Important Manual

Manual
Rotary indexing table controller EF2
R01-2013
Document: Manual
Valid for: Rotary indexing table controller
Type: EF2
Revision R01-2013
Revisions
Date Revision Chapter Reason
15.01.2013 R01 - 2013 All Created
This document has been prepared by
WEISS GmbH, Siemensstrasse 17, D-74722 Buchen
© Copyright
All rights in this document are the copyright of WEISS GmbH. This document may not be copied or reproduced,
in whole or in part, without the written permission of WEISS GmbH. This document is only intended for the user
of the product described and may not be passed on to third parties, in particular competitors.
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Table of contents
1. Introduction ................................................................................................ 7
1.1. Definition ......................................................................................................7
1.2. Intended use .................................................................................................7
1.3. Target group .................................................................................................7
1.4. Structure .......................................................................................................8
1.5. Further applicable documents ..................................................................10
1.6. Manual ........................................................................................................10
1.6.1. Validity .........................................................................................................10
1.6.2. Standard scope ............................................................................................10
1.6.3. Explanation of safety instructions in this manual .........................................11
1.6.4. Legend .........................................................................................................11
1.6.5. Figures .........................................................................................................11
1.6.6. Directory of valid pages ...............................................................................11
2. Safety ........................................................................................................ 12
2.1. Fundamental safety instructions ..............................................................12
2.1.1. Operator‘s obligation to exercise diligence ..................................................12
2.1.2. Technical safety ...........................................................................................13
2.1.3. Electrostatic safety .......................................................................................14
2.1.4. Ambient and operating conditions ...............................................................14
2.2. Emergency-off circuit ................................................................................14
2.3. Residual hazards .......................................................................................15
3. Component descriptions ........................................................................ 17
3.1. Power Module PM340 ................................................................................17
3.1.1. Safety instructions .......................................................................................17
3.1.2. Power Module PM340; frame size FSA / 0.37 kW .......................................18
3.1.3. Power Module PM340; frame size FSA / 1.5 kW .........................................19
3.1.4. Power Module PM340; frame size FSB .......................................................20
3.1.5. Technical data .............................................................................................21
3.1.6. Overview Power Module PM340 ..................................................................22
3.2. SIMOTION D410-2 Control Unit .................................................................23
3.2.1. Technical data .............................................................................................24
3.2.2. MAC Addresses ...........................................................................................25
3.2.3. CompactFlash Card .....................................................................................25
3.3. Terminal Module TM15 ..............................................................................26
3.4. Brake Relay ................................................................................................27
3.4.1. Technical data .............................................................................................27
3.4.2. Brake Relay connection example ................................................................28
3.5. Motor contactor ..........................................................................................29
3.5.1. Technical data .............................................................................................29
3.6. Safety relay .................................................................................................30
3.6.1. Technical data .............................................................................................30
3.7. External braking resistor (option) ............................................................32
3.7.1. Technical data .............................................................................................32
4. Function and signal descriptions .......................................................... 33
4.1. Signal description of the software inputs ...............................................33
4.2. Signal description of the software outputs .............................................35
4.3. Functions and signals TM15 .....................................................................36
4.3.1. Terminal Module TM15 connection example ...............................................36
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2
4.4. Interface assignment D410-2 ................................................................... 37

4.4.1. Interface X120 ............................................................................................. 37
4.4.2. Interface X121 ............................................................................................. 38
4.4.3. Interface X124 ............................................................................................. 38
4.4.4. Interface X127 ............................................................................................. 39
4.4.5. Interface X130 ............................................................................................. 40
4.4.6. Interface X131 ............................................................................................. 41
4.5. Interface assignment TM15 ...................................................................... 42
4.5.1. Interface X520 ............................................................................................. 42
4.5.2. Interface X521 ............................................................................................. 42
4.5.3. Interface X522 ............................................................................................. 43
5. Safety functions ...................................................................................... 44
5.1. Safety Integrated Functions (SIL 2) ......................................................... 44
5.2. Safety Integrated Extended Functions (SIL 3) ........................................ 44
6. Installation ............................................................................................... 48
6.1. Power Module PM340; frame size FSA / FSB ......................................... 48
6.1.1. Mounting the power module ........................................................................ 48
6.1.2.1.Frame size EF2037 to EF2150 ....................................................... 49
6.1.3.2.Frame size EF2220 to EF2300 ....................................................... 50
6.1.4. Connecting the power supply ...................................................................... 51
6.1.5.1.Terminal block for the line supply connection
1 AC 200 V - 240 V / 0.37 kW 51
3 AC 380 V - 480 V / 1.5 kW ........................................................... 51
3 AC 380 V - 480 V / 2.2 - 3.0 kW ................................................... 52
6.1.8. Connecting the motor .................................................................................. 53
6.1.9.1.Motor connection PM340, frame size FSA / 0.37 kW ..................... 53
6.1.10.2.Motor connection PM340, frame size FSA / 1.5 kW ..................... 54
6.1.11.3.Motor connection PM340, frame size FSB / 2.2 - 3.0 kW ............. 55
6.1.12.4.Connecting the motor .................................................................... 56
6.1.13.Mounting / connecting the braking resistor ................................................. 57
6.1.14.1.Mounting the braking resistor ........................................................ 57
6.1.15.2.Connection of Braking Resistor PM340, frame size FSA .............. 57
6.1.16.3.Braking Resistor Connection PM340, frame size FSB .................. 58
6.2. SIMOTION D410-2 Control Unit ................................................................ 59
6.2.1. Mounting the control unit ............................................................................. 59
6.2.2. Inserting the CF card ................................................................................... 60
6.2.3. Creating a shield connection ....................................................................... 61
6.3. Terminal Module TM15 ............................................................................. 62
6.3.1. Mounting Terminal Module TM15 ............................................................... 62
7. EF2 - PC connection ............................................................................... 63
7.1. Presettings ................................................................................................. 63
7.2. Ethernet communication via TCP/IP (via switch) ................................... 65
8. Operation / Description of WEISS Software ......................................... 66
8.1. Start page ................................................................................................... 66
8.1.1. User interface on the start page .................................................................. 67
8.1.2. Access restrictions ...................................................................................... 68
8.2. Overview .................................................................................................... 69
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8.3. Machine configuration ...............................................................................70
8.3.1. First step: Indexer configuration ...................................................................72
8.3.2.1.New indexer configuration ...............................................................72
8.3.3.2.Indexer configuration via file ............................................................74
8.3.4.3.Comment regarding indexer configuration data file .........................76
8.3.5. Second step: I/O configuration ....................................................................77
8.3.6.1.New I/O configuration ......................................................................77
8.3.7.2.I/O configuration via file ................................................................... 83
8.3.8.3.EF1 compatible configuration ..........................................................85
8.3.9.4.Comment regarding I/O configuration data file ................................89
8.3.10.Third step: System time ..............................................................................90
8.3.11.Fourth step: Restart ....................................................................................91
8.3.12.Dynamic parameters ...................................................................................92
8.3.13.I/O mapping ................................................................................................93
8.4. Maintenance ...............................................................................................94
8.4.1. Configuration file / Diagnostic file .................................................................95
8.4.2.1.Request diagnostic file ....................................................................95
8.4.3.2.Request configuration file (controller internal backup file) ...............96
8.5. Operation and Monitoring .........................................................................97
8.5.1. I/O monitoring ..............................................................................................97
8.5.2.1.Monitoring inputs and outputs .........................................................97
8.5.3.2.Forcing via the "Request authority of control" button .......................98
8.5.4.3.Forcing via the "Open separate user screen" button: ......................99
8.5.5. Manual operation .......................................................................................100
8.5.6.1.Manual operation: Opening a second browser window .................101
8.5.7.2.Manual operation: Setting inputs ...................................................102
8.5.8.3.Manual operation: Measuring cycle quick stop ..............................103
8.5.9.4.Manual operation: Optimization of stop delay time ........................104
8.5.10.5.Manual operation: Continuous mode ...........................................105
8.5.11.Statistical data ...........................................................................................106
8.5.12.Messages ..................................................................................................107
8.5.13.Siemens default pages .............................................................................107
8.6. Help ...........................................................................................................108
9. Communication with a higher-level controller ................................... 109
9.1. Profibus DP ..............................................................................................109
9.1.1. Interface X21 .............................................................................................112
9.2. Profinet IO RT ...........................................................................................113
9.2.1. Interface X150 ...........................................................................................117
10. Diagnostics ............................................................................................ 118
10.1. Messages ..................................................................................................118
10.2. Error and state indicators .......................................................................119
10.3. Error messages ........................................................................................120
11. Standards and approvals ...................................................................... 125
11.1. CE marking ...............................................................................................125
11.2. Electromagnetic compatibility ................................................................125
11.3. cULus approval ........................................................................................126
12. Appendix ................................................................................................ 127
12.1. EF2; 0.37 kW Controller connection examples .....................................127
12.1.1.SIL2 Power Module connection example ..................................................127
12.1.2.SIL2 PLC connection example ..................................................................128
12.1.3.SIL2 Interface I/O Module TM15 (option) connection example .................129
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12.1.4.SIL3 Power Module connection example ................................................. 130
12.1.5.SIL3 PLC connection example ................................................................. 131
12.1.6.SIL3 Interface I/O Module TM15 (option) connection example ................ 132
12.2. EF2; 1.5 kW to 3.0 kW Controllers connection examples ................... 133
12.3. Illustration index ..................................................................................... 139
12.4. Personal notes ........................................................................................ 142
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Introduction 1
1.1 Definition
1 Introduction
1.1 Definition
The EF2 rotary indexing table controller is used for the comfortable and time-optimized
control of rotary indexing tables of the TC and TR series in all frame sizes.
The controller is optimally designed for operation with the TC and TR rotary indexing
tables and offers you the following benefits:
• Frequency converter control system designed specifically for WEISS electromechani-
cal rotary indexing tables
• Intuitive, web-based user interface for fast commissioning
• No brake wear, soft start-up from intermediate positions is gentle on gearing
• Increased performance through fully automatic optimisation cycle
• Remote support and remote diagnostics options
• Worldwide use due to various network configurations
• Compact hardware (all-in-one)
• Fieldbus connection: PROFIBUS and PROFINET on board
• Interface: Digital I/O optional with TM15 module
• Integrated safety function SIL2
• Available with additional SIL3 measures
1.2 Intended use

The components for the controller and drive are approved for industrial and commercial
application in industrial networks.
All information regarding the technical data and the permissible conditions at the location
of use must be complied with.
Commissioning (starting the intended operation) of the machine in which the components
described here are to be installed is prohibited until the conformity of the machine with
the EMC Directive 2004/108/EC and the Machinery Directive 2006/42/EC has been
determined.
The operation of the controller is permissible only in enclosed housings or in superordi-
nate control cabinets with closed protective covers while using all protective equipment.
1.3 Target group

These instructions are intended for persons who are responsible for planning, installa-
tion, as well as maintenance and service, and have the adequate qualification and skills
to perform these tasks.
Handling the components of the controller is permitted only by qualified and trained per-
sonnel who know and comply with all safety instructions as stated on the components
and in the relevant technical user documentation.
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1 Introduction
1.4 Structure
1.4 Structure
2 3
FSA FSB
4 5 6 7
Fig. 1: Controller components
The components of the controller are delivered as individual modules. Their assembly
and connection are the responsibility of the user.
Pos. Component Type / Characteristics
(1) Control unit SIMOTION D410-2
Power module PM340
(2) (frame size FSA to 1.5 kW)
(3) (frame size FSB to 3.0 kW)
(4) Module TM15 Option: for digital inputs/outputs
(5) Motor contactor Option: for applications up to SIL3
(6) Safety relay Option: for applications up to SIL3
(7) External Braking resistor Siemens (optional)
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Introduction 1
1.4 Structure
24 VDC
Fieldbus (Profibus / Profinet)
Digital I/O
SIMOTION
D410-2
Digital I/O
Ethernet PM340 / FSB
L1
L2
L3
TC
TR
Fig. 2: Block diagram of EF2 controller
Manual EF2 R01-2013 9/144

1 Introduction
1.5 Further applicable documents
1.5 Further applicable documents

In addition to this manual, further documents are required for installation of the controller
and safe operation of a machine with this controller. You must observe and comply with
the information in these documents.
Operating instructions, mechanics documentation rotary index table TC / TR
Siemens_Documentations on the CF card
1.6 Manual
This manual describes the components of the controller and the installation and commis-
sioning of a rotary indexing table with the EF2 controller.
We reserve the right to undertake modifications because of technical developments to
the data and illustrations contained in these instructions.
The operating manual and the associated valid documentation are not subject to an auto-
matic revision service.
Information on the respective current edition can be obtained from the manufacturer.
Local regulations must be observed.
This manual describes how to use the controller and contains important information that
will support you in using the device as intended.
This manual describes handling of the machine and contains important instructions and
information to assist you in correct use of the machine.
A PDF file with these instructions is also available on the CompactFlash card of the con-
troller.
Safety instructions in individual chapters should be observed.
The manual is to be kept for further use and must be handed over to subsequent owners,
users or end customers.
1.6.1 Validity
These instructions are valid for EF controllers of the series:
• EF2037A For motors up to 0.25 kW
1.6.2 Standard scope

The scope of the functionality described in this document can differ from the scope of the
functionality of the drive system that is actually delivered.
Other functions that are not explained in this document may be available in the drive
system. However, there is no entitlement to these functions when the equipment is first
delivered or when it is being serviced.
The documentation can also contain descriptions of functions that are not available in a
particular product version of the drive system. The functionalities of the supplied drive
system should only be taken from the ordering documentation.
Extensions or changes made by the machine manufacturer must be documented by the
machine manufacturer.
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Introduction 1
1.6 Manual
1.6.3 Explanation of safety instructions in this manual

This manual contains instructions that you should observe for your personal safety and to
avoid material damage.
Safety instructions for your personal safety are highlighted by a sign containing a warning
triangle and signal word. The associated text describes the hazard involved, avoidance
options and the consequences which may result from failure to observe the safety
instruction.
General instructions or instructions relating to possible material damage are highlighted
by a sign without a warning triangle.
They are, depending on the degree of risk involved, illustrated as follows:
A warning triangle with the signal word DANGER
DANGER indicates an immediate hazardous situation, which, if
not avoided, will lead to fatalities or severe injuries.
A warning triangle with the signal word WARNING
WARNING indicates an potential hazardous situation, which, if
not avoided, can lead to fatalities or severe injuries.
A warning triangle with the signal word CAUTION
CAUTION indicates an potential hazardous situation, which, if
not avoided, can lead to light or medium injuries.
A sign with the signal word NOTICE indicates
NOTICE potential material damage or provides additional
information, which should be observed when
operating the machine.
1.6.4 Legend
Symbols and abbreviations with the following meaning are used in this manual to make
its content more clear:
1. Indicates a numbered list.
a) Indicates the second level of a numbered list.
• Indicates a list.
` Indicates the second level of a list.
The book symbol before a section of text indicates further applicable documents.
L The information symbol before a section of text marks an additional note or an
important tip for use.
1.6.5 Figures
The figures used show the parts of the controller as examples. There may be differences
between the illustrations and the actual delivered controller.
1.6.6 Directory of valid pages

Pages of this manual including the title page: 144
Manual EF2 R01-2013 11/144

2 Safety
2.1 Fundamental safety instructions
2 Safety

The controller corresponds to the state of the art and the applicable stipulations of the
VDE. It provides a high level of safety.
This safety can only be achieved during actual operation, however, when all associated
necessary measures have been performed. It is the duty of the operator to plan these
measures and to inspect their execution.
Only suitably qualified personnel may install, commission, and maintain the machine.
This personnel must take into account the information provided in the technical customer
documentation for the product, and be familiar with and observe the specified danger and
warning notices.
2.1.1 Operator‘s obligation to exercise diligence

The operator must ensure that
• The controller and the machine controlled by it are only used as intended.
• The controller and the machine controlled by it are only operated in perfect working
condition and the mechanical and electrical safety equipment are present.
• this manual and all other applicable documentation is maintained at all times in legible
condition and is accessible at the implementation site of the machine. Ensure that all
personnel who must execute activities tasks on the machine can access the manuals
at all times..
• all safety instructions and warnings affixed to the product are not removed and must
remain legible.
• national accident prevention guidelines and company-internal guidelines are complied
with.
• VDE regulations are complied with.
• the EMC legislation is complied with during installation.
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Safety 2
2.1.2 Technical safety
WARNING
During operation, electrical equipment and motors have parts and components with
hazardous voltage levels, and if touched, can cause severe bodily injury or death.
All work on the electrical system must be carried out when the system has been discon-
nected from the power supply (de-energized).
In combination with the drive system, the controllers are generally approved for operation
on TN and TT systems with a grounded neutral point.
During operation on IT systems, the occurrence of a first fault between an active part
and the ground must be signalled by a monitoring device. In accordance with HD 60364-
4-41, it is recommended that the first fault be eliminated as quickly as practically possi-
ble.
Operation in different networks is not permissible.
In systems with a grounded external conductor, an isolating transformer with grounded
neutral point (secondary side) must be connected between the supply and the drive
system to protect the motor insulation from excessive stress. The majority of TT systems
have a grounded external conductor, so in this case an isolating transformer must be
used.
Correct and safe operation of the controller assumes correct transportation in the trans-
portation packaging, correct long-term storage in the transport packaging, proper setup
and installation, as well as careful operation and maintenance.
In addition to the danger and warning information provided in the technical customer
documentation, the applicable national, local, and system-specific regulations and requi-
rements must also be taken into account.
To ensure compliance with EN 61800-5-1 and UL 508, only safety extra-low voltages
may be connected to connections and terminals on the electronic modules.
Using protection against direct contact via DVC A (PELV) is only permissible in areas
with equipotential bonding and in dry rooms indoors. If these conditions are not fulfilled,
then other protective measures against electric shock must be taken (e.g. touch protec-
tion).
NOTICE
As part of routine material tests, the controller components will undergo a voltage test in
accordance with EN 61800-5-1. Before the voltage test is performed on the electrical
equipment of machines acc. to EN 60204-1, Section 19.4, all connectors of the controller
component must be disconnected / unplugged to prevent the equipment from being
damaged.
Motors should be connected according to the circuit diagram supplied with the motor
(refer to the connection examples for motor modules). Direct connection to the three-
phase supply is not permitted because it would damage them.
Operating the equipment in the immediate vicinity (<1.8 m) of mobile telephones with a
transmitter power of >1 W may cause the components to malfunction.
Manual EF2 R01-2013 13/144

