) the mains contactor is opened.
Schneider Electric
69
Figure 6-17: Function block diagram (FBD) for switching off the mains contactor
All conditions for the activation of Inverter Enable are combined. If a signal is missing,
the STO of the connected MC-4 drives is triggered immediately. The positively driven
IEO contacts are monitored by the output function block itself. If an error is detected,
an alarm is triggered in SMX12, which results in the switch-off of all outputs and thus
the disengagement of the mains contactor K1.
70
Schneider Electric
Figure 6-18: Function block diagram (FBD) for switching off the Inverter Enable signal
Schneider Electric
71
6.3.3
Validation example of the SMX12 safety functions

The following tests only check the correct monitoring limits and the call up of the correct
safety functions. The safety functions for the specific application depend on the out
come of the risk analysis.
Validation of the safety functions used in the example
No.
1
Setting
Test of automatic mode
It must be possible to drive axes 1-3 in
automatic mode
Test emergency stop function

Immediate EmergencyStop message
from SMX to PLC.
PLC must be able to stop drive.
Following a delay (1s) the IE must disen
gage.
Following reset IE switched on again.
The mains contactor must not disengage.
Test of the safety gate function

from SMX to PLC.
PLC must be able to stop the drive.
After a delay, IE must disengage. (Alter
natively, an SOS should be executed)
Following reset IE switched on again.
The mains contactor must not disengage.
Test of the OFF function

from SMX to PLC.
Following delay IE must disengage.
After 5s the mains contactor should dis
engage.
Test activation of the setup mode

from SMX to PLC.
When jogging, move at reduced velocity.
72
Result/comment
Switch on the machine

Automatic mode OK
Select automatic mode
Close safety gate
Quit error(s)
Press the ON button and/or let the ma
chine run
Switch on as described under 1

Emergency stop function
Press emergency stop
OK
Lift emergency stop
Press reset
chine run

safety gate function OK
Open safety gate
Lift safety gate
Press reset
chine run

Press OFF button

Jogging mode OK
Let drives run
Select setup mode
Safety gate may be open or closed (test
both options)
Press JOG button (let drives run)
OFF function OK
Test of safety functions "safely reduced velocity" in setup mode

When jogging at excessive velocity, the
Inverter Enable signal must disengage im
mediately.
In addition, the mains contactor may dis
engage as a following error.
The error can be quitted when the velocity
has been reduced.
Test procedure
Select setup mode.

Velocity monitoring OK
Safety gates may be open or closed (test
both options)
Press JOG button.
(Let drives run at 10% excess velocity)
Test of safety functions "JSS (jogging skip supervision)" in setup mode

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No.
Setting
If the relative maximum path/angle is ex
ceeded, the Inverter Enable signal must
disengage immediately.
Error can be quitted.
Select setup mode.

Position area OK
Safety gate may be open or closed (test
both options)
Press JOG button.
(Let drives move beyond the position
range at rated speed)
Select setup mode.

Zero speed control OK
Safety gate may be open or closed. (test
both options)
Do not press JOB button.
Move drive manually.
Test of mains contactor monitoring "K1 Test"

Mains contactor must not engage.
10
Result/comment
Test of safety functions "ZSC (Zero Speed Control)" in setup mode

If the relative maximum path/angle is ex
ceeded, the Inverter Enable signal must
disengage immediately.
Error can be quitted.
Test procedure
Switch off machine.

