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DIAS-Drive 310-23
Date of creation: 01.10.2013 Current version: 01.06.2021 Article No.: 10-501-101-23E
Publisher: SIGMATEK GmbH & Co KG
A-5112 Lamprechtshausen
Tel.: +43/6274/4321
Fax: +43/6274/4321-18 e-mail: [email protected]
WWW.SIGMATEK-AUTOMATION.COM
Copyright © 2013
SIGMATEK GmbH & Co KG
Translation from German
All rights reserved. No part of this work may be reproduced in any form whatever (printing, photocopying, microfilm or any other process), or processed, duplicated or distributed by means of electronic systems, without express permission.
We reserve the right to make changes to the content without notice. SIGMATEK GmbH & Co KG shall not be held responsible for technical or printing errors in this manual and shall accept no liability for damages caused as a result of using this manual.
DIAS-Drive 310-23
The manual describes the servo amplifier of the DIAS-Drive series. Additional information on the safety functions and the existing inputs and outputs in the installed VAC 013 interface module can be found in the corresponding chapter.
Individual chapters:
•
Technical Data
•
Assembly and Installation
•
Description of interfaces
•
Servo amplifier settings
•
Accessories
•
Transport, Storage, Maintenance, Disposal
Abbreviations used in this manual
IGBT
LED
PELV
RES
R int.
R tr
V AC
V DC
Abbreviation Definition
AWG American Wire Gauge (American cable coding)
BGND
CE
CLOCK
EMC
EN
Mass for the 24V auxiliary and braking supply
Communité
Clock signal
Europeenne
Electromagnetic Compatibility
European Norm
Insulated Gate Bipolar Transistor
Light Emitting Diode protected Extra Low Voltage
Resolver
Internal regen resistor connection
Brake chopper connection
Alternating Current
Direct current
DIAS-DRIVE 310-23
01.06.2021 Page 1
DIAS-DRIVE 310-23
Contents
1 General .................................................................................... 6
Symbols used in this manual ...................................................... 6
Safety Guidelines .......................................................................... 7
Servo Amplifier Components .................................................... 10
European Guidelines and Standards ........................................ 11
Designated Use ........................................................................... 12
Non-designated Use ................................................................... 13
Block Diagram ............................................................................. 14
DIAS-Drive Concept .......................................................................... 16
Software Functions ............................................................................ 17
Technical Data ............................................................................ 18
Environmental Conditions, Ventilation and Mounting ............ 20
Auxiliary Supply Voltage ............................................................ 20
2 Installation ..............................................................................21
Important Instructions ................................................................ 21
Construction of the Control Cabinet ........................................ 23
Wiring Diagram and Pin Assignment ................................................. 23
Mechanical Construction and Mounting ............................................. 25
Laying the Motor and Control Cables ................................................ 27
Connector Models ............................................................................. 28
Voltage Supply Options ..................................................................... 30
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DIAS-DRIVE 310-23
Usage of Cooling Devices ................................................................. 31
Turn on/off Response of the Servo Amplifier .................................... 33
Holding Brake Control ....................................................................... 34
3 Connections........................................................................... 35
Main Power supply (X1B) ........................................................... 35
24 V Auxiliary supply – Holding Brake supply (X1A) .............. 36
DC-link (X1B) ............................................................................... 37
External Regen Resistor (X1B) .................................................. 37
Motor Connection (X3, X4, X5) .................................................. 38
Standard configuration ...................................................................... 38
Classic Emergency Stop Functions (Stop Category 0) ..................... 39
Personnel-Safe Holding Brake Control ............................................. 40
Feedback (X6, X7, X8) ................................................................. 41
Resolver Feedback ........................................................................... 42
EnDAT ® Signal Encoder ................................................................... 43
Hiperface ® Signal Encoder ................................................................ 44
Sine/Cosine & TTL Encoder Feedback ............................................. 45
4 Maintenance........................................................................... 46
Replace and Repair..................................................................... 46
5 Appendix ................................................................................ 48
Transport, Storage and Disposal .............................................. 48
Correcting Errors ........................................................................ 50
Amplifier Malfunctions ....................................................................... 51
Status Register ................................................................................. 52
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DIAS-DRIVE 310-23
6 DIAS Drive 300 Accessories .................................................56
Shielding Plate with Strain Relief .............................................. 56
Mounting Instructions ........................................................................ 56
Mounting Set ............................................................................... 57