2 Safety
2.2 Emergency-off circuit
2.1.3 Electrostatic safety
NOTICE
Electrostatic sensitive devices (ESDs) are individual components, integrated circuits, or
modules that may be damaged by either electrostatic fields or electrostatic discharge.
Regulations for handling ESD components:
When handling electronic components, make sure that personnel, workstations, and pak-
kaging are well earthed!
Personnel may only come into contact with electronic components, if
• they are grounded with an ESD wrist band, or
• they are in ESD areas with conductive flooring, ESD shoes or ESD grounding straps.
Electronic modules should only be touched if absolutely necessary.
They must only be handled on the front panel or, in the case of circuit boards, at the
edge.
Electronic modules must not come into contact with plastics or items of clothing contai-
ning synthetic fibres.
Electronic modules must only be placed on conductive surfaces (work surfaces with ESD
surface, conductive ESD foam, ESD packing bag, ESD transport container).
Do not place electronic modules near display units, monitors, or television sets (minimum
distance from screen > 10 cm).
Measurements can only be taken on electronic modules when the measuring device is
grounded (e.g. via protective conductors) or, in the case of an isolated measuring device,
when the measuring probe is briefly discharged before measurements are taken (e.g. by
touching a bare metal housing).
2.1.4 Ambient and operating conditions
NOTICE
The components must be protected against conductive contamination, for example:
- Compliance with the standards (see chap. 11 „Standards and approvals“ on page 125)
- Inspection of the safety equipment
- Installation in a cabinet with a degree of protection IP54B according to EN 60529
Under the circumstances that conductive contamination at the installation site can defini-
tely be excluded, a lower degree of cabinet protection may be permitted.
2.2 Emergency-off circuit

For immediate shutdown and to prevent unexpected startup, an emergency-off cir-
cuit must be used.
Generation of a suitable safety concept for operation of a machine with the descri-
bed controller is the responsibility of the operator.
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Safety 2
2.3 Residual hazards

When carrying out a risk assessment of a machine in accordance with the EC Machinery
Directive, the machine manufacturer must consider the following residual risks which
emanate from the components of the controller and the drive:
• Unintentional movements of driven machine components during commissioning, ope-
ration, maintenance, and repairs caused by, for example:
` Hardware malfunctions and/or software errors in the sensors, controllers, actua-
tors, and connection technology
` Response times of the controller and drive
` Operating and/or ambient conditions which are not within the scope of the specifi-
cation
` Condensation/conductive contamination
` Parameterization, programming, cabling, and installation errors
` Use of radio devices / cellular phones in the immediate vicinity of the controller
` External influences / damage
• Extreme temperatures as well as emissions of light, noise, particles, or gases caused
by, for example:
` Component malfunctions
` Software errors
cation
• Hazardous shock voltages caused by, for example:
` Component malfunctions
` Influence of electrostatic charges
` Induction of voltages in moving motors
cation
` Condensation/conductive contamination
• Electrical, magnetic and electromagnetic fields generated in operation that can pose a
danger to persons with a pacemaker, implants or metal replacements, etc. if they are
too close
• Release of environmental pollutants or emissions as a result of improper operation of
the system and/or improper disposal of components
L For more information about residual risks of the components in the controller, refer
to the relevant chapters in this document.
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2 Safety
WARNING
Electric shock
Power and control connections can still conduct electricity even if the machine is at a
standstill. Work on electrical equipment should only be performed by qualified electricians
in compliance with the instructions in the operating manual for the electrical system docu-
mentation. Electrical connections for the machine should only be disconnected or
plugged in when the power supply is deactivated and secured against reactivation.
Touching energised components can lead to serious or fatal injuries.
Residual energy
After the frequency converter has been disconnected from the power supply, a residual
charge may still be present. After shutting down the device and before disconnecting the
plugs, wait at least five minutes and then check whether the capacitor has been
discharged to a voltage of < 65V DC at the "DCP" and "DCN" terminals. The fact that the
LEDs on the drive are off is not an indication that the unit is disconnected from the line
supply and there is no voltage. Touching live parts can result in death or serious injury.
Electrical, magnetic, or electromagnetic fields
Electrical, magnetic and electromagnetic fields (EMFs) generated in operation can pose
danger to persons who are present in the immediate vicinity of the product - especially to
persons with pacemakers, implants, or similar devices.
The relevant directives and standards have to be observed by the machine / plant opera-
tors and persons present in the vicinity of the product! These are, for example, EMF
Directive 2004/40/EEC and standards EN 12198-1 to -3 for the European Economic Area
(EEA) and in the Federal Republic of Germany, the accident prevention regulation BGV
11 and the associated rule BGR 11 "Electromagnetic fields" from the German employer's
liability accident insurance association.
They state that a hazard analysis must be performed for every workplace and measures
must be derived from it and applied in order to reduce dangers and their impact on
persons, and that exposure and danger zones must be defined and observed.
The relevant safety instructions in each chapter must be observed.
RCD
When using the EF2 controller, RCDs are not suitable for establishing safety circuits for
the protection of persons against electrical hazards.
The implementation of suitable protective measures is the responsibility of the operator.
Switching elements (main switches, contactors), for switching the power drive system on
and off must have a max. delay time of 35 ms between the closing/opening of the indivi-
dual main contacts.
Risk of injury due to absent safety equipment.
Safety equipment and covers that have been removed for maintenance purposes must
be put back into place before switching the machine back on. Operation without safety
equipment and covers is prohibited.
The implementation of a safety concept is the responsibility of the operator. The operator
must plan for and provide sufficient protective measures such as fences, light barriers,
emergency-stop circuits, covers, warning signs, etc.
CAUTION
Risk of injuries due to burning.
Depending on their design, components (motor, frequency converter) may have hot
surfaces during operation. Operating temperatures > 60° C are possible. Touching hot
components will lead to burns.
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Component descriptions 3
3.1 Power Module PM340
3 Component descriptions

The power modules are designed as follows:
• Line-side diode rectifier
• DC-link electrolytic capacitors with pre-charging circuit
• Output inverter IGBT
• Braking chopper for (external) braking resistor
• 24 V DC / 1 A power supply
• Gating unit, actual value acquisition
• Fan to cool the power semiconductors
The power modules cover a power range from 0.37 kW to 3.0 kW (versions without line
filter).
3.1.1 Safety instructions
WARNING
Electric shock
After all voltages have been disconnected, a hazardous voltage may still be present in the
power unit for up to 5 minutes. The cover for the terminals may only be opened after this
time has elapsed.
The DC-link discharge time must be declared on component in the corresponding
language.
Damaged components may not be operated further. Non-observance can result in
damage and accidents.
The drive components generate high leakage currents in the protective conductor. The
components must only be operated in cabinets or in closed electrical operating areas and
must be connected with the protective conductor. To provide protection against electric
shock, the protective conductor connection on the cabinet or machine must be imple-
mented in accordance with one of the following measures:
- Fixed connection and protective conductor connection by means of ≥ 10 mm2Cu or ≥ 16
mm2 Al
- Stationary connection and automatic shutdown of the power supply if the protective
conductor is interrupted
Ground / Protective earth
The power module housing must always be grounded. If the power module is not correctly
grounded, then extremely hazardous states can develop which, under certain circum-
stances, can result in death.
NOTICE
Connection authorization
Power modules have been designed for use in industrial environments and generate
current harmonics on the line side as a result of the rectifier circuit.
When connecting a machine with integrated power modules to the public low-voltage line
supply, authorization is required in advance from the local power supply company (utility
company) if:
- the rated input current of the machine ≤ 16 A per conductor, and
- the rated input current of the machine does not comply with the requirements specified
in EN 61000-3-2 regarding current harmonics.
Manual EF2 R01-2013 17/144

3.1.2 Power Module PM340; frame size FSA / 0.37 kW
2 5
3 4
Fig. 3: Interfaces of Power Module PM340; frame size FSA / 0.37 kW
Pos. Interface Description

(1) L/N Line connection
(2) PE Protective earth connection for the line supply cable
(3) U2 / V2 / W2 Motor connection
(4) PE Protective earth connection for the motor cable
(5) R1 / R2 Braking resistor connection
Connection to the module brake control (Safe Brake
(6) -
Relay)
(7) - Power module interface
(8) - Shield terminal connection set
(9) - Brake Relay
18/144 Manual EF2 R01-2013

3.1.3 Power Module PM340; frame size FSA / 1.5 kW
2 5
3 4
9
Fig. 4: Interfaces of Power Module PM340; frame size FSA / 1.5 kW

(1) L1 / L2 / L3 Line connection
Connection to the module brake control (Safe Brake
(6) -
Relay)
(9) - Brake Relay
Manual EF2 R01-2013 19/144

3.1.4 Power Module PM340; frame size FSB
2 5 9
3 4
Fig. 5: Interfaces of Power Module PM340; frame size FSB

(1) L1 / L2 / L3 Line connection
(6) - Connection to the module brake control (Safe Brake Relay)
(9) - Brake Relay
20/144 Manual EF2 R01-2013

3.1.5 Technical data

PM340 6SL3210- 1SB12-3UA0 1SE14-1UA0 1SE16-0UA0 1SE17-7UA0
Frame size FSA FSA FSB FSB
Output current
Rated current In A 2.3 4.1 5.9 7.7
Base-load current Ih A 2.0 3.6 5.2 6.8
for S6 operation (40%) Is6 A 3.3 4.5 6.4 8.3
Peak current Imax A 4.6 8.2 11.8 15.4
Line supply voltage V AC 1 x 200 - 240 3 x 380 - 480 3 x 380 - 480 3 x 380 - 480
Unit rating based on In1) kW 0.37 1.5 2.2 3
Unit rating based on IH1) kW - 1.5 2.2 3
Rated pulse frequency kHz 4 4 4 4
Power loss kW 0.075 0.11 0.14 0.16
Cooling air requirement m3/s 0.005 0.005 0.009 0.009
Sound pressure level LpA (1 m) dB < 45 < 45 < 50 < 50
24 V DC supply for the control unit A 1.0 1.0 1.0 1.0
Rated input current 2) A
with/without integrated line reactor 4/6 4.1 / 4.8 5.6 / 6.7 7.5 / 8.9
Class J UL safety fuses
Rated current A 10 10 10 12
Rated short-circuit current SCCR kA 65 65 65 65
Safety fuses NH - 3NA3803 3NA3803 3NA3805
Rated current A - 10 10 16
Circuit breaker type designation 5SJ4210- - - -
EN60947 7HG41 - - -
Rated current A 10 - - -
Circuit breaker type designation - 3RV1021- 3RV1021- 3RV1021-
IEC60947 - 1HA10 1KA10 4AA10
Rated current A - 5.5 - 8.0 9.0 - 12.5 11 - 16
Circuit breaker type designation 5SJ4210- - - -
UL489/ CSA/ C22.2 No. 5-02 7HG41
Rated current A 10 - - -
Rated short-circuit current SCCR kA 14 - - -
Resistance value of the external braking
Ohm > 180 > 390 > 160 > 160
resistor Rext
Max. cable length to braking resistor Rext m 15 15 15 15
Line supply connection L,N
Screw terminals for cable
Motor connection U2, V2, W2 Screw terminals for cable cross-sections
cross-sections
DC-link connection 1.0 to 2.5 mm2
1.0 to 6.0 mm2
Connection for braking resistor
PE connection On housing, M4 screw On housing, M5 screw
Max. cable length 3)
shielded/unshielded m 50 / 75
(without external options)
Degree of protection IP20 or IPXXB
Weight kg 1.3 1.2 4.0 4.0
Manual EF2 R01-2013 21/144

3.1.6 Overview Power Module PM340

3 AC 380 V ... 480 V 1 AC 200 V ... 240 V
L1L2 L3 PE L N PE
W1/L3
U1/L1
V1/L2
PE
L N PE
PM340
Bus P24
intern
R2
DCP/R1
μP
DCN
U2
V2
W2
PE
I max = 2A
Safe M
Brake
Relay 3
DC 24 V, 2A
Fig. 6: Overview Power Module PM340
22/144 Manual EF2 R01-2013

3.2 SIMOTION D410-2 Control Unit

SIMOTION D is the drive-based version of SIMOTION based on the SINAMICS S120
drive family.
In SIMOTION D, the SIMOTION PLC and motion control functionalities as well as the
SINAMICS S120 drive software run on shared control hardware.
SIMOTION D410-2 is a compact control unit predestined for single-axis applications.
The SIMOTION D410-2 Control Unit is snapped directly on to the Power Module PM340.
The firmware and preset parameters for operation are stored on a memory card that can
be inserted into the slot on the Control Unit D410-2.
The control unit communicates with external components via the interfaces.
LEDs indicate the operating statuses.
A
2
B
3
7
8
9
Fig. 7: Interfaces and front elements of the Control Unit D410-2 DP / PN
Manual EF2 R01-2013 23/144

Pos. Description
[A] LED status indicators
[B] Memory card slot
[C] Type plate
(1) PM-IF Interface to the power module (on the rear)
(2) X150 PROFINET IO interfaces
(3) X21 PROFIBUS DP interface
(4) X124 Electronics power supply
Temperature sensor connection
(5) X120 Fail-safe digital inputs
EP terminals
Isolated digital inputs
(6) X121
High-speed digital inputs / outputs
Isolated digital input
(7) X130
Fail-safe digital output
High-speed digital inputs / outputs
(8) X131
Analog input
(9) X127 Ethernet interface

System data, dimensions, weight
Dimensions W x H x D 73 x 190.7 x 74.4 mm
Permissible temperature Storage -25 °C....+55 °C
range Operation 0 °C....+55 °C
Protection class IP 20 (EN 60529)
Class I (with protective conductor connection) and class
Protection class
III (PELV) acc. to EN 61800-5-1:2007
0.8 kg (without packaging)
Maximum weight
1.0 kg (with packaging)
Electrical connection values
Power supply 24 V DC (permissible range: 20.4 ... 28.8 V)
Ripple Max. 5% at 24 VDC
Max. 35 VDC
Non-periodic overvoltage (Condition: Max. 500 ms, 50 s recovery time, max. 10
results/h)
Current consumption, typi-
< 0.8 A
cal 1)
Starting current, typical 1) 3.0 A
Power loss, typical 1) < 20 W
1) With no load on Inputs/Outputs and no 24 V supply via DRIVE-CLiQ or PROFIBUS interface
24/144 Manual EF2 R01-2013

3.2.2 MAC Addresses

A second type plate for the MAC address of the Ethernet interface and the PROFINET
interface is attached to the front of the device.
(1) Data matrix code
2 1
(2) Module designation
(3) Order number 3
Ethernet interface
(4)
MAC address of X127 4
PROFINET IO interface
(5)
MAC address of X150 5
(6) Serial number
(7) HW version 6 7
3.2.3 CompactFlash Card

L The CompactFlash card is mandatory for operation of the SIMOTION D410-2.
The SIMOTION Kernel (SIMOTION D410-2 firmware) and the software used to control
the drives (WEISS firmware) are stored on the CompactFlash card.
The CompactFlash card is used for:
• Backing up the technology packages and user data (programs, configuration data,
parameter assignments)
• Update (e.g. SIMOTION firmware update)
The licenses for the technology functions are linked to the serial number of the Compact-
Flash card.
Manual EF2 R01-2013 25/144

3.3 Terminal Module TM15

The terminal provides 24 DI/DO (digital I/Os).
In the case of EF2, the digital inputs and outputs are permanently assigned as 12 DI and
12 DO.
The TM15 terminal module is connected to the SIMOTION D410-2 via DRIVE-CLiQ. It
has a separate 24 V supply.
In the case of the EF2 option DI/DO, the TM15 terminal module is delivered with an inclu-
ded a DRIVE-CLiQ cable.
1
2
3
4
5
Fig. 8: Interfaces of the TM15 Terminal Module

(1) X501 DRIVE-CLiQ interface
(2) X502 DRIVE-CLiQ interface
(3) X502 Electronics power supply
(4) LED Status indicator
(5) X520 8 digital inputs
(6) X521 4 digital inputs / 4 digital outputs
(7) X522 8 digital outputs
(8) Shield Shield connection
(9) PE Protective earth connection
26/144 Manual EF2 R01-2013