Remove the "K1-Test" signal from
SMX12 (simulates a stuck mains con
tactor)
Repeatedly press ON and Reset but
tons.
Mains contactor diagnos

tic OK
Test of the Inverter Enable relay "ieo-Signal"

When the Inverter Enable relay disengag
es, the mains contactor must disengage
as well.
Switch the machine to automatic mode IE relay diagnostic OK

as described under 1.
Move drives.
Remove the "ieo-Signal" from the
SMX12 (simulates a stuck IneverterEn
able relay)
ACtivate emergency stop or safety gate
Table 6-6: Test plan for switching off the Inverter Enable signal
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6.4
Circuit suggestion: PacDrive system with DB-5 and iSH
6.4.1
InverterEnable function
With the Inverter Enable function (IE) you can bring drives to a safe stop. This Inverter
Enable function relates to the components
PS-5
DB-5
iSH
The Inverter Enable function requires further components, e.g. emergency stop, safety
switching unit (optional) and connections. The following chapter describes the correct
use of the Inverter Enable function.
The Inverter Enable function must be used correctly to enable proper operation. Nev
ertheless, the accidental loss of the Inverter Enable function cannot be ruled out. Such
losses are only restricted to the upper limit required by the relevant safety standards.
(see 6.4.8 Safety standards) This is expressed by the following characteristic values:
PFH and SFF according to IEC 61508:2010

MTTF_d and DC_avg according to EN ISO 13849-1
In the sense of the relevant standards, the requirements of the stop category 0 (Safe
Torque Off, STO) and stop category 1 (Safe Stop 1, SS1) can be met. Both categories
lead to a torque-free motor while SS1 takes this state after a predefined time. As a
result of the hazard and risk analysis, it may be necessary to choose an additional
brake as a safety option (e.g. for hanging loads).
Scope of operation (designated safety function)
The Inverter Enable function ranges over PS-5, DB-5 and iSH, referred to as "iSH
System".
The function is selected via a signal (pair) on the input of the PS-5 (2), which is for
warded to all the drives (7) of this PS-5 group. The supply voltage (AC) needs not be
interrupted (see figure below).
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6.4 Circuit suggestion: PacDrive system with DB-5 and iSH
1
2
3
6
AC
IE
Figure 6-19: iSH system with emergency stop

1
control cabinet
PacDrive Power Supply PS-5
Contactor
Safety switching device (e.g. Preventa XPS AV)
PacDrive Distribution Box DB-5
Intelligent Servo Module iSH
Operating prin The Inverter Enable function safely switches off the motor torque. It is sufficient to set
ciple a logical zero at the function input. There is no need to interrupt the power supply.
Standstill, however, is not monitored.
Safe Inverter Enable is synonymous with "Safe Torque Off (STO)" according to IEC
state 61800-5-2:2007. This torque-free state is automatically entered when potential errors
are detected and is therefore the safe state of the drive.
Mode of opera By setting a logical one for the "Inverter Enable" input on the PS-5, the power stage
tion control of all iSH drives connected to this PS-5 become possible (necessary condition).
If, on the other hand, this input is set to a logical zero, the power supply at the Inverter
Enable input is interrupted and no torque can be built up in the connected iSH
drives.
This "Inverter Enable" input has a redundant design (a.c. voltage from which the PS-5
generates d.c. voltage which is fed to the hybrid cables.). The failure of one of the two
channels already results in the logical zero. When the power supply is cut off, the power
stage becomes de-energized, and an diagnostic message is generated. The motor
can no longer generate torque and stops unbraked.
You can use the InverterEnable function to implement the control function "Stopping
in case of emergency" (EN 60204-1) for stop categories 0 and 1. Use a suitable ex
ternal safety circuit to prevent the unexpected restart of the drive after a stop, as re
quired in the machine directive (see application proposal (see 6.4.3 Application pro
posals)).
Stop In stop category 0 (Safe Torque Off, STO) the drive stops in an uncontrolled manner.
category 0 If this means a hazard to your machine, you must take suitable measures (see hazard
and risk analysis).
Stop For stops of category 1 (Safe Stop 1, SS1) you can request a controlled stop via the
category 1 PacDrive Controller. The controlled stop by the PacDrive Controller is not safe, not
monitored and not guaranteed to work in case of power outage or a potential error.
The final switch off in the safe state is ensured by switching off the "Inverter Enable"
input. This has to be implemented by means of an external safety switching device
with safe delay (see application proposal).
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Execute Proceed as follows to deactivate the InverterEnable function:

muting
WARNING
UNCONTROLLED AXIS MOVEMENT
Ensure that no-one has access to the hazard area as long as the DC bus still
has residual charge.
You can deactivate the Inverter Enable function by using the optional module
DIS1.
The safe state can only be achieved if the power supply is switched off.
To avoid misconfigurations, you now have to define the configuration that is to be
used with the parameter InverterEnableConfig of the iSH in the PLC con
figuration.
If the set mode does not match the real configuration of the iSH, then the diagnostic
message 123 Error inverter enable with "Ext. diagnostic = x(HW)!=y(Cfg)" is trig
gered. The drive does not switch to control mode as long as the configuration is wrong.
The error can only be acknowledged if the set InverterEnableConfig corresponds
to the real configuration. This can be used to divide the drives on a PS-5 in two groups
if it is technically not possible to use two PS-5 for the two groups in the existing ma
chine.
If only some of the drives shall be put in the safe state on a PS-5 (1), this can be
achieved via the configuration of the drives. This can be of interest e.g. for cleaning
modes (6). If an optional module DIS1 (9) is set, then the IE signal is ignored. To
implement the emergency stop, the supply voltage on the PS-5 has to be interrupted,
see figure below.
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1
2
3
4
5
AC
IE
PacDrive Power Supply PS-5
control cabinet
Contactor
Safety switching device (e.g. Preventa XPS AV)
Switch: Operating mode (normal/cleaning)
PacDrive Distribution Box DB-5
Intelligent servo module iSH (without DIS1)
Intelligent servo module iSH (with DIS1)
Table 6-7: Implementation of "Emergency stop" and "Cleaning mode with InverterEnable" in
two protective circuits
iSH
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Cleaning
Emergency stop
Parameter InverterEna
ble mode
iSH without DIS1 (8)
Torque-free motor
Torque-free motor
Standard/1
iSH with DIS1 (9)
Torque-free motor
Off/0
77
Validity of the safety case

The safety case for the Inverter Enable function of the iSH system applies to the fol
lowing hardware codes:
UNICODE
Device
Hardware code:
iSH 070/xx
VIA070xxxxxxxxx
xx401xxxxx, xx402xxxxx, xx403xxxxx, xx404xxxxx,

xx511xxxxx, xx512xxxxx, xx513xxxxx, xx514xxxxx
iSH 100/xx
VIA100xxxxxxxxx
iSH 140/xx
VIA140xxxxxxxxx
iSH DIS1
VW3E702000000
1xx
PS-5
VPM02D20xxxx
(e.g. VPM02D20AA00)
xx4xxxxx, xx5xxxxx
DB-5
VBO03Sxx
(e.g. VBO03S00)
2xxxxx, 3xxxxx, 4xxxxx, 5xxxxx
Hybrid cable
VW3E1117Rxxx
VW3E1118Rxxx
VW3E1119Rxxx
VW3E1120Rxxx
VW3E1121Rxxx
Not existing
iSH HCN1
VW3E6007
1xx
A safety case for higher hardware codes is also planned.

For questions on this, please contact your Schneider Electric partner.
Interface and control
The operation of the InverterEnable function takes place via the switching thresholds
of the InverterEnable input (IE1 an Pin1, IE2 an Pin2) on the PS-5.
Technical data of the input:
Max. test pulse width: None

Max. switching frequency of the input signal: 10 Hz
Technical data and information on the electrical connections of the iSH system or the
PS-5 can be found under of the operating instruction "PacDrive Intelligent Servo Mod
ule iSH and Optional Module" or "Power Supply PS-5 and Distribution Box DB-5".
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Response time
WARNING
UNCONTROLLED MOVEMENT OF THE SYSTEM
Should a response time be required because of the risk assessment of the ma

chine, the total response time of the machine has to be considered.
All components related to the safety functions from the sensor to the drive shaft
or the driven mechanics have to be considered.

