Product Manual

Servo Positioning Controller ARS 2100 FS

designed for Functional Safety

Metronix Meßgeräte und Elektronik GmbH Phone: +49-(0)531-8668-0

Kocherstraße 3 Telefax: +49-(0)531-8668-555

38120 Braunschweig E-mail: [email protected]

Germany http://www.metronix.de
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Translation of the original instructions

Copyrights

© 2015 Metronix Meßgeräte und Elektronik GmbH. All rights reserved.

The information and data in this document have been composed to the best of our knowledge.
However, deviations between the document and the product cannot be excluded entirely. For the
devices and the corresponding software in the version handed out to the customer, Metronix
guarantees the contractual use in accordance with the user documentation. In the case of serious
deviations from the user documentation, Metronix has the right and the obligation to repair, unless it
would involve an unreasonable effort. A possible liability does not include deficiencies caused by
deviations from the operating conditions intended for the device and described in the user
documentation.

Metronix does not guarantee that the products meet the buyer’s demands and purposes or that they
work together with other products selected by the buyer. Metronix does not assume any liability for
damages resulting from the combined use of its products with other products or resulting from
improper handling of machines or systems.

Metronix Meßgeräte und Elektronik GmbH reserves the right to modify, amend, or improve the
document or the product without prior notification.

This document may, neither entirely nor in part, be reproduced, translated into any other natural or
machine-readable language nor transferred to electronic, mechanical, optical or any other kind of data
media, without expressive authorisation by the author.

Trademarks

Any product names in this document may be registered trademarks. The sole purpose of any
trademarks in this document is the identification of the corresponding products.

ServoCommander® is a registered trademark of Metronix Meßgeräte und Elektronik GmbH.

Product Manual “Servo Positioning Controller ARS 2100 FS“ Version 5.0
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Revision Information

Author: Metronix Meßgeräte und Elektronik GmbH

Manual title: Product Manual „Servo Positioning Controller ARS 2100 FS“

File name: P-HB_ARS2100_FS_5p0_EN.docx

Version 5.0 August 2015

Product Manual “Servo Positioning Controller ARS 2100 FS“ Version 5.0
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TABLE OF CONTENTS:

1 GENERAL ........................................................................................................ 15
1.1 Documentation........................................................................................ 15
1.2 Scope of supply ...................................................................................... 16

2 SAFETY NOTES FOR ELECTRICAL DRIVES AND CONTROLLERS ........... 17

2.1 Used symbols ......................................................................................... 17
2.2 General notes .......................................................................................... 18
2.3 Danger resulting from misuse ............................................................... 20
2.4 Safety notes ............................................................................................ 21
2.4.1 General safety notes .................................................................. 21
2.4.2 Safety notes for assembly and maintenance ............................. 23
2.4.3 Protection against contact with electrical parts .......................... 25
2.4.4 Protection against electrical shock by means of
protective extra-low voltage (PELV) ........................................... 26
2.4.5 Protection against dangerous movements ................................. 26
2.4.6 Protection against contact with hot parts ................................... 27
2.4.7 Protection during handling and assembly .................................. 28

3 PRODUCT DESCRIPTION ............................................................................... 29

3.1 General .................................................................................................... 29
3.2 Power supply .......................................................................................... 32
3.2.1 Single-phase AC supply with active PFC ................................... 32
3.2.1.1 Behaviour during switch-on ...................................................................32
3.2.1.2 Behaviour during normal operation and control characteristics ............33
3.2.2 DC bus coupling, DC supply ...................................................... 34
3.2.2.1 DC bus coupling ....................................................................................34
3.2.2.2 DC supply ..............................................................................................34
3.2.3 Mains fuse ................................................................................. 34
3.3 Brake chopper......................................................................................... 35
3.4 Communication interfaces ..................................................................... 35
3.4.1 Serial interface [X5].................................................................... 36
3.4.2 USB interface [X19] ................................................................... 36
3.4.3 UDP interface [X18] ................................................................... 36
3.4.4 CAN interface [X4] ..................................................................... 36
3.4.5 Technology module: PROFIBUS ............................................... 37
3.4.6 Technology module: Sercos II ................................................... 37

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3.4.7 Technology module: EtherCAT .................................................. 37

3.4.8 I/O functions and device control ................................................. 37

4 TECHNICAL DATA .......................................................................................... 39

4.1 General Technical data .......................................................................... 39
4.2 Operating and display elements............................................................ 41
4.3 Supply [X9] .............................................................................................. 42
4.4 Motor connection [X6] ............................................................................ 44
4.4.1 Current derating ......................................................................... 44
4.5 Motor feedback connection [X2A] and [X2B] ....................................... 49
4.5.1 Resolver connection [X2A] ......................................................... 50
4.5.2 Encoder connection [X2B] ......................................................... 51
4.6 Communication interfaces ..................................................................... 53
4.6.1 RS232 [X5] ................................................................................ 53
4.6.2 USB [X19] .................................................................................. 53
4.6.3 Ethernet [X18] ............................................................................ 54
4.6.4 CAN bus [X4] ............................................................................. 54
4.6.5 SD/MMC card ............................................................................ 54
4.6.6 I/O interface [X1] ........................................................................ 55
4.6.7 Incremental encoder input [X10] ................................................ 56
4.6.8 Incremental encoder output [X11] .............................................. 57

5 FUNCTION OVERVIEW ................................................................................... 58

5.1 Motors...................................................................................................... 58
5.1.1 Synchronous servo motors ........................................................ 58
5.1.2 Linear motors ............................................................................. 58
5.2 Functions of the servo positioning controller ARS 2100 FS............... 59
5.2.1 Compatibility .............................................................................. 59
5.2.2 Pulse width modulation (PWM) .................................................. 60
5.2.3 Setpoint management ................................................................ 60
5.2.4 Torque-controlled mode ............................................................. 61
5.2.5 Speed-controlled mode .............................................................. 61
5.2.6 Torque-limited speed control ..................................................... 62
5.2.7 Synchronization to the external clock signal .............................. 62
5.2.8 Load torque compensation for vertical axes .............................. 62
5.2.9 Positioning and position control ................................................. 62
5.2.10 Synchronisation, electronic gearing ........................................... 63
5.2.11 Brake management.................................................................... 63

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5.3 Positioning control ................................................................................. 64

5.3.1 Overview .................................................................................... 64
5.3.2 Relative positioning .................................................................... 65
5.3.3 Absolute positioning ................................................................... 65
5.3.4 Driving profile generator ............................................................. 65
5.3.5 Homing ...................................................................................... 66
5.3.6 Positioning sequences ............................................................... 67
5.3.7 Optional stop input ..................................................................... 67
5.3.8 Contouring control with linear interpolation ................................ 67
5.3.9 Time-synchronized multi-axis positioning .................................. 68

6 FUNCTIONAL SAFETY TECHNOLOGY ......................................................... 69

6.1 General .................................................................................................... 69
6.1.1 DIP switch .................................................................................. 70
6.1.2 Assignment of the DIP switch .................................................... 71
6.2 Integrated safety technology (schematic representation) .................. 73
6.3 Module variants ...................................................................................... 74
6.3.1 FBA module ............................................................................... 74
6.3.2 FSM 2.0 – STO (Safe Torque Off) ............................................. 75
6.3.3 FSM 2.0 – MOV ......................................................................... 75

7 MECHANICAL INSTALLATION ....................................................................... 76

7.1 Important notes....................................................................................... 76
7.2 View of the device................................................................................... 78
7.3 Mounting ................................................................................................. 80

8 ELECTRICAL INSTALLATION ........................................................................ 81

8.1 Connector configuration ........................................................................ 81
8.2 ARS 2100 FS complete system.............................................................. 82
8.3 Connection: Power supply [X9] ............................................................. 84
8.3.1 Device side [X9] ......................................................................... 84
8.3.2 Counterplug [X9] ........................................................................ 84
8.3.3 Pin assignment [X9] ................................................................... 85
8.3.4 Cable type and design [X9] ........................................................ 85
8.3.5 Connection notes [X9]................................................................ 86
8.4 Connection: Motor [X6] .......................................................................... 87
8.4.1 Device side [X6] ......................................................................... 87
8.4.2 Counterplug [X6] ........................................................................ 87
8.4.3 Pin assignment [X6] ................................................................... 88

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8.4.4 Cable type and design [X6] ........................................................ 88

8.4.5 Connection notes [X6]................................................................ 89
8.5 Connection: I/O communication [X1] .................................................... 91
8.5.1 Device side [X1] ......................................................................... 93
8.5.2 Counterplug [X1] ........................................................................ 93
8.5.3 Pin assignment [X1] ................................................................... 94
8.5.4 Cable type and design [X1] ........................................................ 95
8.5.5 Connection notes [X1]................................................................ 95
8.6 Connection: Resolver [X2A] .................................................................. 96
8.6.1 Device side [X2A]....................................................................... 96
8.6.2 Counterplug [X2A]...................................................................... 96
8.6.3 Pin assignment [X2A]................................................................. 96
8.6.4 Cable type and design [X2A] ..................................................... 97
8.6.5 Connection notes [X2A] ............................................................. 97
8.7 Connection: Encoder [X2B] ................................................................... 98
8.7.1 Device side [X2B]....................................................................... 98
8.7.2 Counterplug [X2B]...................................................................... 98
8.7.3 Pin assignment [X2B]................................................................. 99
8.7.4 Cable type and design [X2B] ................................................... 101
8.7.5 Connection notes [X2B] ........................................................... 102
8.8 Connection: Incremental encoder input [X10] ................................... 104
8.8.1 Device side [X10] ..................................................................... 104
8.8.2 Counterplug [X10] .................................................................... 104
8.8.3 Pin assignment [X10] ............................................................... 104
8.8.4 Cable type and design [X10] .................................................... 105
8.8.5 Connection notes [X10]............................................................ 105
8.9 Connection: Incremental encoder output [X11] ................................. 106
8.9.1 Device side [X11] ..................................................................... 106
8.9.2 Counterplug [X11] .................................................................... 106
8.9.3 Pin assignment [X11] ............................................................... 106
8.9.4 Cable type and design [X11] .................................................... 107
8.9.5 Connection notes [X11]............................................................ 107
8.10 Connection: CAN-Bus [X4] .................................................................. 108
8.10.1 Device side [X4] ....................................................................... 108
8.10.2 Counterplug [X4] ...................................................................... 108
8.10.3 Pin assignment [X4] ................................................................. 108
8.10.4 Cable type and design [X4] ...................................................... 109
8.10.5 Connection notes [X4].............................................................. 109

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8.11 Connection: RS232/COM [X5] .............................................................. 111

8.11.1 Device side [X5] ....................................................................... 111
8.11.2 Counterplug [X5] ...................................................................... 111
8.11.3 Pin assignment [X5] ................................................................. 111
8.11.4 Cable type and design [X5] ...................................................... 112
8.11.5 Connection notes [X5].............................................................. 112
8.12 Connection: USB [X19] ........................................................................ 113
8.12.1 Device side [X19] ..................................................................... 113
8.12.2 Counterplug [X19] .................................................................... 113
8.12.3 Pin assignment [X19] ............................................................... 113
8.12.4 Cable type and design [X19] .................................................... 113
8.13 SD/MMC card......................................................................................... 114
8.13.1 Supported card types ............................................................... 114
8.13.2 Supported functions ................................................................. 114
8.13.3 Supported file systems............................................................. 114
8.13.4 File names ............................................................................... 114
8.13.5 Pin assignment SD/MMC card ................................................. 115
8.13.6 BOOT-DIP-Switch .................................................................... 116
8.14 Notes on safe and EMC-compliant installation .................................. 117
8.14.1 Definitions and terms ............................................................... 117
8.14.2 General information on EMC ................................................... 117
8.14.3 EMC areas: first and second environment ............................... 118
8.14.4 EMC-compliant cabling ............................................................ 118
8.14.5 Operation with long motor cables............................................. 119
8.14.6 ESD protection ......................................................................... 120

9 ADDITIONAL REQUIREMENTS FOR THE SERVO DRIVES

CONCERNING THE UL APPROVAL ............................................................. 121
9.1 Circuit protection .................................................................................. 121
9.2 Wiring and environment regards......................................................... 121
9.3 Motor temperature sensor ................................................................... 121

10 INITIAL OPERATION ..................................................................................... 122

10.1 General notes on connection .............................................................. 122
10.2 Tools / material ..................................................................................... 122
10.3 Connecting the motor .......................................................................... 123
10.4 Connecting the servo positioning controller ARS 2100 FS to
the power supply .................................................................................. 123
10.5 Connecting the PC (serial interface) ................................................... 123

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10.6 Connecting the PC (USB interface, alternative) ................................. 124

10.7 Checking operability ............................................................................ 124

11 SERVICE FUNCTIONS AND ERROR MESSAGES....................................... 125

11.1 Protection and service functions ........................................................ 125
11.1.1 Overview .................................................................................. 125
11.1.2 Overcurrent and short-circuit monitoring .................................. 125
11.1.3 Overvoltage monitoring for the DC bus .................................... 126
11.1.4 Temperature monitoring of the heat sink ................................. 126
11.1.5 Monitoring of the motor ............................................................ 126
11.1.6 I²t monitoring ............................................................................ 126
11.1.7 Power monitoring for the brake chopper .................................. 127
11.1.8 I²t monitoring for the PFC stage ............................................... 127
11.1.9 Initial operation status .............................................................. 127
11.1.10 Rapid discharge of the DC bus ................................................ 127
11.1.11 Operating hours counter .......................................................... 127
11.2 Display of operating mode and error messages ................................ 128
11.2.1 Operating mode and error display............................................ 128
11.2.2 Error messages........................................................................ 129

12 TECHNOLOGY MODULES ............................................................................ 166

12.1 EA88 interface (terminal extension) .................................................... 166
12.1.1 Product description .................................................................. 166
12.1.2 Technical data.......................................................................... 166
12.1.2.1 General data ........................................................................................166
12.1.2.2 Digital inputs ........................................................................................167
12.1.2.3 Digital outputs ......................................................................................167
12.1.3 Pin assignment and cable specifications ................................. 168
12.1.3.1 Power supply .......................................................................................168
12.1.3.2 Pin assignments ..................................................................................168
12.1.3.3 Counterplug .........................................................................................169
12.1.3.4 Connection notes .................................................................................169

12.2 PROFIBUS-DP interface ....................................................................... 170

12.2.1 Product description .................................................................. 170
12.2.2 Technical data.......................................................................... 170
12.2.3 Pin assignments and cable specifications ................................ 172
12.2.3.1 Pin assignment ....................................................................................172
12.2.3.2 Counterplug .........................................................................................172
12.2.3.3 Cable type and configuration ...............................................................172
12.2.4 Termination and bus terminating resistors ............................... 173
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12.3 Sercos II module ................................................................................... 174

12.3.1 Product description .................................................................. 174
12.3.2 Technical data.......................................................................... 175
12.3.3 Optical waveguide specification ............................................... 176
12.4 EtherCAT ............................................................................................... 177
12.4.1 Product description .................................................................. 177
12.4.2 Characteristics of the EtherCAT technology module................ 177
12.4.3 Technical data.......................................................................... 178
12.4.4 Display elements...................................................................... 179
12.4.5 EtherCAT interface .................................................................. 179
12.5 MC 2000 “Drive-In” 4-Axis Motion Coordinator ................................. 180
12.5.1 Product description .................................................................. 180
12.5.2 Features ................................................................................... 181
12.5.2.1 Compact...............................................................................................181
12.5.2.2 Fast ......................................................................................................182
12.5.2.3 Easy .....................................................................................................182
12.5.3 Technical data.......................................................................... 183
12.6 General installation notes for technology modules .......................... 184

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Table of Figures:

Figure 1: Type key .......................................................................................................................29

Figure 2: Schematic setup of PFC stage .....................................................................................33

Figure 3: Performance curve of the PFC stage ...........................................................................43

Figure 4: Control scheme of the ARS 2100 FS............................................................................59

Figure 5: Driving profiles of servo positioning controller ARS 2100 FS .......................................65

Figure 6: Path program ................................................................................................................67

Figure 7: Linear interpolation between two data values ..............................................................68

Figure 8: Schematic representation of the integrated safety technology (MOV) .........................73

Figure 9: FBA module: Front view ...............................................................................................74

Figure 10: Servo positioning controller ARS 2100 FS: Installation space .....................................77

Figure 11: Servo positioning controller ARS 2102 FS: Front view.................................................78

Figure 12: Servo positioning controller ARS 2102 FS: Top view ...................................................79

Figure 13: Servo positioning controller ARS 2102 FS: Bottom view..............................................79

Figure 14: Servo positioning controller ARS 2100 FS: Mounting plate .........................................80

Figure 15: Connection to power supply and motor ........................................................................81

Figure 16: Complete setup of the ARS 2100 FS with motor and PC .............................................83

Figure 17: Supply [X9]....................................................................................................................86

Figure 18: Motor connection [X6] ...................................................................................................89

Figure 19: Connecting a holding brake with high current draw (> 1A) to the device .....................90

Figure 20: Basic circuit diagram connector [X1] ............................................................................92

Figure 21: Pin assignment: Resolver connection [X2A] .................................................................97

Figure 22: Pin assignment: Analog incremental encoder – optional [X2B] ..................................102

Figure 23: Pin assignment: Incremental encoder with serial communication interface
(for example EnDat, HIPERFACE) – optional [X2B] ..................................................102

Figure 24: Pin assignment: Digital incremental encoder – optional [X2B] ...................................103

Figure 25: Pin assignment: Input of the incremental encoder [X10] ............................................105

Figure 26: Pin assignment: Incremental encoder output [X11] ....................................................107

Figure 27: Cabling example for CAN-Bus ....................................................................................109

Figure 28: Integrated CAN terminating resistor ...........................................................................110

Figure 29: Pin assignment: RS232 null modem cable [X5] .........................................................112

Figure 30: Pin assignment: USB interface [X19], front view ........................................................113

Figure 31: Pin assignment: SC/MMC card...................................................................................115

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Figure 32: E88: Position of the pin-and-socket connectors [X21] and [X22] at the
front plate ....................................................................................................................169

Figure 33: PROFIBUS-DP interface: Front view ..........................................................................171

Figure 34: PROFIBUS-DP interface: Connection with external terminating resistors .................173

Figure 35: Sercos II module: Front view ......................................................................................175

Figure 36: EtherCAT module: Front view.....................................................................................178

Figure 37: MC 2000 4-Axis Motion Coordinator...........................................................................181

Figure 38: MC 2000 4-Axis Motion Coordinator maximum capacity............................................181

Figure 39: Servo positioning controller with integrated technology module

MC 2000 (example) ....................................................................................................184

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Table of Tables:
Table 1: Scope of supply ............................................................................................................16

Table 2: Connector set: POWER connector ...............................................................................16

Table 3: Connector set: DSUB connector...................................................................................16

Table 4: Connector set: Shield connector...................................................................................16

Table 5: Technical data: Ambient conditions and qualification ...................................................39

Table 6: Technical data: Dimensions and weight .......................................................................39

Table 7: Technical data: Cable specifications ............................................................................40

Table 8: Technical data: Motor temperature monitoring .............................................................40

Table 9: Display elements and RESET button ...........................................................................41

Table 10: Technical data: Performance data [X9] ........................................................................42

Table 11: Technical data: Internal brake resistor [X9] ..................................................................42

Table 12: Technical data: External brake resistor [X9] .................................................................42

Table 13: Performance data of PFC stage ...................................................................................43

Table 14: Technical data: Motor connection [X6] .........................................................................44

Table 15: ARS 2102 FS: Rated current for an ambient temperature of ≤ 40 °C ..........................46

Table 16: ARS 2105 FS: Rated current for an ambient temperature of ≤ 40 °C ..........................46

Table 17: ARS 2108 FS: Rated current for blocked or slowly rotated
servo motor (fel) ≤ 2 Hz and for an ambient temperature of ≤ 40 °C ............................47

Table 18: ARS 2108 FS: Rated current for rotated servo motor (fel) ≥ 3 Hz and
for an ambient temperature of ≤ 40 °C .........................................................................48

Table 19: Technical data: Resolver [X2A] ....................................................................................50

Table 20: Technical data: Resolver interface [X2A] .....................................................................50

Table 21: Technical data: Encoder evaluation [X2B] ....................................................................51

Table 22: Technical data: RS232 [X5] ..........................................................................................53

Table 23: Technical data: USB [X19] ............................................................................................53

Table 24: Technical data: Ethernet [X18] .....................................................................................54

Table 25: Technical data: CAN bus [X4].......................................................................................54

Table 26: Technical data: SD/MMC card ......................................................................................54

Table 27: Technical data: Digital inputs and outputs [X1] ............................................................55

Table 28: Technical data: Analog inputs and outputs [X1] ...........................................................56

Table 29: Technical data: Incremental encoder input [X10] .........................................................56

Table 30: Technical data: Incremental encoder output [X11] .......................................................57

Table 31: Output voltage at the motor terminals in the case of a DC bus circuit
voltage (UZK) of 360 V ...................................................................................................60

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Table 32: Table overview of the DIP switch functionality .............................................................70

Table 33: Fieldbus specific assignment of the DIP switches ........................................................72

Table 34: Pin assignment: [X9] .....................................................................................................85

Table 35: Pin assignment: [X6] .....................................................................................................88

Table 36: Pin assignment: I/O communication [X1] ......................................................................94

Table 37: Pin assignment: [X2A] ..................................................................................................96

Table 38: Pin assignment: Analog incremental encoder – optional [X2B] ....................................99

Table 39: Pin assignment: Incremental encoder with serial interface

(for example EnDat, HIPERFACE) – optional [X2B] ..................................................100

Table 40: Pin assignment: Digital incremental encoder – optional [X2B] ...................................101

Table 41: Pin assignment: Incremental encoder input [X10] ......................................................104

Table 42: Pin assignment: Incremental encoder output [X11] ....................................................106

Table 43: Pin assignment: CAN-Bus [X4] ...................................................................................108

Table 44: Pin assignment: RS232 interface [X5] ........................................................................111

Table 45: Pin assignment: USB interface [X19]..........................................................................113

Table 46: Pin assignment: SD card ............................................................................................115

Table 47: Pin assignment: MMC card .........................................................................................115

Table 48: EMC requirements: First and second environment ....................................................118

Table 49: Operating mode and error display ..............................................................................128

Table 50: Error messages...........................................................................................................130

Table 51: Technical data: EA88 interface ...................................................................................166

Table 52: Digital inputs: EA88 interface [X21] ............................................................................167

Table 53: Digital outputs: EA88 interface [X22] ..........................................................................167

Table 54: EA88: Connector [X21] for 8 digital inputs ..................................................................168

Table 55: EA88: Connector [X22] for 8 digital outputs ...............................................................168

Table 56: Technical data: PROFIBUS-DP interface: Ambient conditions, dimensions

and weight...................................................................................................................170

Table 57: Technical data: PROFIBUS-DP interface: Interfaces and communication.................171

Table 58: Pin assignment: PROFIBUS-DP interface ..................................................................172

Table 59: Technical data: Sercos II module: Ambient conditions, dimensions and weight ........175

Table 60: Technical data: EhterCAT module: Ambient conditions, dimensions and weight ......178

Table 61: Display elements.........................................................................................................179

Table 62: Signal level and differential voltage ............................................................................179

Table 63: Technical data: MC 2000 4-Axis Motion Coordinator .................................................183

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1 General
1.1 Documentation
This product manual serves the purpose of a safe use of the ARS 2100 FS series servo positioning
controllers. It contains safety notes, which must be complied with.

Further information can be found in the following manuals of the ARS 2000 FS product range:

 Product Manual "Servo Positioning Controller ARS 2300 FS": Description of the technical
data and the device functionality plus notes concerning the installation and operation of
ARS 2302 FS, ARS 2305 FS and ARS 2310 FS servo positioning controllers.

 Product Manual “MC 2000”: Description of the technical data and the device functionality
as well as notes on the installation and the operation of the Motion Coordinator MC 2000
(German version).

 Product Manual “FSM 2.0 - STO”: Description of the technical data and device functionality plus
notes on the installation and operation of the FSM 2.0 – STO.

 Product Manual “FSM 2.0 - MOV”: Description of the technical data and device functionality plus
notes on the installation and operation of the FSM 2.0 – MOV (German version).

 PROFIBUS Manual “Servo Positioning Controller ARS 2000”: Description of the implemented
PROFIBUS-DP protocol.

 CANopen Manual “Servo Positioning Controller ARS 2000“: Description of the implemented
CANopen protocol as per DSP402.

 ETHERNET Manual “Servo Positioning Controller ARS 2000”: Description of the implemented
Ethernet protocol (UDP).

 EtherCAT Manual “Servo Positioning Controller ARS 2000”: Description of the implemented
EtherCAT protocol (CoE) (German version).

 Sercos Manual “Servo Positioning Controller ARS 2000”: Description of the implemented
Sercos functionality.

You can find all these documents on our homepage at the download area (http://www.metronix.de).

Certificates and declarations of conformity for the products described in this manual can be found at
http://www.metronix.de.

The entire software functionality of the new ARS 2000 FS product range will be implemented in the
course of a step-by-step development process.

This version of the product manual contains the functions of the firmware version 4.1.0.1.2.

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1.2 Scope of supply

The scope of supply includes:

Table 1: Scope of supply

1x Servo positioning controller ARS 2100 FS

Type ARS 2102 FS ARS 2105 FS ARS 2108 FS

Metronix order number 9200-2102-20 9200-2105-20 9200-2108-21

Counterplugs for power, controller or shaft encoder connections, as well as for shield connection are
not included in the standard scope of supply. They can, however, be ordered as accessories.

Table 2: Connector set: POWER connector

1x Connector set: POWER connector

This plug set contains the counterplugs for the following connections:
- Supply [X9]
- Motor connection [X6]

Type ARS 2102 FS ARS 2105 FS ARS 2108 FS

Metronix order number 9200-0210-20 9200-0218-20

Table 3: Connector set: DSUB connector

1x Connector set: DSUB connector

This connector set includes the counterplugs for the following connections:
- I/O interface [X1]
- Angle encoder connection [X2A]
- Angle encoder connection [X2B]
- CAN fieldbus interface [X4]
- Incremental encoder input [X10]
- Incremental encoder output [X11]

Type ARS 2102 FS ARS 2105 FS ARS 2108 FS

Metronix order number 9200-0200-00

Table 4: Connector set: Shield connector

1x Connector set: Shield connector

This connector set includes two shield terminals (SK14)

Type ARS 2102 FS ARS 2105 FS ARS 2108 FS

Metronix order number 9200-0202-00

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2 Safety notes for electrical drives

and controllers
2.1 Used symbols

Information
Important information and notes.

Caution!
Nonobservance may result in severe property damages.

DANGER!
Nonobservance may result in property damages and in personal injuries.

Caution! Dangerous voltages.

The safety note indicates a possible perilous voltage.

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2.2 General notes

In case of damage resulting from non-compliance with the safety notes in this manual, Metronix
Meßgeräte und Elektronik GmbH will not assume any liability.

Prior to the initial use you must read the Safety notes for electrical drives and controllers
starting on page 17 and chapter 8.14 Notes on safe and EMC-compliant installation,
starting on page 117.

If the documentation in the language at hand is not understood accurately, please contact and inform
your supplier.