3.4 Brake Relay
3.4 Brake Relay

A Brake Relay is required for operating motors with holding brakes up to 2 A (included in
the scope of delivery).
The Brake Relay is the interface between the CU / Power Modules Blocksize and the 24
V DC motor brake.
The motor brake is electronically controlled.
The supply voltage for the motor brake must be separately connected to the Brake Relay.
1
2 3
Fig. 9: Interfaces of the Brake Relay

(1) - Connection for the solenoid of the motor brake
(2) - Connection for a 24 V DC power supply
Connection for the cable harness (CTRL) to the power
(3) - module, blocksize format (included in the scope of deli-
very)

Pos. Inter-
Description
face
DC 20.4 to 28.8 V
Recommended nominal value of the power
Power supply supply 26 V DC (to equalize and compen-
sate for the voltage drop along the length of
the feeder cable to the 24 V DC solenoid of
the motor brake)
Current requirement, max.
Motor brake A 2
at 24 VDC A 0.05 + current drawn by the motor brake
Conductor cross-section, max. mm2 2.5
Dimensions (W x H x D) mm 69 x 63 x 33
Weight kg approx. 0.17
Manual EF2 R01-2013 27/144

3.4 Brake Relay
3.4.2 Brake Relay connection example
Brake Relay
Fig. 10: Brake Relay connection example
28/144 Manual EF2 R01-2013

3.5 Motor contactor
3.5 Motor contactor

A power contactor can be used as a switching device for switching the motor to comply
with safety requirements according to SIL 3.
The Motor Contactor 3RT2017 is suitable for switching motors of up to 5.5 kW / 400 V
(AC-3) and resistive loads of up to 50 A (AC-1).
The following illustration shows an example of the features of the Motor Contactor
3RT2017-1BB42 for switching motor loads.
8
1
2
3
5
7
6
Fig. 11: Motor Contactor 3RT2017-1BB42
1 Coil terminal on the front side

Openings for voltage tap of the main circuit (communication-capable power
2
contactor only)
3 Location hole for surge suppression
4 Location hole for 1-, 2-, and 4-pole auxiliary switch blocks
5 Labelling plate
6 1 integrated auxiliary contact ( 1 normally closed contact)
Main circuit terminals of the contactor to the load/motor connection (T1, T2,
7
T3)
8 Main circuit terminals of the contactor to the power network (L1, L2, L3)

Permissible mounting position AC and DC operation
1 2
The contactors are designed for operation on a vertical
mounting surface (1) and for an upright mounting position
(2).
Mechanical durability
Basic device 30 Mio Switching cycles
Basic device with snap-on auxiliary switch block 10 Mio Switching cycles
Solid-state compatible auxiliary switch block 5 Mio Switching cycles
Rated isolation voltage Ui V 690
(degree of contamination 3)
Rated impulse withstand voltage Uimp kV 6
Protective separation between coil and main con- V 400
tacts acc. to DIN EN 60947-1, Annex N
Manual EF2 R01-2013 29/144

3.6 Safety relay
3.6 Safety relay

The safety relay is suitable for performing safety-related functions as a part of a com-
plete system or machine.
The 3TK2842 is designed for the evaluation of actuator and sensor circuits according to
DIN EN / IEC 60204-1 in operating mode "Automatic start" and in operating mode "Moni-
tored start".
The PL or SIL level which is achievable depends on the external connections.
Depending on the ambient conditions, the device must be installed in a control cabinet
with the degree of protection IP32, IP43 or IP54 (degree of contamination 3).
Fig. 12: Sirius Safety Relay

Safety Relay 3TK2842
Equipment identification
• According to DIN40719 extendable acc. to IEC 204-2 / KT
according to IEC 750
• According to DIN EN 61346-2 F
Number of sensor inputs 1-channel or 2-channel 1
Cascading or operatio-
Design of the cascading
nal switching
Single-channel and
Design of the safety-related wiring of the inputs
dual-channel
Product feature transverse contact-secure Yes
SIL according to IEC 61508 SIL3
SIL claim limit (for a subsystem) according to EN 62061 3
SIL for time-delayed enabling circuit according to IEC 61508 3
Performance Level (PL)
• According to ISO 13849-1 e
• For time-delayed enabling circuit according to ISO 13849-1 e
Category
• According to ISO 13849-1 4
Safety device type according to IEC 61508-2 Type B
30/144 Manual EF2 R01-2013

3.6 Safety relay
Safety Relay 3TK2842

PFHD: Probability of dangerous failure per hour with high
0.5-10
demand rate according to EN 62061
T1 value for proof test interval or service life according to IEC
20
61508
Switching capacity current of semiconductor outputs for enab-
1.5 A
ling circuit for DC-13 / at 24 V
Type of control supply voltage DC
Control supply voltage 1 for DC rated value
24 VDC
• For DC rated value
Manual EF2 R01-2013 31/144

3.7 External braking resistor (option)
3.7 External braking resistor (option)

The Power Modules PM340 are assigned to fixed values of the braking resistors:
0.37 kW, 1 AC 220 ... 240 V, FMA : 180 Ohm, peak power = 1 kW
1.50 KW, 3 AC 380 ... 480 V, FMA: 390 Ohm, peak power = 1.7 KW
2.20 ... 3,00 KW, 3 AC 380 ... 480 V, FMB: 160 Ohm, peak power = 4.1 KW
The peak power is limited to a maximum of 12 sec. in an interval of 240 sec., if there is no
performance in the remaining period. It may be necessary to test the stopping time.
Fig. 13: Load diagram for braking resistors in blocksize format
ta = 12 s
t = 240 s

EF2037A EF2150A EF2220A / EF2300A
Order number
6SE6400-4BC05-0AA0 6SE6400-4BD11-0AA0 6SL3201-0BE12-0AA0
Suitable for power modules of
FSA FSB
frame size
Resistance Ohm > 180 > 390 > 160
Unit rating PDB kW 0.05 0.1 0.2
Peak power Pmax kW 1.0 1.7 4.0
Load duration for peak power
s 27.6 13.8 12.6
Ta for Pmax
Period duration of braking duty
s 276 276 252
cycle T
Power connections (including
Pigtail 3 x 1.5 mm2 shielded, length 0.5m
PE)
Thermostatic switch (NC con-
tact) maximum contact load 250 VAC, 2.5 A
connecting cable
Weight kg 1.0 1.0 1.6
32/144 Manual EF2 R01-2013

Function and signal descriptions 4
4.1 Signal description of the software inputs
4 Function and signal descriptions

Default configura-
tion
Signal Function
Inputs
PEW 256
The output stage of the controller is enabled if the signal level is
HIGH.
The output stage of the controller is disabled if the signal level is
Enable Bit 0 LOW. In addition, the brake is activated.
The input signal "Enable" in the controller by itself

does not meet the requirements to trigger an EMERGENCY-OFF.
With this command, all started movements are stopped and new
Stop movements are blocked. The brake is not activated.
Bit 1
(low-active) This input signal is not intended for use as EMER-
GENCY-OFF.
With this command, the rotary indexing table starts one cycle in the
Cycle CW Bit 2 direction of rotation "right" (CW).
A LOW/HIGH edge starts one cycle.
Cycle CCW Bit 3 direction of rotation "left" (CW).
A LOW/HIGH edge starts one cycle.
direction of rotation "right" (CW).
The signal must be present the entire time during the movement and
Cycle CW level Bit 4 should only be cancelled when the signal "Ready to start" is received.
Cancelling the signal during rotation leads to an immediate stop. A
restart outside of the cam is carried out with Parameter set 3 until the
cam is reached.
direction of rotation "left" (CW).
The signal must be present the entire time during the movement and
Cycle CCW level Bit 5 should only be cancelled when the signal "Ready to start" is received.
Cancelling the signal during rotation leads to an immediate stop. A
restart outside of the cam is carried out with Parameter set 3 until the
cam is reached.
The set values for Parameter 1 (launch pad, frequency, stop ramp)
are driven.
Parameter set 1 Bit 6
If no signal for parameter selection is received, the values of parame-
ter set 1 are driven.
The set values for parameter 2 (launch pad, frequency, stop ramp)
are driven.
Parameter set 2 Bit 7
If no signal for parameter selection is received, the values of parame-
ter set 1 are driven.
Manual EF2 R01-2013 33/144

Default configura-
tion
Signal Function
Inputs
PEW 256
Parameter set 3 is used for starting from an intermediate position.
Only if the limit switch of the rotary indexing table has been activated
and a "Start" is executed.
This parameter is permanently programmed and cannot be changed.
Ignore parame- If this parameter is chosen, depending on the signals Parameter set 1
Bit 8
ter set 3 or Parameter set 2, the intermediate position will not be approached
slowly, but according to the values of the selected parameter set.
It is recommended to start with a fast start ramp (>100ms) and a low
frequency (f < 30Hz) in order to be gentle on the mechanics of the
indexer.
If STO is active and the "Open brake" input signal is HIGH, the con-
Open brake Bit 9
nected brake is released.
On a rising edge (> 30 ms) all existing error messages are acknowled-
Reset error Bit 10
ged.
As long as this signal is HIGH, the rotary indexing table will rotate right
Jog CW
(CW) with Parameter set 3.
As long as this signal is HIGH, the rotary indexing table will rotate left
Jog CCW
(CCW) with Parameter set 3.
When starting with the signal "Cycle CW level", the table will start to
move - and movement will continue - as long as this signal is HIGH.
Not allocated If the table reaches the position cam, the setting is switched to Para-
meter set 2 and the table will continue to move without stopping.
Special mode When the cam is left again, the setting will return to Parameter set 1.
If the signal "Special mode" goes to LOW, then the current cycle will
be completed.
If a low frequency is specified in Parameter set 2, then the standstill
time of the indexer can be extended within certain limits.
34/144 Manual EF2 R01-2013

4.2 Signal description of the software outputs
4.2 Signal description of the software outputs

Default configu-
ration
Signal Function
Outputs
PAW 256
Enable active Bit 0 Displays that the drive is in the state Enable.
This output signal indicates that the controller can accept a "Start" com-
Ready to start Bit 1
mand or that the old command has been processed.
This output signal indicates that the rotary indexing table is in a valid
position. A cam is mounted on the table for this purpose. The signal from
the position cam is sent to this output without being changed (1:1).
If this output signal is HIGH, then processing can be started because the
indexing table is no longer moving. The motor of the indexing table will
Indexer in posi- however continue to move the distance specified by the stop delay or
Bit 2
tion stop ramp that was set, in order to reach an optimal starting position for
the next cycle.
If, however, this output signal is LOW, then processing

must be stopped immediately because the indexing table has left its posi-
tion.
Stop selected Bit 3 Direct feedback from the Stop input.
Rotary indexing table does not reach its next position within the specified
Alarm timeout Bit 4
time.
This output signal indicates that the sensor of the rotary indexing table
Alarm position was overrun.
Bit 5
run over If this error message is received, then processing must
be stopped immediately because the indexing table has left its position.
Alarm safety Bit 6 The safety function has detected an error.
Sum error Bit 7 This output displays all malfunctions as a group message.
Sum warning Bit 8 This output displays all warnings as a group message.
Forced dynamic Indicates that the internal safety function has requested a forced dynami-
Bit 9
sampling zation.
Limit switch left Bit 10 Function not implemented yet.
Limit switch
Bit 11 Function not implemented yet.
right
Sum error This output can be connected to a lamp that flashes when an error
Not allocated
[flashing] occurs.
Manual EF2 R01-2013 35/144

4.3 Functions and signals TM15
4.3 Functions and signals TM15
4.3.1 Terminal Module TM15 connection example

+ 24 DC + 24 DC
-X501 DRIVE-CLIQ
-X500
-
-
-X524 +
+
DI 0
L1 + TM 15
DI 0 RDY
DI 1
DI 1
DI 2
DI 2
DI 3
DI 3 -X520
DI 4
DI 4
DI 5
DI 5
DI 6
DI 6
DI 7
DI 7
M1
L2 +
DI 8
DI 8
DI 9
DI 9
DI 10
DI 10
DI 11
DI 11 -X521
DO 0
DO 0
DO 1
DO 1
DO 2
DO 2
DO 3
DO 3
M2
L3 +
DO 4
DO 4
DO 5
DO 5
DO 6
DO 6
DO 7
DO 7 -X522
DO 8
DO 8
DO 9
DO 9
DO 10
DO 10
DO 11
DO 11
M3
- -
PE PE
Fig. 14: Terminal Module TM15 connection example
36/144 Manual EF2 R01-2013

4.4 Interface assignment D410-2
4.4.1 Interface X120

Electric shock
Only temperature sensors that meet the safety isolation specifications specified in EN
61800-5-1 may be connected to terminals "+Temp" and "-Temp". If safe electrical sepa-
ration cannot be guaranteed (for linear motors or third-party motors, for example), a
Sensor Module External (SME120 or SME125) or Terminal Module TM120 must be used.
If these instructions are not complied with, there is a risk of electric shock!.
Representa- Pin
Name Description
tion
1 + Temp Motor temperature sensor input
Temperature sensors:
KTY84–1C130 / PTC
2 - Temp
Measuring current via temperature
sensor connection: 2 mA
3 DI 16 STO (+ 24 V)
4 F-DI 0 2) DI 17+ STO (+ 24 V)
5 DI 17- -M
6 DI 18
Fail-safe digital input 1 or digital
7 F-DI 1 2) DI 19+
inputs 18 and 19
8 DI 19- 1)
9 DI 20
Fail-safe digital input 2 or digital
10 F-DI 2 2) DI 21+
inputs 20 and 21
11 DI 21- 1)
Reference potential for:
• DI 16, DI 18 and DI 20 (or F-DI 0
12 M1
to FDI 2; first shutdown path)
• DO 16+ (or F-DO 0)
Colour coding in the description:
Green: relevant for EF2
Yellow: not used for EF2 do not use
1) Reference potential for DI 17+ / DI 19+ / DI 21+ (or F-DI 0 to F-DI 2; second shutdown path)
2) Functionality depends on the parameterized Safety Integrated functions.
The functionality of the digital inputs DI 16 to DI 21 depends on the parameterized Safety

Integrated functions.
Manual EF2 R01-2013 37/144


Representa- Pin
Name Description
tion
1 DI 0 Motor temperature sensor
2 DI 1 Limit switch left
3 DI 2 Limit switch right
4 DI 3 Motor contactor feedback
5 M2 Ground reference for DI 0 … DI 3
6 M Ground reference of the electronics 1)
7 DI / DO 8 Indexer sensor
8 DI / DO 9 Quick stop
10 DI / DO 10 Default IP
11 DI / DO 11 Controller RUN

White: Possible assignment
1) Reference potential for the digital inputs /digital outputs and analog input
An open input is interpreted as "Low".

The use of the digital inputs (DI 0 ... DI 3) requires that the terminal M2 has been connec-
ted. This can be achieved by:
• also routing the ground reference of the digital inputs, or
• a jumper to terminal M. This removes the electrical isolation for these digital inputs.

The X124 interface is provided for connection of the external power supply.
When using external power supplies (e.g. SITOP), the ground poten-
tial must be connected with the protective ground terminal (PELV).
Representation Terminal Description
+ Electronics power supply
+ + Electronics power supply
M Electronic ground
M
M Electronic ground

38/144 Manual EF2 R01-2013


SIMOTION D410-2 has an X127 interface for connection to industrial Ethernet.
Industrial Ethernet is a communication network with a transmission rate of 10/100 Mbit/s.
SIMOTION D410-2 offers the following functions via the Ethernet interface:
• Ethernet basic services (e.g. DCP, LLDP, SNMP)
` These Ethernet basic services provide uniform functions for the address assign-
ment and diagnostics, they do not provide PROFINET IO communication for the
connection of, for example, drives or I/O modules.
• Communication with STEP 7 and SIMOTION SCOUT
• Communication between SIMOTION and SIMATIC NET OPC
` The "SIMATIC NET SOFTNET-S7 (S7-OPC server)" software must be installed on
the PG/PC for this function.
• Connection of HMI systems
• Communication with other devices over TCP/IP or UDP communication
• IT communication (via SIMOTION IT DIAG, SIMOTION IT OPC XML-DA, SIMOTION
IT Virtual Machine)
Representa- Pin
Name Description
tion
1 TXP Output Ethernet transmit differential signal
2 TXN Output Ethernet transmit differential signal
3 RXP Input Ethernet receive differential signal
4 - - Reserved, do not use
6 RXN Input Ethernet receive differential signal
Manual EF2 R01-2013 39/144


L This interface is not assigned in the standard version!
Representa- Pin
Name Description
tion
1 DI 22+ Isolated digital input
2 DI 22- 2)
• DI 22+
3 M2 Ground reference for DI 0 … DI 3
• DI 16, DI 18 and DI 20 (or F-DI 0
5 M1
to FDI 2; first shutdown path)
• DO 16+ (or F-DO 0)
Power supply for:
6 24 V1
• DO 16+ (or F-DO 0)
7 DO 16+ 3)
4) Fail-safe digital output 0 or digital out-
F-DO 0
8 DO 16- 5) put 16

2) Reference potential for DI 20+
3) The proper function of the DO 16 requires that the terminals 5/6 are connected.
4) F-DO 0 for Safety Integrated extended functions
5) For applications "without safety function", DO 16- does not function
An open input is interpreted as "Low".