Mounting Instructions ........................................................................ 58
Dimensions incl. Mounting Set .......................................................... 59
7 VARAN Interface for DIAS Drive 3xx (VAC 013) ..................60
Technical Data ............................................................................ 61
Electrical Requirements ..................................................................... 61
Input Specifications ........................................................................... 61
Relay Specifications .......................................................................... 62
Safety Conformity .............................................................................. 62
Environmental Conditions .................................................................. 63
Mechanical Dimensions ............................................................. 64
Connector Layout ....................................................................... 65
Status Displays ........................................................................... 67
Additional Safety Information.................................................... 68
Additional Information ............................................................... 70
"Safe Restart Lock" STO (Safe Torque Off) ...................................... 70
Addressing .................................................................................. 80
Recommended Shielding for VARAN ....................................... 84
Wiring from the Control Cabinet to an External VARAN Component . 85
Wiring Outside of the Control Cabinet ............................................... 86
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DIAS-DRIVE 310-23
Shielding for Wiring within the Control Cabinet ................................. 87
Connecting Noise-Generating Components...................................... 88
Shielding Between Two Control Cabinets ......................................... 89
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DIAS-DRIVE 310-23
1 General
1.1 Symbols used in this manual
Danger! Electric shock
Caution! General
Caution! Hot surface
Danger to personal from electricity and its effects
Danger to machines
General warning
Hot surface more than 80 °C (176 °F)
Important note See Manual
Page 6 01.06.2021
1.2 Safety Guidelines
DIAS-DRIVE 310-23
The safety instructions must be read before installation and initial startup of the servo amplifier.
Improper handling of the servo amplifier can lead to personal injury or material damage.
Compliance with the technical data and connection specifications (nameplate and documentation) mandatory.
Only qualified personnel may perform tasks such as transportation, assembly, Initial startup and maintenance.
Qualified personnel are those who are familiar with the transport, assembly, installation, setup and operation of the product, and have the appropriate qualifications for their task.
The machine manufacturer must perform a safety analysis for the entire machine.
With the appropriate measures, the manufacturer ensures that no injuries or damage can be caused by unexpected movements.
Improper operation of the servo amplifier or failure to follow the following guidelines and improper handling of the safety equipment can result in damage to the machine, personnel injury, electrical shock or in extreme cases, death.
Annotations
Danger! Shock current
After disconnecting the servo amplifier from the voltage supply, a wait-time of at least 5 minutes is required before current conducting components of the amplifier (e.g. clamps) can be touched or connectors removed. After turning off the voltage supply, the internal capacitors can have dangerous voltage levels for up to 5 minutes. For safety purposes, measure the voltage in the intermediate circuit and wait until the voltage is below 40 V.
The electrical connectors of the servo amplifier can never be removed while voltage is applied. The danger of electrical arcing exists, which could cause personal injury as well as damage to the contacts.
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DIAS-DRIVE 310-23
When using a ground fault interrupter in the circuit, a Type B FI-switch must be used. If an FI switch of Type A is used, a DC ground fault could cause it to malfunction.
Failure to follow these instructions can lead to death, serious injury or damage to the machine.
Warning General
The use of the servo amplifier is defined by EN61800-3. In living areas, this product can cause EMC interference problems. In such a case, the user must take additional filtering measures.
The servo amplifier contains electrostatic-sensitive components, which can be damaged by improper handling. Before touching the servo amplifier, the user must discharge their body by touching a grounded object with a conductive surface. Contact with highly insulated material (synthetic fiber, plastic foil etc.) must be avoided. The servo amplifier must be placed on a conductive surface.
Opening the device is not allowed. During operation, keep all covers and control cabinet doors closed. The danger of severe damage to health or material, as well as death exists.
During operation, servo amplifiers
– according to their protection type – may have bare, voltage-carrying components. Control and power connections may be live, even if the motor is not turning.
The main voltage supply for the DIAS-Drive requires a fixed connection. If the servo amplifier is mounted on a moveable part of a machine with a connector plug, the ground connection must have a minimum cross-section of 10 mm²
(8 AWG) because of the high leakage current of the servo amplifier
(> 3.5 mA).
The +24 V auxiliary power supply and the power supply for the
+24V-BR holding brake supply must be galvanically separated as protective extra-low voltage (PELV) according to EN 60950.
Failure to follow the above safety measures can lead to severe injuries and machine damage.
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DIAS-DRIVE 310-23
Caution! Hot surface
During operation, the heat sink of the servo amplifier can reach temperatures of over 80° C (176° F). The heat sink temperature should be checked before handling and it may be necessary to wait until it has fallen below 40 °C (104
°F).
Failure to follow the above safety measures can lead to severe injuries.
Caution! Electromagnetic Fields (EMF)
Risk of death!