Response time The response time until the shutdown with the InverterEnable function (without using
with InverterEn the DIS1) is no more than 20 ms. This is the time from the corresponding change of
able the InverterEnable input at the PS-5 to the torque-free motor (Safe Torque Off, STO).
function
Muting re The Muting response time for switching off (i.e. without the Inverter Enable function)
sponse time depends on the load on the machine and has to be determined from the application.
The axes without Inverter Enable function become torque-free via the mains contactor
and come to a stop.
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6.4.2
Setup, installation, and mounting

Prevent possible functional disorder
The following measures prevent a possible functional disorder through conductive
pollution or parts falling into the device:
DANGER
Install PS-5 in a control cabinet or housing of at least IP 54.

Compliance with the clearances and creepage distances according to EN 50178
Avoid overvoltages
To avoid overvoltages in the system, proceed as follows:
DANGER
PacDrive iSH must only be operated with power supplies certified according
to EN 60950 or EN 50178 (so-called "safe voltage outputs"). These power
supply units do not deliver an overvoltage over 120 Vdc for more than 120ms
or no permanent overvoltage over 60 Vdc.
Only operate the drive system with approved, specified cables, accessories- and
spare parts by Schneider Electric.
Avoid unintentional restart
DANGER
UNINTENTIONAL RESTART OF THE MOTOR
Ensure that the restart of the motor (e.g. when the power supply returns after an
outage or after a safety requirement has been removed) to reach the stop cate
gory is only possible after receipt of an enable signal.
Ensure that the enable signal meets the specified safety criteria.
To avoid that the system is in a safe state continuously, proceed as follows:

Observe the specified maximum configuration (number of devices, network struc
ture and cable length), or else a power drop of the InverterEnable signal will occur
over the cable length and therefore the system will be in the safe state continu
ously. The system may only contain max. 4 PS-5, 40 DB-5 and 95 iSH motors.
Do not use pulsed semiconductor outputs with external safety switch devices.
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Perform muting with the optional module DIS1

How to install the optional module DIS1:
Open main switch.
Prevent main switch from being switched back on.
Remove the Green, transparent cover plate on the motor.
Remove plugged in jumpers J1 and J2 (see figure).
J5
J4
J3
J2
J1
Plug optional module DIS1 onto contact pins, as shown in the following figure.
The module is plugged in.
Plug the Green, transparent cover plate on the motor and tighten it.
How to disassemble the optional module DIS1:

Open main switch.
Prevent main switch from being switched back on.
Remove the Green, transparent cover plate on the motor.
Remove the optional module DIS1.
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81
Plug in jumpers J1 and J2 (see figure).
J5
J4
J3
J2
J1
6.4.3
Plug the Green, transparent cover plate on the motor and tighten it.
Application proposals
There are three application proposals to implement the safe stop of category 1 (SS1):
EL-1054-05-xx: InverterEnable circuit iSH/PS-5 using the PacDrive Controller

Cx00 with safety switch device for two protective circuits
EL-1055-05-xx: InverterEnable circuit iSH/PS-5 and MC-4 using the PacDrive
Controller Cx00 with safety switch device for two protective circuits
EL-1056-05-xx: InverterEnable circuit iSH/PS-5 and DIS1 when using the PacDrive
Controller Cx00 with a safety switch device
Notes on application proposals

General
All application proposals provide for a protected IE+/IE- wiring (control cabinet
IP54) from the safety switch device to the PS-5, as faults need to be ruled out.
All application proposals are designed with two protective circuits (emergency stop
and safety gate). As required, one of those can be removed.
Protection against automatic restart is ensured by the external safety switch device.
Notes on The mains contactor K1 in this circuit proposal is not necessary for functional safety
EL-1054 purposes. It is, however, used in the application proposal for the device protection of
PS-5/iSHs.
Notes on To monitor the mains contactor, the positively driven contacts of the mains contactor
EL-1055 K1 must be monitored by the PacDrive Controller when switching it on. This can be
accomplished by using the ContactorControl software component either separately

or integrated into the template.
Notes on To monitor the mains contactors, the positively driven contacts of the mains contactors
EL-1056 K1 and K2 must be monitored by the PacDrive Controller when switching them on.
This can be accomplished by using the ContactorControl software component either

separately or integrated into the template.
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Schneider Electric
Figure 6-20: EL-1054-05-xx Sheet 1