If M1 or M2 is connected with M, the electrical isolation no longer exists.
40/144 Manual EF2 R01-2013


Representa- Pin
Name Description
tion
Feedback 24-V power supply of
1 DI/DO 12
brake relay
High-speed digital input / digital out-
2 DI/DO 13 put
not electrically isolated
4 DI/DO 14 put
5 DI/DO 15 put
7 AI 0+
Analog voltage or current input
8 AI 0-
The common mode range must not be exceeded. This means that the
analog differential voltage signals can have a maximum offset voltage of ±12 V with
respect to the reference potential. If the range limits are exceeded, incorrect results may
occur during analog/digital conversion.
A 24 V supply voltage must be connected to terminal X124 for the digital outputs to be
used.
If momentary interruptions in the voltage occur in the 24 V supply, the digital outputs will
be deactivated for this time.
Manual EF2 R01-2013 41/144

4.5 Interface assignment TM15

The terminal provides 24 DI/DO (digital I/Os).
In the case of EF2, the digital inputs and outputs are permanently assigned as 12 DI and
12 DO.

Representation Terminal Name
1 L1+
2 DI 0
3 DI 1
4 DI 2
5 DI 3
6 DI 4
7 DI 5
8 DI 6
9 DI 7
10 M1 (GND)
Screw terminal
Max. connectable cross-section: 1.52
L1+: A 24 V DC power supply for DI/DO 0 to 7 (first potential group) must always be connected if at least one
DI/DO in the potential group is used as an output.
M1: A ground reference for DI/DO 0 to 7 (first potential group) must always be connected if at least one DI/DO
in the potential group is used as an output.
DI/DO: Digital input / output

1 L2+
2 DI 8
3 DI 9
4 DI 10
5 DI 11
6 DO 0
7 DO 1
8 DO 2
9 DO 3
10 M2 (GND)
Screw terminal

L2+: A 24 V DC power supply for DI/DO 8 to 15 (second potential group) must always be connected if at least
one DI/DO of the potential group is used as an output.
M2: A ground reference for DI/DO 8 to 15 (second potential group) must always be connected if at least one
DI/DO of the potential group is used as an output.
42/144 Manual EF2 R01-2013


1 L3+
2 DO 4
3 DO 5
4 DO 6
5 DO 7
6 DO 8
7 DO 9
8 DO 10
9 DO 11
10 M3 (GND)
Screw terminal

L3+: A 24 V DC power supply for DI/DO 16 to 23 (third potential group) must always be connected if at least
one DI/DO of the potential group is used as an output.
M3: A ground reference for DI/DO 16 to 23 (third potential group) must always be connected if at least one DI/
DO of the potential group is used as an output.
Manual EF2 R01-2013 43/144

5 Safety functions
5.1 Safety Integrated Functions (SIL 2)
5 Safety functions
5.1 Safety Integrated Functions (SIL 2)

The integrated safety functions of the SINAMICS S120 devices satisfy the requirements
of the standard IEC 61508 SIL 2, as well as PL d acc. to ISO 13849-1 and Category 3
acc. to ISO 12849-1 or EN 954-1.
The following integrated safety functions are currently provided by the SINAMICS S120
drive system:
• STO - Safe Torque OFF
5.2 Safety Integrated Extended Functions (SIL 3)

The safety function SIL 3 according to IEC 61508 can be fulfilled by the implementation
of additional measures.
• Additional motor contactor
• Safe brake control by means of a safety relay
• Contactor with mirror contact (forced) and feedback to the safety relay
power supply
SIMOTION D410
SS1
ST
safe sensor
safety relay
motor contactor
motor
Fig. 15: SIL 3 - basic concept
Evidence of SIL 3 capability can be demonstrated with the Siemens Evaluation Tool
"SET", which is available at (http://www.industry.siemens.com/topics/global/de/safety-
integrated/maschinensicherheit/safety-evaluation-tool/Seiten/Default.aspx). Examples of
the relevant configuration pages are shown below.
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Safety functions 5
Fig. 16: SET screen: Calculation for FC
Fig. 17: SET screen: Calculation for motor contactor
Manual EF2 R01-2013 45/144

5 Safety functions
The PFHD value of the combination of the SINAMICS S120 drive including the Sirius
Safety Relay 3TK2842-1BB41 and the selected Motor Contactor 3RT2017-1BB42 is
1.64 E-08.
A sensor can be added to the safety function, a light curtain for example. Its PFHD value
must be less than ~ 8.3 E-08 so that the total can achieve SIL3.
PFH = Probability of Failure per Hour
PFH values:
• SIMOTION D410-2 = 10*10E-09
• SINAMICS PM340 = 18*10E-09
• Encoderless safety function = 05*10E-09
sensor connection
channel 1 channel 2
L+ (24V DC)
400V
power supply
A1 Y11 Y12 Y21 Y22 Y32 Y35 1
3TK2842 - 1BB41
A1 A2 28 Y34 possible extension

SIMOTION D410 - 2
3(DI 16)
4(DI 17+)
X120 connection Y32:
5(DI 17-)
12 (M1)
ON activation
autostart (otherwise
5 (M2) controlled start)
X121 1 (DI 0)
ON: ON - button (for

controlled start)
A1 1 3 5 21 connection Y35:
3RT20 17-
1BB42
activation
cross-circuit detection
A2 2 4 6 22
M
M
Fig. 18: SIL 3 - Solution with motor contactor and safety relay
Emergency-off sequence (SIL3):

By forcing an emergency off, the drive is first brought to a standstill (T1) on an unsafe
quick-stop ramp by means of the "Quick stop" function.
After a delay time (T2) which is set in the safety relay, the safety relay activates the STO
function in the drive and the motor contactor is separated.
If the drive does not come to a standstill in the available shutdown time (T1), then it was
not possible to prevent the motor contactor from switching under load.
This situation, however, can be detected via the feedback contact of the motor contactor
to the SIMOTION D410-2.
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Safety functions 5
Forced dynamization:
The forced dynamization of the shutdown paths serves the purpose of detecting errors
on time that occur in the software and hardware of the two monitoring channels of the
integrated safety functions of the SINAMICS S120. It is automatically carried out by sel-
ecting / deselecting the STO function.
Safety monitoring error:
When a safety error occurs, such as "simultaneous monitoring", the drive will come to a
standstill by coasting down on its own.
The correct operation of the safety device must be checked afterwards, e.g. by pressing
the "emergency-off" switch again.
The drive can be moved again only after the safety error has been eliminated and the
safety device is reset.
Manual EF2 R01-2013 47/144

6 Installation
6.1 Power Module PM340; frame size FSA / FSB
6 Installation
6.1.1 Mounting the power module
BEACHTE Cooling and mounting clearances for power modules

Power modules must be mounted in the vertical position.
The following clearances must be observed between the components when mounting1):
- Frame size FSA: 30 mm (1.18 inch)
- Frame size FSB: 40 mm (1.57 inch)
The following cooling clearances must be observed above and below the component:
- Frame sizes FSA and FSB: 100 mm (3.93 inch)
The following cooling clearances must be observed in front of the component:

- Frame sizes FSB: 30 mm (1.18 inch)
Devices which could restrict the cooling air flow may not be mounted in this area. It must
be ensured that the cooling air flow of the power modules is not blocked.
1) The power modules can be mounted side by side without base components up to an ambient temperature of
40 °C.
In combination with base components and at ambient temperatures of 40 °C ... 55 °C, the specified lateral mini-
mum clearances must be observed. Where combinations of different frame sizes are concerned, the longer of
the two clearances shall apply.
1. Drill holes in the circuit cabinet according to the dimension drawings of the respective
power module (see figure 19 on page 49 and figure 20 on page 50).
2. Observe the required cooling and mounting clearances.
3. Screwing on the power module
Retaining type and tightening torques:

Frame size Retaining type Tightening torque
2x M4 studs
FSA 2x M4 nuts 2.5 Nm with washers
2x M4 washers
4x M4 studs
FSB 4x M4 nuts 2.5 Nm with washers
4x M4 washers
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Installation 6
6.1.1.1 Frame size EF2037 to EF2150
73
56
30
5, 2
217
A B
311
283,5
82,5
4, 5
30
214
30 56 30 257,5
Fig. 19: Dimensions of Power Module PM340; frame size FSA
[A] Ventilation clearance

[B] Braking resistor
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6 Installation
6.1.1.2 Frame size EF2220 to EF2300
153
137
40
5 ,2
316
A B
380
410
83
4, 5
40
234
277,5
40 128 40
Fig. 20: Dimensions of Power Module PM340; frame size FSB
[A] Ventilation clearance

[B] Braking resistor
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Installation 6
6.1.2 Connecting the power supply
Cyclical switching of the supply voltage is prohibited. After each

shutdown, wait five minutes before switching it on again.
6.1.2.1 Terminal block for the line supply connection 1 AC 200 V - 240 V / 0.37 kW
Name
L Line phase L
N Line phase N
PE Protective earth
Rated current 10 A
Screw terminals for cable cross-sections
1.0 to 2.5 mm2
Fig. 21: Terminal block for the line supply connection 1 AC 200 V - 240 V / 0.37 kW
6.1.2.2 Terminal block for the line supply connection 3 AC 380 V - 480 V / 1.5 kW
Name
U1 / L1 External conductor L1
V1 / L2 External conductor L2
W1 / L3 External conductor L3
PE Protective earth
Rated current 10 A
Safety fuses NH
Rated current 10 A
1.0 to 2.5 mm2
Fig. 22: Terminal block for the line supply connection 3 AC 380 V - 480 V / 1.5 kW
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6 Installation
6.1.2.3 Terminal block for the line supply connection 3 AC 380 V - 480 V / 2.2 - 3.0 kW
Name
U1 / L1 External conductor L1
V1 / L2 External conductor L2
W1 / L3 External conductor L3
PE Protective earth
Rated current 10 A (2.2 kW) / 12 A (3.0 kW)
Safety fuses NH
Rated current 10 A (2.2 kW) / 16 A (3.0 kW)
1.0 to 6.0 mm2
Fig. 23: Terminal block for the line supply connection 3 AC 380 V - 480 V / 2.2 - 3.0 kW
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Installation 6
6.1.3 Connecting the motor

Electric shock
Cable shields and unused conductors of power cables (e.g. brake conductors) must be
connected to PE potential to prevent capacitive cross-talk charges. Non-observance can
cause lethal shock voltages.
• Only use shielded cables.
• Put the cable shield on both sides (on the cabinet and the motor).
• All cables must comply with the specified requirements on site.
• Connect the shield over a large surface area.
• Terminate HF-shield braiding by PE connection via shield clip or EMC cable gland
• Only use shields with tin or nickel-plated copper braids. Shields with steel braids are
not suitable.
• Overlap of the shield braid: At least 70% to 80% with 90° overlap angle.
• Use low-capacitance cables:
` Core/core < 75pf/m
` Core/shield < 150pf/m
6.1.3.1 Motor connection PM340, frame size FSA / 0.37 kW
Name
U2 Motor phase U
V2 Motor phase V
W2 Motor phase W
PE Protective earth
Motor terminal block with delta bridge

Fig. 24: Motor connection PM340, frame size FSA / 0.37 kW
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6 Installation
6.1.3.2 Motor connection PM340, frame size FSA / 1.5 kW

Name
U2 Motor phase U
V2 Motor phase V
W2 Motor phase W
PE Protective earth
Motor terminal block with star bridge

Fig. 25: Motor connection PM340, frame size FSA / 1.5 kW
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Installation 6
6.1.3.3 Motor connection PM340, frame size FSB / 2.2 - 3.0 kW

Name
U2 Motor phase U
V2 Motor phase V
W2 Motor phase W
PE Protective earth
Motor terminal block with star bridge

Fig. 26: Motor connection PM340, frame size FSB / 2.2 - 3.0 kW
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6 Installation
6.1.3.4 Connecting the motor

The following measures are absolutely necessary to avoid EMC problems:
Cable for the motor:
• A shielded cable must be used for the motor connection (U, V, W, PE).
• The cable shield must be connected on both sides,
` that means the cable shield must also be connected to the motor (see figure
below)!
Cable for the holding brake:

• A suitable cable must be used for the 24 V holding brake (2x1 mm² or 5x1 mm² if a
temperature switch is connected).
L The lines for the brake must not be routed together with the motor cable!
` Use a separate cable!
Cable for the temperature switch:

• A suitable cable must be used for the temperature switch of the motor.
L The lines for the temperature switch must not be routed together with the motor
cable!
` Use a separate cable or a free wire in the cable for the holding brake!
Cable for the limit switch:

• A separate cable must be used for the limit switch.
L The lines for the limit switch must not be routed together with the motor cable!
` Use a separate cable!
An EMC screw connection must always be used for the shield contact on motors with
metal terminal box.
The shield must be connected to the PE screw on motors with plastic terminal box.
1 3 4
1 PE wire 3 PE wire, shield, ferrule

2 Shield 4 PE clamping point
Fig. 27: Connecting the motor cable to the motor
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Installation 6
6.1.4 Mounting / connecting the braking resistor

The PM340 Power Modules cannot recover generated power and feed it back into the
grid.
For operations which produce energy, e.g. braking of a rotating mass, a braking resistor
must be connected to convert the generated power into heat.
6.1.4.1 Mounting the braking resistor
1. Mount the braking resistor under the power module.
2. Connect the cable of the braking resistor to the terminals R1 and R2 of the power
module (see Chapter 6.1.4.2 or 6.1.4.3).
6.1.4.2 Connection of Braking Resistor PM340, frame size FSA
BEACHTE To connect the cable lugs of the braking resistor cable to the Power
Module PM340 of frame size FSA, the nose on connection R2 has to be cut with a thin
wire cutter. Make sure that none of the plastic falls into the housing while doing so.
Terminal Name
1 R1 Braking resistor cable
Fig. 28: Connection of Braking Resistor PM340, frame size FSA
6SE6400-4BC05- 6SE6400-4BD11-
Order number
0AA0 0AA0
FSA (1 AC) FSA (3 AC)
frame size
Resistance Ohm > 180 > 390
Unit rating PDB kW 0.05 0.1
Peak power Pmax kW 1.0 1.7
Load duration for peak power Ta
s 27.6 13.8
for Pmax
s 276 276
cycle T
PE)
tact) maximum contact load con- 250 VAC, 2.5 A
necting cable
Weight kg 1.0 1.0
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6 Installation
6.1.4.3 Braking Resistor Connection PM340, frame size FSB

Terminal Name
Fig. 29: Braking Resistor Connection PM340, frame size FSB
Order number 6SL3201-0BE12-0AA0

FSB (3 AC)
frame size
Resistance Ohm > 160
Unit rating PDB kW 0.2
Peak power Pmax kW 4.0
Load duration for peak power Ta
s 12.6
for Pmax
s 252
cycle T
PE)
tact) maximum contact load con- 250 VAC, 2.5 A
necting cable
Weight kg 1.6
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Installation 6
6.2.1 Mounting the control unit

Mounting the control unit:
2.
1.
Fig. 30: Mechanical assembly of Control Unit D410-2
The SIMOTION D410-2 Control Unit is snapped directly on to the Power Module PM340.
1. Attach the control module to the recesses of the power module using the hooks.
2. Press the control module against the power module.
` The blue lock must snap into place.
Disassembly of the control unit:
1.
2.
3.
Fig. 31: Mechanical disassembly of Control Unit D410-2
1. Press the blue lock down.

2. Swivel the control unit to the front.
3. Remove the control unit.
Manual EF2 R01-2013 59/144

6 Installation
6.2.2 Inserting the CF card

The CF card is mandatory for operation of the SIMOTION D410-2. The SIMOTION Ker-
nel (SIMOTION D firmware) and the software used to control the drives ( firmware) are
contained on the CompactFlash card. To load the SIMOTION Kernel, the CF card must
be in the plug-in slot during Startup of the SIMOTION D410-2.
NOTICE
The CompactFlash card may only be inserted or removed while the SIMOTION D410-2
Control Unit is in a de-energized state! The SIMOTION D410-2 is in a de-energized state
when all the LEDs are OFF. The CompactFlash card is an electrostatic sensitive compo-
nent. When removing and inserting the CompactFlash card, observe the ESD regulati-
ons.
3
Compactflash
Fig. 32: Inserting the CF card into the D410-2 Control Module
1. Align the CF card (1) according to the arrows (2).

` There is one arrow (2) on the plug-in slot and on the CF card.
2. Insert the CF card gently into the empty slot (3) of the SIMOTION D410-2 until it
snaps in.
L When properly inserted, the CF card is flush with the housing.
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Installation 6
6.2.3 Creating a shield connection

Using shielded cables
The following options are available for the shield connection when using shielded cables:
• A shield connection using a separately attachable shielding bus
• Shield connection via the M3 screw-on shield connecting element on the housing of
the SIMOTION D410-2
Using a shielding bus:

If a shielding bus is used, proceed as follows:
1. Attach the cable shield to a grounded shielding bus after the cable entry point in the
cabinet. Strip the isolation off the cable first.
2. Continue routing the shielded cable up to the module, but do not make the connection
to the shield there.
Using a shield connection on the SIMOTION D410-2:

1. Unscrew the holding clamp of the M3 shield connection (Torx screwdriver T10) at the
top of the SIMOTION D410-2 until there is a space below the clamp.
2. Insert the cable. The cable shield must first be exposed.
3. Tighten the fixing bracket so that the cable shield and cable are pressed against the
shield connection (tightening torque 0.8 Nm).
The following figure shows how to connect the cable shield.
Cable shield exposed
Cable routing from F-GI (e.g.