Sound and safe operation of the servo positioning controller requires proper and professional
transportation, storage, mechanical installation, and project planning – with a consideration of the risks
as well as the protective and emergency measures – plus the proper and professional electrical
installation, operation, and maintenance of the devices.

Only trained and qualified personnel is authorised to handle electrical devices and systems:

TRAINED AND QUALIFIED PERSONNEL

in the sense of this product manual or the safety notes on the product itself are persons who are
sufficiently familiar with the project, the setup, assembly, commissioning and operation of the product
as well as all warnings and precautions as per the instructions in this manual and who are sufficiently
qualified in their field of expertise:

 Education and instruction concerning the standards and accident prevention regulations for the
application, or authorisation to switch devices/systems on and off and to ground them as per the
standards of safety engineering and to efficiently label them as per the job demands.

 Education and instruction as per the standards of safety engineering regarding the maintenance
and use of adequate safety equipment.

 First aid training.

The following notes must be read prior to the initial operation of the system to prevent personal injuries
and/or property damages:

These safety notes must be complied with at all times.

Do not try to install or commission the servo positioning controller before carefully
reading all safety notes for electrical drives and controllers contained in this document.
These safety instructions and all other user notes must be read prior to any work with the
servo positioning controller.

In case you do not have any user notes for the servo positioning controller, please
contact your sales representative. Immediately demand these documents to be sent to
the person responsible for the safe operation of the servo positioning controller.

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If you sell, rent and/or otherwise make this device available to others, these safety notes
must also be included.

The user must not open the servo positioning controller for safety and warranty reasons.

Professional control process design is a prerequisite for sound functioning of the servo
positioning controller!

DANGER!
Inappropriate handling of the servo positioning controller and non-compliance
with the warnings as well as inappropriate intervention in the safety features may
result in property damage, personal injuries, electric shock or in extreme cases
even death.

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2.3 Danger resulting from misuse

DANGER!
High electrical voltages and high load currents!
Danger to life or serious personal injury from electrical shock!

DANGER!
High electrical voltage caused by wrong connections!
Danger to life or serious personal injury from electrical shock!

DANGER!
Surfaces of device housing may be hot!
Risk of injury! Risk of burning!

DANGER!
Dangerous movements!
Danger to life, serious personal injury or property damage due to unintentional
movements of the motors!

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2.4 Safety notes

2.4.1 General safety notes

The servo positioning controller corresponds to IP20 degree of protection as well as

pollution degree 2. Make sure that the environment corresponds to this degree of
protection and pollution degree.

Only use replacement parts and accessories approved by the manufacturer.

The devices must be connected to the mains supply as per EN regulations, so that they
can be cut off the mains supply by means of corresponding separation devices (for
example main switch, contactor, power switch).

The servo positioning controller may be protected using an AC/DC sensitive 300 mA
fault current protection switch, type B (RCD = Residual Current protective Device).

Gold contacts or contacts with a high contact pressure should be used to switch the
control contacts.

Preventive interference rejection measures should be taken for control panels, such as
connecting contactors and relays using RC elements or diodes.

The safety rules and regulations of the country in which the device will be operated must
be complied with.

The environment conditions defined in the product documentation must be kept. Safety-
critical applications are not allowed, unless specifically approved by the manufacturer.

For notes on installation corresponding to EMC, please refer to chapter 8.14 Notes on
safe and EMC-compliant installation (page 117). The compliance with the limits required
by national regulations is the responsibility of the manufacturer of the machine or
system.

The technical data and the connection and installation conditions for the servo
positioning controller are to be found in this product manual and must be met.

DANGER!
The general setup and safety regulations for work on power installations (for example
DIN, VDE, EN, IEC or other national and international regulations) must be complied
with.
Non-compliance may result in death, personal injury or serious property damages.

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Without claiming completeness, the following regulations and others apply:

VDE 0100 Erection of power installations with nominal voltages up to 1000 V

EN 1037 Safety of maschinery - Prevention of unexpected start-up

EN 60204-1 Safety of machinery - Electrical equipment of machines

Part 1: General requirements

EN 61800-3 Adjustable speed electrical power drive systems

Part 3: EMC requirements and specific test methods

EN 61800-5-1 Adjustable speed electrical power drive systems

Part 5-1: Safety requirements - Electrical, thermal and energy

EN 61800-5-2 Adjustable speed electrical power drive systems

Part 5-2: Safety requirements - Functional

EN ISO 12100 Safety of machinery - General principles for design - Risk assessment and
risk reduction

EN ISO 13849-1 Safety of machinery - Safety-related parts of control systems

Part 1: General principles for design

EN ISO 13849-2 Safety of machinery - Safety-related parts of control systems

Part 2: Validation

More standards to be respected by the user:

EN 574 Safety of machinery - Two-hand control devices

EN 1088 Safety of machinery - Interlocking devices associated with guards

EN ISO 13850 Safety of machinery - Emergency stop

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2.4.2 Safety notes for assembly and maintenance

The appropriate DIN, VDE, EN and IEC regulations as well as all national and local safety regulations
and rules for the prevention of accidents apply for the assembly and maintenance of the system. The
plant engineer or the operator is responsible for compliance with these regulations:

The servo positioning controller must only be operated, maintained and/or repaired by
personnel trained and qualified for working on or with electrical devices.

Prevention of accidents, injuries and/or damages:

Additionally secure vertical axes against falling down or lowering after the motor has
been switched off, for example by means of:

 Mechanical locking of the vertical axle,

 External braking, catching or clamping devices or

 Sufficient balancing of the axle

The motor holding brake supplied by default or an external motor holding brake driven by
the drive controller alone is not suitable for personal protection!

Keep the electrical equipment voltage-free using the main switch and protect it from
being switched on again until the DC bus circuit is discharged, in the case of:

 Maintenance and repair work

 Cleaning

 long machine shutdowns

Prior to carrying out maintenance work make sure that the power supply has been
turned off, locked and the DC bus circuit is discharged.

The external or internal brake resistor carries dangerous DC bus voltages during
operation of the servo positioning controller and up to 5 minutes thereafter. Contact may
result in death or serious personal injury. Wait for this time prior to performing any work
on the affected connections. Measure the voltages for your own protection. Contact with
these high DC bus circuit voltages may result in death or serious personal injury.

Be careful during the assembly. During the assembly and also later during operation of
the drive, make sure to prevent drill chips, metal dust or assembly parts (screws, nuts,
cable sections) from falling into the device.

Also make sure that the external power supply of the controller (24 V) is switched off.

The DC bus circuit or the mains supply must always be switched off prior to switching off
the 24 V controller supply.

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Safety notes for electrical drives and controllers Page 24

Carry out work in the machine area only, if AC and/or DC supplies are switched off.
Switched off output stages or controller enablings are no suitable means of locking. In
the case of a malfunction the drive may accidentally be put into action.
This does not apply to drives with the special “Safe Stop” feature in accordance with EN
954-1 CAT 3 or with the “Safe Torque Off” feature in accordance with EN 61800-5-2.
This feature can be achieved with the ARS 2100 FS by integrating the module FSM 2.0
– STO for example.

Initial operation must be carried out with idle motors, to prevent mechanical damages for
example due to the wrong direction of rotation.

Electronic devices are never fail-safe. It is the user’s responsibility, in the case an
electrical device fails, to make sure the system is transferred into a secure state.

The servo positioning controller and in particular the brake resistor, externally or
internally, can assume high temperatures, which may cause serious burns.

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2.4.3 Protection against contact with electrical parts

This section only concerns devices and drive components carrying voltages exceeding 50 V. Contact
with parts carrying voltages of more than 50 V can be dangerous for people and may cause electrical
shock. During operation of electrical devices some parts of these devices will inevitably carry
dangerous voltages.

DANGER!
High electrical voltage!
Danger to life, danger due to electrical shock or serious personal injury!

The appropriate DIN, VDE, EN and IEC regulations as well as all national and local safety regulations
and rules for the prevention of accidents apply for the assembly and maintenance of the system. The
plant engineer or the operator is responsible for compliance with these regulations:

Before switching on the device, install the appropriate covers and protections against
accidental contact. Rack-mounted devices must be protected against accidental contact
by means of a housing, for example a switch cabinet. The national regulations for
safety/accident prevention must be complied with!

Always connect the ground conductor of the electrical equipment and devices securely
to the mains supply. Due to the integrated line filter the leakage current exceeds 3.5 mA!

Comply with the minimum copper cross-section for the ground conductor over its entire
length (see for example EN 60800-5-1).

Prior to the initial operation, even for short measuring or testing purposes, always
connect the ground conductor of all electrical devices as per the terminal diagram or
connect it to the ground wire. Otherwise the housing may carry high voltages which can
cause electrical shock.

Do not touch electrical connections of the components when switched on.

Prior to accessing electrical parts carrying voltages exceeding 50 Volts, disconnect the
device from the mains or power supply. Protect it from being switched on again.

For the installation the amount of DC bus voltage must be considered, particularly
regarding insulation and protective measures. Ensure proper grounding, wire
dimensioning and corresponding short-circuit protection.

The device comprises a rapid discharge circuit for the DC bus as per EN 60204-1. In
certain device constellations, however, mostly in the case of parallel connection of
several servo positioning controllers in the DC bus or in the case of an unconnected
brake resistor, this rapid discharge may be rendered ineffective. The servo positioning
controllers can carry voltage until up to 5 minutes after being switched off (residual
capacitor charge).

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2.4.4 Protection against electrical shock by means of protective extra-low

voltage (PELV)
All connections and terminals with voltages of up to 50 Volts at the servo positioning controller are
protective extra-low voltage, which are designed safe from contact in correspondence with the
following standards:

 International: IEC 60364-4-41

 European countries within the EU: EN 61800-5-1

DANGER!
High electrical voltages due to wrong connections!
Danger to life, risk of injury due to electrical shock!

Only devices and electrical components and wires with a protective extra low voltage (PELV) may be
connected to connectors and terminals with voltages between 0 to 50 Volts.

Only connect voltages and circuits with protection against dangerous voltages. Such protection may
be achieved by means of isolation transformers, safe optocouplers or battery operation.

2.4.5 Protection against dangerous movements

Dangerous movements can be caused by faulty control of connected motors, for different reasons:

 Improper or faulty wiring or cabling

 Error in handling of components

 Error in sensor or transducer

 Defective or non-EMC-compliant components

 Software error in superordinated control system

These errors can occur directly after switching on the device or after an indeterminate time of
operation.

The monitors in the drive components for the most part rule out malfunctions in the connected drives.
In view of personal protection, particularly the danger of personal injury and/or property damage, this
may not be relied on exclusively. Until the built-in monitors come into effect, faulty drive movements
must be taken into account; their magnitude depends on the type of control and on the operating state.

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DANGER!
Dangerous movements!
Danger to life, risk of injury, serious personal injuries or property damage!

For the reasons mentioned above, personal protection must be ensured by means of monitoring or
superordinated measures on the device. These are installed in accordance with the specific data of
the system and a danger and error analysis by the manufacturer. The safety regulations applying to
the system are also taken into consideration. Random movements or other malfunctions may be
caused by switching the safety installations off, by bypassing them or by not activating them.

2.4.6 Protection against contact with hot parts

DANGER!
Housing surfaces may be hot!
Risk of injury! Risk of burning!

Do not touch housing surfaces in the vicinity of heat sources! Danger of burning!

Before accessing devices let them cool down for 10 minutes after switching them off.

Touching hot parts of the equipment such as the housing, which contain heat sinks and
resistors, may cause burns!

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2.4.7 Protection during handling and assembly

Handling and assembly of certain parts and components in an unsuitable manner may under adverse
conditions cause injuries.

DANGER!
Risk of injury due to improper handling!
Personal injury due to pinching, shearing, cutting, crushing!

The following general safety notes apply:

Comply with the general setup and safety regulations on handling and assembly.

Use suitable assembly and transportation devices.

Prevent incarcerations and contusions by means of suitable protective measures.

Use suitable tools only. If specified, use special tools.

Use lifting devices and tools appropriately.

If necessary, use suitable protective equipment (for example goggles, protective

footwear, protective gloves).

Do not stand underneath hanging loads.

Remove leaking liquids on the floor immediately to prevent slipping.

Product Manual “Servo Positioning Controller ARS 2100 FS“ Version 5.0
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3 Product description
3.1 General
The servo positioning controller ARS 2000 FS (ARS servo 2nd generation for Functional Safety) series
devices are intelligent AC servo inverters with substantial parameterisation possibilities and extension
options. They are flexible and can be easily adapted to a number of different applications.

These servo positioning controllers are designed for receiving so-called FSM modules (Functional
Safety Modules). Thanks to their integrated safety features, external monitoring devices can be
omitted for numerous applications.

The series includes types with single-phase and three-phase supply.

Type key:

Example using the ARS 2102 FS

ARS - 2 1 02 FS

Functional Safety
RMS output current
Power supply line:
1 = single-phase
3 = three-phase
2nd generation
Type denomination

Figure 1: Type key

The single-phase supply types are designed for connection to the 230 VAC mains and comprise an
active PFC stage (Power Factor Control, with the ARS 2108 FS being an exception). The PFC stage is
an active mains current converter required to fulfil the corresponding standards on the limitation of the
mains harmonics (for category C2, residential areas).

The PFC stage also serves the active control of the DC bus voltage. The PFC stage works according
to the boost operation principle and provides a nominal DC bus voltage of 380 VDC. This voltage is
available regardless of the quality of the mains voltage and therefore also in the case of fluctuating
main voltages or undervoltage. This is an important advantage regarding the selection of the servo
motor, because, as compared to devices with a passive mains supply, higher rotational speeds can be
achieved and/or higher torque constants can be selected.

Furthermore, due to the active PFC stage, the device is also suitable for varying voltage operation
down to 100 VAC mains supply. However, the limitation of the active power input due to the allowed
maximum current of the PFC stage must be taken into consideration in this case.

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All servo positioning controller ARS 2000 FS series devices have the following features:

 Space-saving compact design, directly cascadable

 High quality of control due to extremely high-quality sensor technology, far superior to
conventional market standards, and better than average computer resources

 Complete integration of all of the components for the controller and power module, including USB,
Ethernet, and RS232 for the PC communication, plus CANopen for the integration into automation
systems

 SD card: support of FW downloads (initialisation via boot switches) and uploads and downloads of
parameter sets

 Integrated universal encoder evaluation for the following encoders:

 Resolver

 Incremental encoder with/without commutation signals

®
 High-resolution Stegmann incremental encoders, absolute encoders with HIPERFACE

 High-resolution Heidenhain incremental encoders, absolute encoders with EnDat

 Compliance with current European regulations and associated standards without any additional
external measures

 Device design as per UL standards, cULus certified

 Completely closed, EMC-optimized metal housing for mounting to conventional control cabinet
plates. All devices comply with the IP20 degree of protection

 Integration of all filters to fulfil the EMC regulations (industrial) inside the device, for example line
filter, motor output filter, filter for 24 V-supply as well as inputs and outputs

 Integrated brake resistor. External resistors can be connected for higher braking energies

 Automatic identification of externally connected brake resistors

 Complete galvanic separation of controller and power output stage as per EN 61800-5-1. Galvanic
separation of the 24 V potential area with the digital inputs and outputs, analog electronics and the
controller electronics

 Operation as speed controller, torque controller or positioning controller

 Integrated positioning control with wide range of functions as per CAN in Automation (CiA)
DSP402 and numerous additional application-specific functions

 Jerk limit or time-optimal positioning relative or absolute to a point of reference

 Point-to-point positioning (with or without S-ramps)

 Speed and angle synchronisation with electronic gear system via incremental encoder input or
fieldbus

 Extensive modes of operation for synchronisation

 Various methods for homing

 Jogging

 Teach-in mode

Product Manual “Servo Positioning Controller ARS 2100 FS“ Version 5.0
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 Short cycle times, in current control circuit 50 µs (20 kHz), in speed control circuit 100 µs (10 kHz)

 Switchable clock frequency for the power output stage

 Freely programmable I/O‘s

 User-friendly parameterisation with the Metronix ServoCommander® software

 Menu-driven first set up

 Automatic motor identification

 Easy coupling to host controller, for example to a PLC via I/O level or fieldbus

 High-resolution 16-bit analog input

 Technology slots for extensions such as I/O extension module or PROFIBUS interface.
Note: Depending on the current consumption, only one technology module with an additional
fieldbus interface may be used

 Option “STO” (Safe Torque Off, corresponds to EN 60204 Stop 0), SIL 3 in accordance with ISO
EN 61800-5-2 / PL e in accordance with ISO EN 13849-1

Product Manual “Servo Positioning Controller ARS 2100 FS“ Version 5.0
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3.2 Power supply

3.2.1 Single-phase AC supply with active PFC

The servo positioning controller ARS 2100 FS fulfils the following demands on a servo positioning
controller with active PFC stage (with the ARS 2108 FS being an exception):

 Fulfilment of current standards regarding mains harmonics (EN 61000-3-2)

 cosϕ° > 0.97 at nominal operation (at rated output power of the PFC stage)

 Sinusoidal mains current, harmonic distortion < 4 % (at rated output power of the PFC stage)

 Controlled average value of DC bus voltage of 380 VDC

 Insensitive in the case of weak mains and short mains interruptions. In such cases the device
maintains stable (within the physical possibilities) without malfunctions

 Wide input voltage range, rated voltage 230 VAC

 Frequency range nominal 50-60 Hz ±10 %

 Electrical impulse load capacity for possible combination of several servo positioning controllers.
The servo positioning controller ARS 2100 FS allows dynamic conversion in both directions
between motor and generator operation without dead times

 No parameterisation by user necessary

3.2.1.1 Behaviour during switch-on

 As soon as the servo positioning controller ARS 2100 FS is supplied with the input voltage, the DC
bus is charged (< 1 s) using the brake resistor as a precharging resistor, the DC link relay
deactivated. During this the PFC remains inactive

 After precharging of the DC bus the relay is energized and the DC bus is coupled hard to the
mains power without the precharging resistor. Subsequently, the PFC stage is activated and the
DC bus is boosted to the full DC bus voltage

 If the DC bus voltage after precharging is too small, because the input mains voltage is below the
PFC operation input voltage range, the PFC stage remains inactive and an error message on the
seven segment display is shown

 If the servo positioning controller ARS 2100 FS is supplied with less than the nominal voltage of
230 VAC, the actual DC bus voltage after the precharge is used to compute a power derating for
the PFC stage (see chapter 4.3 Supply [X9], page 42 and Figure 3)

Product Manual “Servo Positioning Controller ARS 2100 FS“ Version 5.0
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3.2.1.2 Behaviour during normal operation and control characteristics

 During operation the PFC stage controls the power input of the servo positioning controller
ARS 2100 FS from the supply. Based on an analog closed-loop control the mains current is
regulated to a sinusoidal waveform with a phase shift near to 0 °. The effective amplitude is
adjusted according to the demanded input power

 A superimposed digital closed-loop control adjusts the DC bus voltage to an average value close
to 380 VDC. To relieve the voltage control that is relatively sluggish, during load changes
(acceleration/deceleration of the drive) the output/input power delivered from the servo positioning
controller ARS 2100 FS to the motor is measured and used for the pre-control of the PFC stage

F L D

+
3 phase
M
100V ... 230V AC ~ ~ T8 C power
3~
+/- 10% stage
-

U_in I_in U_Zk i_u i_v motor

feedback

IC for power factor PWM u_q

correction
voltage
motion controller
controller i_q

microcontroller

Figure 2: Schematic setup of PFC stage

 The control system includes the following values:

 digital control of the DC bus voltage to an average value of 380 VDC

 analog control of the input mains current

 Keeping of a sinusoidal mains current under stationary load conditions

 cosϕ > 0.97 at nominal operation (at rated output power of the PFC stage)

 By use of the parameterisation program Metronix ServoCommander® the PFC stage

(Parameters/Device parameters/PFC) can be switched on and off. With deactivated PFC the DC
bus behaves like a normal DC bus with a rectifier bridge

 Under stationary load conditions the DC bus voltage is regulated to a constant average value,
which is independent from the actual power transferred to the motor.

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3.2.2 DC bus coupling, DC supply

3.2.2.1 DC bus coupling

 It is possible to couple multiple servo positioning controllers of the ARS 2100 FS series when they
have the same DC bus voltage. For this purpose, the PFC stage has to be deactivated

 When they have the same DC bus voltage, the servo positioning controllers ARS 2100 FS can be
coupled with the servo positioning controllers of the previous ARS and ARS 2000 series. For this,
deactivation of the PFC stage is mandatory

Caution!
DC bus coupling is not allowed while the PFC stage is active. This can otherwise result
in damages to the servo positioning controller.

Caution!
When the DC buses are connected, the power supplies must be connected to the same
mains phase.
This means, if two ARS 2105 FS are coupled in the DC bus, only the connection L1/N is
possible for both devices. It is not allowed to connect the DC Busses if the devices are
connected to different mains phases.
It is forbidden to supply device 1 via L1/N and device 2 via L2/N, when the DC buses are
coupled.

Caution!
Operation with DC bus coupling together with devices of the ARS 2300 FS series is not
allowed.

3.2.2.2 DC supply
 The direct DC supply is supported for a supply with voltages ≥ 60 VDC by the DC-bus connection
instead of the connection to the mains

The digital motor temperature measurement system requires a DC-link voltage of

120 VDC minimum. Below this voltage, the system will always identify the digital motor
temperature sensor as open.

3.2.3 Mains fuse

A slow-blow (B16) single-phase automatic circuit breaker of 16 A has to be installed in the mains
supply line.

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3.3 Brake chopper

A brake chopper with a brake resistor is integrated into the power output stage. If during the generator
operation the permissible charging capacity of the DC bus is exceeded, the braking energy can be
converted into heat by the internal brake resistor. The brake chopper is software-driven. The internal
brake resistor is overload-protected by means of software and hardware.

If in a special application the power of the internal resistors should be insufficient, they can be cut off
by removing the bridge between the pin BR-CH and BR-INT of the [X9] plug. Instead, an external
brake resistor is inserted between the pins BR-CH and ZK+. This brake resistor must fulfil certain
minimum specifications (see Table 12, page 42). The output is protected against short-circuiting in the
brake resistor or its cable.

Pin BR-CH lies on positive DC bus potential and is thus not protected against ground
fault or short-circuits against mains voltage or negative DC bus voltages.

Simultaneous use of the internal and external brake resistors is not possible. The external resistors
are not automatically overload-protected by the device.

3.4 Communication interfaces

The servo positioning controller ARS 2000 FS has several communication interfaces. The basic
device itself is already equipped with many of these interfaces.

The following communication interfaces are included in the basic device:

 Serial interface [X5]: RS232/RS485

 USB interface [X19]: USB

 UDP interface [X18]: Ethernet

 Fieldbus system [X4]: CANopen

 I/O interface [X1]: Digital and analog In- and outputs

The serial, Ethernet, and USB interface are particularly important for the connection of a PC and for
the use of the Metronix ServoCommander® parameterisation tool.

The fieldbus systems PROFIBUS-DP, Sercos and EtherCAT are extension options that can be
implemented in the form of plug-in modules. If required, customer-specific fieldbus protocols can also
be realised.

In any case, the servo positioning controller of this design always works as a slave to the fieldbus.

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3.4.1 Serial interface [X5]

The RS232 protocol is mainly intended to be a parameterisation interface, but also allows the control
of the servo positioning controller ARS 2000 FS.

3.4.2 USB interface [X19]

This interface, too, was mainly intended as a parameterisation interface, but it can also be used for
controlling the ARS 2000 FS servo positioning controller.

3.4.3 UDP interface [X18]

The UDP communication enables the connection of the ARS 2000 FS servo positioning controller to
the Ethernet fieldbus system. The communication via the UDP interface [X18] is realised with the aid
of a standard cabling.

3.4.4 CAN interface [X4]

The CANopen protocol as per DS301 with application profile DSP402 is implemented.

The specific Metronix CAN protocol of the previous ARS devices is no longer supported
by the ARS 2000 FS series. The servo positioning controller ARS 2000 FS supports the
CANopen protocol as per DS301 with application profile DSP402.

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3.4.5 Technology module: PROFIBUS

Support of PROFIBUS communication as per DP-V0. For drive technology applications the functions
as per PROFIDRIVE Version 3.0 are available. The features include functions as per Application
Class 1 (speed and torque control) as well as per Application Class 3 (point-to-point positioning).

It is also possible to include the device into control systems via an I/O mapping via PROFIBUS. From
a control point of view, this option offers the same functionality as a conventional PLC coupling via
parallel wiring with the device’s digital I/Os.

Via a special Metronix telegram it is also possible to access all device-specific functions, exceeding
the functionality defined by PROFIDRIVE.

The Metronix PROFIBUS-profile of the previous ARS series is no longer supported by

the ARS 2000 FS series.

3.4.6 Technology module: Sercos II

The Sercos II interface is a slave fieldbus module that enables the use of the ARS 2000 FS servo
positioning controllers in numerically-controlled, highly dynamic drive applications, for example in
machine tools. The Sercos II interface enables the position, speed, or torque control in accordance
with the functionality of the compliance classes A and B.

The connected module is automatically identified. Since the data exchange between the CNC system
and the controller is realised via optical fibre cables, mutual interference can be avoided. The drive
address is set, and the bus is activated, via the Metronix ServoCommander® parameterisation tool.
The transmission rate can be set to a value between 2 and 16 Mbit/s.

3.4.7 Technology module: EtherCAT

The EtherCAT interface enables the connection of the ARS 2000 FS servo positioning controller to the
EtherCAT fieldbus system. The communication via the EtherCAT interface (IEEE-802.3u) is realised
with the aid of EtherCAT standard cabling.

3.4.8 I/O functions and device control

Ten digital inputs provide the elementary control functions (see chapter 4.6.6 I/O interface [X1],
page 55):

The ARS 2000 FS comprises a target table, in which the positioning targets are stored and from which
they can later be retrieved. At least four digital inputs serve the purpose of target selection; one input
is used as a start input.

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The limit switches serve the safety limitation of the motion space. During a homing one of the two limit
switches may serve as a reference point for the positioning control.

Two inputs are used for the power stage enabling on the hardware side as well as for the controller
enabling on the software side.

High-speed sample inputs are available for different time-critical applications (for example homing,
special applications).

The servo positioning controller ARS 2000 FS has three analog inputs for input levels in the range of
+10V to -10V. One input is designed as a differential input (16 bit), to guarantee high interference
immunity. Two inputs (10 bit) are single-ended. The analog signals are quantized and digitalized by an
analog-digital converter at a resolution of 16 bit or 10 bit. The analog signals provide the setpoints
(speed or torque) for the control.

In common applications the existing digital inputs are already used for basic functions. For the use of
further functions such as teach-in mode, separate “start homing” input or stop input, the analog inputs
AIN 1, AIN 2 as well as the digital outputs DOUT 2 and DOUT 3, which are also usable as digital
inputs, can optionally also be used. Alternatively the I/O extension module EA88 can be inserted.