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84
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86
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88
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89
90
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6.4.4
Commissioning
6.4.5
Carry out a functional test of the STO function for all drives that need the safety
function.
Especially check the correct application of the axes without Inverter Enable func
tion.
Complete installation in accordance with the EMC regulations and further speci
fications in the device operating manuals.
Then commission the drive systems.
Prevention of reasonably foreseeable misuse
WARNING
STAYING IN THE HAZARD AREA
At plant start-up, the connected drives are normally outside the range of vision
of the plant personnel and cannot be monitored directly.
Only start the plant if there are no persons within the working area of moving plant
components and when the plant can be operated safely.
Checkplug
connections
Check all terminals, connectors and other connections on all system components
for correct and firm fit.
Only use robust connectors and secure fixings.
Check the protective earth ground 24Vdc PELV supply.
Check the wiring of the safety function to the axes to avoid an interchange of the
IEA and IEB inputs as well as the 24V supply.
Use coded connectors and perform a commissioning test.
Use only suitable transport packaging to forward or return individual devices.
Acting of The safe state of the motor is the torque-free output shaft. If external forces act upon
external the output shaft, it will not necessarily maintain its position. Take additional precautions
forces if this is one of the safety targets of the hazard and risk analysis.
Hanging &
pulling
loads
WARNING
UNCONTROLLED MOVEMENT OF THE AXES
Do not use the internal holding brake as a safety function.

Only use specified external brakes as safety function.
If a safe blocking from hanging / pulling loads is the safety target of the machine,
then you are only able to perform this by adding an appropriate brake as a safety
function.
The device does not provide its own safe output to connect an external safety brake.
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6.4.6
Maintenance
As the Inverter Enable function has been designed for a defined lifetime (see 6.4.8
Safety standards), no routine checks are necessary to maintain or verify functional
safety. After this lifetime has elapsed a statement about the Inverter Enable function
cannot be made due to the aging of the component. If you want to ensure the func
tionality in terms of safety standards and product liability after this period, you need to
replace the device that includes the safety function.
Subject the device to a complete function test after replacement.
Keep a logbook for tracing the maintenance history of the machine and note the re
placed components (as per EN 62061:2005).
See the "Installation and Maintenance" of this operating instruction chapter for infor
mation about initial start-up and maintenance.
6.4.7
Physical environment
The system is not protected against physical or chemical sources of danger by any
design features. Possible sources of danger include:
toxic,
explosive,
corrosive,
highly reactive, or
inflammable types.
WARNING
LOSS OF THE INVERTER ENABLE FUNCTION
Observe the ambient, storage and transport temperatures of the individual com
ponents indicated in the operating manuals of the components.
Please prevent the formation of moisture during the operation, storage and trans
port of individual components.
Please adhere to the vibration and shock requirements specified in the operating
manuals for the components when operating, storing and transporting system
components.
In principle, all plugs and plug-in connectors which include InverterEnable must be
designed according to IP54 or higher. Control cabinet devices like for example an PS-5
do not possess this high protection class and are therefore only intended for use in
environments according to IP54 or higher (e.g. control cabinets).
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93
6.4.8
Safety standards
The InverterEnable function was developed and tested according to the following
standards for the functional safety:
IEC 61508: 2010

IEC 61800-5-2: 2007
EN ISO 13849-1:2008
IEC 62061:2005
Certification was performed by TV NORD SysTec GmbH & Co. KG (86150 Augsburg,
Germany).
The components that include the InverterEnable function are generally tested accord
ing to
CE
cULus
According to the above listed standards, the figures for the devices are as follows:
Standard characteristics
PS-5
iSH
SFF (IEC 61508)