X120) to shield support
Fig. 33: Shield connection of Control Unit D410-2
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6 Installation
6.3.1 Mounting Terminal Module TM15
Fig. 34: Mounting Terminal Module TM15
L The Terminal Module TM15 is designed to be mounted on a hat rail.
1. Snapping Terminal Module TM15 on to a hat rail.

2. Observe the dimensions according to figure 34, „Mounting Terminal Module TM15,“
on page 62.
3. Observe the required cooling and mounting clearances.
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EF2 - PC connection 7
7.1 Presettings
7 EF2 - PC connection
The connection of the EF2 Controller to a PC or Notebook is established using a network

cable.
X127 (LAN)
Fig. 35: PC - EF2 Controller connection
7.1 Presettings
1. Go to SYSTEM PROPERTIES (CONTROL PANEL) \ INTERNET OPTIONS \ CON-
NECTIONS \ LAN SETTINGS and make the following settings:
` Activate "Automatically detect settings".
` Deactivate "Use a proxy server for your LAN".
It is necessary to adjust the Internet settings or network settings on the PC or notebook.
Fig. 36: Adjusting the Internet options
L Should it not be possible to establish a connection using these settings, then the
LAN settings have to be changed manually (see next step).
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7 EF2 - PC connection
7.1 Presettings
2. Go to CONTROL PANEL \ NETWORK AND SHARING CENTER \ CHANGE ADAP-

TER SETTINGS \ LAN CONNECTION \ PROPERTIES and make the following set-
tings:
` Clear (if selected) the check box in front of Internet Protocol Version 6 (TCP/IPv6).
` Select Internet Protocol Version 4 (TCP/IPv4).
` Double-click Internet Protocol Version 4 (TCP/IPv4).
` Configure a higher or lower IP address than the default IP of the controller, e.g.: IP
address 169.254.11.21 subnet mask 255.255.255.0
Default IP address of the EF2 controller: 169.254.11.22
Fig. 37: Changing the adapter settings
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EF2 - PC connection 7
7.2 Ethernet communication via TCP/IP (via switch)
7.2 Ethernet communication via TCP/IP (via switch)

The SIMOTION D410-2 DP/PN has an onboard IE interface which is called X127 (SS-
IE). This interface has an IP address and communicates via TCP/IP. As part of the TCP/
IP communication between the SIMOTION D410-2 DP/PN and the connected compu-
ters, an " Address Resolution Protocol" (ARP), a mapping table of the network address of
a device to the hardware address ( MAC address) of the device, is created and stored on
the computer. This process remains hidden for the user, which is done automatically, so
that the use of this protocol is only noticeable when a communication error occurs.
The validity period of an ARP address can become a problem if there are incorrect ent-
ries or entries which are no longer valid. As long as the incorrect entry exists it is not pos-
sible to communicate with the respective host. The error is usually not attributed to the
ARP protocol but to the devices or network. To update an incorrect or old ARP table, the
command <arp -d> can be entered into the MS DOS command prompt in Windows as
shown in following figure.
• Entering a command into the DOS command prompt in Windows <arp -d>
Manual EF2 R01-2013 65/144

8 Operation / Description of WEISS Software
8.1 Start page
Fig. 38: Entering the IP address of the EF2 controller
The Web browser of the PC or Notebook can be used to access the EF2 controller.
1. Start the Web browser.
2. Enter the IP address of the controller and confirm with ENTER.
Default IP address of the EF2 controller: 169.254.11.22
L If all presettings were made correctly, as described in Chapter 7.1, then the start
page of the controller will appear.
8.1 Start page
Fig. 39: Start page of the EF2 controller
The status display area on the start page shows the status of the controller and the state
of the rotary indexing table.
` Connection active (green = yes / grey = no)
` Startup done (green = yes / grey = no)
` Indexer configured (green = yes / grey = no)
` Quick stop monitoring (green = yes / grey = no)
` Indexer state: e.g. NOT_READY
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Operation / Description of WEISS Software 8
8.1 Start page
8.1.1 User interface on the start page
B C
Fig. 40: Description of the user interface of the EF2 controller
The start page is divided into three areas:

[A] Status indicator
[B] Navigation
[B] Information / Selection
Area Topic Section
` Green: Action successfully completed Grey: Action not executed

Controller
yet
Status indicator
Rotary indexing ` Indexer state: e.g. NOT_READY
table
` Operating state of the controller

Overview ` Configured indexer type
(see chapter 8.2) ` Communication
` Data
` Ethernet interface
Machine configu- ` Indexer configuration (see chapter 8.3.1.3)
ration ` Dynamic parameters (see chapter 8.3.5)
` I/O mapping of the inputs/outputs(see chapter 8.3.6)
Navigation
Maintenance ` Config + Diagnostic file
(see chapter 8.4) ` User manager; only for WEISS Service
` I/O monitoring of the inputs and outputs (see chapter 8.5.1)
` Manual operation (see chapter 8.5.2)
Operation and ` Statistical data (see chapter 8.5.3)
Monitoring ` Messages (see chapter 8.5.4)
` Siemens default pages; only for WEISS Service personnel (see
chapter 8.5.5)
Help ` Contact details for WEISS GmbH, with current documentation
(see chapter 8.6) (Operating and Instruction Manuals) and GSD files.
Information / Sel- Information and comments about the indexer configuration

ection Selection and/or input/modification of parameters for the indexer configuration
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8.1 Start page
8.1.2 Access restrictions

Certain sections in the user interface are reserved for authorized personnel.
A user name and password have to be entered to access these sections.
Each controller comes with a user name and password.
User name: operator
Password: 100
Enter this user name and password when you are asked for them.
Fig. 41: Enter user name and password
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8.2 Overview
8.2 Overview
Fig. 42: Description of the "Overview" page
The "Overview" page provides an overview of the current state of the rotary indexing
table, as well as the configuration and the system data.
L Useful data is only displayed on this page after a rotary indexing table has been
configured.
The content on the "Overview" page is informative and it cannot be changed on this
page. Exception:
` By clicking the RESET button next to "Piece counter", the count will be set to zero.
Available information:
` Indexer state: e.g. WAIT_FOR_ENABLE
` Operating state of the controller
` Configured indexer type
` Communication
` Data
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8.3 Machine configuration

L The following configuration diagram shows all possible configurations. Follow the
paths and branches of the diagram.
Machine configuration start
[Table configuration: New table]
[Table configuration from file]
Select type of indexer +

Select data file
options
[Data file selected]
Display input field

for data file
[Decline]
Input comment for

[Confirmation] data file
I/O configuration
[I/O configuration EF1 compatible

Select data file
from file] [EF1 compatible I/O configuration] I/O configuration
[Data file selected] [New I/O configuration]

[Terminal] [PROFINET]
Display input field New
[PROFIBUS]
for data file I/O configuration
Display Display Display

interconnection terminals interconnection PROFIBUS interconnection PROFINET
[Terminal] [PROFINET]
PROFIBUS PROFINET
[PROFIBUS]
settings settings
I/O-Mapping: I/O-Mapping: I/O-Mapping:

interconnection terminals interconnection PROFIBUS interconnection PROFINET
PROFIBUS PROFINET
[Decline] settings settings
Input comment for

[Confirmation] data file
System time indexer

+ transfer configuration
Transfer complete
configuration
Configuration
transfered
Note for optimization

+ restarting controller
Fig. 43: EF2 configuration diagram
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L Only authorized persons are allowed to access certain sections. User name and
password are supplied with the controller (chapter 8.1.2 „Access restrictions“ on
page 68).
Before beginning with the machine configuration, the Ethernet interface should be chek-
ked.
L If necessary, the settings can be changed.
1 3
Fig. 44: Configuring the Ethernet interface
• (1) Displays the user-defined IP setting

• (2) Input fields for the entry of new user-defined IP settings
• (3) Displays the default IP setting
` This is the default IP setting for the supplied controller and cannot be changed.
` The default IP setting can be used to restore the initial setting.
Changing the IP settings
1. Under "New user-defined IP settings", an IP address and subnet mask can be
entered.
2. Confirm new IP setting.
After checking the Ethernet interface, the rotary indexing table can be configured.
Manual EF2 R01-2013 71/144

Configuration is always carried out in four steps.
First step: Indexer configuration

Go to chapter 8.3.1 „First step: Indexer configuration“ on page 72
Second step: I/O configuration

Go to chapter 8.3.2 „Second step: I/O configuration“ on page 77
Third step: Setting the system time:

Go to chapter 8.3.3 „Third step: System time“ on page 90
Fourth step: Restarting the controller

Go to chapter 8.3.4 „Fourth step: Restart“ on page 91
8.3.1 First step: Indexer configuration

The first step of the complete machine configuration is to configure the rotary indexing
table.
There are two different ways to configure a rotary indexing table.
[A] New indexer configuration

Go to chapter 8.3.1.1 „New indexer configuration“ on page 72
[B] Indexer configuration via file

Go to chapter 8.3.1.2 „Indexer configuration via file“ on page 74
8.3.1.1 New indexer configuration
2.
1.
1. Start "New indexer configuration".

2. Confirm the message with OK.
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3.
4.
5.
3. Select the type of indexer.

4. Select the motor equipment.
5. Confirm the indexer configuration.
➱ After confirmation, an input field will appear in which you can make comments.
Go to chapter 8.3.1.3 „Comment regarding indexer configuration data file“ on

page 76
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8.3.1.2 Indexer configuration via file

"Indexer configuration via file" is not possible during initial startup
because no configuration file has been stored yet.
2.
1.
1. Start "Indexer configuration via file".
3. b
a
3. Choose action.
Selection:
• (a) "Load file" - load configuration file from computer
• (b) "Load backup file" - load from the controller internal backup file
• (c) Abort configuration
➱ Aborting configuration => back to the start page
L Follow the instructions in the selection window.
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4.
5. a b c
4. The comment is for describing the chosen data file.

5. Choose action.
Selection:
• (a) Abort configuration
• (b) Reject data file
➱ Reject data file => back to the selection
• (c) Accept data file
Go to chapter 8.3.1.3 „Comment regarding indexer configuration data file“ on

page 76
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8.3.1.3 Comment regarding indexer configuration data file

This window contains a free text field for entering comments and notes about the data
file.
1.
2.
Fig. 45: Comment regarding indexer configuration data file
1. Enter a comment for the data file.

2. Confirm comment.
The first step of configuring a rotary indexing table is now finis-

hed. Next step:
Go to chapter 8.3.2 „Second step: I/O configuration“ on page 77
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8.3.2 Second step: I/O configuration

The second step of the complete machine configuration is to configure the inputs and
outputs.
There are three different ways to configure the inputs and outputs.
[A] New I/O configuration

Go to chapter 8.3.2.1 „New I/O configuration“ on page 77
[B] I/O configuration via file

Go to chapter 8.3.2.2 „I/O configuration via file“ on page 83
[C] EF1 compatible configuration

Go to chapter 8.3.2.3 „EF1 compatible configuration“ on page 85
8.3.2.1 New I/O configuration
1.
1. Start "New I/O configuration".
L Configure the inputs and outputs with regard to the interface used.
[A] PROFIBUS communication, if you are using a PROFIBUS connection
Go to chapter „[A] PROFIBUS communication“ on page 78
[B] PROFINET communication, if you are using a PROFINET connection

Go to chapter „[B] PROFINET communication“ on page 81
[C] Terminal block connection, if you are using a Terminal Module (TM15) for the
Inputs / outputs
Go to chapter „[C] Terminal block connection“ on page 82
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[A] PROFIBUS communication
1.
1. Start "PROFIBUS communication".

L A default configuration can be used for the I/O mapping. Alternatively, the control
commands can be assigned to the inputs / outputs manually.
Default configuration:
2.
3.
2. Select default configuration.

➱ Inputs and outputs are assigned to the control functions which are defined as
default.
➱ Individual assignments can be deleted or changed.
➱ Functions that appear grey in the "Control functions" selection field are already
assigned, those that appear black can still be assigned.
3. Confirm the assignment.
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4.
5.
6.
4. Enter the PROFIBUS DP address.

5. Choose the PROFIBUS baudrate.
6. Confirm the entry.
Go to chapter 8.3.2.4 „Comment regarding I/O configuration data file“ on page 89
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Manual input terminal assignment:
3.
1. 2.
4.
1. Choose a "Control function".

2. Assign the chosen control function to a terminal.
3. Assign output terminals in the same way.
4. Confirm the assignment.
5.
6.
7.

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[B] PROFINET communication

L I/O mapping for the PROFINET communication is done in the same way as the I/O
mapping for the PROFIBUS communication and the terminal block connection.
` Use default configuration or
` Manual I/O mapping of the PROFINET inputs/outputs
For description see chap. „[A] PROFIBUS communication“ on page 78
In addition, further PROFINET settings have to made.
The station name has to match the name that was previously declared
in the higher-level controller!
Rules for assigning names:
• Only lowercase letters
• Letters a-z and numbers 0-9 are permitted
• Special characters are not allowed: !"§$%&/()=?`*'_:;#+<>|~[]{}
• Spaces are not allowed either
• The name can have a maximum total length of 240 characters
• Reserved names which cannot be used:
` "port-xyz" or "port-xyz-abcde…"
• The engineering system replaces unpermitted characters with an "x".
1.
2.
3.
1. Enter PROFINET station name.

2. If necessary: Carry out new PROFINET IP configuration again.
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[C] Terminal block connection

L I/O mapping for the terminal block connection is done in the same way as the I/O
mapping for the PROFIBUS communication and the PROFINET communication.
` Use default configuration or
` Manuals I/O mapping of the input / output terminals
For description see chap. „[A] PROFIBUS communication“ on page 78
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8.3.2.2 I/O configuration via file

"I/O configuration via file" is not possible during initial startup because
no configuration file has been stored yet.
1.
1. Start "I/O configuration via file".
2.
b
a
2. Choose action.
Selection:
• (a) "Load file" - load configuration file from computer
• (b) "Load backup file" - load from the controller internal backup file
• (c) Abort configuration
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3.
4. a b c

4. Choose action.
Selection:
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8.3.2.3 EF1 compatible configuration
1.
1. Start "EF1 compatible configuration".
L Configure the inputs and outputs with regard to the interface used.
C A B
2.
2. Select the type of I/O configuration.

Selection:
[A] PROFIBUS communication, if you are using a PROFIBUS connection
[B] PROFINET communication, if you are using a PROFINET connection
[C] Terminal block connection, if you are using a Terminal Module (TM15) for the
Inputs / outputs
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[A] PROFIBUS communication EF1

With the EF1 compatible I/O configuration, the interfaces are compatible to the WEISS
rotary indexing table controller EF1.
default.
➱ Individual assignments cannot be deleted or changed.
➱ The display of control functions is informative.
3. a b
3. Choose action.
Selection:
• (b) Accept data file
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4.
5.
6.

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[B] PROFINET communication EF1

default.
In addition, further PROFINET settings have to made.
The station name has to match the name that was previously declared
in the higher-level controller!
1.
2.
3.
1. Enter PROFINET station name.

2. If necessary: Carry out new PROFINET IP configuration again.
[C] Terminal block connection EF1

default.
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8.3.2.4 Comment regarding I/O configuration data file
3. a b c

5. Choose action.
Selection:
The I/O configuration of a rotary indexing table is now finished.

Next step:
Go to chapter 8.3.3 „Third step: System time“ on page 90
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8.3.3 Third step: System time

The third step of the complete machine configuration is setting the system time.
1.
2.
1. Adjust system time.

` The currently displayed time can be used as the system time, a new time can be
defined, or the PC time can be transferred.
2. Transfer adjustments.
The system time has now been set. Next step:

Go to chapter 8.3.4 „Fourth step: Restart“ on page 91
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8.3.4 Fourth step: Restart

The fourth and last step of the complete machine configuration is restarting the control-
ler.
1.
1. Confirm the prompt for a restart.
L The status indicator displays the state of the rotary indexing table after the restart.
In the example shown:
` Connection active
` Startup done
` Indexer configured
` Quick stop monitoring inactive
` Indexer state: WAIT_FOR_ENABLE
The complete configuration of the rotary indexing table is now

finished.
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8.3.5 Dynamic parameters

The default dynamic parameters that were taken on during selection of the rotary inde-
xing table can be adjusted to meet the requirements of the customer.
Changing the dynamic parameters influences the movements of the

table top and the system behaviour of the rotary indexing table. A process value which is
outside the set limits (upper limit / lower limit) is not permitted!
1. Enter a new process value and confirm with OK.

` The new process value will be transferred to the field "Current process value".
2. Save changes in the configuration file.
` The new process values will be transferred to the configuration file which was
created during indexer configuration.
3.
1.
2.
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8.3.6 I/O mapping

Inputs and outputs can be changed later during operation. A new configuration of the
rotary indexing table is not necessary.
1. Click the red cross behind a terminal to delete the current terminal configuration.
` The red cross will be hidden.
` The "Assign" button that appears indicates that this terminal can be assigned to a
controller function.
2. Choose an available control function.
3. Assign the chosen control function to a terminal.
4. Write configuration.
` The I/O mapping configuration will be activated and the controller internal backup
file of the machine configuration will be replaced.
1.
2.
3.
4.
5.
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8.4 Maintenance
8.4 Maintenance
Fig. 46: Description of the "Maintenance" page
The "Maintenance" page contains the sections "Config + Diagnostic file" and "User
manager".
In the "Config + Diagnostic file" section, a diagnostic file can be requested as a text file,
and a configuration file can be requested as an XML file.
The "User manager" area is reserved for WEISS service personnel.