Due to the electromagnetic fields generated during operation of the servo amplifier, people with pacemakers or implants are particularly at risk if they are in the immediate vicinity of the device.
Caution must therefore be taken to ensure that such persons maintain the necessary safety distance of at least 2 m.
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DIAS-DRIVE 310-23
1.3 Servo Amplifier Components
Page 10 01.06.2021
1.4 European Guidelines and Standards
DIAS-DRIVE 310-23
Servo amplifiers are components designed for installation in electrical systems/machines for industrial use. During the installation into machines/systems, the servo amplifier should not be operated until it has been determined that the machine/system meets the requirements of the machine guideline 2006/42/EC and the EMC guideline 2014/30/EU.
Note: The machine manufacturer must perform a safety analysis for the entire machine.
With the appropriate measures, the manufacturer ensures that no injuries or damage can be caused by unexpected movements.
− Conformity
With the delivery of servo amplifiers within the European Union, compliance with the EMC
2014/30/EU and low voltage 2014/35/EU guidelines is mandatory.
The harmonized standard EN 61800-5-1 (Electrical Power Amplifier Systems with
Adjustable Speed - part 5-1: Requirements for the Safety of Electrical, Thermal and
Energetic Demands) was included with the 2014/35/EU low voltage guideline for this servo amplifier.
The harmonized standard EN 61800-3 (Electrical Power Amplifier systems with Adjustable
Speed - Part 3: EMC product standard including special test methods) was included with the 2014/30/EU for this servo amplifier.
To meet the EMC conditions for the installation, the documentation contains detailed information on:
•
shielding
•
grounding
•
control cabinet wiring
•
filters (if necessary)
The servo amplifier from the DIAS-Drive series was tested with the system components and the corresponding configuration defined in this document. Any change in the configuration and installation described in this document requires new measurements to ensure the standards are met.
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DIAS-DRIVE 310-23
1.5 Designated Use
The servo amplifier from SIGMATEK GmbH & Co KG was designed and produced with state of the art technology. The product was tested for reliability before delivery, especially in terms of fail-safe conditions. It is an installed component for electrical systems and can only be operated as an integral part. Before installation, the following conditions for designated use must be met:
•
Each user of the product must read and understand the safety instructions for designated and non-designated use.
•
The machine manufacture must perform a safety analysis of the machine in order to ensure that no injuries or damage is caused to personnel and equipment by unexpected movements.
•
The servo amplifier must be operated under the assembly and installation conditions described in this document. The environmental conditions (temperature, protection class, humidity, voltage supply, EMC and mounting position) must be observed in particular.
•
The amplifier can only be operated in a control cabinet with minimum IP54 .
•
The Servo amplifier must be operated in the original condition without any mechanical or electrical changes.
•
Mechanically or electrically defective or faulty servo amplifiers may be not installed or operated.
•
The servo amplifier is provided for the control of synchronous servo, linear and torque motors, as well as frequency, torque, speed or position control of asynchronous motors.
•
The specified rated voltage of the motor must be at least as high as the power supply voltage of the servo amplifier (230 V, 400 V or 480 V).
•
Only motors with star circuit may be used.
•
This product can lead to EMC disruptions in living areas. In such a case, the user must take additional filtering measures.
Page 12 01.06.2021
1.6 Non-designated Use
DIAS-DRIVE 310-23
If a servo amplifier is operated according to the environmental conditions described in this document, it is "designated use".
•
Single-phase operation is not authorized as standard use, but is allowed for initial startup and demonstration purposes.
•
Because of saline and therewith, conductive contamination, the servo amplifier cannot be used on ships (sea operation) or in offshore applications.
•
The servo amplifier cannot be operated under any environmental conditions other than those described in this documentation (meaning without a control cabinet, incorrect assembly etc.)
Particular caution is required in production facilities, in which conductive material such as carbon fiber, graphite, and cast iron or similar material is used. In such cases, the control cabinet must be hermetically sealed (no forced ventilation with fan filters) or placed outside of the contaminated area. Especially during the initial start-up, the danger posed by open control cabinet doors is extremely high. Contaminated servo amplifiers may no longer be used.
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DIAS-DRIVE 310-23
1.7 Block Diagram
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1.7.1 Hardware
DIAS-DRIVE 310-23
•
The main supply is connected to a rectifier, input filter and a charging circuit, which reduces the load current for the power-up moment.
•
IGBT – Power output stage with separate current measurement (short circuit protected).
•
Short circuit proof brake chopper with internal brake resistor. For insufficient power, the internal resistor can be disconnected and replaced by an external one.
•
DC link for connection to additional amplifiers.