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4 Technical data
4.1 General Technical data
Table 5: Technical data: Ambient conditions and qualification

Range Values

Admissible temperature Storage temperature: -25 °C to +70 °C

ranges
Operating 0 °C to +40 °C
temperature: +40 °C to +50 °C at reduced power 2,5 %/K

Admissible installation Mounting height maximum 2000 m above msl, above 1000 m
height above msl with power reduction 1% per 100 m

Humidity Relative humidity up to 90 %, not bedewing

Protection degree IP20

Protection class I

Pollution degree 2
CE conformity
Low-voltage directive: 2006/95/EC
verified by application of the harmonised standard EN 61800-5-1
EMC directive: 2004/108/EC
verified by application of the harmonised standard EN 61800–3

cULus certification Listed according to UL 508C, C22.2 No. 274-13

Table 6: Technical data: Dimensions and weight

Type ARS 2102 FS ARS 2105 FS ARS 2108 FS

Dimensions including the 261 mm*54,6 mm*205 mm

mounting plate (H*W*D)

Dimensions (H*W*D) 200 mm*54 mm*200 mm

Weight approx. 2,0 kg approx. 2,1 kg approx. 1,8 kg

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Table 7: Technical data: Cable specifications

Range ARS 2102 FS ARS 2105 FS ARS 2108 FS

Maximum motor cable length for interference emission as per EN 61800-3 for fPWM ≤ 10 kHz

Category C2 l ≤ 25 m
Switch cabinet assembly (see chapter 8.14 Notes
on safe and EMC-compliant installation)

Category C3 l ≤ 25 m
(industrial area)

Cable capacity of a phase against shield or C‘ ≤ 200 pF/m

between two lines

Derating of the cable length (see also chapter 8.14.5 Operation with long motor cables)

fPWM = 12 kHz l ≤ 21 m

fPWM = 16 kHz l ≤ 15 m

fPWM = 20 kHz l ≤ 12 m

Table 8: Technical data: Motor temperature monitoring

Motor temperature Values

monitoring

Digital Sensor Normally closed Rcold < 500 Ω Rhot > 100 kΩ
contact:

Analog Sensor Silicon temperature sensor, for example KTY81, 82 or similar

R25 ≈ 2000 Ω
R100 ≈ 3400 Ω

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4.2 Operating and display elements

On the front the servo positioning controller ARS 2100 FS has two LEDs and one seven-segment
display to indicate the operating status.

Table 9: Display elements and RESET button

Element Function

Seven segment display Display of operating mode and a coded error number in the case
of a malfunction

LED 1 Operational state respectively fault

(two-color LED, green/red)

LED 2 (green) Controller enable

LED 3 (yellow) Status display CAN bus

RESET-Button Hardware reset for processor

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4.3 Supply [X9]

Table 10: Technical data: Performance data [X9]

Type ARS 2102 FS ARS 2105 FS ARS 2108 FS

Supply voltage 1 x 100 ... 230 VAC [± 10 %], 50 ... 60 Hz

In continuous operation maximum of 2,4 ARMS 4,7 ARMS 10 ARMS

mains current

Intermediate circuit voltage (at an 310 ... 320 VDC (without PFC) 310 ... 320 VDC
operating voltage of 230 VAC) 360 ... 380 VDC (with active PFC)

Alternative DC supply 60 ... 380 VDC 60 ... 320 VDC

24 V supply 24 VDC [± 20 %] 24 VDC [± 20 %]

(0,55 A) *) (0,65 A) *)
*)
plus current consumption of a possibly connected holding brake and I/Os

Table 11: Technical data: Internal brake resistor [X9]

Type ARS 2102 FS ARS 2105 FS ARS 2108 FS

Brake resistance 60 Ω 60 Ω 37 Ω

Pulse power 2,8 kW 2,8 kW 3,9 kW

Continuous power 10 W 20 W 25 W

Threshold limit (without PFC) 389 V 389 V 389 V

(with active PFC) 440 V 440 V (no PFC)

Over-current (without PFC) 400 V 400 V 400 V

detection (with active PFC) 460 V 460 V (no PFC)

Table 12: Technical data: External brake resistor [X9]

Type ARS 2102 FS ARS 2105 FS ARS 2108 FS

Break resistance ≥ 50 Ω ≥ 50 Ω ≥ 25 Ω

Continuous power ≤ 2500 W

Operating voltage ≥ 460 V ≥ 460 V ≥ 400 V

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Table 13: Performance data of PFC stage

Type ARS 2102 FS ARS 2105 FS

For a nominal supply voltage of 230 VAC [± 10%]:

Continuous power output 500 W 1000 W

Peak power output 1000 W 2000 W

Below the nominal supply voltage, the power output of the PFC stage is reduced linearly. These
performance curves are shown in the following figure (Figure 3: Performance curve of the PFC stage).
PFC power output
[kW]

1 2

PFC power output

(Peak power output)

0,5 1

0,25 0,5
PFC power output
limited by l2t (50%)
ARS 2102 FS:

ARS 2105 FS:

Supply voltage
100 200 255 [Veff]

Figure 3: Performance curve of the PFC stage

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4.4 Motor connection [X6]

Table 14: Technical data: Motor connection [X6]

Type ARS 2102 FS ARS 2105 FS ARS 2108 FS

Specifications for operation with 1x 230 VAC [± 10 %], 50 Hz

Output power 0,5 kVA 1,0 kVA 1,5 kVA

Max. output power for 5s 1,0 kVA 2,0 kVA 3,0 kVA

Output current 2,5 ARMS 5 ARMS 8 ARMS

Max. output current for 5s 5 ARMS 10 ARMS 16 ARMS

Max. output current 0,5s 10 ARMS 20 ARMS 32 ARMS

(fel ≥ 3 Hz) *)

Current derating from 12 kHz 12 kHz 10 kHz

Max. clock frequency approx. 20 kHz

Holding brake 24 V Signal level dependent on switch status, high side / low side
switch / max. 2 A

Motor temperature sensor N.C. and N.O. contact, PTC, KTY …

+ 3,3 V / 5 mA

Power loss/efficiency typical 8% / 92%

(with regard to the rated output
power)**)

*) with smaller electrical rotational frequencies (fel) shorter permissible times are valid with ARS 2108 FS; see the
following tables
**) "As a guideline".

4.4.1 Current derating

Differently from the indicated technical motor data the servo positioning controllers ARS 2100 FS have
a current derating during nominal operation. The rated current and the time of the maximum allowed
peak current of the servo positioning controller depend on different factors.

These factors are:

 Output current level (the higher the output current, the shorter the allowed time)

 Power stage clock frequency (the higher the clock frequency, the shorter the allowed time)

 Electrical rotational frequency of the motor (speed multiplied by pole pair number; the higher the
rotational frequency, the longer the allowed time)

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The last point (electrical rotational frequency) only applies to the ARS 2108 FS. For a better clarity, we
only distinguish between electrical rotational frequencies less than 2 Hz and those over 3 Hz. For
rotational frequencies lying in between these two values, interpolation is required.

Therefore, in the following you will find two tables for the ARS 2108 FS: the first one applies to blocked
or slowly rotated motors (electrical rotational frequency ≤ 2 Hz); the second one applies to faster
rotated motors (electrical rotational frequency ≥ 3 Hz).

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Table 15: ARS 2102 FS: Rated current for an ambient temperature of ≤ 40 °C

Parameter Values

Power stage clock frequency (kHz) ≤ 12

Output current (ARMS) 2,5

Max. output current (ARMS) 5 7,5 10

Max. allowed time (s) 5 1,3 0,5

Power stage clock frequency (kHz) 16

Output current (ARMS) 2,2

Max. output current (ARMS) 4,4 6,6 8,8

Max. allowed time (s) 5 1,3 0,5

Power stage clock frequency (kHz) 19

Output current (ARMS) 1,9

Max. output current (ARMS) 3,8 5,7 7,6

Max. allowed time (s) 5 1,3 0,5

Table 16: ARS 2105 FS: Rated current for an ambient temperature of ≤ 40 °C

Parameter Values

Power stage clock frequency (kHz) ≤ 12

Output current (ARMS) 5

Max. output current (ARMS) 10 15 20

Max. allowed time (s) 5 1,3 0,5

Power stage clock frequency (kHz) 16

Output current (ARMS) 4,4

Max. output current (ARMS) 8,8 13,2 17,6

Max. allowed time (s) 5 1,3 0,5

Power stage clock frequency (kHz) 19

Output current (ARMS) 3,7

Max. output current (ARMS) 7,4 11,1 14,8

Max. allowed time (s) 5 1,3 0,5

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Table 17: ARS 2108 FS: Rated current for blocked or slowly rotated servo motor (fel)
≤ 2 Hz and for an ambient temperature of ≤ 40 °C

Parameter Values

Power stage clock frequency (kHz) ≤ 10

Output current (ARMS) 8

Max. output current (ARMS) 16 24 32

Max. allowed time (s) 5 0,7 0,2

Power stage clock frequency (kHz) 12

Output current (ARMS) 7,4

Max. output current (ARMS) 14,8 22,2 29,6

Max. allowed time (s) 5 0,7 0,2

Power stage clock frequency (kHz) 16

Output current (ARMS) 6,3

Max. output current (ARMS) 12,6 18,9 25,2

Max. allowed time (s) 5 0,7 0,2

Power stage clock frequency (kHz) 19

Output current (ARMS) 5,2

Max. output current (ARMS) 10,4 15,6 20,8

Max. allowed time (s) 5 0,7 0,2

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Table 18: ARS 2108 FS: Rated current for rotated servo motor (fel) ≥ 3 Hz and for an ambient
temperature of ≤ 40 °C

Parameter Values

Power stage clock frequency (kHz) ≤ 10

Output current (ARMS) 8

Max. output current (ARMS) 16 24 32

Max. allowed time (s) 5 1,3 0,5

Power stage clock frequency (kHz) 12

Output current (ARMS) 7,4

Max. output current (ARMS) 14,8 22,2 29,6

Max. allowed time (s) 5 1,3 0,5

Power stage clock frequency (kHz) 16

Output current (ARMS) 6,3

Max. output current (ARMS) 12,6 18,9 25,2

Max. allowed time (s) 5 1,3 0,5

Power stage clock frequency (kHz) 19

Output current (ARMS) 5,2

Max. output current (ARMS) 10,4 15,6 20,8

Max. allowed time (s) 5 1,3 0,5

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4.5 Motor feedback connection [X2A] and [X2B]

Different feedback systems can be connected to the servo positioning controller ARS 2100 FS via the
universal encoder interface:

 Resolver (interface [X2A])

 Encoder (interface [X2B])

 Incremental encoders with analog and digital track signals

 SinCos encoder (single-turn/multi-turn) with HIPERFACE

 Multiturn absolute encoder with EnDat

The encoder type is determined in the Metronix ServoCommander® parameterisation software.

The feedback signal is available via the incremental encoder output [X11] for master-slave
applications.

It is possible to evaluate two shaft encoder systems in parallel. Typically, the resolver for the current
control is connected to [X2A], and for example an absolute encoder is connected to [X2B] as a
feedback system for the positioning control.

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4.5.1 Resolver connection [X2A]

The 9-pin D-SUB connection [X2A] is used to evaluate standard resolvers. Single- and multi-pole
resolvers are supported. The user can state the number of pairs of poles of the servo motor in
the "Motor Data" menu of the Metronix ServoCommander® parameterization program so that the
ARS 2100 FS determines the speed correctly. However, the number of pairs of poles can also be
identified automatically. The number of pairs of poles of the motor (P0Motor) is always an integer
multiple of the number of pairs of poles of the resolver (P0Resolver). Wrong combinations such as, for
example, P0Resolver = 2 and P0Motor = 5 lead to an error message during motor identification.

The resolver offset angle, which is determined automatically during the identification, is readable and
writeable for service purposes.

Table 19: Technical data: Resolver [X2A]

Parameter Values

Transformation ratio 0,5

Carrier frequency 5 to 10 kHz

Excitation voltage 7 VRMS, short circuit-proof

Impedance excitation (at 10kHz) ≥ (20 + j20) Ω

Impedance stator ≤ (500 + j1000) Ω

Table 20: Technical data: Resolver interface [X2A]

Parameter Values

Resolution 16 Bit

Delay time signal detection < 200 µs

Speed resolution approximately 4 min-1

Absolute accuracy of angle < 5´

detection

Max. rotational speed 16.000 min-1

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4.5.2 Encoder connection [X2B]

At the 15-pole D-Sub connection [X2B], motors with encoder can be fed back. The possible
incremental encoders for the encoder connection are divided into several groups. If you want to use
other types of encoders, please contact your sales representative.

Table 21: Technical data: Encoder evaluation [X2B]

Parameter Values

Parameterisable number of encoder 1 - 218 lines/revolution

lines

Angular resolution / Interpolation 10 Bit/period

Encoder signals A, B 1 VPP differential; 2.5 V offset

Encoder signal N 0.2 to 1 VPP differential; 2.5 V offset

Commutation track A1, B1 (optional) 1 VPP differential; 2.5 V offset

Input impedance encoder signals Differential input 120 Ω

Limit frequency fLimit > 300 kHz (high-resolution signal)

fLimit approximately 10 kHz (commutation track)
®
Additional communication interface EnDat (Heidenhain) and HIPERFACE (Sick-Stegmann)

Output supply 5 V or 12 V; max. 300 mA; current-limited

control via sensor lines
Setpoint programmable via SW

Standard incremental encoders without commutation signals:

This type of encoder is used with low-cost linear motor applications, to save the costs for the provision
of the commutation signals (hall sensor). With this type of encoder the servo positioning controller
ARS 2100 FS must carry out an automatic pole position determination after power-on.

Standard incremental encoders with commutation signals:

These are standard incremental encoders with three binary hall sensor signals. The number of lines of
the encoder can be freely parameterized (1 – 214 lines/rotation).

There is an additional offset angle for the hall sensor signals. It is determined during motor
identification or can be set via the parameterisation software Metronix ServoCommander®. In general,
the hall sensor offset angle is zero.

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Sick-Stegmann encoders:
®
Single-turn and multi-turn shaft encoders with HIPERFACE made by Sick-Stegmann are supported.
The following series of encoders can be connected:

 Singleturn SinCos encoders: SCS 60/70, SKS 36, SRS 50/60/64, SEK 37/52

 Multiturn SinCos encoders: SCM 60/70, SKM 36, SRM 50/60/64, SEL 37/52

 Singleturn SinCos Hollow shaft encoders: SCS-Kit 101, SHS 170, SCK 25/35/40/45/50/53

 Multiturn SinCos Hollow shaft encoders: SCM-Kit 101, SCL 25/35/40/45/50/53

In addition, the following Sick Stegmann encoder systems can be connected and evaluated:

 Absolute, non-contact length measuring system L230 and TTK70 (HIPERFACE®)

 Digital incremental encoder CDD 50

®
SinCoder encoders like SNS 50 or SNS 60 are no longer supported.

Heidenhain encoders:

Incremental and absolute encoders by Heidenhain are evaluated. The following series of encoders
can be connected:

 Analog incremental encoders: ROD 400, ERO 1200/1300/1400, ERN 100/400/1100/1300

 Singleturn absolute encoders (EnDat 2.1/2.2): ROC 400, ECI 1100/1300, ECN 100/400/1100/1300

 Multiturn absolute encoders (EnDat 2.1/2.2): ROQ 400, EQI 1100/1300, EQN 100/400/1100/1300

 Absolute length measuring system (EnDat 2.1/2.2): LC 100/400

Yaskawa encoders:

Digital incremental encoders with zero-pulse [Σ (sigma 1), Yaskawa-OEM-protocol] made by Yaskawa
are supported.

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4.6 Communication interfaces

4.6.1 RS232 [X5]

Table 22: Technical data: RS232 [X5]

Communication interface Values

RS232 As per RS232 specification, 9600 Baud to 115.2 kBaud

4.6.2 USB [X19]

Table 23: Technical data: USB [X19]

Communication interface Values

Function USB 2.0, Slave–Client, 12 MBaud to 480 MBaud

Connector type USB-B, no current consumption from the bus (integrated power
supply)

Communication protocol Metronix specific (generic device)

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4.6.3 Ethernet [X18]

Table 24: Technical data: Ethernet [X18]

Communication interface Values

Function Ethernet, 10/100 MBaud (auto select)

Connector type RJ45

4.6.4 CAN bus [X4]

Table 25: Technical data: CAN bus [X4]

Communication interface Values

CANopen controller ISO/DIS 11898, full CAN controller, max. 1 Mbaud

CANopen protocol as per DS301 and DS402

4.6.5 SD/MMC card

Table 26: Technical data: SD/MMC card

Communication interface Values

Card type SD, SDHC and MMC

File system FAT12, FAT16 and FAT32

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4.6.6 I/O interface [X1]

Table 27: Technical data: Digital inputs and outputs [X1]

Digital inputs/outputs Values

Signal level 24 V (8 V ... 30 V) active high, conforming with DIN EN 61131-2

Logic inputs general

DIN 0 Bit 0 \ (lsb  least significant bit)
DIN 1 Bit 1, \ Target selection for positioning
DIN 2 Bit 2, / 16 targets selectable from target table
DIN 3 Bit 3 / (msb  most significant bit)

DIN 4 Control input power stage (enable at High)

DIN 5 Controller enable at high signal, acknowledge error with falling edge

DIN 6 Limit switch input 0

DIN 7 Limit switch input 1

DIN 8 Control signal Start positioning or

Homing switch for homing or saving of positions

DIN 9 Control signal Start positioning or

Homing switch for homing or saving of positions

Logic outputs general Galvanically separated, 24 V (8 V ... 30 V) active high

DOUT 0 Operational state 24 V, max. 100 mA

DOUT 1 Freely configurable 24 V, max. 100 mA

DOUT 2 Freely configurable, optional use as input 24 V, max. 100 mA

DIN 10

DOUT 3 Freely configurable, optional use as input 24 V, max. 100 mA

DIN 11

DOUT 4 [X6] Holding brake 24 V, max. 1 A

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Table 28: Technical data: Analog inputs and outputs [X1]

Analog inputs/outputs Values

High-resolution ± 10 V input range, 16 Bit, differentially,

analog input, AIN 0 < 250 µs delay time

Analog input, AIN 1 Optionally, this input can also be ± 10 V, 10 Bit, single ended,
parameterized as digital input < 250 µs delay time
DIN AIN 1 with a switching
threshold at 8 V

Analog input, AIN 2 Optionally, this input can also be ± 10 V, 10 Bit, single ended,
parameterized as digital input < 250 µs delay time
DIN AIN 2 with a switching
threshold at 8 V

Analog outputs, AOUT 0 and ± 10 V output range, 10 mA,

AOUT 1 9 bit resolution, fLimit > 1 kHz

4.6.7 Incremental encoder input [X10]

The input supports all common incremental encoders.

For example encoders corresponding to the industry standard ROD426 by Heidenhain or encoders
with single-ended TTL outputs as well as open collector outputs.

Alternatively, the A and B encoder signals are interpreted by the device as pulse-direction signals, so
that the controller can also be driven by stepping motor control boards.

Table 29: Technical data: Incremental encoder input [X10]

Parameter Values

Parameterisable line count 1 – 228 lines/revolution

Trace signals: A, #A, B, #B, N, #N In accordance with RS422

specification

Max. input frequency 1000 kHz

Pulse direction interface: CLK, #CLK, DIR, #DIR, RESET, In accordance with RS422
#RESET specification

Supply output 5 V, 100 mA max.

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4.6.8 Incremental encoder output [X11]

The output provides incremental encoder signals for processing in superimposed controls.

The signals are generated from the encoder’s angle of rotation with a freely programmable number of
lines.

Besides the encoder signals A and B, the emulation also provides a reset pulse, which goes to high
once per rotation (for the programmed number of lines), for the duration of a ¼ signal period (as long
as the encoder signals A and B are high).

Table 30: Technical data: Incremental encoder output [X11]

Parameter Values

Number of lines Programmable 1 – 213 and 214 lines/revolution.

Connection level Differential / RS422 specification

Encoder signals A, B, N As per RS422 specification

speciality N-Trace disconnectable

Output impedance Ra,diff = 66 Ω

Limit frequency fLimit > 1,8 MHz (lines/s)

Edge sequence Can be limited by parameters

Output supply 5 V, max. 100 mA

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5 Function overview
5.1 Motors

5.1.1 Synchronous servo motors

Typically, permanently excited synchronous motors with sinusoidal EMF are used. The servo
positioning controller ARS 2100 FS is a universal servo positioning controller, which can be operated
with standard servo motors. The motor specifications are determined and parameterized by means of
an automatic motor identification.

5.1.2 Linear motors

Besides rotary applications, the servo positioning controllers ARS 2100 FS are also suitable for linear
drives. Here also, permanently excited synchronous linear motors are supported. Due to the high
signal processing quality, the ARS 2000 FS series is particularly suitable for driving air-core and iron-
core synchronous motors with low motor inductances (2 … 4 mH).

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5.2 Functions of the servo positioning controller

ARS 2100 FS

5.2.1 Compatibility
For compatibility reasons, from the user’s point of view, the control structure of the ARS 2100 FS has
mostly the same characteristics, interfaces and parameters as the previous ARS family.

Set point management:

- Analogue inputs
- Fixed values
- Synchronization
- Ramp generator

Positioning control and

Interpolation
Trajectories calculation: Power Angle encoder
- Reference position stage Motor 1 and 2
- Motorspeed precontrol
- Motorcurrent precontrol PWM M E1 E2

Positioning Speed Current

controller controller controller

X2A
X2B Actual value management
X10

Figure 4: Control scheme of the ARS 2100 FS

Figure 4 shows the basic control structure of the ARS 2100 FS. Current controller, speed controller
and positioning controller are arranged in a cascade. Due to the rotor-oriented control principle the
current can be set separated in active current (iq) and reactive current (id). Therefore there are two
current controllers, both of them PI controllers. To provide a better overview, however, the id controller
does not appear in Figure 4.

The planned basic modes of operation are torque control, speed control and positioning.

Functions such as synchronisation, “flying saw” and so on are variants of these basic modes of
operation.
Furthermore, individual functions of these modes of operation can be combined with each other, for
example torque control with speed limitation.

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5.2.2 Pulse width modulation (PWM)

The servo positioning controller ARS 2100 FS is able to vary the clock frequency in the current
controller circuit.
In most cases the settings can be made using the parameterisation software Metronix
ServoCommander®. In order to minimize switching losses, the clock of the pulse width modulation can
be cut in half as compared to the frequency in the current controller circuit.

The servo positioning controller ARS 2100 FS also features a sine modulation or alternatively a sine
modulation with third harmonic. This increases the effective converter output voltage. The type of
modulation can be selected via the Metronix ServoCommander®. The default setting is sine
modulation.

Table 31: Output voltage at the motor terminals in the case of a

DC bus circuit voltage (UZK) of 360 V

Output voltage converter Output voltage at the motor terminals

Uout,(sin) ULL,motor = approx. 210 VRMS

Uout,(sin+sin3x) ULL,motor = approx. 235 VRMS

5.2.3 Setpoint management

For speed controlled and torque controlled modes of operation, the setpoint can be set via a setpoint
management.

Possible setpoint sources are:

 3 analog inputs:

 AIN 0, AIN 1 and AIN 2

 3 fixed values:

 1st value: setting depending on controller enabling logic:

 fixed value 1 or

 RS232 interface or

 CANopen bus interface or

 PROFIBUS-DP interface or

 Sercos interface

 2nd and 3rd value: setting of fixed values 2 and 3

 Process controller

 SYNC input

 Additional incremental encoder input [X10]

If no setpoint source is activated, the setpoint is zero.

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The setpoint management has a ramp generator with a preceding adder. Any of the above-mentioned
setpoint sources can be selected via the corresponding selectors and run through the ramp generator.
Additional sources can be selected as setpoints using two more selectors. These, however, cannot be
run through the ramp generator. The total setpoint is then a summation of all values. The acceleration
and deceleration times of the ramp are directionally parameterisable.

5.2.4 Torque-controlled mode

In torque control mode a certain setpoint torque is set, which the servo positioning controller generates
in the motor. In this case only the current controller is activated, since the torque is proportional to the
motor current.

5.2.5 Speed-controlled mode

This mode of operation is used, if the motor speed is to be kept constant regardless of the acting load.
The motor speed exactly follows the speed set by the setpoint management.

The cycle time of the speed control loop for the servo positioning controller ARS 2100 FS is twice the
PWM period duration, thus typically 208,4 µs. However, it can also be set as an integer multiple of the
current controller cycle time.

The speed controller is a PI controller with an internal resolution of 12 bits per rpm. In order to
eliminate wind-up effects, the integrator function is stopped upon reaching subsidiary limitations.

In speed control mode only the current controller and the speed controller are active. In the case of
setting via analog setpoint inputs it is optionally possible to define a “safe zero”. If the analog setpoint
is within this range, the setpoint is then set to zero (“dead zone”). This can suppress interferences or
offset drifts. The function of a dead zone can be activated and deactivated and the width can be set.

The setpoints of the speed as well as the actual position are generally determined from the encoder
system inside the motor, which is also used for commutation. For the actual value feedback to the
speed control any encoder interface may be selected (for example reference encoder or
corresponding system at external incremental encoder input). The actual speed value for the speed
controller is then fed back for example via the external incremental encoder input.

The setpoint for the speed can also be set internally or can be derived from the data of an external
encoder system (speed synchronisation via [X10] for speed controller).

Product Manual “Servo Positioning Controller ARS 2100 FS“ Version 5.0
Function overview Page 62

5.2.6 Torque-limited speed control

The servo positioning controllers ARS 2100 FS support torque-limited speed-controlled operation with
the following features:

 Fast updating of the limit value, for example in 200 µs cycle

 Addition of two sources of limitation (for example for servo control values)

5.2.7 Synchronization to the external clock signal

The controllers work with sinusoidal constrained current operation. The cycle time is always bound to
the PWM frequency. In order to synchronise the current control to the external clock signal (for
example Sercos, CANopen, EtherCAT) the device has a corresponding PLL. Accordingly the cycle
time varies within certain limits, to allow synchronisation to the external clock signal. For
synchronisation to an external clock signal the user must enter the rated value of the synchronous
cycle time.

5.2.8 Load torque compensation for vertical axes

For vertical axis applications, the holding torque at standstill can be determined and stored.

It is then added to the torque control loop and improves the start-up behaviour of the axes after
releasing the holding brake.

5.2.9 Positioning and position control

In positioning mode a superordinated positioning controller is active in addition to the speed control,
which processes deviation of the actual position from the set position and converts it into the
corresponding setpoints for the speed controller.

The position controller is a P-controller. By default, the cycle time of the position control circuit is twice
the speed controller cycle time. However, it can also be set as an integer multiple of the speed
controller cycle time.

When the positioning controller is activated, it receives its setpoints from the positioning or from the
synchronisation controller. The internal resolution is up to 32 bits per motor revolution (depending on
the used encoder).

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5.2.10 Synchronisation, electronic gearing

The servo positioning controller ARS 2100 FS allows master-slave operation, which in the following
will be called synchronisation. The controller can serve as master or slave.

If the servo positioning controller ARS 2100 FS is the master, it can provide the slave with its current
rotor position at the incremental encoder output [X11].

With this information the slave can determine the current position and/or speed of the master via the
incremental encoder input [X10]. Of course it is also possible to derive this information needed for the
slave via an external encoder [X2B].

The synchronisation can be activated or deactivated via communication interfaces or via digital inputs.

The speed feed forward can be calculated by the servo positioning controller ARS 2100 FS itself. All
inputs can be activated/deactivated. The internal encoder can optionally be shut off, if another input is
selected as actual-value encoder. This also applies to speed control mode. The external inputs can be
weighed with transmission factors. The different inputs can be used individually or simultaneously.