Access to this area is possible only by entering a user name and password. Neither of
the two is identical with the user name and password that were supplied with the control-
ler.
The configuration file or the diagnostic file are shown in a pop-up window.
Depending on the settings of the Web browser which is used, a pop-up

blocker may appear.
Blocking pop-ups may prevent the configuration file or the diagnostic file from being dis-
played.
To enable the display of the configuration file or the diagnostic file, you must disable the
pop-up blocker in your browser's settings.
Alternatively, you can add the pop-ups that display the configuration file or the diagnostic
file to the list of exceptions. This has no effect on all other Web sites whose pop-ups will
be blocked as they were before.
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8.4 Maintenance
8.4.1 Configuration file / Diagnostic file

8.4.1.1 Request diagnostic file
Fig. 47: Request diagnostic file
Click the button "Request diagnostic file" to request a text file.

This file can either be opened for viewing or saved on a PC.
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8.4 Maintenance
8.4.1.2 Request configuration file (controller internal backup file)
Fig. 48: Request configuration file (controller internal backup file)
By clicking the button " Request configuration file", the current configuration file can be
requested as an XML file.
This file can either be opened for viewing or saved on a PC.
This file contains all configuration settings that were made.
It can therefore be used as the controller internal backup file or to restore a configuration.
The function "Indexer configuration via file" (see chap. 8.3.1.2 „Indexer
configuration via file“ on page 74) can only be carried out if beforehand the configuration
file of a completely configured rotary indexing table was requested and stored.
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8.5 Operation and Monitoring

L Only authorized persons are allowed to access certain sections. User name and
password are supplied with the controller (chapter 8.1.2 „Access restrictions“ on
page 68).
8.5.1 I/O monitoring

In the "I/O monitoring" section, the following actions can be performed to monitor and
force peripheral inputs and/or outputs:
• Monitoring inputs and outputs
• Forcing via the "Request authority of control" button
• Forcing via the "Open separate user screen" button
8.5.1.1 Monitoring inputs and outputs
1.
Fig. 49: Monitoring inputs and outputs
The start page of the "I/O monitoring" section shows the status of the onboard inputs and
the peripheral inputs/outputs during operation with a higher-level controller.
This display is informative.
L To force peripheral inputs and/or outputs, it is necessary to request authority of
control or to open a separate user screen.
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8.5.1.2 Forcing via the "Request authority of control" button
2. 4.
3.
Fig. 50: Forcing via the "Request authority of control" button
With an separate user screen or second browser window open, forcing

can always only be carried out by the browser window from which the operating option
was requested.
1. Request authority of control (indicated by the yellow warning symbol in the window).
` The signals from a higher-level controller can be overwritten or forced - if there is
no controller.
2. Activate forcing for an input or output.
3. Set the force value for the activated input or output.
` The green light indicates that the process state is active.
4. Release authority of control after forcing is done.
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8.5.1.3 Forcing via the "Open separate user screen" button:
4.
2.
3.
1.
Fig. 51: Forcing via the "Open separate user screen" button
With an separate user screen or second browser window open, forcing

can always only be carried out by the browser window from which the operating option
was requested.
1. Open separate user screen.

` Opening a separate user screen can make it unnecessary to open a second brow-
ser window.
` Opening this window gives the user an operating option.
` The window underneath it is now only used for monitoring.
` The signals from a higher-level controller can be overwritten or forced - if there is
no controller.
2. Activate forcing for an input or output.
3. Set the force value for the activated input or output.
` The green light indicates that the process state is active.
4. Close the separate user screen.
` The operating option is ended by closing the window.
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8.5.2 Manual operation
Fig. 52: Manual operation: Start screen
In the "Manual operation" section, a rotary indexing table - which is decoupled from a hig-
her level controller - can be operated manually with following actions:
• Setting inputs
• Measuring cycle quick stop
• Optimization of stop delay time
• Continuous mode
L In order to operate a rotary indexing table manually, it is necessary to request
authority of control (1).
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8.5.2.1 Manual operation: Opening a second browser window
Fig. 53: Manual operation: Opening a second browser window
Sometimes it is helpful to open a second browser window during manual operation.

That enables manual operation in the window for which there is authority of control (1),
and also makes it possible to view other topics of the navigation in the second browser
window (2).
The procedure used to open a second browser window depends on the Web browser
which is used.
With a second browser window open, manual operation can only be

carried out by the browser window by which authority of control was requested.
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8.5.2.2 Manual operation: Setting inputs
2.
3.
4.
1. 5.
Fig. 54: Manual operation: Setting inputs
1. Request authority of control.

` The authority of control of the browser window is indicated by the yellow and black
frame around the input field.
2. Set the inputs "Enable" and "Stop low-active".
` These two inputs have to be set in order to enable manual operation.
3. The input "Reset error" can be used to reset any existing errors.
` The display changes from green to grey.
4. Operate inputs manually.
5. After finishing manual operation: Release authority of control.
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8.5.2.3 Manual operation: Measuring cycle quick stop
3.
4.
2.
5.
1. 6.
Fig. 55: Manual operation: Measuring cycle quick stop
The function "Measuring cycle quick stop" is used to determine the stopping time. The
measurement triggers movement (CW or CCW) of the rotary indexing table.
The result of the measurement is dependent on the mass moment of inertia of the load
and the rotary indexing table. The rotary indexing table must be able to rotate freely
during the measuring cycle.
2. Start "Measuring cycle quick stop" (CW and/or CCW)
` The stopping time is determined and displayed.
3. Confirm determined stopping time.
` The determined stopping time is then saved and - after restarting the controller - is
monitored during further operation.
4. IMPORTANT for SIL 3: Adjust a delay time which is longer than the measured stop-
ping time on the safety switching device.
5. Quit the "Measuring cycle quick stop" with OK.
The process must be repeated for every change of the rotary indexing
table (e.g. change of load).
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8.5.2.4 Manual operation: Optimization of stop delay time
2.
1. 3.
Fig. 56: Manual operation: Optimization of stop delay time
The "Optimization of stop delay time" function is used to calculate the optimal starting
time for the movement of the rotary indexing table.
The function can be applied for CW, CCW, and Jog movements.

2. Start the "Optimization of stop delay time" function.
` The determined stop delay time will be displayed in the dynamic parameters (see
chap. 8.3.5 „Dynamic parameters“ on page 92).
The process must be repeated for every change of the rotary indexing
table (e.g. change of load).
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8.5.2.5 Manual operation: Continuous mode
3. 2.
1. 4.
Fig. 57: Manual operation: Continuous mode
The "Continuous mode" function can be used to switch a rotary indexing table to a
demonstration mode.
The function can be applied for CW or CCW movements.

2. Enter a time (in seconds) for the waiting time in stopover.
` Waiting time in stopover = time between two cycle commands
3. Start and stop "Continuous mode" function.
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8.5.3 Statistical data
1.
2
Fig. 58: Statistical data
The "Statistical data" section shows statistical data that was recorded during operation.
In this section, a number of cycles (1) for the rotary indexing table can be set as a service
interval.
The rotary indexing table cycles are counted and the counter value is displayed in the
"Current counter service interval" (2).
The following counter values can be reset by the operator - e.g. after performing service
(2).
` Current counter service interval
` Cycle counter (counter of user)
` Counter of incorrect power supply switches (counter of user)
L All other data is informative for the operator and can only be reset by the service
personnel from WEISS GmbH.
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8.5.4 Messages
Fig. 59: Messages
The "Messages" section displays active and stored error messages.

` The "Active messages" window displays all current messages that have not been
acknowledged yet.
` The "Message archive" window displays the last 20 error messages.
By clicking the respective button (1) it is possible to switch between the two windows.
Active messages can be acknowledged by clicking the acknowledge button (2).
8.5.5 Siemens default pages

L The "Siemens default pages" section is reserved exclusively for service personnel
from WEISS GmbH and is not accessible for the operator.
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8.6 Help
8.6 Help
Fig. 60: Help
The "Help" section contains contact information, manuals, and product information.
In the "CONTACT" section you will find the address, phone number and e-mail address
of WEISS GmbH.
The "Documentation" section contains

• WEISS manuals
` Technical documentation of the TC and TR Rotary Indexing Tables
• SIEMENS manuals
` Technical documentation of the Siemens components
• GSD files
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Communication with a higher-level controller 9
9.1 Profibus DP
9 Communication with a higher-level controller
System requirements:
Automation software Step 7
as of software version V5.5
9.1 Profibus DP
The following example describes the connection of a SIMOTION D 410-2 DP/PN with a
SIMATIC S7 315-2 PN/DP. For this purpose, the SIMOTION is connected to the DP
master system as a standard slave using a GSD file. The X21 interface on the SIMO-
TION should be used here. Integrating a SIMATIC S7 315 CPU into an existing project is
not described in this manual, and is considered a prerequisite for further action.
Procedure:
• Import GSD file into STEP 7 HW Config. To do so, double-click "Hardware" in the wor-
king area of the SIMATIC manager.
• Import the GSD file via the Options menu - Install GSD file in STEP 7 HW Config.
Afterwards, the SIMOTION will appear in the HW catalogue under "PROFIBUS DP/
ADDITIONAL FIELD DEVICES/PLC/SIMOTION, from where it can be dragged and
dropped onto a DP master system of an S7 station.
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9.1 Profibus DP
• By double-clicking slot 4 or 5, the start address proposed by HW Config can be reas-

signed to the desired address.
• By double-clicking the DP slave SIMOTION, the PROFIBUS DP address proposed by

HW Config can be reassigned to the desired address. In this case, the preset value is
PROFIBUS address 3. Any changes must also be considered in the machine configu-
ration on the Web interface of the SIMOTION.
L Baudrates of 187.5 kbit to 12 Mbit are possible.
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9.1 Profibus DP
• Afterwards, the station has to be saved and translated. If the translation is free of
errors, the station can be loaded into the S7 controller.
• To test the configured connection, a corresponding variable table can be created in
the SIMATIC Manager.
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9.1 Profibus DP
9.1.1 Interface X21

Representation Pin Name Type Description
2 M VO Ground to P24_SERV
3 1RS_DP B RS-485 differential signal
5
9
4 1RTS_DP O Request to send
4 5 1M VO Ground to 1P5
8
5 V power supply for bus terminal,
3 6 1P5 VO
7 external, short-circuit proof
2
24 V for teleservice, short-circuit
6 7 P24_SERV VO
1
proof, 150 mA maximum
8 1XRS_DP B RS-485 differential signal
The 1P5 voltage is provided exclusively for the bus terminal.
No OLPs are permitted.
Signal type: VO = Voltage output (power supply); O = Output; B = Bidirectional
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9.2 Profinet IO RT
9.2 Profinet IO RT
The following example describes the connection of a SIMOTION D 410-2 DP/PN with a
SIMATIC S7 315-2 PN/DP. For this purpose, the SIMOTION is connected to the PROFI-
NET IO system as an I device using a GSDML file. The X150 P1 or P2 on the SIMOTION
should be used as the interface in this case. Integrating a SIMATIC S7 315 CPU into an
existing project is not described in this manual, and is considered a prerequisite for fur-
ther action. For the I device of a SIMOTION V4.3, an S7-300 CPU must have at least
firmware V3.2 or higher, an S7-400 CPU must have at least firmware V6.0 or higher.
Both the IP address which is used and the subnet of the SIMATIC controller must be
considered in the machine configuration on the Web interface of the SIMOTION control-
ler.
Procedure:
• Import the GSDML file into STEP 7 HW Config. To do so, double-click "Hardware" in
the working area of the SIMATIC manager.
• Close the open station and then import the GSDML file into STEP 7 HW Config via
the Options menu - Install GSD files.
• A dialog box will appear for selection of the source folder with the GSDML file to
install. Please select the source folder and confirm with OK.
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9.2 Profinet IO RT
• In the following dialog, select the desired GSDML file and accept it by pressing the
"Install" button in the HW catalogue of HW Config.
• Afterwards, the SIMOTION will appear in the HW catalogue from where it can be
dragged and dropped onto a PROFINET IO system of an S7 station.
• Double-clicking the pasted I device opens the properties dialog box. Here, the device
name proposed by HW Config "unnamed" can now be changed to the desired name.
The new device name must also be considered in the machine configuration on the
Web interface of the SIMOTION.
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9.2 Profinet IO RT
Rules for assigning names:

• Only lowercase letters
• Letters a-z and numbers 0-9 are permitted
• Special characters are not allowed: !"§$%&/()=?`*'_:;#+<>|~[]{}
• Spaces are not allowed either
• The name can have a maximum total length of 240 characters
• Reserved names which cannot be used:
` "port-xyz" or "port-xyz-abcde…"
• The engineering system replaces unpermitted characters with an "x".
• The check in front of "Assign IP address via controller" must be removed.

• By double-clicking slot 2.1000 or 2.1001, the start address proposed by HW Config
can be reassigned to the desired address.
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9.2 Profinet IO RT
• Afterwards, the station has to be saved and translated. If the translation is free of
errors, the station can be loaded into the S7 controller.
• To test the configured connection, a corresponding variable table can be created in
the SIMATIC Manager.
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9.2 Profinet IO RT

PROFINET is an open component-based industrial communication system using Ether-
net for distributed automation systems.
SIMOTION D410-2 DP/PN has a PROFINET interface with two ports (X150 P1-P2)
onboard. The PROFINET interface supports operation of a SIMOTION D410-2 DP/PN as
an IO controller and/or as an I device.
Representation Pin Name Description

1 TXP Output Transmit data +
2 TXN Output Transmit data -
3 RXP Input Receive data +
6 RXN Input Receive data -
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10 Diagnostics
10.1 Messages
10 Diagnostics
10.1 Messages
States of the rotary indexing table
Rotary indexing table is not ready
Possible causes
NOT_READY • Controller is not in RUN
• Failed to initialize the CF card
• Table is not configured
Executing the quick stop that is controlled via the DI 9
STOP_EMERGENCY
(terminal X121.8)
Controlling the safety function STO via F-DI0
SAFE_TORQUE_OFF
(terminal X120.3-X120.5)
WAIT_FOR_ACKNOWLEDGE_ERROR At least one unacknowledged error is still active
WAIT_FOR_ENABLE Waiting for enable to be set
WAIT_FOR_SET_NOSTOP_INPUT Waiting for setting the stop input (low active)
Waiting for the resetting of at least one control bit that is still
WAIT_FOR_RESET_COMMAND_BITS
current
WAIT_FOR_COMMAND_BIT Waiting for the setting of a control bit
The rotary indexing table is executing a sent control command;
RUNNING
the table is moving
The rotary indexing table is executing the measuring cycle
RUNNING_MEASURECYCLE_QUICKSTOP
quick stop function
The rotary indexing table is executing the measuring cycle stop
RUNNING_MEASURECYCLE_DELAYTIME
delay time function
STOPOVER_DELAY_TIME_RUNNING Stopover during execution of the continuous mode
Reserved for future applications
ENERGY_SAFE_MODE Energy-saving mode of the rotary indexing table is active
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Diagnostics 10
10.2 Error and state indicators
10.2 Error and state indicators

L The LED displays are located next to the CompactFlash card plug-in slot on the
SIMOTION D410-2.
The following table describes the LEDs and their meanings.
LED display
LED Description
Status indicator of the SINAMICS Inte-
RDY
grated
RUN/STOP SIMOTION D410-2 operating states
Encoder current supply > 5 V (TTL/
HTL)
OUT > 5V/SY Synchronization status (SY) of the
onboard PROFINET IO interface
(X150)
SF/BF Group error / bus error
LED status
LED Colour Description
System startup
orange
RDY Drive not ready for operation
green Drive ready for operation
orange STOP
RUN/STOP
green RUN
OUT > 5V/SY - Not relevant for EF2
Continuous red light Error
SF/BF Flashing red 0.5 Hz IT license missing
Flashing red 2.0 Hz Bus error
L For information about diagnostics using LED displays, refer to the SIMOTION
D410-2 Commissioning and Hardware Installation Manual, Section "Diagnostics
using LED displays".
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10 Diagnostics
10.3 Error messages
10.3 Error messages