Safe Failure Fraction
99.9%
100%
HFT (IEC 61508)

Hardware Fault Tolerance
Type (IEC 61508)
SIL (IEC 61508)

Safety Integrity Level
SILCL (IEC 62061)
Safety Integrity Level claim limit
PFH (IEC 61508)

Probabilty of Dangerous Failures per
Hour
3.66*10-9/h
PL (cat) (EN ISO 13849-1)

Performance Level (Category)
e (3)
e (3)
MTTFd (EN ISO 13849-1)

Mean Time to Dangerous Failure
408 years
n/a (see PFH = 0)
DC (EN ISO 13849-1)

Diagnostic Coverage
99.1%
100%
Lifetime
15 years
15 years
DB-5: in proportion to PS-5 and iSH included

Note:
The values specified are rounded individually and are therefore not a result of a conversion by e.g. PFH
in MTTFd or the comparative tables from EN ISO13849-1:2008.
Table 6-8: Standard characteristics
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7.1 Increased ambient temperature
Special Conditions
7.1
Increased ambient temperature

If the ambient temperature exceeds 40C / 104F, then the performance of the entire
system is reduced.
The permissible ambient temperature for the MC-4 servo amplifier and the PS-5 power
supply is 45 C / 113 F. At higher ambient temperatures up to max. 55 C / 131 F
the rated current drops 2 % per C.
1
1
0,8
0,6
0,4
0,2
0
35
40
45
50
55
Figure 7-1: Power reduction by increased ambient temperature

1
Capacity factor
Ambient temperature C
The maximum permissible ambient temperature for the PacDrive Controllers is 55 C /

131 F.
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95
7 Special Conditions
7.2
Low air pressure

If the installation altitude exceeds the specified rated installation altitude, the perform
ance of the entire system is reduced.
No power reduction is necessary below an altitude of 1000 m above sea level. Above
an altitude of 1000 m, the maximum rated current should be reduced as shown in the
diagram below. This applies to both the MC-4 servo amplifier and the PS-5 power
supply.
1
1
0,8
0,6
0,4
0,2
1000
2000
3000
Figure 7-2: Power reduction at increased installation altitude

1
Capacity factor
Setup factor via NN in m
Multiply the values with the permanent current at 40C / 104F in order to receive the
final permanent current value, depending on the required installation altitude.
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7.3 Long cable
7.3
Long cable
Power reduction of MC-4 servo amplifier with long motor cables
The load on the end stage increases because of increasing cable capacitance when
long motor cables are used. This causes additional heating in the end stage. For cables
> 15 m, the rated current may need to be reduced. With PacDrives MC-4 / 1.5 A ; 3 A;
5 A, for example, the rated current has to be reduced to 75 % for a 40 m long cable
(see table below).
1
1
MC-4 / 22 A
MC-4 / 10 A
MC-4 / 1,5 A;3 A;5 A
0,8
0,6
0,4
0,2
2
0
10
20
Capacity factor
Motor cable length in m
30
40
Table 7-1: Power reduction with long motor cables

Power reduction with motor cables longer than 15 m
Servo Drives
PacDrive MC-4 / 1.5 A ; 3 A; 5 A
-1 % / m
PacDrive MC-4 / 10 A
-0.6 % / m
PacDrive MC-4 / 22 A
-0.5 % / m
Table 7-2: Power reduction dependant on motor cable length
If a power reduction is required for several reasons, the corresonding load factors must
be multiplied.
Lengths for connection cables of the iSH drive system
The maximum cable length of the PS-5 up to the last DB-5 is 20 m.
The maximum cable length of the DB-5 up to the iSH is 5 m.
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97
Index
Index
A
iSH 82
Air pressure 96
Ambient temperature 95
life support systems 7