5.2.11 Brake management

The servo positioning controller ARS 2100 FS can directly actuate a holding brake. The holding brake
is operated with programmable delay times. In positioning mode an additional automatic braking
function can be activated, which shuts down the power stage of the ARS 2100 FS after a
parameterized idle time and which lets the brake fall in. This mode of operation is compatible with the
functions of the previous ARS and ARS 2000 series of devices.

Product Manual “Servo Positioning Controller ARS 2100 FS“ Version 5.0
Function overview Page 64

5.3 Positioning control

5.3.1 Overview
In positioning mode a certain position is set, which is to be approached by the motor. The current
position is derived from the information provided by the internal encoder evaluation. The position
deviation is processed in the position controller and is passed on to the speed controller.

The integrated positioning control allows jerk-limited or time-optimal positioning relative or absolute to
a point of reference. It provides the position controller and - to improve the dynamics - the speed
controller also, with the setpoints.

In the case of absolute positioning a set target position is directly approached. In the case of relative
positioning a parameterized route is run. The positioning space of 232 full revolutions allows any
number of relative positioning in one direction.

The positioning control is parameterized via a target table. The target table includes entries for the
parameterisation of a target via a communication interface and also target positions, which can be
retrieved via the digital inputs. For each entry it is possible to set the positioning method, the driving
profile, the acceleration and the deceleration times as well as the maximum speed. All targets can be
pre-parameterized. The only thing to do for positioning is then to select an entry and start the action. It
is also possible to change the target parameters online via the communication interface.

The servo positioning controller ARS 2100 FS provides 256 configurable positioning sets.

The following settings are possible for all positioning sets:

 Target position

 Driving speed

 Final speed

 Acceleration

 Deceleration

 Torque feed forward

 Remaining distance trigger

 Additional flags:

 Relative / relative to last target / absolute

 Wait for end / interrupt / ignore start

 Synchronized

 Rotary axis

 Option: automatic deceleration in case of missing following positioning

 Different options on the setup of path programs

The positioning sets can be activated via all bus systems or via the parameterisation software
Metronix ServoCommander®. The positioning process can be controlled via digital inputs.

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5.3.2 Relative positioning

In the case of relative positioning, the target position is added to the current position. Since no fixed
zero is required, referencing is not compulsory. It does, however, make sense in many cases, in order
to bring the drive to a defined position.

Adding of relative positionings allows for example endless positioning in one direction for a trimming
unit or a conveyor belt (incremental dimension).

5.3.3 Absolute positioning

The target position is approached independent of the current position. In order to execute an absolute
positioning we recommend prior referencing of the drive. In the case of absolute positioning the target
position is a fixed (absolute) position referred to the zero or reference point.

5.3.4 Driving profile generator

Driving profiles are categorized in time-optimal and jerk-limited positioning. In the case of time-optimal
positioning the maximum set acceleration is used for starting and braking. The drive approaches the
target in the shortest time possible, the velocity profile is trapezoidal, and the acceleration profile is
block-shaped.

In the case of jerk-limited positioning the acceleration profile is trapezoidal and the velocity profile is
therefore of third order. Since the acceleration changes continuously, the drive is extremely gentle on
the mechanics.

at time optimal jerk limit jerk limit

a(t) a(t) a(t)

t t t

v(t) v(t) v(t)

t t t

Figure 5: Driving profiles of servo positioning controller ARS 2100 FS

Product Manual “Servo Positioning Controller ARS 2100 FS“ Version 5.0
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5.3.5 Homing
Every positioning control requires a defined zero at start-up, which is determined by means of a
homing. The servo positioning controller ARS 2100 FS can do this homing on its own. As reference
signals it evaluates different inputs, for example the end switch inputs.

A homing can be started by means of a command via the communication interface or automatically
with the controller enabling. Optionally a start via a digital input can be programmed using the
parameterisation program Metronix ServoCommander®, to carry out a specific homing independent of
the controller enabling. The controller enabling acknowledges (with falling edge) for example error
messages and can be switched off depending on the application, without requiring another homing
with a new enabling. Since the existing digital inputs are used in standard applications, the use of the
analog inputs AIN 1, AIN 2 as digital inputs DIN AIN 1 and DIN AIN 2 as well as the digital outputs
DOUT 2 and DOUT 3 as digital inputs DIN 10 and DIN 11 are optionally available.

Several methods as per the CANopen manual and following DSP 402 are implemented for the
homing. Most methods first search for a switch at search velocity. The further movement depends on
the method of communication. If a homing is activated via the fieldbus, there is generally no following
positioning to zero. This is done optionally during the start via the controller enabling or RS232. A
following positioning is always an option. The default setting is “no following positioning”.

Ramps and velocities are parameterisable for the homing. The homing can also be time-optimal and
jerk-limited.

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5.3.6 Positioning sequences

Positioning sequences consist of a series of positioning sets. These are run consecutively. A
positioning set can be made part of a path program by means of its path program options, thus
generating a linked list of positions:

START

POS13 END
POS1
POS19

POS5 POS6
POS7 POS8

Figure 6: Path program

Via the start position of the path program the user determines which position series to run. In
principle, linear or cyclic series are possible.

The start position of a path program can be determined:

 via fieldbus

 via digital inputs

The number of positions in the corresponding positioning sequence is only limited by the number of
totally available positions. Every user-defined positioning set (0 to 255) can be used in the path
program.

For further information, please refer to the software manual “Servo Positioning Controller
ARS 2000 FS”.

5.3.7 Optional stop input

The optional stop input can interrupt the ongoing positioning by setting the selected digital input.
Resetting the digital input will resume positioning to the original target position.

5.3.8 Contouring control with linear interpolation

The implementation of the Interpolated Position Mode allows setting position values in a multi-axis
application of the controller. For that purpose set position values are provided by a superordinated
control at a fixed time pattern (synchronisation interval). If this interval exceeds a position control
cycle, the controller autonomously interpolates the data values between two set position values, as
shown in the following illustration. The servo positioning controller also calculated a corresponding
speed feed forward.

Product Manual “Servo Positioning Controller ARS 2100 FS“ Version 5.0
Function overview Page 68

y
t s y n c
: synchronisation interval

t P
t P

: Interpolation data t
: Setposition, intern interpolated
t : Cycle time position control / positioning
p

: Interpolated characteristic of the position (reference value)

: Driven characteristic of the position (actual value)
Figure 7: Linear interpolation between two data values

5.3.9 Time-synchronized multi-axis positioning

The implementation of the clock synchronisation allows simultaneous movements for multi-axis
applications in conjunction with “interpolated positioning mode”. All servo positioning controllers of the
ARS 2100 FS family, that is the entire controller cascade, will be synchronized to the external clock
signal. Pending positioning values in the case of multiple axes are then taken over and executed
simultaneously without jitter. The sync message of a CAN bus system or the EtherCAT “DC”
(Distributed Clock) can for example be used as a clock signal.

That way it is for example possible to send several axes with different path lengths and velocities to
the destination at the same time.

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Functional safety technology Page 69

6 Functional safety technology

6.1 General
With an increasing degree of automation, the protection of persons against dangerous movements
becomes increasingly important. The so-called functional safety describes the necessary measures in
the form of electrical or electronic devices in order to reduce or eliminate the hazards that are caused
by malfunctions. Under normal operating conditions, protective devices prevent human access to
dangerous areas. In certain operating modes, however, for example during the set-up, persons are
required to be present in these dangerous areas. In these situations, the machine operator must be
protected by drive- and control-internal measures.

The integrated safety technology provides the control- and drive-specific conditions for the optimal
realisation of protective functions. Planning and installation become less labour-intensive. Compared
to conventional safety technology, the machine functionality and availability can be increased by the
use of integrated safety technology.

In their delivery status, the servo positioning controllers of the ARS 2000 FS product range are not
equipped with integrated features for the safety-relevant monitoring and control of movements but they
are equipped with an extension slot for a safety module.

As a standard, the ARS 2000 FS series servo positioning controllers come supplied with the module
FSM 2.0 – FBA (Fieldbus Activation Module) integrated in the extension slot for safety modules. You
can remove the FBA module and replace it with a Functional Safety Module.

If the safety modules of the FSM 2.0 series (Functional Safety Module) are used, external monitoring
devices are no longer required for numerous applications. The wiring of the entire system is simplified
and the number of components as well as the costs of the system solution can be reduced.

The design of the safety modules ensures that they can be simply plugged into the basic device from
the outside. As a result, the servo positioning controllers can be quickly adapted to the specific safety
requirements of the overall system. Retrofitting of these modules (or the later use of a different safety
module), thereby, becomes possible. The module is supplied with power via the power supply of the
basic device.

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Functional safety technology Page 70

6.1.1 DIP switch

The FBA module (Fieldbus Activation Module) and all of the integrated functional safety modules
(FSM 2.0) are equipped with a DIP switch (8 poles). Under certain conditions, substantial parts of the
parameters of the fieldbus communication can be configured with the aid of this DIP switch.
Depending on the fieldbus that is used, it is possible, for example, to adjust the fieldbus node number
or the baud rate, and so on This DIP switch does not have a safety-relevant function.

The following applies in order to achieve downward compatibility with the previous ARS 2000 devices:

 If all of the switches on the module are set to zero (factory setting), the fieldbus communication
parameters of the parameter data set of the basic device will be used.

The position of the DIP switch is read in only once after a reset. Modifications of the
switch positions during the operation, therefore, do not affect the current operation.

Table 32: Table overview of the DIP switch functionality

Technology module (type) Functionality of the DIP switch

Communication Baudrate Settings
On/Off station address
-- (CAN, in the basic device)   
PROFIBUS  -- (via Master) 
Sercos (without DIP switch)   
Sercos (with DIP switch) -- -- --
1)
EtherCAT -- -- --
1)
The control of EtherCAT via the DIP switches is not planned. By using the EtherCAT fieldbus technology
module the bus will be switched on automatically.

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6.1.2 Assignment of the DIP switch

The firmware of the ARS 2000 FS servo positioning controllers distinguishes itself by the universal
support of various types of fieldbuses. Since every fieldbus requires a specific hardware, the fieldbus
is selected based on the fieldbus module that is plugged into one of the technology slots. Depending
on the identified technology module, the individual switches have an influence on the activation and
perhaps also on the configuration of this specific fieldbus. If the system does not find any fieldbus
technology module, the switch settings affect the fieldbus CAN whose interface is integrated into the
basic device. This means that if, for example, a PROFIBUS-module is installed, the switch positions
cannot be used to activate the CAN communication.

The assignment of the individual switch positions to a specific function depends on the fieldbus that is
used. As far as this is possible, the function of a switch is the same for all of the fieldbuses such as, for
example, switch 8 for activating/deactivating the communication. The functions are listed in

Table 33.

The following general rules apply to the communication parameterisation of the technology modules
that are listed in

Table 33:

 Switch position = 0:
Activation of the communication. The baud rate and the fieldbus address will be taken from the
parameter data set or – depending on the parameterisation – optionally also by an addition of
digital inputs

 Switch position <> 0:

The configuration of the communication parameters via the DIP switch takes precedence over the
corresponding settings in the parameter data set:

 Activation of the communication via DIP switch

 Selection of the baud rate (if it can be adjusted) via DIP switch

 Setting of the fieldbus address via DIP switch (addition to the basic node number taken from
the parameter data set)

 If the communication is deactivated via the DIP switch, it is optionally possible to reactivate or
deactivate it via the Metronix ServoCommander® parameterisation software

 The fieldbus address that is set via the DIP switch is checked internally for validity and, if
necessary, it is limited

 Fieldbus-specific functions (for example CAN: check for double node numbers) are configured via
the settings in the parameter data set

 If no fieldbus technology module is connected, the DIP switch is used for the configuration of the
CAN hardware that is integrated in the basic device.
The control of operating parameters for the RS485 communication that is also supported in the
basic device is not possible in favour of the parameterisation of the CAN interface

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Functional safety technology Page 72

Table 33: Fieldbus specific assignment of the DIP switches

DIP switch Functionally of the DIP switch (fieldbus specific with technology module)

CAN PROFIBUS Sercos (without EtherCAT

(in the basic device) DIP switch)
8 Communication: Communication: Communication: Communication:
1: On 1: On 1: On 1: On
0: Off 0: Off 0: Off 0: Off 1)

7 Baudrate: Slave address Baudrate: No function1)

11: 1 MBaud respectively 11: 16 MBaud
10: 500 kBaud address offset 2): 10: 8 MBaud
6 01: 250 KBaud 0 .. 127 01: 4 MBaud
00: 125 kBaud valid range: 00: 2 MBaud

5 Node address 3 .. 125 Drive address

respectively address respectively address
4 offset 2): offset 2):
3 1 ... 31 1 ... 31

1
1
If all DIP switches == 0: automatic start-up of EtherCAT is activated  EtherCAT is switched on.
If at least one of the DIP switches 1 to 7 <> 0 and DIP switch 8 == 0: no automatic start-up of EtherCAT 
EtherCAT is switched off.
2)
If necessary, the addresses will be added as an offset of a predefined base address of the corresponding bus
system. The base address can be predefined in the Metronix ServoCommander® and can then be saved in
the parameter set of the ARS 2000 FS.

The activation of a fieldbus via the DIP switch takes precedence over the activation of the fieldbus
based on the parameter data set. In order to be nonetheless able to change settings and test different
configurations during the operation, the fieldbus menu of the Metronix ServoCommander® can be
used.

After a reset, however, the setting of the DIP switches will be checked and used.

Example:

 DIP switch position <> 0 and DIP8 = ON

 fieldbus always activated, can be changed via Metronix ServoCommander®

DIP switch position <> 0 and DIP8 = OFF

 fieldbus always off, can be changed via Metronix ServoCommander®

 DIP switch position = 0

 fieldbus configuration based on the parameter set. Can be changed and saved via
Metronix ServoCommander® (downward-compatible)

Product Manual “Servo Positioning Controller ARS 2100 FS“ Version 5.0
Functional safety technology Page 73

6.2 Integrated safety technology (schematic

representation)

Filter + Rectifier IntermediMte circuit Power inverter

MMins Synchronus mMchine

L1
L2
L3

IntermediMte circuit 2
voltMge Fontrol signMls
6
Power switch
Set vMlues / ActuMl vMlues
FommunicMtion Fontrol module
Field bus
I/Os PMrMmeterisMtion Furrent
SignMl processing + Fontrol
digitMl, DiMgnostics
MnMlogue Angle
Motor speed Encoder
/ommunication

Safety module FSM 2.0

Figure 8: Schematic representation of the integrated safety technology (MOV)

Product Manual “Servo Positioning Controller ARS 2100 FS“ Version 5.0
Functional safety technology Page 74

6.3 Module variants

6.3.1 FBA module

As a standard, the basic device comes supplied with a so-called “FBA module” (Fieldbus Activation
Module) that has a DIP switch (8 poles) on its front panel. Under certain conditions, substantial parts
of the parameters of the fieldbus communication can be configured with the aid of this DIP switch.
Depending on the fieldbus that is used, it is possible, for example, to adjust the fieldbus node number
or the baud rate, and so on This means that a servo positioning controller that is supplied in its original
state (that is without a parameterisation or fieldbus data settings) can be installed and commissioned
in a system.

In addition, the FBA module is required for enabling the driver power supply for the power stage.

8 ON

Fieldbus Parameter
7
6
5
4
3
2
1

ON

Figure 9: FBA module: Front view

Product Manual “Servo Positioning Controller ARS 2100 FS“ Version 5.0
Functional safety technology Page 75

6.3.2 FSM 2.0 – STO (Safe Torque Off)

Please refer to the Original instructions “FSM 2.0 – STO” for further information.

6.3.3 FSM 2.0 – MOV

Module for the safety functions SLS, SOS, SBC etc.

Please refer to the Original instructions “FSM 2.0 – MOV” for further information.

Product Manual “Servo Positioning Controller ARS 2100 FS“ Version 5.0
Mechanical installation Page 76

7 Mechanical installation
7.1 Important notes
 Only use the servo positioning controller ARS 2100 FS as a built-in device for switch cabinets

 Mounting position vertical with supply lines [X9] on top

 Mount to control cabinet plate using a fastening strap

 Installation spaces:
Keep a minimum distance of 100 mm to other components each above and underneath the device
to ensure sufficient venting.

 The servo positioning controller ARS 2100 FS may be installed adjacently in one switch cabinet
without a gap, proper usage and installation on a heat-dissipating rear panel provided. Please
note that excessive heat may cause premature aging and/or damaging of the device. In case the
servo positioning controller ARS 2100 FS are subject to high thermal stress, a space of 59 mm is
recommended!

The connections shown in the following illustrations for the servo positioning controller
ARS 2102 FS also apply to the servo positioning controller ARS 2105 FS and
ARS 2108 FS!

Product Manual “Servo Positioning Controller ARS 2100 FS“ Version 5.0
Mechanical installation Page 77

Figure 10: Servo positioning controller ARS 2100 FS: Installation space

Product Manual “Servo Positioning Controller ARS 2100 FS“ Version 5.0
Mechanical installation Page 78

7.2 View of the device

FBA module (FieldNus ActivMtion

Module) RitO DHP sRitcO
LED stMtus
- READY servo drives

- ERROR ARS 2102 FS

READY/
ERROR
- ENABLE ENABLE

- FAN ON

FSM
CAN ON

RESET
RESET Nutton

STATE
StMtus displMy

[X19] USB
LX1E] USB interfMce
[X18] ETHERNET

LX18] EtOernet interfMce

Fonnection for
[X5] RS232 / RS485

Fieldbus Adress
- LX4] FANopen interMfce
6
5
[X4] C AN

- LXD] seriMl interfMce RS232

4
3
2
1
ON 0

[X4] [X5]
OFF

TECH 1/TECH 2
C AN TERM

TerminMting resistor for FANopen

ON

SDCMMF cMrd slot

TecOnology slots
SD-/MMC - C ARD

TEFH1 Mnd TEFH2 for

- MF 2000
- SERFOS HH
- PROFHBUS-DP
OFF

- EtOerFAT
BO OT

- EA88
ON

- Service memory module Risk of electric shock! Do not touch electrical!

Connectors for 5 minutes after switching power off!
Read manual before installing!
Risk of electric
High leakageshock! DoFirst
current! not touch electrical
connect to earth!
connectors for 5 minutes after switching
Boot Mction power off! Read manual before installing!
High leakage current! First connect to earth!

Mounting plMte

FMstening NrMcket of sOield

connection terminMl Nlock SK14
- Motor cMNle
- Angle encoder cMNle

Figure 11: Servo positioning controller ARS 2102 FS: Front view

Product Manual “Servo Positioning Controller ARS 2100 FS“ Version 5.0
 [X9]: Power Supply
L: mains phase 230VAC
N: mains neutral conductor
ZK+: pos. DC bus voltage
ZK-: neg. DC bus voltage
[X2B]: Connection for the encoder BR-INT: brake chopper (internal)
BR-CH: brake chopper
[X9]

PE: ground conductor from

Mechanical installation

mains
+24V: 24VDC
GND24V: GND 24VDC

[X2A]: Connection for the resolver

[X2B] ENCODER [X2A] RESOLVER

[X11]: Incremental encoder output
[X11] OUT

[X10]: Incremental encoder input

Product Manual “Servo Positioning Controller ARS 2100 FS“

[X10] IN

[X6]: Motor Connection Figure 12: Servo positioning controller ARS 2102 FS: Top view
BR-: holding brake

Figure 13: Servo positioning controller ARS 2102 FS: Bottom view
BR+: holding brake
PE: Connection for inner shield
(holding brake + temperature sensor)
MT-: motor sensor

[X6]
MT+ motor sensor [X1]: I/O interface
[X1] I/O

PE: motor ground conductor

W: motor phase 3
V: motor phase 2
U: motor phase 1
Fastening bracket of shield connection
terminal block SK14

Version 5.0
Page 79
Mechanical installation Page 80

7.3 Mounting
The servo positioning controller ARS 2100 FS has attachment lugs on the top and the bottom of the
device. These lugs are used to mount the servo positioning controller vertically to a control cabinet
plate. The lugs are part of the cooling body profile. This is why the best possible heat transfer to the
control cabinet plate has to be ensured.

Recommended tightening torque for an M5 screw of property class 5.6: 2.8 Nm.

Please use M5 screws for the mounting of the servo positioning controllers ARS 2102 FS,
ARS 2105 FS und ARS 2108 FS.

R2,5 M4 flush head stud

R5

261 mm
255,5 mm
251 mm
247,3 mm

R2,5
31,5 mm
21 mm

4,5 mm
28,8 mm
54,6 mm

Figure 14: Servo positioning controller ARS 2100 FS: Mounting plate

Product Manual “Servo Positioning Controller ARS 2100 FS“ Version 5.0
Electrical installation Page 81

8 Electrical installation
8.1 Connector configuration
The servo positioning controller ARS 2100 FS is connected to the supply voltage, the motor, the brake
resistor and the holding brakes as shown in Figure 15.

ARS 2100 FS
100 VAC ... 230 VAC
+/- 10 % main fuse Power Supply [X9]
L L Mains phase

N N Mains neutral conductor

PE ZK+ Pos. DC bus voltage

Bridge circuit
External for internal ZK- Neg. DC bus voltage
brake brake resistor Connection of internal brake
resistor BR-INT
resistor
Brake chopper connection for
BR-CH
alternative ! internal/external brake resistor
Connection ground conductor from
PE
mains
F1
+24 V +24V +24 V supply
24 V Supply
0V GND24V Reference ground for +24 V supply

Ground conductor from motor

Permanent-magnet
synchronous maschine Motor [X6]
U Motor phase 1
T
SM V Motor phase 2

W Motor phase 3

PE Ground connection from motor

MT+ Motor temperature sensor,

normally closed contact, PTC,
MT- KTY...
Cable shield from holding brake
PE
and motor temperature sensor
24 V / 1 A BR+ Holding brake (motor), signal level
for the depentdent on switch status,
holding brake BR- high side / low side switch

Motor feedback [X2A] / [X2B]

E Resolver / Encoder

Motor feedback

Figure 15: Connection to power supply and motor

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Electrical installation Page 82

The operation of the servo positioning controller ARS 2100 FS requires a 24V voltage supply source
for the electronics supply, which is connected to the terminals +24V and GND24V.

The connection to the supply for the power output stage is either made to terminals L1 and N for AC
supply or to ZK+ and ZK- for DC supply.

The motor is connected to terminals U, V and W. The motor temperature switch (analogue or digital) is
connected to terminals MT+ and MT–, if it is lead into one cable together with the motor phases. If an
analog temperature sensor is used in the motor (for example KTY81), the connection is realized via
the encoder cable to [X2A] or [X2B].

The connection of the shaft encoder via the D-Sub connector to [X2A] / [X2B] is roughly shown in
Figure 15.

The servo positioning controller ARS 2100 FS must be connected to ground with its PE connection.

The ARS 2100 FS must be completely wired first. Only then the operating voltages for the DC bus and
the electronics may be switched on. In the case of inversed wiring of the operating voltage
connections, excessive operating voltage or in the case of confusing the connections for operating
voltage and motor the servo positioning controller will be damaged.

8.2 ARS 2100 FS complete system

The complete servo positioning controller ARS 2100 FS system is shown in Figure 16. The following
components are required for using the servo positioning controller:

 Main switch mains supply

 Fault current protection switch (RCD), AC/DC sensitive 300mA (if this is required by an
application)

 Automatic circuit breaker

 Servo positioning controller ARS 2100 FS

 Motor with motor cable

 Mains cable

The parameterisation requires a PC with serial or USB connection.

A slow-blow (B16) single-phase automatic circuit breaker of 16 A has to be installed in the mains
supply line.

Product Manual “Servo Positioning Controller ARS 2100 FS“ Version 5.0
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Figure 16: Complete setup of the ARS 2100 FS with motor and PC

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8.3 Connection: Power supply [X9]

The servo positioning controller ARS 2100 FS receives its 24 VDC power supply for the control
electronics via connector [X9].

The mains voltage supply is single-phase. As an alternative to AC feed or for the purpose of DC bus
coupling a direct DC supply for the DC bus is possible.

8.3.1 Device side [X9]

 ARS 2102 FS and ARS 2105 FS PHOENIX MINI-COMBICON MC1.5/9-G-5.08 BK

 ARS 2108 FS PHOENIX COMBICON MSTBA 2,5/9-G-5.08 BK

8.3.2 Counterplug [X9]

 ARS 2102 FS and ARS 2105 FS PHOENIX MINI-COMBICON MC1.5/9-ST-5.08 BK

 ARS 2108 FS PHOENIX COMBICON MSTB 2,5/9-ST-5,08 BK

 ARS 2102 FS and ARS 2105 FS PHOENIX MINI-COMBICON connector housing 12-pole,
KGG-MC1,5/12 BK

 ARS 2108 FS PHOENIX COMBICON connector housing 12-pole,

KGS-MSTB 2,5/9 BK

 Coding to PIN 9 (GND24V)

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8.3.3 Pin assignment [X9]

Table 34: Pin assignment: [X9]

Pin No. Denomination Values Specification

1 L 100 ... 230 VAC [± 10 %], Phase conductor

50 ... 60 Hz
2 N Neutral conductor

3 ZK+ < 440 VDC Pos. DC bus voltage

4 ZK- GND_ZK Neg. DC bus voltage

5 BR-INT < 460 VDC Connection of internal brake

resistor (bridge to BR-CH when
using the internal resistor)

6 BR-CH < 460 VDC Brake chopper connection for

internal brake resistor against
BR-INT and external brake resistor
against ZK+

7 PE PE Connection ground conductor from

mains

8 +24V 24 VDC Supply for control module

[± 20 %],
0,55 A *) ARS 2102 FS

0,65 A *) ARS 2105 FS and

ARS 2108 FS

9 GND24V GND (0 VDC) Reference potential supply

*)
Plus current consumption of a possibly connected holding brake and I/Os

8.3.4 Cable type and design [X9]

The mentioned cable denominations refer to cables by Lapp. They have proven effective and are
successfully used in many applications. However, similar cables from other manufacturers, for
example Lütze or Helukabel, may also be used.

For the 230 VAC supply:

 LAPP KABEL ÖLFLEX-CLASSIC 110; 3 x 1.5 mm²

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8.3.5 Connection notes [X9]

PHOENIX PHOENIX
Power connector MINI-COMBICON COMBICON
at the X9 at the X9
L 1
N 2
ZK+ 3
ZK- 4
alternative !
Bw-INT 5
Bw-CI external 6
brake resistor
t9 7
+24V 8
GND24V 9

Figure 17: Supply [X9]

ARS 2102 FS and ARS 2105 FS: PHOENIX MINI-COMBICON MC 1,5/ 9-ST-5,08 BK
ARS 2108 FS: PHOENIX COMBICON MSTB 2,5/9-ST-5,08 BK

The servo positioning controller ARS 2100 FS has an internal brake chopper with brake resistor. For
more brake power it is possible to connect an external brake resistor to the connector [X9].

If no external brake resistor is used, a bridge must be connected between PIN 5 and
PIN 6 so that the DC bus precharge, when the mains power supply is “ON”, and the DC
bus rapid discharge can function properly!