Event
Category Reaction Event text Cause Remedy
number
Check power supply
The DC-link voltage of the
Incoming supply is not Check supply voltage
1 Error 2 power unit cannot be
ready level
precharged.
Replace power unit
The "Enable" signal was
Input "Enable" removed removed during opera-
2 Error 4 Check control logic
during operation tion of the rotary indexing
table.
Simultaneous selection of
Multiple control com-
3 Error 1 multiple control com- Check control logic
mands were executed.
mands
Control command is not The special mode is Deactivate "Special
4 Error 1 available when the spe- active when the control mode" and activate
cial mode is selected. command is selected. control command again
Check temperature
Temperature sensor not
5 Error 1 Motor overtemperature sensor connection and
connected or defect
function
Check brake supply
voltage
Brake relay supply The brake relay cannot be
6 Error 3 Check wiring of feed-
voltage faulty controlled properly.
back signal of the
brake relay
Check if configuration
"Evaluate additional
In the configuration "Eva- motor contactor " is
luate additional motor correct.
Motor contactor feedback
7 Error 4 contactor", the feedback
error
from the motor contactor Check if the feedback
cannot be evaluated. contact of the motor
contactor is wired cor-
rectly.
There was a timeout Check the dynamic
Time monitoring error in parameter settings.
8 Error 3 during execution of the
sequencer
program. Contact WEISS GmbH
Deactivate "Conti-
Control command is not The continuous mode is
nuous mode" and acti-
9 Error 1 available when the spe- active when the control
vate control command
cial mode is selected. command is selected.
again
Simultaneous selection of
"Special mode" and "Con-
"Special mode" and "Con- Deactivate one of the
10 Error 1 tinuous mode" are selec-
tinuous mode" is not sup- two commands.
ted simultaneously.
ported.
After switching off the
Unauthorized switch-on Observe stop time
power supply, a defined
11 Error 1 cycles while precharging before switching on
stop time must be obser-
the DC link again
ved
The sensor was overrun Check the dynamic
12 Error 3 position overrun
at the end of the cycle. parameter settings.
120/144 Manual EF2 R01-2013

Diagnostics 10
10.3 Error messages
Event
number
Check if mechanical
components run
Time monitoring for the smoothly
13 Error 3 Movement timeout
cycle has been triggered.
Check feedback of the
sensor signal
The motor contactor was Check electrical con-
Motor contactor switched
14 Error 4 switched during move- nection of the motor
under load
ment. contactor
The shutdown of the drive
during an emergency-off Check the load of the
Stopping was not possi- is monitored. If the stop- rotary indexing table
15 Error 4 ble within the calculated ping time cannot be kept, Execute the "Measu-
monitoring time. the drive will be switched ring cycle quick stop"
torque-free by the soft- function again.
ware.
Check the motor con-
Error determining the The monitoring time for nection
monitoring time of the the quick stop cannot be Check the load of the
16 Info -1
measuring cycle quick determined using the rotary indexing table
stop measuring cycle function. Repeat measuring
cycle quick stop
The configuration data is
Configuration data of the checked by the software
17 Info -1 rotary indexing table is for plausibility and, if None
limited necessary, adjusted auto-
matically.
Check validity of the IP
address and of the
subnet mask
Check gateway
The configuration of the The configuration must
Error in Ethernet configu-
18 Info -1 Ethernet interface cannot not be within the sub-
ration net of the Profinet
be set.
interface. Set the
default IP address via
the input for selecting
the default IP configu-
ration.
Switch controller on
Error reading out the The device supply voltage and off
19 Info -1
device supply voltage cannot be read.
Contact WEISS GmbH
Manual EF2 R01-2013 121/144

10 Diagnostics
10.3 Error messages
Event
number
address and of the
subnet mask
Check gateway
Ethernet configuration The configuration of the The configuration must
20 Info -1 cannot be set when star- Ethernet interface cannot not be within the sub-
ting the controller. be set. net of the Profinet
interface. Set the
default IP address via
the input for selecting
the default IP configu-
ration.
Profibus configuration The configuration of the
21 Info -1 cannot be set when star- Profibus interface cannot Contact WEISS GmbH
ting the controller. be set.
address and of the
Profinet configuration The configuration of the subnet mask
22 Info -1 cannot be set when star- Profinet interface cannot The configuration must
ting the controller. be set. not be within the sub-
net of the Ethernet
interface.
The Profinet device name The device name of the
Check the validity of
23 Info -1 cannot be set when star- Profinet interface cannot
the device name.
ting the controller. be set.
Timeout when booting the Parts of the controller Switch controller on
24 Info -1 controller internal drive were not able to finish and off
system startup on time. Contact WEISS GmbH
The maximum permissi- The motor contactor is
ble number of switching only allowed to perform a Replace the motor con-
25 Info -1 cycles of the motor con- certain number of cycles tactor and reset the
tactor has been excee- in order to maintain the counter.
ded. safety function.
The number of rotary
indexing table cycles for a The service interval must Carry out service inter-
26 Info -1
service interval has been be carried out. val
reached.
Check dynamic para-
The sensor was overrun meters
Optimization of stop delay
27 Error 3 during optimization of
time: position overrun Execute optimization
stop delay time.
again
Check dynamic para-
It is not possible to deter- meters
Error during optimization
28 Error 3 mine a optimized stop
of stop delay time Execute optimization
delay time.
again
The CF card does not
Invalid CF card serial
29 Info -1 contain a valid serial num- Contact WEISS GmbH
number
ber.
The initialization file of the
Failed to load the initiali-
30 Info -1 controller cannot be Contact WEISS GmbH
zation file
loaded.
122/144 Manual EF2 R01-2013

Diagnostics 10
10.3 Error messages
Event
number
Failed to save the initiali-
zation file
saved.
Failed to initialize the CF The CF card cannot be
32 Info -1 Contact WEISS GmbH
card initialized.
The initialization file could
not be found.
found.
After the initialization file
Waiting for the controller
is created, the controller Switch controller on
34 Info -1 to restart after saving the
has to be switched off and and off
initialization file
on again.
The configuration cannot
Error while deactivating be created for the inter-
35 Info -1 the PROFIBUS Dummy face configurations "Profi- Contact WEISS GmbH
DP Slave. net" and "Terminal/
TM15".
The sensor monitor was
Sensor switches (leaving
triggered while the rotary Check function of the
36 Error 4 the sensor during stand-
indexing table was stan- sensor
still)
ding still.
A braking resistor is requi- Connect the braking
Braking resistor is requi-
37 Info -1 red to operate the rotary resistor
red
indexing table. Minimize load
Acknowledge error on
the Weiss user inter-
Unauthorized switch-on face on the Statistical
cycles while precharging After switching off the data page with pass-
the DC link power supply, a defined word level for Operator;
38 Info 1
Acknowledgeable only by stop time must be obser- afterwards the error
OPERATOR on the ved can be acknowledged.
Weiss user interface Observe stop time
before switching on
again
Acknowledge error on
the Weiss user inter-
face on the Statistical
Unauthorized switch-on data page with pass-
cycles while precharging After switching off the word level for Service;
the DC link power supply, a defined afterwards the error
39 Info 1
Acknowledgeable only by stop time must be obser- can be acknowledged
SERVICE on the Weiss ved Contact WEISS GmbH
user interface
Observe stop time
before switching on
again
Wait out the waiting
Waiting time after After switching off the time and acknowledge
unauthorised switch-on power supply, a defined error
40 Info 1
cycle when precharging stop time must be obser- Observe stop time
the DC link ved before switching on
again
Manual EF2 R01-2013 123/144

10 Diagnostics
10.3 Error messages
Description of the reactions

-1 No reaction
Execution of a quick stop and subsequent cancellation of the "Enable" signal as the reaction to a
0
system error
1 Execution of a stop after cycle end
2 Execution of a quick stop without cancellation of the "Enable" signal
3 Execution of a quick stop and subsequent cancellation of the "Enable" signal
4 Drive coasts down immediately
124/144 Manual EF2 R01-2013

Standards and approvals 11
11.1 CE marking
11 Standards and approvals
11.1 CE marking
Our products satisfy the requirements and protection objectives of

the EC Directives and comply with the harmonized European stan-
dards (EN).
11.2 Electromagnetic compatibility

Standards for EMC are satisfied, if the EMC Installation Guideline is observed.
SIMOTION products are designed for industrial use in accordance with product standard
DIN EN 61800-3:2004, Category C3.
Category C3 is complied with:
• used cable length < 15 m
• network impedance (e.g. uk) = 1%
L Superior categories can be achieved by using additional provisions.
USA
This equipment has been tested and found to comply with the
limits for a Class A digital device, pursuant to Part 15 of the FCC
Rules.
Federal These limits are designed to provide reasonable protection against
Communications harmful interference when the equipment is operated in a commer-
Commission cial environment.
Radio This equipment generates, uses, and can radiate radio frequency
Frequency energy and, if not installed and used in accordance with the
Interference instruction manual, may cause harmful interference to radio com-
Statement munications.
Operation of this equipment in a residential area is likely to cause
harmful interference in which case the user will be required to cor-
rect the interference at his own expense.
Shielded cables must be used with this equipment to maintain
Shielded Cables
compliance with FCC regulations.
Changes or modifications not expressly approved by the manufac-
Modifications
turer could void the user’s authority to operate the equipment.
This device complies with Part 15 of the FCC Rules.
Conditions of Operation is subject to the following two conditions: (1) this device
Operations may not cause harmful interference, and (2) this device must
accept any interference received, including interference that may
cause undesired operation.
CANADA
Canadian Notice This Class B digital apparatus complies with Canadian ICES-003.
Manual EF2 R01-2013 125/144

11 1
Standards and approvals
2
11.3 cULus approval
SOUTH KOREA
For sellers or other users, please keep in mind that this device is an A-grade electroma-
gnetic wave device. This device is intended to be used in areas other than at home.
The EMC limit values to be observed for Korea correspond to the limit values of the
EMC product standard for variable-speed electric drives EN 61800-3 of category C2 or
the limit value class A, Group 1 to EN55011.
By implementing appropriate additional measures, the limit values according to category
C2 or limit value class A, Group 1, are observed.
For this purpose, additional measures, such as the use of an additional RFI suppression
filter (EMC filter) may be necessary.
In addition, measures for EMC-compliant configuration of the system are described in
this Manual and/or the Configuration Manual "EMC Installation Guideline".
Please note that it is ultimately always the label on the device that provides the relevant
information about the compliance with standards.
AUSTRALIA
D410-2 DP and D410-2 DP/PN meet the requirements of the

AS61800-3.
11.3 cULus approval
Listed component mark for United States and the Canada Under-
writers Laboratories (UL) according to Standard UL 508, File
E164110, File E115352, File E85972.
126/144 Manual EF2 R01-2013

1 2 3 4 5 6 7 8
12
L1 L1
N N
PE PE
/2.1
+24 DC +24 DC
/2.1
Manual EF2 R01-2013

1
-F1
10 A 2
Appendix
L1 N PE R1
Siemens
Bremswiderstand
brake resistor
(optional) Siemens
Frequenzumrichter 0,37kW
frequency inverter
Simotion
D 410-2
CTRL
Sinamics S120
Power Module PM340 monitoring 24 V brake relay
/2.8
Power 0,37 Kw
PE thermo-click DI 0
/2.8
limit switch DI 8
/2.8
U2 V2 W2 R2 PE PE
PE
12.1.1 SIL2 Power Module connection example
B-R2
B+R1
Bremsrelais
brake relay
18 - 30 VDC
CTRL
12.1 EF2; 0.37 kW Controller connection examples
+ + - -
BR-
BR+
black
brown
PE
Appendix
drive motor indexer 3 x 230 V

- +
blue
U V W PE
blue
brown
delta connection M
Θ 3 A
thermo-click
brake limit switch

indexer in position
1
2
- -
/2.1
06.02.2013 ahorn Datum 02.02.2013 Anlage

Weiss GmbH EF2 0,37 kw Kunde: Weiss GmbH
Bearb. ahorn Ort
Siemensstraße 17 1
Gepr. Blatt-Nr.
74722 Buchen/Odw. wiring example SIL 2 POWER MODUL Version 1.0
Zustand Änderung Datum Name Norm Bl von Anz 1/3
12
127/144
12
128/144
1 2 3 4 5 6 7 8
/1.8
+24 DC +24 DC
/3.1
1
2
Power Module PM340

DRIVE-CLIQ
/3.1
X100 DQ P1 X150 PN (LAN) P2

11 21
P1 P2
control contact
NOT-HALT X21DP/MPI
12 22
+ Simotion
D 410-2
+ RDY
- RUN/STOP
- OUT>5V/SY
X124 SF/BF
X120 X121
Appendix
1 1 thermo-click DI 0
/1.8
STO DI 16
12.1.2 SIL2 PLC connection example
CF
STO DI 17
limit switch DI 8
/1.8
quick-stop DI 9
Default IP
controller RUN DO 11
12 12
X130 X131 1 monitoring 24 V brake relay
1
/1.8
8 8
X127 LAN
/1.8
- -
/3.1
/1.8
PE PE
/3.1

Bearb. ahorn Ort
Siemensstraße 17 2
Gepr. Blatt-Nr.
74722 Buchen/Odw. wiring example SIL 2 PLC Version 1.0
Manual EF2 R01-2013

1 2 3 4 5 6 7 8
/2.8
+24 DC +24 DC
-X501 DRIVE-CLIQ
Manual EF2 R01-2013

/2.8
DRIVE-CLIQ
-X500
-
-
-X524 +
+
L1 + TM 15
DI 0
DI 0 RDY
DI 1
DI 1
DI 2
DI 2
DI 3
DI 3 -X520
DI 4
DI 4
DI 5
DI 5
DI 6
DI 6
DI 7
DI 7
M1
L2 +
DI 8
DI 8
DI 9
DI 9
DI 10
DI 10
DI 11
DI 11 -X521
DO 0
DO 0
DO 1
DO 1
DO 2
DO 2
DO 3
DO 3
M2
L3 +
DO 4
DO 4
DO 5
DO 5
DO 6
DO 6
DO 7
DO 7 -X522
DO 8
DO 8
DO 9
DO 9
DO 10
DO 10
DO 11
DO 11
M3
12.1.3 SIL2 Interface I/O Module TM15 (option) connection example
Appendix
/2.8
- -
/2.8
PE PE
1
2

Bearb. ahorn Ort
Siemensstraße 17 3
Gepr. Blatt-Nr.
74722 Buchen/Odw.
12
Zustand Änderung Datum Norm Interface I/O Modul TM 15 (optional) Version 1.0
Name Bl von Anz 3/3
129/144
12
130/144
1 2 3 4 5 6 7 8
L1 L1
N N
1
2
PE PE
/2.1
+24 DC +24 DC
/2.1
1
-F1
10 A 2
L1 N PE R1
Siemens
Bremswiderstand
brake resistor
(optional) Siemens
Frequenzumrichter 0,37kW
frequency inverter
Simotion
Appendix
D 410-2
CTRL
Sinamics S120
/2.8
Power 0,37 Kw
/2.8
limit switch DI 8
/2.8
U2 V2 W2 R2 PE PE
PE
B-R2
B+R1
Bremsrelais
brake relay 1 3 5
18 - 30 VDC
CTRL
-K1
/2.2
2 4 6
+ + - -
BR-
BR+
black
brown
PE
drive motor indexer 3 x 230 V - +
blue
U V W PE
blue
brown
delta-connection Θ M
3 A
thermo-click
brake limit switch

-
indexer in position
-
/2.1

Bearb. ahorn Ort
Siemensstraße 17 1
Gepr. Blatt-Nr.
Manual EF2 R01-2013

1 2 3 4 5 6 7 8
/1.8
+24 DC +24 DC
/3.1
control contact
NOT - HALT Power Module PM340
Manual EF2 R01-2013

channel 1 channel 2 DRIVE-CLIQ
/3.1
P1 P2
A1+ Y11 Y12 Y21 Y22 Y32 Y35 1
X21DP/MPI
safety switching dev
Sicherheitsschaltgerät + Simotion
D 410-2
3TK2842-1BB41 + RDY
- RUN/STOP
- OUT>5V/SY
X124 SF/BF
A2- 14 28 Y34 X120 X121
/1.8
STO DI 16
monitoring motor contactor DI 3
CF
STO DI 17
limit switch DI 8
/1.8
quick-stop DI 9
Default IP
controller run DO 11
12 12
1
/1.8
A1 21NC
-K1
8 8
3RT2017-1BB42 -K1
A2 2
motor contactor 22NC
X127 LAN
Appendix
/1.8
- -
/3.1
/1.8
PE PE
/3.1
1
2
1 2
/1.7
3 4
/1.7
5 6
/1.7
21NC 22NC
3

Bearb. ahorn Ort
Siemensstraße 17 2
Gepr. Blatt-Nr.
12

131/144
12
132/144
1 2 3 4 5 6 7 8
/2.8
+24 DC +24 DC
1
2
-X501 DRIVE-CLIQ
/2.8
DRIVE-CLIQ
-X500
-
-
-X524 +
+
L1 + TM 15
DI 0
DI 0 RDY
DI 1
DI 1
DI 2
DI 2
DI 3
DI 3 -X520
DI 4
DI 4
DI 5
Appendix
DI 5
DI 6
DI 6
DI 7
DI 7
M1
L2 +
DI 8
DI 8
DI 9
DI 9
DI 10
DI 10
DI 11
DI 11 -X521
DO 0
DO 0
DO 1
DO 1
DO 2
DO 2
DO 3
DO 3
M2
L3 +
DO 4
DO 4
DO 5
DO 5
DO 6
DO 6
DO 7
DO 7 -X522
DO 8
DO 8
DO 9
DO 9
DO 10
DO 10
DO 11
DO 11
M3
/2.8
- -
/2.8
PE PE

Bearb. ahorn Ort
Siemensstraße 17 3
Gepr. Blatt-Nr.
74722 Buchen/Odw. Interface I/O Modul TM 15 (optional) Version 1.0
Manual EF2 R01-2013