Load circuit 39
Long motor cables 97
Braking 37
C
Climatic 12
Condensate 18
Contactors 48
Control circuit 40
Cooling units 18
D
DC circuit 37
Degree of protection 12
domestic appliances 7
Drag chains 20
Machine grounding 19
Mains chokes 30
Mains contactor 32
Mains contactor group 30
Mains filter 26
Mains power supply 31
Maximum configuration 80
MC-4 51
Mechanical 12
Minimum bending radius 20
Minimum cross sections 19
Misuse 55, 92
mobile systems 7
Muting 76
O
Optical fiber cables 20
Opto-coupler 43
Emergency stop 75
P
F
Fault currents 33
floating systems 7
flying systems 7
Function block diagram 68
H
Hazard and risk analysis 42, 55, 92
hazardous, explosive atmospheres 7
Hazards 8
Heat dissipation 14
Hot spot 13
Hybrid cable 20
I
Input capacitance 37
Input elements 66
Installation 47, 80
InverterEnable 41, 44
InverterEnable input 75, 78
98
portable systems 7
Power reduction 95
Q
Qualification of Personnel 8
Qualified person 8
R
Ready contact 41
Residual risks 8
S
Safe state 75
Safe stop 41, 43, 74
Safety function 74
Safety switching unit 48
Standards 57, 94
Stop category 0 43, 74, 75
Stop category 1 43, 74, 75
Schneider Electric
Index
Symbols 6
T
Temperature limit 18
Three-phase supply systems 31
Training 8
U
underground 7
V
Voltage monitoring 37
W
Watchdog 41
Wiring 19
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Projecting

(Translation of the original German Operating Manual)

The information provided in this documentation contains general descriptions and/or

PacDrive Projecting Notes

About this manual

Symbols, designator and display format of safety messages .................................. 5

Proper use ................................................................................................................ 7

Qualification of Personnel ........................................................................................ 8

Residual risks ........................................................................................................... 8

Control cabinet planning

Degree of protection ............................................................................................... 12

Mechanical and climatic environmental conditions in the control cabinet .............. 12

ESD protection measures ...................................................................................... 12

Control cabinet installation of Schneider Electric components ...............................

Bending radii, tightening torques and wire cross sections ..................................... 19

Electromagnetic compatibility, EMC ....................................................................... 24

Mains connection PacDrive MC-4 servo amplifier ..................................................

PacDrive Projecting Notes

Basic Design and Connection

Load circuit ............................................................................................................. 39

Control circuit ......................................................................................................... 40

Functional safety - safety connections

Process minimizing risks associated with the machine .......................................... 42

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

Increased ambient temperature ............................................................................. 95

Low air pressure ..................................................................................................... 96

Long cable .............................................................................................................. 97

PacDrive Projecting Notes

About this manual

Symbols, designator and display format of safety messages

equipment to warn of potential hazards or to call attention to information that clarifies

PacDrive Projecting Notes

1 About this manual

The following symbols and designators are used in this document:

(1), (2), (3)

If the descriptive text contains keywords, such as parameters, they are

PacDrive Projecting Notes

2.1 Proper use

The components must not be used in the following environments:

In hazardous (explosive) atmospheres

(performance data and ambient conditions). Commissioning is prohibited until the

EN 61800-3 Adjustable speed electrical power drive systems - Part 3: EMC re

EN 61800-5-1:2007 Adjustable speed electrical power drive systems - Part 5-1:

PacDrive Projecting Notes

to recognize and avoid the hazards involved.

PacDrive Projecting Notes

2.3 Residual risks

Assembly and handling

Failure to follow these instructions can result in death or serious injury.

Do not stand under hanging loads.

Failure to follow these instructions can result in death or serious injury.

High leakage current

Failure to follow these instructions will result in death or serious injury.

Touching hot surfaces

Failure to follow these instructions can result in injury.

PacDrive Projecting Notes

Touching electrical parts

Do not allow personnel with pacemakers or similar sensitive implants to work in

Failure to follow these instructions can result in death or serious injury.

Missing or incorrect homing of the drive

Failure to follow these instructions will result in death or serious injury.

PacDrive Projecting Notes

2.3 Residual risks

Failure to follow these instructions will result in death or serious injury.