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8.4 Connection: Motor [X6]

8.4.1 Device side [X6]

 ARS 2102 FS and ARS 2105 FS PHOENIX MINI-COMBICON MC1.5/9-G-5.08 BK

 ARS 2108 FS PHOENIX COMBICON MSTBA 2,5/9-G-5.08 BK

8.4.2 Counterplug [X6]

 ARS 2102 FS and ARS 2105 FS PHOENIX MINI-COMBICON MC1.5/9-ST-5.08 BK

 ARS 2108 FS PHOENIX COMBICON MSTB 2,5/9-ST-5,08 BK

 ARS 2102 FS and ARS 2105 FS PHOENIX MINI-COMBICON connector housing 12-pole,
KGG-MC1,5/12 BK

 ARS 2108 FS PHOENIX COMBICON connector housing 12-pole,

KGS-MSTB 2,5/9 BK

 Coding to PIN 1 (BR-)

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8.4.3 Pin assignment [X6]

Table 35: Pin assignment: [X6]

Pin No. Denomination Values Specification

1 BR- 0 V brake Holding brake (motor), signal level

dependent on switch status, high
2 BR+ 24 V brake
side / low side switch

3 PE PE Connection for inner shield

(holding brake + temperature
sensor)

4 MT- GND Motor temperature sensor1), N.C.

5 MT+ + 3,3 V / 5 mA and N.O. contact, PTC, NTC KTY

6 PE PE Motor ground conductor

7 W 0 ... 270 VRMS ARS 2102 FS and Connection of the three motor
ARS 2105 FS phases
8 V 0 ... 230 VRMS ARS 2108 FS

0 ... 2,5 ARMS ARS 2102 FS

9 U
0 ... 5 ARMS ARS 2105 FS
0 ... 8 ARMS ARS 2108 FS
0 ... 1000 Hz
1)
Please comply with Chapter 9 Additional requirements for the servo drives concerning the UL approval on
page 121.

The cable shield of the motor cable must also be connected to the controller housing
(PE screw terminal).

8.4.4 Cable type and design [X6]

The mentioned cable denominations refer to cables by Lapp. They have proven effective and are
successfully used in many applications. However, similar cables from other manufacturers, for
example Lütze or Helukabel, may also be used.

Caution!
Please comply with the prescribed minimum copper cross-section for cables as per EN
60204-1!

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 ARS 2102 FS:

LAPP KABEL ÖLFLEX SERVO 700 CY; 4 G 1,5 + 2 x (2 x 0,75); ∅ 12,7 mm, with tinned total Cu
shield

 ARS 2105 FS and ARS 2108 FS:

LAPP KABEL ÖLFLEX SERVO 700 CY; 4 G 2,5 + 2 x (2 x 0,75); ∅ 14,9 mm, with tinned total Cu
shield

For highly flexible applications:

 ARS 2102 FS:

LAPP KABEL ÖLFLEX SERVO FD 755 P; 4 G 1,5 + 2 x (2 x 0,75) CP; ∅ 14,1 mm, with tinned
total Cu shield for highly flexible use in drag chains

 ARS 2105 FS und ARS 2108 FS:

LAPP KABEL ÖLFLEX SERVO FD 755 P; 4 G 2,5 + 2 x (2 x 0,75) CP; ∅ 15,1 mm, with tinned
total Cu shield for highly flexible use in drag chains

8.4.5 Connection notes [X6]

PHOENIX PHOENIX
MoPor connecPor MINI-COMBICON COMBICON
MP Phe X6 MP Phe X6
BR- 1
BR+ 2
PE (optional) 3
MT- 4
MT+ 5
PE (Motor) 6
Motor Phase W resp. 3 7
Motor Phase V resp. 2 8
Motor Phase U resp. 1 9
Connector housing
Cable shield
Motor housing
(optional)

Figure 18: Motor connection [X6]

ARS 2102 FS and ARS 2105 FS: PHOENIX MINI-COMBICON MC 1,5/ 9-ST-5,08 BK
ARS 2108 FS: PHOENIX COMBICON MSTB 2,5/9-ST-5,08 BK

 Connect the inner shields to PIN 3; maximum length 40 mm.

 Length of unshielded cores maximum 35 mm.

 Connect total shield on controller side flat to PE terminal; maximum length 40 mm.

 Connect total shield on motor side flat to connector or motor housing; maximum length 40 mm.

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Via terminals ZK+ and ZK- the DC buses of several servo positioning controllers ARS 2100 FS can be
interconnected. The coupling of the DC bus is interesting for applications with high brake energies or if
movements have to be carried out even in the case of power failure. For further information please
refer to Application Note 67.

A holding brake can be connected to the terminals BR+ and BR- of the motor. The holding brake is fed
by the servo positioning controller’s power supply. Note the maximum output current provided by the
servo positioning controller ARS 2100 FS. A relay may have to be placed between the device and the
holding brake as shown in Figure 19:

GND Power supply

Power supply
+24 V

1
BR-

2
BR+

Resistor and capacitor

ARS 2100 FS
for spark extinguishing

Free-wheeling diode
GND Holding brake

Motor with
holding brake
Holding brake
+24 V

Figure 19: Connecting a holding brake with high current draw (> 1A) to the device

The switching of inductive direct current via relay produces strong currents and sparking.
For interference suppression we recommend integrated RC suppressor elements, for
example by Evox RIFA, denomination: PMR205AC6470M022 (RC element with 22 Ω in
series with 0.47 µF).

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8.5 Connection: I/O communication [X1]

The following Figure 20 shows the principle function of the digital and analog inputs and outputs. The
servo positioning controller ARS 2100 FS is shown on the right hand side, the control system
connection on the left. The cable design is also visible.

The servo positioning controller ARS 2100 FS features two potential ranges:

Analog inputs and outputs:

All analog inputs and outputs refer to AGND. AGND is internally connected with GND, the reference
potential for the control module with µC and AD converters in the controller. This potential range is
galvanically separated from the 24 V range and from the DC bus.

24 V inputs and outputs:

These signals refer to the 24 V supply voltage of the servo positioning controller ARS 2100 FS which
is fed via [X9], and separated from the reference potential of the control module by means of
optocouplers.

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Control system ARS 2100 FS

AIN 0
#AIN 0

Pin No.
X1
AGND
AIN 0 2
AIN 1 / AIN 2
#AIN 0 15

AIN 1 3
AIN 2 16
AGND

+VREF 4 +VREF
+15 V

AGND 14

AMON 0 17
AGND
AMON 1 5

AMON x
AGND 14
1
AGND
AGND
100 mA +24 VDC
max ! +24 VDC 18 GND AGND

DIN x
DIN 0 19

DIN 9 11
GND 24 V
DOUT 0 24 GND
+24 VDC
100 mA
max !
DOUT 3 13
DOUT x
GND 24 V 6 GND

GND 24 V
GND 24 V

PE PE
Connector housing

Figure 20: Basic circuit diagram connector [X1]

The servo positioning controller ARS 2100 FS comprises one differential (AIN 0) and two single-ended
analog inputs, designed for input voltages within a range of ±10V. The inputs AIN 0 and #AIN 0 are
lead to the control via twisted cables (twisted pair design).

If the control comprises single-ended outputs, the output is connected to AIN 0 and #AIN 0 is put on
the reference potential of the control. If the control has differential outputs, they are to be connected
1:1 to the differential inputs of the servo positioning controller ARS 2100 FS.

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The reference potential AGND is connected to the reference potential of the control. This is necessary
in order to prevent the differential input of the servo positioning controller ARS 2100 FS from being
overridden by high "common-mode interference".

There are two analog monitor outputs with output voltages in the range of ± 10 V and an output for a
reference voltage of + 10 V. These outputs can be led to the superimposed control, the reference
potential AGND must be carried along. If the control has differential inputs, the "+"-input of the control
is connected to the output of the servo positioning controller ARS 2100 FS and "-"-input of the control
with AGND.

8.5.1 Device side [X1]

 D-SUB connector, 25-pole, female

8.5.2 Counterplug [X1]

 D-SUB connector, 25-pole, male

 Housing for 25-pole D-SUB connector with bolting screws 4/40 UNC

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8.5.3 Pin assignment [X1]

Table 36: Pin assignment: I/O communication [X1]

Pin No. Denomination Values Specification

1 AGND 0V Shield for analog signals, AGND

14 AGND 0V Reference potential for analog signals

2 AIN 0 UIn = ± 10 V Setpoint input 0, differential, max. 30 V input

RI ≥ 30 kΩ voltage
15 #AIN 0

3 AIN 1 UIn = ± 10 V Setpoint inputs 1 and 2, single ended, max.

RI ≥ 30 kΩ 30 V input voltage
16 AIN 2

4 +VREF + 10 V Reference output for setpoint potentiometer

17 AMON 0 ± 10 V Analog monitor output 0

5 AMON 1 ± 10 V Analog monitor output 1

18 +24V 24 V / 100 mA Auxiliary voltage for IOs at X1

6 GND24 Reference GND Reference potential for digital I/Os

19 DIN 0 POS Bit 0 Target selection positioning Bit 0

7 DIN 1 POS Bit 1 Target selection positioning Bit 1

20 DIN 2 POS Bit 2 Target selection positioning Bit 2

8 DIN 3 POS Bit 3 Target selection positioning Bit3

21 DIN 4 FG_E Power stage enable

9 DIN 5 FG_R Input controller enable

22 DIN 6 END 0 Input end switch 0 (locks n < 0)

10 DIN 7 END 1 Input end switch 1 (locks n > 0)

23 DIN 8 START Input for positioning start

11 DIN 9 SAMP High-speed input

24 DOUT 0 / READY 24 V / 100 mA Output operational

12 DOUT 1 24 V / 100 mA Output freely programmable

25 DOUT 2 24 V / 100 mA Output freely programmable

13 DOUT 3 24 V / 100 mA Output freely programmable

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8.5.4 Cable type and design [X1]

The mentioned cable denominations refer to cables by Lapp. They have proven effective and are
successfully used in many applications. However, similar cables from other manufacturers, for
example Lütze or Helukabel, may also be used.

 LAPP KABEL UNITRONIC LiYCY (TP); 25 x 0,25mm²; ∅ 10,7 mm

Figure 20 shows the cable between the servo positioning controller ARS 2100 FS and the control. The
cable shown has two cable shields.

The outer cable shield is connected on both sides to PE. Inside the servo positioning controller the
connector housing of the D-Sub connector is connected to PE. When using metal D-Sub connector
housings the cable shield is simply squeezed underneath the strain relief clamp.

Often, an unshielded cable is sufficient for the 24 V signals. In heavily disturbed surroundings or in the
case of long cables (l > 2 m) between the control and the servo positioning controller ARS 2100 FS
Metronix recommends the use of shielded cables.

In spite of the differential design of the analog inputs of the ARS 2100 FS the cables should not be
unshielded, since interferences, for example due to switching contactors or power stage interferences
of the converters can reach high amplitudes. They couple into the analog signals and cause common-
mode interference, which may lead to deviation of the analog measured values.

In the case of limited cable lengths (l < 2 m, wiring inside control cabinet) the outer dual-sided PE
shield is enough to guarantee undisturbed operation.

For optimal interference suppression on the analog signals the cores for the analog signals are to be
shielded together and separate from others. This internal cable shield is connected to AGND (Pin 1 or
14) on one side of the ARS 2100 FS. It can be connected on both sides in order to establish a
connection between the reference potentials of the control and the servo positioning controller ARS
2100 FS. Pins 1 and 14 are directly connected to each other inside the controller.

8.5.5 Connection notes [X1]

The digital inputs are designed for control voltages of 24 V. Due to the high signal level a higher
interference immunity of these inputs is already guaranteed. The servo positioning controller
ARS 2100 FS provides a 24 V auxiliary voltage, which may be loaded with a maximum of 100 mA.
This way the inputs can be activated directly via switches. Activation via the 24 V outputs of a PLC is,
of course, also possible.

The digital outputs are designed as so-called "high-side switches ". That means that the 24 V of the
servo positioning controller ARS 2100 FS are actively switched through to the output. Loads such as
lamps, relays, and so on are thus switched from the output to GND24. The four outputs DOUT 0 to
DOUT 3 can be loaded with a maximum of 100mA each. The outputs can also be lead directly to 24 V
inputs of a PLC.

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8.6 Connection: Resolver [X2A]

8.6.1 Device side [X2A]

 1 D-SUB connector, 9-pole, female

8.6.2 Counterplug [X2A]

 D-SUB connector, 9-pole, male

 Housing for 9-pole D-SUB connector with bolting screws 4/40 UNC

8.6.3 Pin assignment [X2A]

Table 37: Pin assignment: [X2A]

Pin No. Denomination Values Specification

1 S2 3,5 Veff / 5-10 kHz SINE trace signal, differential

6 S4 Ri > 5 kΩ

2 S1 3,5 Veff / 5-10 kHz COSINE trace signal, differential

7 S3 Ri > 5 kΩ

3 AGND 0V Shield for signal pairs (inner shield)

8 MT- GND (0 V) Reference potential temperature sensor

4 R1 7 Veff / 5-10 kHz Carrier signal for resolver

IA ≤ 150 mAeff

9 R2 GND (0 V)

5 MT+ +3,3 V / Ri = 2 kΩ Motor temperature sensor, normally

closed contact, PTC, KTY

The outer cable shield of the angle encoder cable must additionally be applied to the
mounting plate of the controller housing over a large contact area with the aid of the
shield connection clamp SK14.

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8.6.4 Cable type and design [X2A]

The mentioned cable denominations refer to cables by Lapp. They have proven effective and are
successfully used in many applications. However, similar cables from other manufacturers, for
example Lütze or Helukabel, may also be used.

 LAPP KABEL ÖLFLEX SERVO 720 CY; 3 x (2 x 0,14 DY) + 2 x (0,5 DY) CY; ∅ 8.5 mm,
with tinned total Cu shielding, Error during angle detection up to approx. 1.5° at 50 m cable length

 2 x (0,5 DY) use carriers for the resolver!

For highly flexible applications:

 LAPP KABEL ÖLFLEX SERVO FD 770 CP; 3 x (2 x 0,14 D12Y) + 2 x (0,5 D12Y) CP; ∅ 8.3 mm,
with tinned total Cu shielding, Error during angle detection up to approximately 1.5° at 50 m cable
length

 2 x (0.5 D12Y) use carriers for the resolver!

8.6.5 Connection notes [X2A]

D-SUB connector Resolver output at the
at X2A motor

1 S2 / SIN+
6 S4 / SIN-
1 2 S1 / COS+
6
7 S3 / COS-
3
8 AGND TEMP
9
5 4 R1 / carrier+
Male 9 R2 / carrier-
5 TEMP+
Connector Cable shield
housing (optional)
Connector housing

Figure 21: Pin assignment: Resolver connection [X2A]

 The outer shield is always connected to PE (connector housing) on the controller side.

 The three inner shields are connected on one side of the servo positioning controller
ARS 2100 FS to PIN3 of [X2A].

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8.7 Connection: Encoder [X2B]

8.7.1 Device side [X2B]

 D-SUB connector, 15-pole, female

8.7.2 Counterplug [X2B]

 D-SUB connector, 15-pole, male

 Housing for 15-pole D-SUB connector with bolting screws 4/40 UNC

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8.7.3 Pin assignment [X2B]

Table 38: Pin assignment: Analog incremental encoder – optional [X2B]

Pin No. Denomination Values Specification

1 MT+ +3,3 V / Motor temperature sensor1), normally

Ri = 2 kΩ closed contact, PTC, KTY

9 U_SENS+ 5 V ... 12 V / Sensor cables for encoder supply

RI ≈ 1 kΩ
2 U_SENS-

10 US 5 V / 12 V / ± 10 % Supply voltages for high-resolution

Imax = 300 mA incremental encoder

3 GND 0V Reference potential encoder supply and

motor temperature sensor

11 R 0,2 VSS … 0,8 VSS Reset pulse trace signal (differential) from
RI ≈ 120 Ω high-resolution incremental encoder
4 #R

12 COS_Z12) 1 VSS / ± 10 % COSINE commutation signal (differential)

RI ≈ 120 Ω from high-resolution incremental encoder
5 #COS_Z1 2)

13 SIN_Z12) 1 VSS / ± 10 % SINE commutation signal (differential) from

RI ≈ 120 Ω high-resolution incremental encoder
6 #SIN_Z12)

14 COS_Z02) 1 VSS / ± 10 % COSINE trace signal (differential) from high-

RI ≈ 120 Ω resolution incremental encoder
7 #COS_Z02)

15 SIN_Z02) 1 VSS / ± 10 % SINE trace signal (differential) from high-

RI ≈ 120 Ω resolution incremental encoder
8 #SIN_Z02)
1)
Please comply with Chapter 9 Additional requirements for the servo drives concerning the UL approval on
page 121.
2)
Heidenhain encoder: A=SIN_Z0; B=COS_Z0; C=SIN_Z1; D=COS_Z1

The outer cable shield of the angle encoder cable must additionally be applied to the
mounting plate of the controller housing over a large contact area with the aid of the
shield connection clamp SK14.

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Table 39: Pin assignment: Incremental encoder with serial interface (for example EnDat,
HIPERFACE) – optional [X2B]

Pin No. Denomination Values Specification

1 MT+ +3,3V / Ri = 2 kΩ Motor temperature sensor1), , normally

closed contact, PTC, KTY

9 U_SENS+ 5 V ... 12 V Sensor cables for encoder supply

RI ≈ 1 kΩ
2 U_SENS-

10 US 5 V / 12 V / ± 10 % Supply voltages for high-resolution

Imax = 300 mA incremental encoder

3 GND 0V Reference potential encoder supply and

motor temperature sensor

11

12 DATA 5 VSS Bidirectional RS485 data line (differential)

RI ≈ 120 Ω (EnDat/HIPERFACE)
5 #DATA

13 SCLK 5 VSS Clock output RS485 (differential)

RI ≈ 120 Ω
6 #SCLK (EnDat)

14 COS_Z02) 1 VSS / ± 10 % COSINE trace signal (differential) from high-

RI ≈ 120 Ω resolution incremental encoder
7 #COS_Z02)

15 SIN_Z02) 1 VSS / ± 10 % SINE trace signal (differential) from high-

RI ≈ 120 Ω resolution incremental encoder
8 #SIN_Z02)
1)
Please comply with Chapter 9 Additional requirements for the servo drives concerning the UL approval on
page 121.
2)
Heidenhain encoder: A=SIN_Z0; B=COS_Z0

The outer cable shield of the angle encoder cable must additionally be applied to the
mounting plate of the controller housing over a large contact area with the aid of the
shield connection clamp SK14.

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Table 40: Pin assignment: Digital incremental encoder – optional [X2B]

Pin No. Denomination Values Specification

1 MT+ +3,3 V / Ri = 2 kΩ Motor temperature sensor1), , normally

closed contact, PTC, KTY

9 U_SENS+ 5 V ... 12 V Sensor cables for encoder supply

RI ≈ 1 kΩ
2 U_SENS-

10 US 5 V / 12 V / ± 10 % Supply voltages for high-resolution

Imax = 300 mA incremental encoder

3 GND 0V Reference potential encoder supply and

motor temperature sensor

11 N 2 VSS … 5 VSS Reset pulse trace signal RS422

RI ≈ 120 Ω (differential) from digital incremental
4 #N encoder

12 H_U 0V/5V Phase U hall sensor for commutation

RI ≈ 2 kΩ
5 H_V Phase V hall sensor for commutation
at VCC
13 H_W Phase W hall sensor for commutation

14 A 2 VSS … 5 VSS A trace signal RS422 (differential) from

RI ≈ 120 Ω digital incremental encoder
7 #A

15 B 2 VSS … 5 VSS B trace signal RS422 (differential) from

RI ≈ 120 Ω digital incremental encoder
8 #B
1)
Please comply with Chapter 9 Additional requirements for the servo drives concerning the UL approval on
page 121.

The outer cable shield of the angle encoder cable must additionally be applied to the
mounting plate of the controller housing over a large contact area with the aid of the
shield connection clamp SK14.

8.7.4 Cable type and design [X2B]

We recommend using the encoder connection cables released for their product by the corresponding
manufacturer (Heidenhain, Stegmann, and so on). If the manufacturer does not recommend a
particular cable, we recommend the assembly of the encoder connection cables as described below.

For the angle encoder supply US and GND, we recommend

 a minimum cross-section of 0.25 mm² for an angle encoder cable length up to 25 m,
and

 a minimum cross-section of 0.5 mm² for an angle encoder cable length up to 50 m.

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8.7.5 Connection notes [X2B]

D-SUB connector at Output of the analogue incremental
X2B encoder interface at the motor

TEMP-
1 TEMP+
9 U_SENS+
2 U_SENS-
10 US
3 GND
1
9
11 R
4 #R
12 COS_Z1
5 #COS_Z1
13 SIN_Z1
8 15
6 #SIN_Z1
Male 14 COS_Z0
7 #COS_Z0
15 SIN_Z0
8 #SIN_Z0
Connector Cable shield
housing (optional)
Connector housing

Figure 22: Pin assignment: Analog incremental encoder – optional [X2B]

Output of the incremental encoder

D-SUB connector
with serial communication
at X2B
interface at the motor

TEMP-
1 TEMP+
9 U_SENS+
2 U_SENS-
10 US
3 GND
1
9
11
4
12 DATA
5 #DATA
13 SCLK
8 15
6 #SCLK
Male 14 COS_Z0
7 #COS_Z0
15 SIN_Z0
8 #SIN_Z0
Connector Cable shield
housing (optional)
Connector housing

Figure 23: Pin assignment: Incremental encoder with serial communication interface (for
example EnDat, HIPERFACE) – optional [X2B]

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D-SUB connector Output of the digital incremental

at X2B encoder at the motor

TEMP-
1 TEMP+
9 SENSE+
2 SENSE-
10 VCC
3 GND
1
9
11 N
4 N#
12 HALL_U
5 HALL_V
13 HALL_W
8 15
6
Male 14 A
7 A#
15 B
8 B#
Connector Cable shield
housing (optional)
Connector housing

Figure 24: Pin assignment: Digital incremental encoder – optional [X2B]

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8.8 Connection: Incremental encoder input [X10]

8.8.1 Device side [X10]

 D-SUB connector, 9-pole, female

8.8.2 Counterplug [X10]

 D-SUB connector, 9-pole, male

 Housing for 9-pole D-SUB connector with bolting screws 4/40 UNC

8.8.3 Pin assignment [X10]

Table 41: Pin assignment: Incremental encoder input [X10]

Pin No. Denomination Values Specification

1 A / CLK 5 V / RI ≈ 120 Ω Incremental encoder signal A /

Stepper motor signal CLK
pos. polarity as per RS422

6 A# / CLK# 5 V / RI ≈ 120 Ω Incremental encoder signal A /

Stepper motor signal CLK
neg. polarity as per RS422

2 B / DIR 5 V / RI ≈ 120 Ω Incremental encoder signal B /

Stepper motor signal DIR
pos. polarity as per RS422

7 B# / DIR# 5 V / RI ≈ 120 Ω Incremental encoder signal B /

Stepper motor signal DIR
neg. polarity as per RS422

3 N 5 V / RI ≈ 120 Ω Incremental encoder index pulse N

pos. polarity as per RS422

8 N# 5 V / RI ≈ 120 Ω Incremental encoder index pulse N

neg. polarity as per RS422

4 GND Reference GND for encoder

9 GND Shield for the connection cable

5 VCC + 5 V / ±5 % Auxiliary supply (short circuit-proof), load with

100 mA 100 mA maximum

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8.8.4 Cable type and design [X10]

We recommend encoder connection cables twisted in pairs and individually protected.

8.8.5 Connection notes [X10]

Input [X10] can be used to process incremental encoder signals as well as pulse direction signals, as
generated by control boards for stepper motors.

The input amplifier at the signal input is designed for the processing of differential signals as per
interface standard RS422. Processing of other signals and levels (for example 5V single-ended or
24VHTL from a PLC) may be possible. Please contact your sales representative.

D-SUB connector
Incremental encoder
at X10
(e.g. ROD 426)
Incremental encoder input

1 A / CLK
6 A# / CLK#
1 2 B / DIR
6
7 B# / DIR#
3 N
8 N#
9
5 4 GND
Male 9
5 VCC
Connector Cable shield
housing (optional)
Connector housing

Figure 25: Pin assignment: Input of the incremental encoder [X10]

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8.9 Connection: Incremental encoder output [X11]

8.9.1 Device side [X11]

 D-SUB connector, 9-pole, female

8.9.2 Counterplug [X11]

 D-SUB connector, 9-pole, male

 Housing for 9-pole D-SUB connector with bolting screws 4/40 UNC

8.9.3 Pin assignment [X11]

Table 42: Pin assignment: Incremental encoder output [X11]

Pin No. Denomination Values Specification

1 A 5 V / RA ≈ 66 Ω *) Incremental encoder signal A

6 A# 5 V / RA ≈ 66 Ω *) Incremental encoder signal A#

2 B 5 V / RA ≈ 66 Ω *) Incremental encoder signal B

7 B# 5 V / RA ≈ 66 Ω *) Incremental encoder signal B#

3 N 5 V / RA ≈ 66 Ω *) Incremental encoder index pulse N

8 N# 5 V / RA ≈ 66 Ω *) Incremental encoder index pulse N#

4 GND Reference GND for encoder

9 GND Shield for connection cable

5 VCC +5V/±5% Auxiliary supply, to be loaded with maximal

100 mA 100 mA, but short-circuit-proof!

*) The value for RA is the differential output resistance

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8.9.4 Cable type and design [X11]

We recommend encoder connection cables twisted in pairs and individually protected.

8.9.5 Connection notes [X11]

D-SUB connector Incremental encoder input
at X11 (e.g. servo positioning controller
Incremental encoder output ARS 2000 FS, X10)

1 A
6 A#
1 2 B
6
7 B#
3 N
8 N#
9
5 4 GND
Male 9
5
Connector Cable shield
housing (optional)
Connector housing

Figure 26: Pin assignment: Incremental encoder output [X11]

The output driver at the signal output provides differential signals (5 V) as per interface standard
RS422.

Up to 32 other servo positioning controllers may be driven by one device.

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8.10 Connection: CAN-Bus [X4]

8.10.1 Device side [X4]

 D-SUB connector, 9-pole, female

8.10.2 Counterplug [X4]

 D-SUB connector, 9-pole, male

 Housing for 9-pole D-SUB connector with bolting screws 4/40 UNC

8.10.3 Pin assignment [X4]

Table 43: Pin assignment: CAN-Bus [X4]

Pin No. Denomination Values Specification

1 Not occupied

6 GND 0V CAN-GND, galvanically connected to GND in

controller
*)
2 CANL CAN-Low signal line
*)
7 CANH CAN-High signal line

3 GND 0V See Pin no. 6

8 Not occupied

4 Not occupied

9 Not occupied

5 Shield PE Connection for cable shield

*) External terminating resistor 120 Ω required on both ends of the bus. If the bus ends are not formed by
ARS 2100 FS servo positioning controllers with integrated terminating resistors, we recommend using metal film
resistors with a 1 % tolerance of type 0207, for example made by BCC, order no.: 232215621201.

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8.10.4 Cable type and design [X4]

The mentioned cable denominations refer to cables by Lapp. They have proven effective and are
successfully used in many applications. However, similar cables from other manufacturers, for
example Lütze or Helukabel, may also be used.