1 2 3 4 5 6 7 8
L1 L1
L2 L2
L3 L3
Manual EF2 R01-2013

PE PE
/2.1
+24 DC +24 DC
/2.1
1 3 5
-F1
10A....16A 2 4 6
L1 L2 L3 PE R1
Siemens
Bremswiderstand
brake resistor
(optional) Siemens
Frequenzumrichter 1,5 - 3 kW
frequency inverter
Simotion
D 410-2
CTRL
Sinamics S120
/2.8
Power 1,5 - 3 Kw
/2.8
limit switch DI 8
/2.8
U2 V2 W2 R2 PE PE
PE
B-R2
B+R1
Bremsrelais
brake relay
18 - 30 VDC
CTRL
12.2 EF2; 1.5 kW to 3.0 kW Controllers connection examples
Appendix
+ + - -
BR-
BR+
black
brown
PE
1
drive motor indexer 3 x 400 V

2
- +
blue
U V W PE
blue
brown
star-connection M
Θ 3 A
thermo-click
brake limit switch

-
indexer in position
-
/2.1

Weiss GmbH EF2 1,5 - 3 kw Kunde: Weiss GmbH
Bearb. ahorn Ort
Siemensstraße 17 1
Gepr. Blatt-Nr.
12

133/144
12
134/144
1 2 3 4 5 6 7 8
/1.8
+24 DC +24 DC
/3.1
1
2
Power Module PM340

DRIVE-CLIQ
/3.1

11 21
P1 P2
control contact
NOT-HALT X21DP/MPI
12 22
+ Simotion
D 410-2
+ RDY
- RUN/STOP
- OUT>5V/SY
X124 SF/BF
Appendix
X120 X121 thermo-click DI 0

1 1
/1.8
STO DI 16
CF
STO DI 17
limit switch DI 8
/1.8
quick-stop DI 9
Default IP
12 12
1
/1.8
8 8
X127 LAN
/1.8
- -
/3.1
/1.8
PE PE
/3.1

Bearb. ahorn Ort
Siemensstraße 17 2
Gepr. Blatt-Nr.
Manual EF2 R01-2013

1 2 3 4 5 6 7 8
/2.8
+24 DC +24 DC
-X501 DRIVE-CLIQ
Manual EF2 R01-2013

/2.8
DRIVE-CLIQ
-X500
-
-
-X524 +
+
L1 + TM 15
DI 0
DI 0 RDY
DI 1
DI 1
DI 2
DI 2
DI 3
DI 3 -X520
DI 4
DI 4
DI 5
DI 5
DI 6
DI 6
DI 7
DI 7
M1
L2 +
DI 8
DI 8
DI 9
DI 9
DI 10
DI 10
DI 11
DI 11 -X521
DO 0
DO 0
DO 1
DO 1
DO 2
DO 2
DO 3
DO 3
M2
L3 +
DO 4
DO 4
DO 5
DO 5
DO 6
DO 6
DO 7
DO 7 -X522
DO 8
DO 8
DO 9
DO 9
DO 10
DO 10
DO 11
DO 11
M3
Appendix
/2.8
- -
/2.8
PE PE
1
2

Bearb. ahorn Ort
Siemensstraße 17 3
Gepr. Blatt-Nr.
74722 Buchen/Odw.
12
Zustand Änderung Datum Norm Interface I/O Modul TM 15 (optional) Version 1.0
Name Bl von Anz 3/3
135/144
12
136/144
1 2 3 4 5 6 7 8
L1 L1
L2 L2
L3 L3
1
2
PE PE
/2.1
+24 DC +24 DC
/2.1
1 3 5
-F1
10A....16A 2 4 6
L1 L2 L3 PE R1
Siemens
Bremswiderstand
brake resistor
(optional) Siemens
Frequenzumrichter 1,5 - 3 kW
frequency inverter
Simotion
Appendix
D 410-2
CTRL
Sinamics S120
/2.8
Power 1,5 - 3 Kw
/2.8
limit switch DI 8
/2.8
U2 V2 W2 R2 PE PE
PE
B-R2
B+R1
Bremsrelais
brake relay 1 3 5
18 - 30 VDC
CTRL
-K1
/2.2
2 4 6
+ + - -
BR-
BR+
black
PE
brown
drive motor indexer 3 x 400 V - +

blue
U V W PE
blue
brown
star-connection M
Θ 3 A
thermo-click
brake limit switch

-
indexer in position
-
/2.1

Bearb. ahorn Ort
Siemensstraße 17 1
Gepr. Blatt-Nr.
Manual EF2 R01-2013

1 2 3 4 5 6 7 8
/1.8
+24 DC +24 DC
/3.1
control contact
NOT - HALT Power Module PM340
Manual EF2 R01-2013

channel 1 channel 2 DRIVE-CLIQ
/3.1
P1 P2
A1+ Y11 Y12 Y21 Y22 Y32 Y35 1
X21DP/MPI
safety switching dev
Sicherheitsschaltgerät + Simotion
D 410-2
3TK2842-1BB41 + RDY
- RUN/STOP
- OUT>5V/SY
X124 SF/BF
A2- 14 28 Y34 X120 X121
/1.8
STO DI 16
monitoring motor contractor DI 3
CF
STO DI 17
limit switch DI 8
/1.8
quick-stop DI 9
Default IP
12 12
1
/1.8
A1 21NC
-K1
8 8
3RT2017-1BB42 -K1
A2 2
motor contractor 22NC
X127 LAN
Appendix
/1.8
- -
/3.1
/1.8
PE PE
/3.1
1
2
1 2
/1.7
3 4
/1.7
5 6
/1.7
21NC 22NC
3

Bearb. ahorn Ort
Siemensstraße 17 2
Gepr. Blatt-Nr.
12

137/144
12
138/144
1 2 3 4 5 6 7 8
/2.8
+24 DC +24 DC
1
2
-X501 DRIVE-CLIQ
/2.8
DRIVE-CLIQ
-X500
-
-
-X524 +
+
L1 + TM 15
DI 0
DI 0 RDY
DI 1
DI 1
DI 2
DI 2
DI 3
DI 3 -X520
DI 4
DI 4
DI 5
Appendix
DI 5
DI 6
DI 6
DI 7
DI 7
M1
L2 +
DI 8
DI 8
DI 9
DI 9
DI 10
DI 10
DI 11
DI 11 -X521
DO 0
DO 0
DO 1
DO 1
DO 2
DO 2
DO 3
DO 3
M2
L3 +
DO 4
DO 4
DO 5
DO 5
DO 6
DO 6
DO 7
DO 7 -X522
DO 8
DO 8
DO 9
DO 9
DO 10
DO 10
DO 11
DO 11
M3
/2.8
- -
/2.8
PE PE

Bearb. ahorn Ort
Siemensstraße 17 3
Gepr. Blatt-Nr.
74722 Buchen/Odw. Interface I/O Modul TM 15 (optional) Version 1.0
Manual EF2 R01-2013

Appendix
1 12
2
12.3 Illustration index

Controller components .................................................................................................................... 8
Block diagram of EF2 controller ...................................................................................................... 9
Interfaces of Power Module PM340; frame size FSA / 0.37 kW ................................................... 18
Interfaces of Power Module PM340; frame size FSA / 1.5 kW ..................................................... 19
Interfaces of Power Module PM340; frame size FSB ................................................................... 20
Overview Power Module PM340 ................................................................................................... 22
Interfaces and front elements of the Control Unit D410-2 DP / PN ............................................... 23
Interfaces of the TM15 Terminal Module ...................................................................................... 26
Interfaces of the Brake Relay ........................................................................................................ 27
Brake Relay connection example .................................................................................................. 28
Motor Contactor 3RT2017-1BB42 ................................................................................................. 29
Sirius Safety Relay ........................................................................................................................ 30
Load diagram for braking resistors in blocksize format ................................................................. 32
Terminal Module TM15 connection example ................................................................................ 36
SIL 3 - basic concept ..................................................................................................................... 44
SET screen: Calculation for FC ..................................................................................................... 45
SET screen: Calculation for motor contactor ................................................................................ 45
SIL 3 - Solution with motor contactor and safety relay .................................................................. 46
Dimensions of Power Module PM340; frame size FSA ................................................................ 49
Dimensions of Power Module PM340; frame size FSB ................................................................ 50
Terminal block for the line supply connection 1 AC 200 V - 240 V / 0.37 kW ............................... 51
Terminal block for the line supply connection 3 AC 380 V - 480 V / 1.5 kW ................................. 51
Terminal block for the line supply connection 3 AC 380 V - 480 V / 2.2 - 3.0 kW ......................... 52
Motor connection PM340, frame size FSA / 0.37 kW ................................................................... 53
Motor connection PM340, frame size FSA / 1.5 kW ..................................................................... 54
Motor connection PM340, frame size FSB / 2.2 - 3.0 kW ............................................................. 55
Connecting the motor cable to the motor ...................................................................................... 56
Connection of Braking Resistor PM340, frame size FSA .............................................................. 57
Braking Resistor Connection PM340, frame size FSB.................................................................. 58
Mechanical assembly of Control Unit D410-2 ............................................................................... 59
Mechanical disassembly of Control Unit D410-2 .......................................................................... 59
Inserting the CF card into the D410-2 Control Module .................................................................. 60
Shield connection of Control Unit D410-2 ..................................................................................... 61
Mounting Terminal Module TM15 ................................................................................................. 62
PC - EF2 Controller connection .................................................................................................... 63
Adjusting the Internet options ........................................................................................................ 63
Changing the adapter settings ...................................................................................................... 64
Entering the IP address of the EF2 controller ............................................................................... 66
Start page of the EF2 controller .................................................................................................... 66
Description of the user interface of the EF2 controller .................................................................. 67
Enter user name and password .................................................................................................... 68
Description of the "Overview" page ............................................................................................... 69
EF2 configuration diagram ............................................................................................................ 70
Configuring the Ethernet interface ................................................................................................ 71
Comment regarding indexer configuration data file ...................................................................... 76
Description of the "Maintenance" page ......................................................................................... 94
Request diagnostic file .................................................................................................................. 95
Request configuration file (controller internal backup file) ............................................................ 96
Monitoring inputs and outputs ....................................................................................................... 97
Forcing via the "Request authority of control" button .................................................................... 98
Forcing via the "Open separate user screen" button .................................................................... 99
Manual operation: Start screen ................................................................................................... 100
Manual operation: Opening a second browser window .............................................................. 101
Manual operation: Setting inputs ................................................................................................. 102
Manual operation: Measuring cycle quick stop ........................................................................... 103
Manual operation: Optimization of stop delay time ..................................................................... 104
Manual operation: Continuous mode .......................................................................................... 105
Statistical data ............................................................................................................................. 106
Messages .................................................................................................................................... 107
Help ............................................................................................................................................. 108
Manual EF2 R01-2013 139/144

12 1
Appendix
2
Index
A
ARP Protocol................................................................................................................................. 65
B
Brake Relay ................................................................................................................ 18, 19, 20, 27
Braking resistor .............................................................................................. 8, 17, 21, 49, 50, 123
Braking resistor, mounting............................................................................................................. 57
C
Cables, shielded ..................................................................................................................... 53, 61
CF Card ........................................................................................................................................ 60
Configuration diagram .................................................................................................................. 70
Configuration file ............................................................................................................... 74, 83, 92
Control unit, disassembly ............................................................................................................. 59
Control unit, mounting .................................................................................................................. 59
Controller....................................................................................................................................... 12
Cooling clearance ................................................................................................................... 49, 50
Current consumption, typical ........................................................................................................ 24
D
Default configuration ........................................................................................................ 78, 81, 82
Default IP ...................................................................................................................................... 66
Default IP of the controller ............................................................................................................ 64
Degree of protection ....................................................................................... 14, 21, 30, 32, 57, 58
Diagnostic file ......................................................................................................................... 94, 95
E
EMC Directive 2004/108/EC ........................................................................................................... 7
EMC Installation Guideline.......................................................................................................... 125
EMC legislation ............................................................................................................................. 12
EN 60204-1 ................................................................................................................................... 13
EN 61800-5-1 ................................................................................................................... 13, 24, 37
Error messages........................................................................................................................... 107
Ethernet interface ....................................................................................... 24, 25, 39, 67, 121, 122
Ethernet interface, checking.......................................................................................................... 71
F
Firmware ...................................................................................................................................... 60
Forcing .............................................................................................................................. 97, 98, 99
G
GSD file............................................................................................................................... 108, 109
I
Industrial network ........................................................................................................................... 7
Internet Protocol Version 4 (TCP/IPv4) ......................................................................................... 64
IT network ..................................................................................................................................... 13
L
LED status indicators .................................................................................................................... 24
M
MAC address ................................................................................................................................ 65
Manual .......................................................................................................................................... 10
Memory card ........................................................................................................................... 23, 24
Messages, active ........................................................................................................................ 107
Messages, archive ...................................................................................................................... 107
Motor contactor ........................................................................................... 8, 44, 46, 120, 121, 122
N
Name assignment PROFINET .............................................................................................. 81, 115
O
Overvoltage, non-periodic ............................................................................................................ 24
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Appendix
1 12
2
P
Password ...................................................................................................................................... 68
Performance Level (PL) ................................................................................................................ 30
Persons, authorized ............................................................................................................... 71, 97
PFH (probability of failure per hour) .............................................................................................. 46
Power loss, typical ........................................................................................................................ 24
Power module ........................................................................................................................... 8, 17
Power module, mounting ........................................................................................................ 23, 59
Power supply, external .................................................................................................................. 38
PROFIBUS baudrate ........................................................................................................ 79, 80, 87
PROFIBUS communication......................................................................................... 77, 78, 85, 86
PROFIBUS DP Address.................................................................................................... 79, 80, 87
PROFINET communication......................................................................................... 77, 81, 85, 88
PROFINET interface ..................................................................................................................... 25
Profinet interface ................................................................................................................. 121, 122
PROFINET station name ........................................................................................................ 81, 88
Protection class ............................................................................................................................ 24
Protection requirements SIL3........................................................................................................ 29
Protective earth ..................................................................................................... 51, 52, 53, 54, 55
R
Residual risks................................................................................................................................ 15
Restart........................................................................................................................................... 91
Revisions......................................................................................................................................... 2
Ripple ............................................................................................................................................ 24
S
Safety ............................................................................................................................................ 12
Safety Function, Extended (SIL3) ........................................................................................... 44, 46
Safety Function, Integrated (SIL2) .......................................................................................... 44, 47
Safety instructions......................................................................................................................... 10
Safety relay ........................................................................................................... 8, 30, 44, 46, 103
Shield connection.......................................................................................................................... 61
Shield terminal connection set .......................................................................................... 18, 19, 20
SIMOTION Kernel ......................................................................................................................... 60
Slot, CF Card ................................................................................................................................ 60
Starting current, typical ................................................................................................................. 24
Supply voltage......................................................................................................................... 24, 27
System time .................................................................................................................................. 90
T
TCP/IP communication ................................................................................................................. 65
Temperature range, permissible.................................................................................................... 24
Terminal block connection .......................................................................................... 77, 82, 85, 88
TM15 Module .................................................................................................................................. 8
TM15 Module, mounting ............................................................................................................... 62
TN network.................................................................................................................................... 13
TT network .................................................................................................................................... 13
U
User name..................................................................................................................................... 68
V
VDE regulations ............................................................................................................................ 12
Manual EF2 R01-2013 141/144

12 1
Appendix
2
12.4 Personal notes
12.4 Personal notes
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Appendix
1 12
2
12.4 Personal notes
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WEISS GmbH | Siemensstraße 17 | D-74722 Buchen
Telefon +49(0)6281-5208-0 | Fax +49(0)6281-520899 | info@weiss-gmbh.de | www.weiss-gmbh.de

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Manual

Rotary indexing table controller EF2

This document has been prepared by

WEISS GmbH, Siemensstrasse 17, D-74722 Buchen

Manual EF2 R01-2013 3/144

4.4. Interface assignment D410-2 ................................................................... 37

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Manual EF2 R01-2013 5/144

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1.2 Intended use

1.3 Target group

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Fig. 1: Controller components

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Fieldbus (Profibus / Profinet)

Ethernet PM340 / FSB

Fig. 2: Block diagram of EF2 controller

Manual EF2 R01-2013 9/144

1.5 Further applicable documents

1.5 Further applicable documents

1.6.2 Standard scope

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1.6.3 Explanation of safety instructions in this manual

1.6.6 Directory of valid pages

Manual EF2 R01-2013 11/144

2.1 Fundamental safety instructions

2.1 Fundamental safety instructions

2.1.1 Operator‘s obligation to exercise diligence

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2.1.2 Technical safety

Manual EF2 R01-2013 13/144

2.2 Emergency-off circuit

2.1.3 Electrostatic safety

2.1.4 Ambient and operating conditions

2.2 Emergency-off circuit

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2.3 Residual hazards

Manual EF2 R01-2013 15/144

2.3 Residual hazards

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3.1 Power Module PM340

3.1.1 Safety instructions

Manual EF2 R01-2013 17/144

3.1 Power Module PM340

3.1.2 Power Module PM340; frame size FSA / 0.37 kW

Fig. 3: Interfaces of Power Module PM340; frame size FSA / 0.37 kW

Pos. Interface Description

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3.1.3 Power Module PM340; frame size FSA / 1.5 kW

Pos. Interface Description

Manual EF2 R01-2013 19/144

3.1 Power Module PM340

3.1.4 Power Module PM340; frame size FSB

Fig. 5: Interfaces of Power Module PM340; frame size FSB

Pos. Interface Description

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3.1.5 Technical data

Manual EF2 R01-2013 21/144

3.1 Power Module PM340