Technical data CAN bus cable: 2 pairs of 2 twisted cores, d ≥ 0.22 mm2, shielded, loop
resistance < 0.2 Ω/m, characteristic impedance 100-120 Ω

 LAPP KABEL UNITRONIC BUS CAN; 2 x 2 x 0.22; ∅ 7.6 mm, with total Cu shielding

For highly flexible applications:

 LAPP KABEL UNITRONIC BUS CAN FD P; 2 x 2 x 0,25; ∅ 8,4 mm, with total Cu shielding

8.10.5 Connection notes [X4]

Caution!
When cabling the servo positioning controllers via the CAN bus, make sure to observe
the following information and notes, to ensure a stable and interference-free system.
Improper cabling may cause the CAN bus to malfunction which in turn can cause the
controller to shut down with an error for safety reasons.

The CAN bus provides a simple and fail-safe way of connecting all components of a system,
assuming, however, compliance with the following notes on cabling.

Figure 27: Cabling example for CAN-Bus

 The individual nodes of a network are always connected in line, so that the CAN cable is looped
through from controller to controller (see Figure 27)

 On both ends of the CAN bus cable must be exactly one terminating resistor of 120 Ω +/- 5 %. The
ARS 2100 FS servo positioning controller is equipped with an integrated terminating resistor that
can be activated/deactivated with the aid of the DIP switch “CAN TERM” that is located on the
front panel (see Figure 11 and Figure 28)

 Shielded cables with exactly two twisted pairs must be used for cabling

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 Use a twisted pair for the connection of CAN-H and CAN-L

 The cores of the other pair are used jointly for CAN-GND

 The shield of the cable is led to the CAN shield connections for all nodes

 For suitable and Metronix-recommended cables please refer to chapter 8.10.4 Cable type and
design [X4]

 We advise against the use of plug adaptors for CAN bus cabling. Should this be necessary
nonetheless, make sure to use metal connector housings to connect the cable shield

 In order to keep interferences as low as possible make sure that

 Motor cables are not installed parallel to signal lines

 Motor cables comply with Metronix specifications

 Motor cables are properly shielded and grounded

 For further information on interference-free CAN bus cabling, please refer to the Controller Area
Network protocol specification, Version 2.0 by Robert Bosch GmbH, 1991

X4, Pin 7
(CAN-H)

integrated
terminating resistor
120 Ω

DIP switch
CAN TERM

X4, Pin 2
(CAN-L)

Figure 28: Integrated CAN terminating resistor

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8.11 Connection: RS232/COM [X5]

8.11.1 Device side [X5]

 D-SUB connector, 9-pole, male

8.11.2 Counterplug [X5]

 D-SUB connector, 9-pole, female

 Housing for 9-pole D-SUB connector with bolting screws 4/40 UNC

8.11.3 Pin assignment [X5]

Table 44: Pin assignment: RS232 interface [X5]

Pin No. Denomination Values Specification

1 Not occupied

6 Not occupied

2 RxD 10 V / RI > 2 kΩ Receive line, RS232 specification

7 - - Not occupied

3 TxD 10 V / RA < 2 kΩ Transmitting line, RS232 specification

8 Not occupied

4 +RS485 reserved for optional RS485 use

9 -RS485 reserved for optional RS485 use

5 GND 0V Interfaces GND, galvanically connected to GND

DGND

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8.11.4 Cable type and design [X5]

Interface cable for serial interface (null modem), 3-core.

8.11.5 Connection notes [X5]

D-SUB connector PC
at X5

5 5
9 9

5 4 4 5
9 9
8 8
3 3
7 7
6 6
1 2 2 1

Female 6 6 Female
1 1
Connector housing Connector housing

Figure 29: Pin assignment: RS232 null modem cable [X5]

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8.12 Connection: USB [X19]

8.12.1 Device side [X19]

 USB female, type B

8.12.2 Counterplug [X19]

 USB male, type B

8.12.3 Pin assignment [X19]

Table 45: Pin assignment: USB interface [X19]

Pin No. Denomination Values Specification

1 VCC + 5 VDC

2 D- Data -

3 D+ Data +

4 GND GND

Figure 30: Pin assignment: USB interface [X19], front view

8.12.4 Cable type and design [X19]

Interface cable for the USB interface, 4 cores, shielded and twisted.

In order to set up a USB connection, it is mandatory to use a twisted and shielded (4-core) cable
since, otherwise, the transmission may be subject to interferences. In addition, it must be ensured that
the cable has a wave impedance of 90 Ω.

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8.13 SD/MMC card

8.13.1 Supported card types

 SD

 SDHC

 MMC

8.13.2 Supported functions

 Load a parameter set (DCO file)

 Save the current parameter set (DCO file)

 Load a firmware file

8.13.3 Supported file systems

 FAT12

 FAT16

 FAT32

8.13.4 File names

Only file and directory names according to the 8.3 standard are supported.

8.3 file and directory names have at most eight characters (letters or numbers) followed
by a period “.” and a filename extension of at most three characters.
File and directory names may only consist of upper-case characters and numbers.

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8.13.5 Pin assignment SD/MMC card

Table 46: Pin assignment: SD card

Pin No Denomination SD Mode SPI Mode

1 DATA3/CS Data Line 3 (Bit 3) Chip Select

2 CMD/DI Command/Response Host to Card Commands and Data

3 Vss1 Supply Voltage Ground Supply Voltage Ground

4 Vcc Supply Voltage Supply Voltage

5 CLK Clock Clock

6 Vss2 Supply Voltage Ground Supply Voltage Ground

7 DAT0/DO Data Line 0 (Bit 0) Card to Host Data and Status

8 DAT1 Data Line 1 (Bit 1) reserved

9 DAT2 Data Line 2 (Bit 2) reserved

Table 47: Pin assignment: MMC card

Pin No Denomination SD Mode SPI Mode

1 RES/CS Not connected or Always „1“ Chip Select

2 CMD/DI Command/Response Host to Card Commands and Data

3 Vss1 Supply Voltage Ground Supply Voltage Ground

4 Vcc Supply Voltage Supply Voltage

5 CLK Clock Clock

6 Vss2 Supply Voltage Ground Supply Voltage Ground

7 DAT/DO Data 0 Card to Host Data and Status

Figure 31: Pin assignment: SC/MMC card

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8.13.6 BOOT-DIP-Switch
During a restart/reset, the BOOT-DIP-Switch is used to determine whether to perform a firmware
download from the SD/MMC card or not.

 BOOT-DIP-Switch in position “ON”  firmware download requested

 BOOT-DIP-Switch in position “OFF”  firmware download not requested

When there is no SD/MMC card in the card slot of the servo positioning controller and the BOOT-DIP-
Switch is in the position “ON” (firmware download requested), the error 29-0 is triggered after a
restart/reset.
This error stops all further performances. This means that there is no communication possible via the
serial interface (RS232) or USB.

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8.14 Notes on safe and EMC-compliant installation

8.14.1 Definitions and terms

Electromagnetic compatibility (EMC) or electromagnetic interference (EMI) includes the following
requirements:

 Sufficient immunity of an electrical installation or an electrical device against outside electrical,

magnetic or electromagnetic interferences via cables or the ambient

 Sufficiently small unwanted emission of electrical, magnetic or electromagnetic interference from

an electrical installation or an electrical device to other devices in the vicinity via cables or the
ambient

8.14.2 General information on EMC

The interference emission and interference immunity of a device always depend on the entire drive
concept consisting of the following components:

 Voltage supply

 Servo positioning controller

 Motor

 Electro mechanics

 Execution and type of wiring

 Superimposed control

In order to increase interference immunity and to decrease interference emissions the servo
positioning controller ARS 2100 FS already comprises output chokes and mains filters, so that it can
be operated without additional shielding and filtering devices in most applications.

The servo positioning controllers ARS 2100 FS are certified as per the product standard
EN 61800-3 for electrical drive systems.
In most cases no external filtering is required (see below).
The conformity certificate for EMC directive 2004/108/EC is available from the
manufacturer.

Caution!
This product can cause high-frequency interference in residential areas, which could
require measures for radio interference suppression.

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8.14.3 EMC areas: first and second environment

Proper installation and wiring of all connecting cables provided, the ARS 2100 FS servo positioning
controllers fulfil the requirements of product standard EN 61800-3. This standard no longer refers to
"classes", but to so-called environments. The first environment includes mains supply networks
supplying residential buildings. The second environment includes mains supply networks exclusively
supplying industrial buildings.

The following applies to ARS 2100 FS servo positioning controllers without external filter measures:

Table 48: EMC requirements: First and second environment

EMC type Environment Compliance with EMC requirements

Interference First environment (domestic Motor cable length up to 25 m

emission environment), C2

Second environment (industrial Motor cable length up to 25 m

environment), C3

Interference First environment (domestic Independent of motor cable length

immunity environment), C2

Second environment (industrial

environment), C3

8.14.4 EMC-compliant cabling

The following must be considered for an EMC-compliant setup of the drive system (see also chapter 8
Electrical installation, page 81):

 In order to keep the leakage currents and the losses in the motor connection cable as small as
possible, the servo positioning controller ARS 2100 FS should be located as close to the motor as
possible (see also the following chapter 8.14.5 Operation with long motor cables , page 119)

 Motor cable and angle encoder cable must be shielded

 The shield of the motor cable is connected to the housing of the servo positioning controller
ARS 2100 FS (shield connection terminal). The cable shield also has to be connected to the
associated servo positioning controller so that the leakage currents can flow back into the
controller causing the leakage

 The mains-end PE connection is connected to the PE connection point of the supply connection
[X9]

 The inner PE conductor of the motor cable is connected to the PE connection point of the motor
connection [X6]

 The signal lines must be as far away from the power cables as possible. They should not be
placed parallel. If intersections cannot be avoided, they should be perpendicular (that is at a 90°
angle), if possible

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 Unshielded signal and control lines should not be used. If their use is inevitable they should at
least be twisted

 Even shielded cables will inevitably have short unshielded ends (unless shielded connector
housings are used). In general, the following applies:

 Connect the inner shields to the corresponding pins of the connectors; Maximum length
40 mm

 Length of the unshielded cores 35 mm maximum

 Connect the total shield on the controller side plane to the PE terminal; Maximum length
40 mm

 Connect the total shield on the motor side plane to the connector housing or motor housing;
Maximum length 40 mm

DANGER!
For safety reasons, all PE ground conductors must be connected prior to initial
operation.
The EN 61800-5-1 regulations for protective earthing must be complied with during
installation!

8.14.5 Operation with long motor cables

Compliance with the EMC standard EN 61800-3 is only guaranteed for motor cable
lengths of up to 25 m. For cable lengths beyond this a new measurement of the
interference emission may possibly be required.

In applications involving long motor cables and/or unsuitable motor cables with an inadvertently high
cable capacity, the filters may be thermally overloaded. To avoid such problems we highly recommend
the following procedure for applications that require long motor cables:

 With cable lengths of more than 25 m use only cables with a capacitance per unit length between
the motor phase and the shield of less than 150 pF/m!
(Please contact the motor cable supplier, if necessary)
 For motor cable lengths of more than 25 m and up to 50 m the following derating applies
regardless of the EMC qualification (see also Table 7, Technical data: Cable specifications):

PWM frequency up to 5 kHz 5,5 kHz 6 kHz 7 kHz 8 kHz

Max. motor cable length 50 m 45 m 40 m 35 m 30 m

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8.14.6 ESD protection

Caution!
Unassigned D-Sub connectors may cause damage to the device or other parts of the
system due to ESD (electrostatic discharge).

To prevent such discharge, protective caps are available (for example Spoerle).

The servo positioning controller ARS 2100 FS has been designed to provide high interference
immunity. For that reason, some individual functional blocks are electrically isolated. Inside the device
the signals are transmitted via optocouplers.

The following isolated areas are distinguished:

 Power module with DC bus and mains input

 Control electronics with processing of analog signals

 24 V supply and digital inputs and outputs

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9 Additional requirements for the

servo drives concerning the UL
approval
This chapter gives further information concerning the UL approval of the ARS 2102 FS, ARS 2105 FS
and ARS 2108 FS.

9.1 Circuit protection

In case of a required UL-certification the following data for the main fuse are to be
considered:
Listed Circuit Breaker according to UL 489, rated 277 Vac, 16 A, SCR 10 kA

9.2 Wiring and environment regards

 Use 60/75 or 75°C copper (CU) wire only.

 The terminal tightening torque is 0.22...0.25 Nm.

 To be used in a Pollution Degree 2 environment only.

9.3 Motor temperature sensor

Motor overtemperature sensing is not provided by the drive according to UL.

When a UL-certification is required, then in order to prevent motor overtemperatures the servo drives
may only be operated in connection with motors that are provided with an integrated motor
temperature sensor. The sensor has to be connected to the servo drive and the temperature
monitoring has to be activated accordingly on the software side.

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10 Initial operation
10.1 General notes on connection

Since the laying of the connection cables is very important in terms of EMC, make sure
to comply with the previous chapter 8.14.4 EMC-compliant cabling (page 118)!

DANGER!
Noncompliance with chapter 2 Safety notes for electrical drives and controllers (page 17)
may result in property damage, person injury, electric shock or in extreme cases in
death.

10.2 Tools / material

 Screwdriver for slotted head screws size 1

 Serial interface cable

 Angle encoder cable

 Motor cable

 Power supply cable

 Controller enabling cable

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10.3 Connecting the motor

 Plug the connector of the motor cable into the corresponding socket of the motor and screw tight

 Plug PHOENIX connector into socket [X6] of the servo positioning controller

 Connect the PE line of the motor to the PE socket

 Plug the connector of the encoder cable into the encoder output socket of the motor and screw
tight

 Plug the D-Sub connector into the socket [X2A] Resolver or [X2B] Encoder of the servo
positioning controller and fasten the bolting screws

 Apply the shield of the motor or angle encoder cable over a large contact area with the aid of the
shield connection clamp SK14

 Check all connections again

10.4 Connecting the servo positioning controller

ARS 2100 FS to the power supply
 Make sure that the power supply has been switched off

 Plug the PHOENIX connector into socket [X9] of the servo positioning controller

 Connect the PE line of the mains to the PE socket

 Connect the 24 V connections to a suitable power supply unit

 Make mains supply connections

 Check all connections again

10.5 Connecting the PC (serial interface)

 Plug the D-Sub connector of the serial interface cable into the socket for the serial interface of the
PC and fasten the bolting screws

 Plug the D-Sub connector of the serial interface cable into the socket [X5] RS232/COM of the
servo positioning controller ARS 2100 FS and fasten the bolting screws

 Check all connections again

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10.6 Connecting the PC (USB interface, alternative)

 Plug the plug A of the USB interface cable into the socket for the USB interface of the PC

 Plug the plug A of the USB interface cable into the socket [X19] USB of the ARS 2100 FS servo
positioning controller

 Check all of the plug-and-socket connections once more

10.7 Checking operability

1. Make sure the controller enabling switch is turned off

2. Switch on the power supply of all devices. The READY / ERROR LED on the front of the servo
positioning controller should now be active green

If the READY LED does not light green but red, there is a malfunction. If the seven-segment display
indicates a number sequence, it is displaying an error message. You have to take care of the
corresponding problem. In this case please continue with chapter 11.2.2 Error messages (page 129).
If the device displays nothing, follow these steps:

3. Switch off the power supply

4. Wait 5 minutes, so the DC bus can discharge

5. Check all connection cables

6. Check the functionality of the 24 V power supply

7. Switch the power supply back on

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11 Service functions and error

messages
11.1 Protection and service functions

11.1.1 Overview
The servo positioning controller ARS 2100 FS has a powerful sensor analysis, which monitors the
proper functioning of the controller, power output stage, motor and communication with the outside
world. All occurring errors are stored in an internal error memory. Most errors will cause the controller
unit to shut down the servo positioning controller and the power output stage. They can only be
switched on again after the error memory has been deleted by acknowledging the error and after the
error has been eliminated or no longer exists.

A powerful sensor analysis and monitoring function provides operational safety:

 Measuring of motor temperature

 Measuring of power module temperature

 Detection of ground faults (PE)

 Detection of connections between two motor phases

 Detection of overvoltage in the DC bus

 Detection of errors with the internal voltage supply

 Failure of the supply voltage.

If the 24 V DC supply voltage fails, approx. 20 ms remain to save parameters and shut down the
controller properly for example.

11.1.2 Overcurrent and short-circuit monitoring

The overcurrent and short-circuit monitoring detects short-circuits between two motor phases as well
as short-circuits at the motor output terminals against the positive and negative reference potential of
the DC bus and against PE. If the error monitoring detects an overcurrent, the power output stage will
be shut down immediately to guarantee the ability to withstand short-circuits.

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11.1.3 Overvoltage monitoring for the DC bus

This monitor responds, if the DC bus voltage exceeds the operating voltage range. The power output
stage will be shut down.

11.1.4 Temperature monitoring of the heat sink

The heat sink temperature of the power output stage is measured with a linear temperature sensor.
The temperature limit varies from device to device.

11.1.5 Monitoring of the motor

The servo positioning controller ARS 2100 FS has the following protective functions to monitor the
motor and the connected encoder:

Monitoring of the encoder: An error of the shaft encoder leads to the shut-down of the power output
stage. In the case of resolvers, for example the encoder signal is monitored. In the case of incremental
encoders the commutation signals are checked. Other “intelligent” encoders provide further means of
error detection.

Measurement and monitoring of the motor temperature: The ARS 2100 FS servo positioning controller
has a digital and analogue input for measuring and monitoring the motor temperature. The analog
signal detection also supports non-linear sensors. The following temperature sensors can be selected:

 At [X2A], [X2B] and [X6]: Input for PTCs, NTCs, normally closed contacts, normally open
contacts and analog sensors, type KTY.

11.1.6 I²t monitoring

The servo positioning controller ARS 2100 FS comprises an I²t monitoring to limit the average power
loss in the power output stage and in the motor. Since the occurring power loss in the power
electronics and in the motor in the worst case increases square with the current, the squared current
value is assumed as the measure for the power loss.

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11.1.7 Power monitoring for the brake chopper

Power monitoring for the internal brake resistor is implemented in the operating software.

When the power monitoring “I²t brake chopper” reaches 100% the power of the internal brake resistor
is switched back to the rated output power.

11.1.8 I²t monitoring for the PFC stage

I²t monitoring for the PFC is implemented in the operating software (except the ARS 2108 FS).

11.1.9 Initial operation status

Servo positioning controllers, which are sent to Metronix for service, will be equipped with a different
firmware and other parameters for testing purposes.

Before the next initial operation at the customer the servo positioning controller ARS 2100 FS must be
parameterized again. The parameterisation software Metronix ServoCommander® queries the initial
operation status and asks the user to parameterize the servo positioning controller. At the same time
the device shows an “A” on the seven-segment display to indicate that it is ready but not yet
parameterized.

11.1.10 Rapid discharge of the DC bus

If the system detects a failure of the mains supply, the DC bus is rapidly discharged within the safety
period in accordance with EN 60204-1.

Delayed activation of the brake chopper according to power classes in the case of parallel operation
and mains supply failure ensures that the main energy during rapid discharge of the DC bus is taken
over through the braking resistors of the higher power classes.

11.1.11 Operating hours counter

An operating hours counter is implemented, which has been designed for at least 200 000 operating
hours. The operating hours counter is displayed in the parameterisation software Metronix
ServoCommander®.

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11.2 Display of operating mode and error messages

11.2.1 Operating mode and error display

The system supports a seven-segment display. The following table describes the display and the
meaning of the symbols shown:

Table 49: Operating mode and error display

Display Meaning

In the operation mode speed control the outer bars “rotate”, depending on the
actual speed resp. the actual position of the rotor.

If the drive is enabled, the center bar of the seven-segment display is on, too.

The servo positioning controller ARS 2000 FS still has to be parameterised

(seven-segment display = “A”).

Operating mode torque control, the two bars on the left hand of the display are
on (seven-segment display = “I”).

P xxx Positioning, “xxx” stands for the position number.

The numbers are successively indicated.

PH x Homing (“x“ stands for the currently active phase of the homing run).
0 : Search phase
1 : Crawling phase
2 : Positioning to zero position
The numbers are successively indicated.

E xxy Error message with index “xx” and subindex “y”.

The numbers are successively indicated.

-xxy- Warning message with Index “xx” and subindex “y”.

A warning is displayed at least twice on the seven-segment-display.
The numbers are successively indicated.

Option “STO” (Safe Torque-Off) active for the ARS 2000 FS devices.
(seven-segment display = “H”, blinking with a frequency of 2 Hz)

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11.2.2 Error messages

If an error occurs, the servo positioning controller ARS 2000 FS will cyclically show an error message
in its seven-segment display. The error message is comprised of an E (for Error), a main index (xx)
and a sub index (y), for example: E 0 1 0.

Warnings have the same code numbers as error messages. As a distinguishing feature, warnings
have a centre bar before and after the number, for example - 1 7 0 -.

The following Table 50 Error messages summarizes the meaning of the messages and the
corresponding measures.

The error messages with the main index 00 do not reflect run time errors. They contain information
and in general there are no measures required by the user. They appear only in the error buffer and
are not displayed on the seven-segment display.

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Table 50: Error messages

Error message Meaning of the error message Measures

Main Sub
index index

00 0 Invalid error Information: Only for connected service module.

An invalid (corrupted) entry in the error buffer has
been marked by this error number.
The system time entry is set to 0.
No measures required.

1 Invalid error detected and Information: Only for connected service module.
corrected An invalid (corrupted) error entry has been
detected in the permanent event memory and
corrected.

2 Error cleared Information: The active errors have been

acknowledged.
No measures required.

4 Serial number/device type Information: Only for connected service module.

changed An exchangeable error buffer has been plugged
(module change) into another device.
No measures required.

7 Log add-on: Permanent event Information: Entry in permanent event memory.

memory and FSM module “An additional record was found.”
No measures required.

8 Servo drive switched on Information: Entry in permanent event memory.

No measures required.

9 Servo drive safety parameters Information: Entry in permanent event memory.

revised No measures required.

11 FSM: Module change (previous Information: Entry in permanent event memory.

type): Permanent event memory No measures required.
and FSM module

12 FSM: Module change (current Information: Entry in permanent event memory.

type): Permanent event memory No measures required.
and FSM module

21 Log entry from the FSM-MOV: Information: Entry in permanent event memory.
Permanent event memory and No measures required.
FSM module

01 0 Stack overflow Incorrect firmware?

If necessary, reload the standard firmware.
Contact the Technical Support.

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Error message Meaning of the error message Measures

Main Sub
index index

02 0 Undervoltage of the DC bus Error priority set too high?

circuit Check the power supply.
Check (measure) the DC bus circuit voltage.
Check the response threshold of the DC bus
circuit monitoring system.

03 0 Motor overtemperature Motor too hot? Check the parameterization

(analogue) (current controller, current limits).

1 Motor overtemperature Suitable sensor?

(digital) Sensor defective?
Check the parameterization of the sensor or the
characteristic curve of the sensor.
If the error occurs also when the sensor is
bypassed, return the device to our sales partner.

2 Motor Overtemperature Check the connecting cables of the temperature

(analogue): wire break sensor (broken wire).
Check the parameterisation of wire break
detection system (threshold value).

3 Motor overtemperature Check the connecting cables of the temperature

(analogue): short circuit sensor (short circuit).
Check the parameterisation of the short-circuit
monitoring system (threshold value).

04 0 Power module overtemperature Plausible temperature indication?

Check the installation conditions. Fan filter mats
dirty?
1 DC bus circuit overtemperature
Device fan defective?

05 0 Failure of internal voltage 1 Disconnect the device from the entire periphery
and check whether the error is still present after
1 Failure of internal voltage 2
a reset.
2 Driver supply failure If the error is still present, return the device to
your sales partner.

3 Undervoltage of the digital I/Os Check the outputs for short circuits or specific
load.
4 Overcurrent of the digital I/Os
If necessary, contact the Technical Support.

5 Technology module supply Technology module defective?

voltage failure Replace the technology module.
If necessary, contact the Technical Support.

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Error message Meaning of the error message Measures

Main Sub
index index

6 X10, X11 and RS232 supply Check the pin assignment of the connected
voltage failure peripheral equipment.
Check the connected peripheral equipment for
short-circuits.

7 Safety module internal voltage Safety module defective?

failure Replace the safety module.
If the error persists, please send the servo
positioning controller to our sales partner.

8 Failure of internal voltage 15 V Please return the device to our sales partner.

9 Faulty encoder supply

06 0 Short circuit in the power output Motor defective?

stage Short circuit in the cable?
Power output stage defective?

1 Brake chopper overcurrent Check the external braking resistor for short
circuits. Check whether the resistance value is
too small.
Check the brake chopper output of the device.

07 0 Overvoltage in the DC bus Check the connection to the braking resistor

circuit (internal/external).
External braking resistor overloaded?
Check the rating.

08 0 Resolver angle encoder error See items 08-2 .. 08-8.

1 Sense of rotation of the serial A and B track mixed up?

and incremental position Check / correct the connection of the tracks.
evaluation systems not identical

2 Incremental encoder Z0 track Angle encoder connected?

signals error Angle encoder cable defective?
3 Incremental encoder Z1 track Angle encoder defective?
signals error Check the configuration of the angle encoder
4 Digital incremental encoder interface.
track signals error The encoder signals are disturbed: Check the
installation for compliance with EMC
5 Incremental encoder Hall
recommendations.
generator signals error

6 Angle encoder communication

error

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Error message Meaning of the error message Measures

Main Sub
index index

7 Incorrect signal amplitude of the

incremental track

8 Internal angle encoder error The internal monitoring system of the angle
encoder at [X2B] has detected an error.
Communication error?
If necessary, contact the Technical Support.

9 Encoder at [X2B] not supported Please contact the Technical Support.

09 0 Old encoder parameter set Save the data in the encoder EEPROM
(type ARS) (reformatting).

1 Encoder parameter set cannot Angle encoder defective?

be decoded Check the configuration of the angle encoder
interface.
The encoder signals are disturbed.
Check the installation for compliance with the
EMC recommendations.

2 Unknown encoder parameter Save the data into the encoder again.
set version

3 Corrupted data structure in If necessary, re-determine the data and save it in

encoder parameter set the encoder again.

4 EEPROM data: faulty customer- Motor repaired: Perform a homing run and save
specific configuration the data in the angle encoder. Then, save to the
basic device.
Motor replaced: Parameterise the basic device,
perform a homing run, save the data in the angle
encoder, and then save to the basic device.

5 Read/Write Error EEPROM Please contact the Technical Support.

parameter set

7 Write protected EEPROM of the Please contact the Technical Support.

angle encoder

9 Insufficient capacity of the angle

encoder EEPROM

10 0 Overspeed Check the offset angle.

(motor overspeed protection) Check the parameterisation of the limit value.

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Error message Meaning of the error message Measures

Main Sub
index index

11 0 Homing: error during the start Controller not enabled.

1 Error during a homing run The homing run has been interrupted, for
example because the controller enabling has
been cancelled.

2 Homing: no valid index pulse The required index pulse is not provided.

3 Homing: timeout The maximum time that has been parameterised

for homing has been reached before the homing
run could be completed. Check the
parameterisation of the time.

4 Homing: wrong/invalid limit The associated limit switch is not connected.

switch Limit switches mixed up?
Move the limit switch so that it is not located in
the area of the index pulse.

5 Homing: I²t/following error Unsuitable parameterisation of the acceleration

ramps.
An invalid stop has been reached, for example
because no reference switch has been installed.
Check the connection of a reference switch.
If necessary, contact the Technical Support.

6 Homing: end of search distance The maximum distance for the homing run has
reached been covered, but the reference point or the
target of the homing run have not been reached.

7 Homing: The deviation fluctuates, e.g. due to gear

Encoder difference control slackness. If necessary, increase the shut-down
threshold.
Check actual-value encoder connection.

12 0 CAN: Check the configuration of the devices that are

two nodes with the same ID connected to the CAN bus.

1 CAN: Check the cabling (compliance with the cable

communication error, bus OFF specification, cable break, maximum cable length
exceeded, correct terminating resistors, cable
shield earthed (grounded), all signals
connected?).
Replace the device.
If the error has been successfully eliminated by
replacing the device, return the replaced device
to your sales partner.

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Error message Meaning of the error message Measures

Main Sub
index index

2 CAN: CAN communication error Check the cabling (compliance with the cable
during the transmission specification, cable break, maximum cable length
exceeded, correct terminating resistors, cable
3 CAN: CAN communication error
shield earthed (grounded), all signals
during the reception
connected?).
Check the start sequence of the application.
Replace the device.
If the error has been successfully eliminated by
replacing the device, return the replaced device
to your sales partner.

4 CAN: Align the cycle time of the remote frames with the
node Guarding PLC or failure of the PLC.
Signals disturbed?

5 CAN: Check the configuration.

RPDO too short

9 CAN: Check the command syntax of the control (record

protocol error the data traffic).
Please contact the Technical Support.

13 0 CAN bus timeout Check the CAN parameterisation.

14 0 Insufficient power supply for the Check the power supply.

identification Check the motor resistor.

1 Current controller identification: The automatic parameter identification process

insufficient measurement cycle delivers a time constant beyond the value range
that can be parameterised. The parameters must
be optimised manually.

2 Power output stage could not The power output stage has not been enabled.
be enabled Check the connection of DIN 4.

3 Power output stage prematurely The power output stage has been disabled
disabled during a running identification process (e.g. via
DIN 4).

4 Selected resolver type not The identification cannot be performed with the
supported by the identification present angle encoder settings.
system Check the configuration of the angle encoder. If
necessary, contact the Technical Support.

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Error message Meaning of the error message Measures

Main Sub
index index

5 Index pulse not found The index pulse could not be found after the
maximum permissible number of electrical
rotations.
Check the index pulse signal.
Check the angle encoder settings.

6 Invalid Hall signals Check the connection.

Check the data sheet as to whether the encoder
provides 3 Hall signals with 120° or 60°
segments.
If necessary, contact the Technical Support.

7 Identification not possible Check the DC bus circuit voltage.

Check the wiring of the motor/encoder system.
Motor blocked (holding brake not released)?

8 Invalid number of pole pairs The calculated number of pole pairs is beyond
the parameterisation range. Check the data
sheet of the motor.
If necessary, contact the Technical Support.

15 0 Division by 0 Please contact the Technical Support.

1 Out of range error

2 Mathematical underflow

16 0 Incorrect program execution Please contact the Technical Support.

1 Illegal interrupt

2 Initialization error

3 Unexpected state

17 0 Max. following error exceeded Increase the error window.

The parameterisation of the acceleration is too
high.

1 Encoder difference monitoring External angle encoder not connected or

defective?
The deviation fluctuates, e.g. due to gear
slackness. If necessary, increase the shut-down
threshold.

2 Current jerk control Please contact the Technical Support.

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Error message Meaning of the error message Measures

Main Sub
index index

18 0 Analogue motor temperature Motor too hot? Check the parameterisation

warning threshold (current controller, current limits).
Suitable sensor?
Sensor defective?
Check the parameterisation of the sensor or the
characteristic curve of the sensor.
If the error occurs also when the sensor is
bypassed, return the device to our sales partner.

21 0 Error 1 current measurement U Please contact the Technical Support.

1 Error 2 current measurement V

2 Error 2 current measurement U

3 Error 1 current measurement V

22 0 PROFIBUS: Technology module defective?

incorrect initialization Replace the technology module.
If necessary, contact the Technical Support.

1 PROFIBUS: reserved Please contact the Technical Support.

2 PROFIBUS: Check the slave address.

communication error Check the bus terminators.
Check the cabling.

3 PROFIBUS: Incorrect slave address. Please select another

invalid slave address slave address.

4 PROFIBUS: error in value Mathematical error during the conversion of

range physical units. The value range of the data and of
the physical units do not match (fieldbus display
units).
If necessary, contact the Technical Support.

23 0 No consumable record Position save and restore failed, homing

required.
1 Record with invalid checksum

2 Flash content inconsistent

25 0 Invalid device type Please return the device to our sales partner.

1 Device type not supported

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Error message Meaning of the error message Measures

Main Sub
index index

2 HW revision not supported Check the firmware version.

If necessary, request an update from the
Technical Support.

3 Device functionality restricted! Please return the device to our sales partner.

4 Invalid power module type Check the firmware version.

If necessary, request an update from the
Technical Support.

5 Incompatibility firmware / Check the firmware version.

hardware. The firmware is not If necessary, request an update from the
suitable for the device. Technical Support.

26 0 No user parameter set Load the default parameter set.

1 Checksum error If the error is still present, return the device to our
sales partner.

2 Flash: write error Please return the device to our sales partner.

3 Flash: delete error

4 Flash: error in the internal flash Reload the firmware.

5 No calibration data If necessary, contact the Technical Support.

6 No user position data set Save and reset.

Load the default parameter set.
If the error occurs again, contact the Technical
Support.

7 Error in data tables (CAM) Load the default parameter set and perform a
start-up procedure.
If necessary, reload the parameter set.
If necessary, contact the Technical Support.

27 0 Following error warning Check the parameterisation of the following error.

threshold Motor blocked?

28 0 No operating hours counter Acknowledge the error.

1 Operating hours counter: write If the error occurs again, contact the Technical
error Support.

2 Operating hours counter

corrected

3 Operating hours counter

converted

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Error message Meaning of the error message Measures

Main Sub
index index

29 0 No SD card Please contact the Technical Support

1 SD card: initialisation error

2 SD card: data error

3 SD card: write error

4 SD card: firmware download

error

30 0 Internal conversion error Please contact the Technical Support.

31 0 Motor I²t Motor blocked?

Check the power rating of the drive.

1 Servo positioning controller I²t Check the power rating of the drive package.

2 PFC I²t Check the power rating of the drive.

Select operation without PFC?

3 Braking resistor I²t Braking resistor overloaded.

Use external braking resistor?

4 I²t active power overload Reduce the active power of the drive.

32 0 DC bus circuit charging time Bridge for the internal brake resistor installed?
exceeded Check the connection of the external braking
resistor.
If necessary, contact the Technical Support.

1 Undervoltage for active PFC Check whether the power supply complies with
the nominal data.

5 Brake chopper overload Check the ON/OFF cycles.

The DC bus circuit could not be
discharged.

6 DC bus circuit discharge time Bridge for the internal brake resistor installed?
exceeded Check the connection of the external braking
resistor.
If necessary, contact the Technical Support.

7 No power supply for the No DC bus circuit voltage?

controller enable signal Check the power supply.
If necessary, contact the Technical Support.

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Error message Meaning of the error message Measures

Main Sub
index index

8 Power supply failure during the Check the power supply.

controller enabling process

9 Phase failure

33 0 Following error, encoder Check the settings of the incremental encoder

emulation emulation (number of lines).
If necessary, contact the Technical Support.

34 0 No synchronisation via the field Failure of synchronization messages from

bus master?

1 Field bus synchronisation error Failure of synchronization messages from

master?
Insufficient synchronisation interval?

35 0 Overspeed protection of the The encoder signals are disturbed. Check the
linear motor installation for compliance with EMC
recommendations.

5 Error during the determination The selected method is not suitable for the
of the commutation position motor. Please contact the Technical Support.

36 0 Parameter limited Check the user parameter set.

1 Parameter not accepted

37 0 Sercos: Check the sercos wiring (clean the optical

received data disturbed waveguide, for example).
Check the luminous power settings.
Check the baud rate.

1 Sercos: Check the sercos wiring (optical waveguide) for

optical waveguide loop breaks.
interrupted Check the connections.

2 Sercos: Check the sercos wiring (optical waveguide).

double MST failure Check the control system (are all of the MSTs
being transmitted?)

3 Sercos: Check the program in the Sercos master.

illegal phase specification in the
MST info

4 Sercos: Check the sercos wiring (optical waveguide).

double MDT failure Check the control system (are all of the MDTs
being transmitted?)

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Error message Meaning of the error message Measures

Main Sub
index index

5 Sercos: Check the settings for the operating modes in

unknown operation mode the IDN S-0-0032 to S-0-0035.
selected

6 Sercos: Increase the baud rate.

T3 invalid Shift the point of time T3 manually.

38 0 sercos prog.: SERCON Technology module defective?

initialisation error Replace the technology module.
If necessary, contact the Technical Support.

1 Sercos: Technology module plugged in correctly?

no technology module present Technology module defective?
Replace the technology module.
If necessary, contact the Technical Support.

2 Sercos: Replace the technology module.

defective technology module If necessary, contact the Technical Support.

3 Sercos: Check the configuration (cyclic data for MDT and

S-0-0127: invalid data in S-0- AT).
0021 Time slot calculation by the master.

4 Sercos: Check the configuration (cyclic data transfer).

S-0-0127: illegal IDNs in AT or
MDT

5 Sercos: Check the weighting settings.

S-0-0128: invalid data in S-0- Check the operating mode settings.
0022
Check the internal/external angle encoder
settings.

6 Sercos: Check the weighting settings.

S-0-0128: faulty weighting
parameters

7 Sercos: Check the configuration of the signal status and

Invalid IDN in S-0-0026 / S-0- signal control word (S-0-0026 / S-0-0027).
0027

8 Sercos: Check the weighting settings.

error during the conversion If necessary, contact the Technical Support.

9 Sercos: Technology module defective?

SERCON 410b mode active Replace the technology module.

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Error message Meaning of the error message Measures

Main Sub
index index

39 0 Sercos: Please contact the Technical Support.

List S-0-0370: invalid
configuration of the MDT Data
container

1 Sercos:
List S-0-0371: invalid
configuration of the AT-Data
container

2 Sercos:
error in the cyclic channel MDT

3 Sercos:
error in the cyclic channel AT

4 Sercos:
error in the cyclic data container
MDT

5 Sercos:
error in the cyclic data container
AT

40 0 Negative SW limit switch Check the negative range limit.

reached

1 Positive SW limit switch Check the positive range limit.

reached

2 Target position beyond the The start of a positioning run has been
negative SW limit switch suppressed, since the target is located beyond
the respective software limit switch.
3 Target position beyond the
Check the target data.
positive SW limit switch
Check the positioning range.

41 0 Path program: synchronisation Check the parameterization.

error If necessary, contact the Technical Support.

42 0 Positioning: no follow-up The positioning target cannot be reached with

position: stop the current positioning options or boundary
conditions.
1 Positioning: reversal of rotation
not permissible: stop Check the positioning parameters.

2 Positioning: reversal of rotation

not permissible after a stop

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Error message Meaning of the error message Measures

Main Sub
index index

3 Positioning start rejected: The change of the mode of operation could not
incorrect operating mode be performed by the position set.

4 Positioning start rejected: Reset the optional parameterisation “homing

homing required required”.
Perform a new homing run.

5 Rotary axis: direction of rotation In accordance with the selected mode, the
not permissible calculated direction of rotation of the rotary axis
is not permissible.
Check the selected mode.

9 Error during the start of the Check the speed and acceleration parameters.
positioning run

43 0 Limit switches: negative The drive has left the intended motion range.
setpoint blocked Technical defect in the system?
1 Limit switches: positive setpoint Check the limit switches.
blocked

2 Limit switches: positioning

suppressed

44 0 Error in the cam disc tables Check whether the index has been assigned
correctly.
Check whether there are cam discs present in
the device.

1 Cam disc: general homing error Ensure that the drive has been homed prior to
the activation of the cam disc.
Delete the “homing required” option.
Ensure that a cam disc cannot be started during
a homing run.

47 0 Timeout (set-up mode) Check the processing of the request by the PLC.
Speed threshold too low or timeout too small?

48 0 Drive not referenced Switch to positioning and perform a homing run.

50 0 CAN: Deactivate the PDOs or increase the SYNC

too many synchronous PDOs interval. The maximum number of PDOs must
not be greater than the factor tp between the
position controller and IPO (menu:
Parameters/Controller parameters/Cycle times).

1 SDO error occurred Please contact the Technical Support.

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Error message Meaning of the error message Measures

Main Sub
index index

51 0 No or unknown FSM module or Cause: Internal voltage error of the safety

faulty driver supply module or of the fieldbus activation
module.

Action: Module presumably defective. If

possible, replace with another module.

Cause: No safety module detected or unknown

module type.

Action:  Install safety or fieldbus activation

module appropriate for the firmware
and hardware.
 Load firmware appropriate for the
safety or fieldbus activation module,
see type designation on the module.

2 FSM: different module type Cause: Type or revision of the module does not
fit the project planning.

Action:  Check whether correct module type

and correct version are being used.
 With module replacement: Module
type not yet configured. Accept
currently integrated safety or
fieldbus activation module.

3 FSM: different module version Cause: Type or revision of the module is not
supported.

Action:  Install safety or fieldbus activation

module appropriate for the firmware
and hardware.
 If only a module with a more recent
version is available: Load firmware
that is appropriate for the module,
see type designation on the module.

Cause: The module type is correct but the

module version is not supported by the
basic device.

Action:  Check module version; if possible

use module of same version after
replacement. Install suitable safety
or fieldbus activation module for the
firmware and hardware.
 If only a module with a more recent
version is available: Load firmware
that is appropriate for the module,
see type designation on the module.

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Error message Meaning of the error message Measures

Main Sub
index index

4 FSM: Fault in SSIO Cause: Error in the internal communication

communication connection between the basic device
and the safety module.

Action:  Identify interfering radiators in the

environment of the servo drive.
 Replace module or basic device.
 Please contact the Technical
Support.

5 FSM: Fault in FSM break Cause: Internal hardware error (brake

control activation control signals) of the safety
module or fieldbus activation module.

Action: Module presumably defective. If

possible, replace with another module.

Cause: Error in brake driver circuit section in

the basic device.

Action: Basic device presumably defective. If

possible, replace with another basic
device.

6 FSM: Non-identical module Cause: Serial number of currently connected

serial number safety module is different from the
stored serial number.

Action: Error only occurs after replacement of

the FSM 2.0 MOV.
 With module replacement: Module
not yet configured. Accept currently
integrated FSM 2.0 MOV.
 Check parameterisation of the
FSM 2.0 – MOV with regard to the
application as modules have been
replaced.

52 1 Safety function: Discrepancy Cause: Control ports STO-A and STO-B are
time overrun not actuated simultaneously.

Action: Check discrepancy time.

Cause: Control ports STO-A and STO-B are

not wired in the same way.

Action: Check circuitry of the inputs.

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Error message Meaning of the error message Measures

Main Sub
index index

Cause: Upper and lower switch supply voltage

not simultaneously activated
(discrepancy time exceeded)

− Error in control / external circuitry of

safety module.
− Error in safety module.

Action:  Check circuitry of the safety module

– are the inputs STO-A and STO-B
switched off on two channels and
simultaneously?
 Replace safety module if you
suspect it is faulty.

2 Safety function: Failure of driver Cause: Failure of driver supply voltage with
active PWM.
supply with active PWM
activation Action: The safe status was requested with
power output stage enabled. Check
integration into the safety-orientated
interface.

3 FSM: Rotational speed limits in Cause: Basic device reports error if the
basic device overlap currently requested direction of
movement is not possible because the
safety module has blocked the setpoint
value in this direction.
Error may occur in connection with the
SSFx safe speed functions if an
asymmetrical speed window is used
where one limit is set to zero. In this
case, the error occurs when the basic
device moves in the blocked direction
in the Positioning mode.

Action: Check application and change if

necessary.

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Error message Meaning of the error message Measures

Main Sub
index index

53 0 USF0: Safety condition violated Cause: Violation of monitored speed limits of

the SSF0 in operation / when USF0 /
SSF0 requested.

Action: Check when the violation of the safety

condition occurs:

a) During dynamic braking to safe

rotational speed.
b) After the drive has reached the safe
speed.

 With a) Check of braking ramp –

record measuring data - can the
drive follow the ramp?

 Change parameters for the

slowdown ramp or start time / delay
times for monitoring.
With b) Check how far the current
speed is from the monitored limit
speed; increase distance if necessary
(parameter in safety module) or correct
speed specified by controller.

1 USF1: Safety condition violated Cause: Violation of monitored speed limits of

the SSF1 in operation / when USF1 /
SSF1 requested.

Action: See USF0, error 53-0.

2 USF2: Safety condition violated Cause: Violation of monitored speed limits of

the SSF2 in operation / when USF2 /
SSF2 requested.

Action: See USF0, error 53-0.

3 USF3: Safety condition violated Cause: Violation of monitored speed limits of

the SSF3 in operation / when USF3 /
SSF3 requested.

Action: See USF0, error 53-0.

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Error message Meaning of the error message Measures

Main Sub
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54 0 SBC: Safety Condition Violated Cause: Brake should engage; no feedback

received within the expected time.

Action:  Check how the feedback signal is

configured – was the correct input
selected for the feedback signal?

 Does the feedback signal have the

correct polarity?

 Check whether the feedback signal

is actually switching.

 Is the parameterised time delay for

the analysis of the feedback signal
appropriate to the brake used
(measure switching time if
necessary)?

2 SS2: Safety Condition Violated Cause: Actual speed outside permitted limits
for too long.

Action: Check when the violation of the safety

condition occurs:
a) During dynamic braking to zero.
b) After the drive has reached zero
speed.
 With a) Check of braking ramp –
record measuring data - can the
drive follow the ramp? Change
parameters for the slowdown ramp
or start time / delay times for
monitoring.
 With a) If the option “Trigger basic
device quick stop” is activated:
Check of the basic device’s quick
stop ramp.
 With b) Check whether the drive
continues to oscillate after reaching
the zero speed or remains at idle
and stable – increase monitoring
tolerance time if necessary.
 With b) If the actual speed value is
very noisy at rest. Check and if
necessary adjust expert parameters
for speed recording and detection of
idling

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3 SOS: Safety Condition Violated Cause: − Angle encoder analysis reports

“Motor running” (actual speed
exceeds limit).
− Drive has rotated out of its position
since reaching the safe state.

Action:  Check the position tolerance for the

SOS monitoring and increase if
necessary, if this is permissible.
 If the actual speed value is very
noisy when at rest: Check and if
necessary adjust expert parameters
for speed recording and detection of
idling.

4 SS1: Safety Condition Violated Cause: Actual speed is outside of permitted

limits for too long.

Action: Check when the violation of the safety

condition occurs:
a) During dynamic braking to zero.
b) After the drive has reached zero
speed.
 With a) Check of braking ramp –
record measuring data - can the
drive follow the ramp? Change
parameters for the slowdown ramp
or start time / delay times for
monitoring.
 With a) If the option “Trigger basic
device quick stop” is activated:
Check of the basic device’s quick
stop ramp.
 With b) Check whether the drive
continues to oscillate after reaching
the zero speed or remains at idle
and stable – increase monitoring
tolerance time if necessary.
 With b) If the actual speed value is
very noisy when at rest: Check and
if necessary adjust expert
parameters for speed recording and
detection of standstill.

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5 STO: Safety Condition Violated Cause: Internal hardware error (voltage error)
of the safety module.

Action: Module presumably defective. If

possible, replace with another module.

Cause: Error in driver circuit section in the

basic device.

Action: Basic device presumably defective. If

possible, replace with another basic
device.

Cause: No feedback received from basic

device to indicate that output stage was
switched off.

Action: Check whether the error can be

acknowledged and whether it occurs
again upon a new STO request – if yes:
Basic device is presumably faulty. If
possible, replace with another basic
device.

6 SBC: Brake not vented for > Cause: Error occurs when SBC is requested
24 hrs and the brake has not been opened by
the basic device in the last 24 hours.

Action:  If the brake is actuated via the

brake driver in the basic device
[X6]: The brake must be energised
at least once within 24 hours before
the SBC request because the circuit
breaker check can only be
performed when the brake is
switched on (energised).
 Only if brake control takes place via
DOUT4x and an external brake
controller: Deactivate 24 hr
monitoring in the SBC parameters if
the external brake controller allows
this.

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7 SOS: SOS requested > 24 hrs Cause: If SOS is requested for more than 24
hours, the error is triggered.

Action: Terminate SOS and move axle at least

once during this time.

55 0 No actual rotational speed / Cause: − Subsequent error when a position

position value available or idle > encoder fails.
− Safety function SSF, SS1, SS2 or
24 hrs
SOS requested and actual
rotational speed value is not valid.

Action: Check the function of the position

encoder(s) (see following error).

1 SINCOS encoder [X2B] - Cause: − Vector length sin²+cos² is outside

Tracking signal error the permissible range.
− The amplitude of one of the two
signals is outside the permissible
range.
− Offset between analogue and digital
signal is greater than 1 quadrant.

Action: Error may occur with SIN/COS and

Hiperface encoders.
 Check the position encoder.
 Check the connection wiring
(broken wire, short between two
signals or signal / screening).
 Check the supply voltage for the
position encoder.
 Check the motor cable / screening
on motor and drive side – EMC
malfunctions may trigger the error.

2 SINCOS encoder [X2B] - Cause: Input signals of the SinCos encoder

Standstill > 24 hrs have not changed by a minimum
amount for 24 hours (when safety
function is requested).

Action: Terminate SS2 or SOS and move axle

at least once during this time.

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3 Resolver [X2A] - Signal error Cause: − Vector length sin²+cos² is outside

the permissible range.
− The amplitude of one of the two
signals is outside the permissible
range.
− Input signal is static (same values to
right and left of maximum).

Action:  Check the resolver.

 Check the connection wiring
(broken wire, short between two
signals or signal / screening).
 Check for a failure of the primary
radiator signal
 Check the motor and encoder cable
/ screening on motor and drive side.
EMC malfunctions can trigger the
error.

7 Other encoder [X2B] - Faulty Cause: − “Angle faulty” message is sent from
angle information basic device when status lasts for
longer than the allowed time.
− Encoder at X2B is analysed by the
basic device.
− Encoder is faulty.

Action:  Check the position encoder at X2B.

 Check the connection wiring
(broken wire, short between two
signals or signal / screening).
 Check the supply voltage for the
ENDAT encoder.
 Check the motor cable / screening
on motor and drive side – EMC
malfunctions may trigger the error.

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8 Impermissible acceleration Cause: − Error in connected position encoder.

detected − EMC malfunctions affecting the
position encoder.
− Impermissibly high acceleration
rates in the movement profiles.
− Acceleration limit parameterised too
low.
− Angle jump after reference
movement in the position data
transmitted from the basic device to
the safety module.

Action:  Check the connected position

encoder: If further error messages
occur in conjunction with the
encoders, then eliminate their cause
first.
 Check the motor and encoder cable
/ screening on motor and drive side.
EMC malfunctions can trigger the
error.
 Check the setpoint specifications /
Movement profiles of the controller:
Do they contain impermissibly high
temperatures above the limit value
for acceleration monitoring
(P06.07)?
 Check whether the limit value for
acceleration monitoring was
parameterised correctly - the limit
value (P06.07) should be at least
30% ... 50% above the maximum
acceleration actually occurring.
 In case of an angle jump in the
position data transmitted from the
basic device - Acknowledge error
once.

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56 8 Rotational speed / angle Cause: − Rotational speed difference

difference, encoder 1 - 2 between encoder 1 and 2 of one µC
outside the permissible range for
longer than the allowed time.
− Angle difference between encoder 1
and 2 of one µC outside the
permissible range for longer than
the allowed time.

Action:  Problem may occur if two position

encoders are used in the system
and they are not “rigidly coupled”.
 Check for elasticity or looseness,
improve mechanical system.
 Adjust the expert parameters for the
position comparison if this is
acceptable from an application point
of view.

9 Error, cross-comparison of Cause: Cross-comparison between µC1 and

encoder analysis µC2 has detected an angle difference
or rotational speed difference or
difference in capture times for the
position encoders.

Action: Timing disrupted. If the error occurs

again after a reset, the safety module is
presumably faulty.

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57 0 Error, I/O self test Cause: − Internal error of digital inputs DIN40
(internal/external) ... DIN43 (detected via internal test
signals).
− Error at brake output at X6
(signalling, detected by test pulses).
− Internal error of brake output
(detected via internal test signals).
− Internal error of digital outputs
DOUT40 – DOUT42 (detected via
internal test signals).

Action:  Check the connection wiring for the

digital outputs DOUT40 ... DOUT42
(short circuit, cross circuit, etc.).
 Check the connection wiring for the
brake (short circuit, cross circuit,
etc.).
 Brake connection: The error may
occur with long motor cables if:
1. The brake output X6 was
configured for the brake (this is
the case with factory settings!)
and
2. A motor without a holding brake
is used and the brake
connection lines in the motor
cable are terminated at X6. In
this case: Disconnect the brake
connection lines at X6.
 If there is no error in the connection
wiring, there may be an internal
error in the module (check by
swapping the module).

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1 Digital inputs - Signal level error Cause:  Exceeding / violation of discrepancy

time with multi-channel inputs
(DIN40 ... DIN43, two-handed
control device, mode selector
switch).

Action:  Check the external active and

passive sensors – do they switch on
two channels and simultaneously
(within the parameterised
discrepancy time).
 Two-handed control device: Check
how the device is operated by the
user – are both pushbuttons
pressed within the discrepancy
time? Give training if necessary.
 Check the set discrepancy times –
are they sufficient?

2 Digital inputs - Test pulse error Cause: One or more inputs (DIN40 ... DIN49)
were configured for the analysis of the
test pulses of the outputs (DOUT40 ...
DOUT42). The test pulses from DOUTx
do not arrive at DIN4x.

Action:  Check the wiring (shorts after 0 V,

24 V, cross circuits).
 Check the assignment – correct
output selected / configured for test
pulse?

6 Electronics temperature too Cause: The safety module's temperature

high monitor has been triggered; the
temperature of µC1 or µC2 was below
-20° or above +75°C.

Action:  Check the operating conditions

(ambient temperature, control
cabinet temperature, installation
situation in the control cabinet).
 If the servo drive is experiencing
high thermal load (high control
cabinet temperature, high power
consumption / output to motor, large
number of occupied slots), a servo
drive of the next higher output level
should be used.

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58 0 FSM: Plausibility check of Cause: The plausibility check in the safety

parameters module produced errors, e.g. an invalid
angle encoder configuration; the error
is triggered when a validation code is
requested by the SafetyTool and when
parameters are backed up in the safety
module.

Action: Note instructions for SafetyTool for

complete validation; check
parameterisation.

1 General error, parameterisation Cause: Parameter session active for > 8 hrs.
The safety module has thus terminated
the parameterisation session.
The error message is saved in the
permanent event memory.

Action: Terminate parameterisation session

within 8 hrs. If necessary, start a new
parameterisation session and continue.

4 Buffer, internal communication Cause: − Communication connection faulty.

− Timeout / data error / incorrect
sequence (packet counter) in data
transmission between the basic
device and safety module.
− Too much data traffic, new requests
are being sent to safety module
before old ones have been
responded to.

Action:  Check communication interfaces,

wiring, screening, etc.
 Check whether other devices have
read access to the servo drive and
safety module during a
parameterisation session - this may
overload the communication
connection.
 Check whether the firmware
versions of the safety module and
basic device and the versions of the
Metronix ServoCommander® and
SafetyTool are compatible.

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5 Communication module - basic Cause: − Packet counter error during

device transmission µC1  µC2
− Checksum error during transmission
µC1  µC2.

Action:  Internal malfunction in the servo

drive.
 Check whether the firmware
versions of the safety module and
basic device and the versions of the
Metronix ServoCommander® and
SafetyTool are compatible.

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6 Error in cross-comparison for Cause: Timeout during cross-comparison (no

processors 1 - 2 data) or cross-comparison faulty (data
for µC1 and µC2 are different).
− Error in cross-comparison for digital
I/O.
− Error in cross-comparison for
analogue input.
− Error in cross-comparison for
internal operating voltage
measurement (5 V, 3.3 V, 24 V) and
reference voltage (2.5 V).
− Error in cross-comparison for
SIN/COS angle encoder analogue
values.
− Error in cross-comparison for
programme sequence monitoring.
− Error in cross-comparison for
interrupt counter.
− Error in cross-comparison for input
map.
− Error in cross-comparison for
violation of safety conditions.
− Error in cross-comparison for
temperature measurement.

Action: This is an internal error in the module

that should not occur during operation.
 Check the operating conditions
(temperature, air humidity,
condensation).
 Check the EMC wiring as specified
and screening design; are there any
external interference sources?
 Safety module may be faulty – is
error eliminated after replacing the
module?
 Check whether new firmware for the
servo drive or a new version of the
safety module is available from the
manufacturer.

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59 1 FSM: Fail-safe mode Cause: Internal error in module in failsafe

supply/safe pulse inhibitor supply circuit section or in the driver
supply for the upper and lower
switches.

Action: Module faulty, replace.

2 FSM: Logic failure / Cause: − Reference voltage 2.5 V outside

intermediate circuit tolerance.
− Logic supply overvoltage +24 V
detected.

Action: Module faulty, replace.

3 FSM: Error internal power Cause: Voltage (internal 3.3 V, 5 V, ADU

supply reference) outside the permissible
range.

Action: Module faulty, replace.

4 FSM: Error management, too Cause: Too many errors have occurred
many errors simultaneously.

Action:  Clarify: What is the status of the

installed safety module - does it
contain a valid parameter set?
 Read out and analyse the
permanent event memory of the
basic device via Metronix
ServoCommander®
 Eliminate error causes step by step.
 Install safety module with “delivery
status” and perform commissioning
of basic device.
 If this is not available: Set factory
settings in the safety module, then
copy data from the basic device and
perform complete validation. Check
whether the error occurs again.

5 FSM: Log file - write error Please contact the Technical Support.

6 FSM: Parameter set - save Please contact the Technical Support.

error

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7 FSM: Flash checksum error Cause: − Voltage interruption / power off

while parameters were being saved.
− Flash memory in safety module
corrupted (e.g. by extreme
malfunctions).

Action: Check whether the error recurs after a

reset. If it does:
 Parameterise the module again and
validate the parameter set again. If
error persists:
 Module faulty, replace.

8 FSM: Internal monitoring, Cause: − Serious internal error in the safety

processor module: Error detected while
dynamising internal signals.
1-2
− Disrupted programme sequence,
stack error or OP code test failed,
processor exception / interrupt.

Action: Check whether the error recurs after a

reset. If it does:
 Module faulty, replace.

9 FSM: Structure error, invalid Cause: Triggering of internal programme

software state sequence monitoring.

Action:  Check the firmware version of the

basic device and the version of the
safety module – update available?
 Safety module faulty; replace.

60 0 Ethernet user-specific (1) Please contact the Technical Support.

61 0 Ethernet user-specific (2) Please contact the Technical Support.

62 0 EtherCAT: general bus error No EtherCAT bus available.

Check the cabling.

1 EtherCAT: initialization error Replace the technology module.

If necessary, contact the Technical Support.

2 EtherCAT: protocol error Wrong protocol (no CAN over EtherCAT)?

Check the EtherCAT wiring.

3 EtherCAT: invalid RPDO length Check the protocol.

4 EtherCAT: invalid TPDO length Check the RPDO configuration of the servo
positioning controller and of the control system.

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5 EtherCAT: faulty cyclic data Check the EtherCAT wiring.

transfer Check the configuration of the master.

63 0 EtherCAT: defective module Technology module defective?

Replace the technology module.

1 EtherCAT: invalid data Check the protocol.

Check the EtherCAT wiring.

2 EtherCAT: Reduce the cycle time (EtherCAT bus).

TPDO data has not been read

3 EtherCAT: Check whether the master supports the

no distributed clocks active “distributed clocks” feature.
If necessary, contact the Technical Support.

4 Missing SYNC message in IPO Check the cycle times of the servo positioning
cycle controller and of the control system.

64 0 DeviceNet: duplicated MAC ID Change the MAC ID.

1 DeviceNet: bus power lost Check the DeviceNet wiring.

2 DeviceNet: overflow of receive Reduce the number of messages per time unit
buffer during the transmission.

3 DeviceNet: overflow of transmit Reduce the number of message per time unit
buffer that are to be transmitted.

4 DeviceNet: IO send error Please contact the Technical Support.

5 DeviceNet: bus Off Check the DeviceNet wiring.

6 DeviceNet: Please contact the Technical Support.

CAN controller overflow

65 0 DeviceNet: no module Technology module defective?

Replace the technology module.

1 DeviceNet: I/O connection Please contact the Technical Support.

timeout

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72 0 Profinet: Initialization error Replace the Profinet module.

1 Profinet: Bus error No communication possible, e.g. because the

bus cable is disconnected. Check the cabling
and restart the Profinet communication.

3 Profinet: Invalid IP configuration IP address, subnet mask or gateway address are

not valid or not permissible.
Change IP configuration.

4 Profinet: Invalid device name According to the Profinet standard, the Profinet
device name is not permissible.
Change device name.

5 Profinet: Technology module Replace the Profinet module.

defect

6 Profinet: Invalid / not supported A Profinet feature has been used that is not
indication supported by the module.
If necessary, contact the Technical Support.

78 0 NRT frame send error Reduce bus traffic, for example by using less
devices in a line.

80 0 IRQ: Please contact the Technical Support.

current controller overflow

1 IRQ:
speed controller overflow

2 IRQ:
position controller overflow

3 IRQ:
interpolator overflow

81 4 IRQ: Please contact the Technical Support.

low-level overflow

5 IRQ:
MDC overflow

82 0 Sequence control: general For information only, no measures required.

1 CO write access started Please contact the Technical Support.

multiple times

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83 0 Invalid technology module Load the correct firmware.

or Check the slot.
Technology module: If necessary, contact the Technical Support.
(slot/combination)

1 Technology module not Load the correct firmware.

supported If necessary, contact the Technical Support.
2 Technology module:
HW revision not supported

3 Service memory module: write Please contact the Technical Support.

error

4 Technology module:
MC2000 watchdog

84 0 State change of the sequence Detailed information concerning internal

control processes.
No measures required. If necessary, select the
option “Entry into buffer” in the error
management.

90 0 Missing hardware component Please contact the Technical Support.

(SRAM)

1 Missing hardware component

(FLASH)

2 Error during booting of FPGA

3 Error during start of SD-ADUs

4 SD-ADU synchronisation error

after start

5 SD-ADU not synchronous

6 IRQ 0 (current controller):

trigger error

7 CAN controller not available

8 Device parameters checksum

error

9 DEBUG-Firmware loaded

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91 0 Internal initialisation error Please contact the Technical Support.

1 Memory error

2 Controller/power stage code

read error

3 Internal software initialization

error

92 0 Error during firmware download Incorrect firmware?

Load the correct firmware.
If necessary, contact the Technical Support.

1 Error during Bootloader Update Please contact the Technical Support.

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12 Technology modules
12.1 EA88 interface (terminal extension)

12.1.1 Product description

The EA88 interface can be used in technology slot TECH 1 or TECH 2 of the ARS 2000 FS servo
positioning controller to extend the already existing digital IOs. Up to two EA88 interfaces can be
supported simultaneously.

This technology module can be used to actuate up to 8 digital 24V outputs independently. In addition,
8 digital 24V inputs are available.

The EA88 interface has the following characteristics:

 Digital 24V inputs

 Digital 24V outputs which can be activated separately and loaded with 100 mA each

 MicroCombicon pin-and-socket connectors made by PHOENIX

 Pin-and-socket connectors via male multipoint connector in accordance with EN 60603-1

 The inputs and outputs are floating due to the optocouplers

 The inputs and outputs are protected against short circuits and overload

12.1.2 Technical data

12.1.2.1 General data

Table 51: Technical data: EA88 interface

Range Values

Storage temperature range -25 °C to +75°C

Operating temperature range / 0°C to 50°C

deratings

Atmospheric humidity 0..90%, non-condensing

Altitude Up to 2000 m above msl

External dimensions (LxWxH): 87mm x 65mm x 19mm; suitable for technology slot
TECH 1 and/or TECH 2

Weight: approx. 50g

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12.1.2.2 Digital inputs

8 digital inputs 24V, protected against inverse polarity and short-circuit-proof.

Table 52: Digital inputs: EA88 interface [X21]

Parameter Values

Input High level switches the input

Nominal voltage 24 VDC

Voltage range -30 V...30 V

"High" detection at UIn > 8 V

"Low" detection at UIn < 2 V

Hysteresis >1V

Input impedance ≥ 4.7 kΩ

Inverse polarity protection Up to -30V

Switching delay up to port pin (low-high transition) < 100 µs

12.1.2.3 Digital outputs

8 digital outputs 24V, protected against inverse polarity and short-circuit-proof, protection against
thermal overload.

Table 53: Digital outputs: EA88 interface [X22]

Parameter Values

Switch type High-side switch

Nominal voltage 24 VDC

Voltage range 18 V...30 V

Output current (nominal) IL,nominal = 100 mA

Voltage loss at IL,nominal ≤1V

Residual current with switch in OFF < 100 µA

position

Protection against short-circuit / > 500mA (approx. value)

overcurrent

Temperature protection Shut-down if the temperature is too high, TJ > 150°

Supply Protection in the case of inductive loads and voltage

supply via the output, also if the supply is turned off

Loads R > 220 Ω; L at random; C < 10nF

Switching delay as of port pin < 100 µs

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12.1.3 Pin assignment and cable specifications

12.1.3.1 Power supply

 The admissible input voltage range during operation is 15VDC….32VDC.

 The digital outputs of the EA88 technology module are supplied with voltage exclusively by an
external 24VDC power supply. The nominal input voltage for the I/O supply is 24VDC.

 If digital inputs are used, the reference potential GND24V of the 24VDC supply also has to be
connected to the EA88 interface technology module.

12.1.3.2 Pin assignments

The following elements can be found on the front plate of the EA88 interface:

 Connector [X21] for 8 digital inputs:

PHOENIX Contact MicroCombicon MC 0.5/9-G-2.5 (9-pin type)

Table 54: EA88: Connector [X21] for 8 digital inputs

Pin 1 2 3 4 5 6 7 8 9

Signal GND In 1 In 2 In 3 In 4 In 5 In 6 In 7 In 8
24V

 Connector [X22] for 8 digital outputs:

PHOENIX Contact MicroCombicon MC 0.5/10-G-2.5 (10-pin type)

Table 55: EA88: Connector [X22] for 8 digital outputs

Pin 1 2 3 4 5 6 7 8 9 10

Signal GND Out 1 Out 2 Out 3 Out 4 Out 5 Out 6 Out 7 Out 8 +24VDC
24V external

The following Figure 32 shows the position of the connectors and their numbering:

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Figure 32: E88: Position of the pin-and-socket connectors [X21] and [X22] at the front plate

12.1.3.3 Counterplug
 Connector [X21] for 8 digital inputs: PHOENIX Contact MicroCombicon FK-MC 0.5/9-ST-2.5

 Connector [X22] for 8 digital outputs: PHOENIX Contact MicroCombicon FK-MC 0.5/10-ST-2.5

12.1.3.4 Connection notes

The MicroCombicon counterplugs made by PHOENIX Contact regarding [X21] (FK-MC 0.5/9-ST-2.5)
and [X22] (FK-MC 0.5/10-ST-2.5) are supplied together with the EA88 interface technology module.
The cables are connected in the form of crimp connections. To do so, first strip the cable at a length of
about 8 mm. Then insert it into the desired opening by pressing down the orange crimp lock using a
suitable screwdriver, the tip of a ball-pen or something similar. Release the lock to fix the cable in
place. The maximum admissible wire cross-section (wire gauge) is 0.5 mm2 or AWG20.

If the EA88 interface is also used to control digital outputs, an additional external 24V supply voltage
has to be connected to [X22], pin 10.

As the lines GND24V and +24Vext. have to transfer the entire current of all outputs connected, their
cross-section has to be sized accordingly (recommended: AWG 20).

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12.2 PROFIBUS-DP interface

12.2.1 Product description

The PROFIBUS-DP interface provides an additional field bus connection. All functions and parameters
can be addressed directly, for example from a Simatic S7 control system. The interface is plugged into
the technology slot TECH 2 of the ARS 2000 FS servo positioning controller.

The PROFIBUS-DP interface is supported solely in the TECH 2 technology slot.

In addition to the PROFIBUS-DP interface, the TECH 1 technology slot can also be used
for the I/O extension module EA88.
Additional technology modules will not be supported if the PROFIBUS-DP interface is
used.
If your specific requirements are more complex, please contact your sales partner in
order to find a solution for your particular application.

As a special feature, S7 function blocks have been developed for the servo positioning controllers.
Using these function blocks, the servo positioning controllers can be controlled directly by the PLC
program and the users can integrate their systems easily and clearly into the Simatic S7 environment.

12.2.2 Technical data

Table 56: Technical data: PROFIBUS-DP interface: Ambient conditions, dimensions and
weight

Range Values

Storage temperature range -25 °C to +75°C

Operating temperature range / 0°C to 50°C

deratings

Atmospheric humidity 0..90%, non-condensing

Altitude Up to 2000 m above msl

External dimensions (LxWxH): approx. 92 x 65 x 19mm

suitable for the technology slot TECH 2

Weight: approx. 50g

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Table 57: Technical data: PROFIBUS-DP interface: Interfaces and communication

Communication interface PROFIBUS module

Controller PROFIBUS controller VPC3+, 12 Mbaud max.

Protocol PROFIBUS-DP,
32-byte telegrams with operating-mode-depending configuration

Interface Floating, D-SUB 9-pin, integrated bus terminating resistors

(can be activated by DIP switches)

Special functions Support of diagnosis data, RTS signal led out, fail-safe mode,
sync/freeze

The following elements can be found on the front plate of the PROFIBUS-DP interface (see
Figure 33):

 a green LED to indicate readiness for operation

 a 9-pin female DSUB connector

 two DIP switches for activating the terminating resistors

Figure 33: PROFIBUS-DP interface: Front view

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12.2.3 Pin assignments and cable specifications

12.2.3.1 Pin assignment

 9-pin DSUB connector, female

Table 58: Pin assignment: PROFIBUS-DP interface

Pin no. Denomination Values Specification

1 Shield - Cable shield

6 +5V +5 V +5V output (floating)1)

2 - - Not used

7 - - Not used

3 RxD / TxD-P B-line transmission / reception data

8 RxD / TxD-N A-line transmission / reception data

4 RTS / LWL Request to Send 2)

9 - - Not used

5 GND5V 0V Reference potential GND 5V 1)

1)
Can be used for external bus termination or to supply the transmitter/receiver of an external optical waveguide
transmission.
2)
The signal is optional. It is used to identify the direction of an external optical waveguide connection.

12.2.3.2 Counterplug
 9-pin DSUB connector, for example Erbic MAX PROFIBUS IDC Switch, made by ERNI

12.2.3.3 Cable type and configuration

The cable names given refer to cables made by Lapp. They have proven to be reliable and are
successfully used in many applications. However, it is also possible to use comparable cables from
other manufacturers, for example Lütze or Helukabel.

 LAPP KABEL UNITRONIC BUS L2/FIP FC; 1 x 2 x 0.64; ∅ 7.8 mm,

with tinned total CU shielding for quick-connect applications with IDC connectors

For highly flexible applications:

 LAPP KABEL UNITRONIC BUS FD P L2/FIP; 1 x 2 x 0.64; ∅ 8 mm,

with tinned total CU shielding for highly flexible use in drag chains

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12.2.4 Termination and bus terminating resistors

Every bus segment of a PROFIBUS network has to be equipped with bus terminating resistors to
minimise line reflections and to adjust a defined rest potential on the line. The bus termination has to
be provided at the beginning and at the end of every bus segment.

Most PROFIBUS connectors come supplied with integrated terminating resistors. For bus connections
with connectors without integrated terminating resistors, the PROFIBUS-DP interface has its own
terminating resistors. They can be activated with the help of the two DIP switches on the module
(switch set to ON).

To ensure safe operation of the network, only one bus termination may be used at a time.

The external connection can also be set up discretely (see Figure 34). The power supply of 5 V
required for the externally connected terminating resistors is supplied at the PROFIBUS connector of
the PROFIBUS-DP interface (see pin assignment in Table 58).

GND 5 V
B-Line
390 Ohm A-Line

220 Ohm

390 Ohm

+5 V
Figure 34: PROFIBUS-DP interface: Connection with external terminating resistors

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12.3 Sercos II module

12.3.1 Product description

The Sercos II module is used to connect the ARS 2000 FS servo positioning controller to a Sercos-
compatible CNC control. The communication on the Sercos II bus uses a ring-shaped optical fibre link
with transmission rates of up to 16 Mbaud. If six servo positioning controllers are connected to one
bus, setpoints and actual values (position, speed and torque values) can be exchanged with the CNC
control every 500 µs.

The Sercos II module is supported solely in the TECH 2 technology slot.

In addition to the Sercos II module, the TECH 1 technology slot can also be used for the
I/O extension module EA88.
Additional technology modules will not be supported if the Sercos II module is used.
If your specific requirements are more complex, please contact your sales partner in
order to find a solution for your particular application.

A special feature of the Sercos II bus is the synchronisation of all the devices connected to the bus. If
several ARS 2000 FS servo positioning controllers are connected, the internal controllers and output
stages of the servo positioning controllers operate in a phase-locked manner.

Via the 8-pole DIP switch the Sercos II bus address can optionally be set. When restarted, the servo
positioning controller checks whether there has been set a bus address via these switches (all
switches in position OFF  no bus address set). If no bus address has been set via the 8-pole DIP
switches, the servo positioning controller uses the bus address set via the Metronix
ServoCommander® (menu: Parameters/Field bus/ Sercos…).

Example for setting the bus address via the 8-pole DIP switch: Switches 1, 4 and 8 are active (in
position ON). From this the (decimal) bus address 137 (89h) is derived.
Switch 1: 20  1
Switch 4: 23  8
Switch 8: 27  128
Sum: 1 + 8 + 128 = 137

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12.3.2 Technical data

Table 59: Technical data: Sercos II module: Ambient conditions, dimensions and weight

Range Values

Storage temperature range -25 °C to +75°C

Operating temperature range / 0°C to 50°C

deratings

Atmospheric humidity 0..90%, non-condensing

Altitude up to 2000 m above msl

External dimensions (LxWxH): approx. 92 x 65 x 19mm

suitable for technology slot TECH 2

Weight approx. 50g

The following elements can be found on the front plate of the Sercos II module (see Figure 35):

 a green LED to indicate that the bus is ready for operation

 a connection for the optical waveguide receiver / type HFD 7000-402 (metal connection)
 Connection directly underneath the 8-pole DIP switch

 a connection for the optical waveguide transmitter / type HFD 7000-210 (plastic connection)
 Connection directly above the LED

 8-pole DIP switch to set the fieldbus address

Figure 35: Sercos II module: Front view

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12.3.3 Optical waveguide specification

More information concerning the type and setup of suitable optical waveguides can be found in the
standard Sercos literature, for example:

http://www.sercos.org/

Interests Group Sercos interface e.V.

Landhausstrasse 20, 70190 Stuttgart

Germany

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12.4 EtherCAT

12.4.1 Product description

The EtherCAT technology module enables the connection of the ARS 2000 FS servo positioning
controller to the EtherCAT fieldbus system. The communication via the EtherCAT interface (IEEE-
802.3u) is realised with the aid of standard EtherCAT cabling.

In the case of the ARS 2000 FS Metronix supports the CoE protocol (CANopen over
EtherCAT) with the FPGA ESC20 made by Beckhoff.

The EtherCAT technology module is supported solely in the TECH 2 technology slot.
In addition to the EtherCAT technology module, the TECH 1 technology slot can also be
used for the I/O extension module EA88.
Additional technology modules will not be supported if the EtherCAT technology module is
used.
If your specific requirements are more complex, please contact your sales partner in order
to find a solution for your particular application.

12.4.2 Characteristics of the EtherCAT technology module

The EtherCAT technology module has the following characteristics:

 It can be fully mechanically integrated in the Metronix servo positioning controllers of the
ARS 2000 FS series

 EtherCAT corresponding to IEEE-802.3u (100Base-TX) with 100 Mbps (full duplex)

 Star and line topology

 Connector: RJ45

 Electrically isolated EtherCAT interface

 Communication cycle: 1ms

 127 slaves max.

 EtherCAT slave implementation based on FPGA ESC20 by Beckhoff

 Support of the “Distributed Clocks” feature for synchronised set value transfer

 LED display for indicating readiness and link-detect

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Figure 36: EtherCAT module: Front view

12.4.3 Technical data

Table 60: Technical data: EhterCAT module: Ambient conditions, dimensions and weight

Range Values

Storage temperature range -25°C to +75°C

Operating temperature range 0°C to 50°C

Atmospheric humidity 0..90%, non-condensing

Altitude up to 2000 m above msl

External dimensions (LxWxH): approx. 92 x 65 x 19 mm

Weight: approx. 55 g

Slot Technology slot TECH 2

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12.4.4 Display elements

The front panel of the EtheCAT technology module is equipped with two LEDs for indicating the
operating states.

Table 61: Display elements

Element Function

LED 1 Run (green), link/activity EtherCAT port 1 (red),

Two-colour-LED (green/red) EtherCAT active (yellow)

LED 2 (red) Link/activity EtherCAT port 2

12.4.5 EtherCAT interface

Table 62: Signal level and differential voltage

Signal level 0 ... 2.5 VDC

Differential voltage 1.9 ... 2.1 VDC

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12.5 MC 2000 “Drive-In” 4-Axis Motion Coordinator

12.5.1 Product description

The technology module MC 2000 motion coordinator can control up to four servo axes of the
ARS 2000 and ARS 2000 FS servo positioning controller series in a multi-axis-coordinated way.

The Motion Coordinator MC 2000 technology module is supported solely in the TECH 2
technology slot.
In addition to the MC 2000 module, the TECH 1 technology slot can also be used for the
I/O extension module EA88.
Additional technology modules will not be supported if the MC 2000 module is used.
If your specific requirements are more complex, please contact your sales partner in
order to find a solution for your particular application.

With the MC 2000 complex motion control can be realised fast and easy, for example.

 Electronic cam drives and gears

 Joint axes

 Point-to-point positioning

 Several types of interpolation (Interpolation, Circular Interpolation, Helical Interpolation).

Simply insert the MC 2000 module into the servo positioning controller. As the MC 2000 master, it can
control up to three additional ARS 2000 servo drive slaves via CANopen DSP402. In addition, an
external encoder can be connected directly to the ARS 2000. This external encoder can then be
evaluated as an additional axis by the MC 2000. All of the available standard I/Os in the ARS 2000
can be used for this purpose.

In addition, the ARS 2000 can be expanded by using the I/O module EA88. A second CAN-interface is
available for connecting external CAN I/Os via the master.

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Figure 37: MC 2000 4-Axis Motion Coordinator

12.5.2 Features

12.5.2.1 Compact
 Plug-in module that is directly integrated in the servo positioning controller

 Controls up to 4 real servo axes

 Easy wiring via CAN-bus

Figure 38: MC 2000 4-Axis Motion Coordinator maximum capacity

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12.5.2.2 Fast
 1 ms cycle time with up to 4 servo axes

 Short start up time with the Trio Motion BASIC software with numerous predefined commands

 High-speed sample input for fast measuring and interpretation of actual values

12.5.2.3 Easy
 Application programming with the proven Trio Motion software “Motion Perfect”

 Program generation of complex motion sequences like camming, gearing and interpolated multi
axis movements

 Minimal external wiring thanks to the integration of the MC 2000 into a servo positioning controller
(technology slot TECH 2)

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12.5.3 Technical data

Table 63: Technical data: MC 2000 4-Axis Motion Coordinator
Size (L x B x H) 92 x 65 x 19 mm

Temperature range 0° C to 50° C

Current consumption Max. 350 mA / 3,3 VDC and 150 mA / 5 VDC

(internally via servo positioning controller)

Max. number of axes 8 (4x servo drives, 1x encoder, 3x virtual)

Additional encoder input Bi-directional connection (via servo positioning controller –X10)

Servo cycle time 1 ms

Built-in digital inputs 6x 24 VDC (via servo positioning controller)

Built-in digital outputs 3x 24 VDC (via servo positioning controller)

Built-in analogue inputs 3x ±10 VDC via servo positioning controller

(1x 16 Bit differential and 2x 10 Bit single ended)

Built-in analogue outputs 2 x ±10 VDC, 9 bit (via servo positioning controller)

Input function Forward limit / reverse limit / datum / F hold

Serial ports 1x RS232 (programming) + 1x RS485 (for example HMI)

CAN ports 2x CAN interfaces (1x remote drive max. 1 Mbaud and 1x
remote CAN I/O max. 500 kBaud via servo positioning
controller)

Extension module EA88 IO extension module (via servo positioning controller)

User memory 512 kBytes

Table memory 32,000 values

Multi-tasking 2 fast tasks + 5 normal tasks

EMC Compliance EN 61800-3

CANopen protocol CiA Draft Standard

Proposal 402

Order number 9200-0008-00

RS232 cable for MC 2000 9200-0008-10

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12.6 General installation notes for technology modules

DANGER!
Non-observance of the instructions that are stated in chapter 2 Safety notes for electrical
drives and controllers (page 17) may lead to property damage, injuries, electric shock, or
– in extreme cases – even death.

DANGER!
Prior to installing technology modules, the servo positioning controller has to be
disconnected from any current-carrying conductors. After the operating voltage has been
disconnected, wait for 5 minutes so that the capacities in the servo positioning controller
can be completely discharged.

Caution!
Make sure that ESD protection measures are taken when handling technology modules.

To insert a technology module into the ARS 2100 FS servo positioning controller, please proceed as
follows:

1. Remove the front plate of the technology slot (TECH 1 or TECH 2) of the servo positioning
controller with a suitable Phillips screwdriver.
2. Push the technology module into the open technology slot so that the lateral guides hold the
board.
3. Push the technology module into the slot until it reaches the stop.
4. Screw the technology module onto the front side of the housing of the servo positioning controller
with the Phillips screw.
5. Ensure that the front plate of the technology module has conducting contact with the housing of
the servo positioning controller (PE).

Figure 39: Servo positioning controller with integrated

technology module MC 2000 (example)

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