•
Auxiliary voltage for the internal supply.
•
Separate voltage supply for the holding brake.
•
Evaluation from the resolver, EnDAT and Hiperface sensors.
•
Micro controller system with communication to the interface
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DIAS-DRIVE 310-23
1.7.2 DIAS-Drive Concept
•
1 and 3-axis amplifiers to reduce machine costs. 3-axis amplifiers have advantages reducing components
•
Auto-range function to optimize the resolution of the actual current value of 10 A axes, in various configurations.
•
Two different mounting options.
➢
On a mounting place in the control cabinet
➢ Through-hole technology
•
Broad input voltage range from 3 x 230 VAC
-10%
… 3 x 480 VAC +10% supplied from TNsupply or TT-supply with grounded neutral point, with a maximum current of symmetrical 5000 A
RMS
.
•
TT supplies without grounded neutral lines require additional measures.
•
Charging circuit for limiting the maximum load current at the power-up moment.
•
Fuse installed by user (phase failure is monitored by the amplifier)
•
1-phase operation is possible, e.g. for initial start-up
•
24 V auxiliary supply, galvanically isolated for independent power.
•
Separate 24 Volt connection to power the holding brakes.
•
Noise filter for the main, 24 V auxiliary and holding brake supplies, class A (industrial use)
•
Housing with connection for the cable shielding
•
Protective functions against:
➢ Under or over voltage in the DC-link circuit.
➢
Several short circuit conditions
➢ Phase error in the main supply
➢
Brake resistance over heating
➢ Over temperature (heat sink, ambient and motor)
•
The overload protection is provided internally by the drive. The load current is limited to
100 % of peak output current. For the thermal protection of the motor the I 2 T regulation is used.
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DIAS-DRIVE 310-23
Integral solid state short circuit protection does not provide branch circuit protection. Branch circuit protection must be provided in accordance with the Manufacturer Instructions, National Electrical Code and any additional local codes.
1.7.3 Software Functions
•
Modified space vector modulation (SVM) technique to reduce the power stage losses
•
Field oriented current controller (update time 62.5 µs)
•
Feedback evaluation and speed controller (update time 62.5 µs)
•
Spline interpolation and position controller (update time 62.5 µs)
•
Full synchronisation up to the output stage to the control frequency with cycle times of
250 µs, 500 µs and 1 ms to 8 ms
•
The servo amplifier has a volatile data storage medium. After power-up, the parameters are loaded into the servo amplifier via the host
•
Starting with FW version 1.82, the electrical rotary field frequency is limited to 599 Hz.
The error bit 18 is set when the frequency is above 599 Hz for more than one second.
The amplifier then changes to error status. The cause could be a high rotation speed with motors that have a high number of poles.
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DIAS-DRIVE 310-23
1.8 Technical Data
Rated values
Rated input voltage (symmetrical opposite to earth) max. 5000 A rms (L1, L2, L3)
Max. peak current at power-up moment (limited by the charging circuit)
Rated power in S1 mode
Rated DC-link voltage
Over voltage protection – limit for the intermediate circuit
Additional voltage supply +24 V
Power from the additional +24 V
Holding brake supply +24 V-BR
Max. holding brake current per axis
Holding brake voltage drop with a load +24 V-BR
Max. switching energy of the holding brake
Rated current for axis 1 (rms +/- 3 %)
Max. standstill current for axis 1 starting from
500 ms
Rated current for axis 2 (rms +/- 3 %)
Max. standstill current for axis 2 starting from
500 ms
Rated current for axis 3 (rms +/- 3 %)
Max. standstill current for axis 3 starting from
500 ms
Max. continuous sum current of all axes (heat sink)
Peak output current axis 1 for a max 5 s (rms +/-
3 %)
Peak output current axis 2 for a max 5 s (rms +/-
3 %)
Peak output current axis 3 for a max 5 s (rms +/-
3 %)
The loss in the power output stage (add the average current of the 3 axis and multiply by the factor) without brake unit losses
Output frequency of the power output stage
Maximum output current for 8 V feedback systems at X6, X7, X8
Minimum output current for 8 V feedback systems at X6, X7, X8
Maximum output current for 5 V feedback systems at X6, X7, X8
Minimum output current for 5 V feedback systems at X6, X7, X8
Maximum residual current
PWM frequency
Regulator frequency
DIM
V
A
A
AC rms rms
W /
A rms kHz mA mA mA mA mA kHz kHz
A kVA
V
DC
V
DC
V
DC
W
V
DC
A
DC
V
DC mJ
A rms
A rms
A rms
A rms
A rms
A rms
A rms
A rms
Page 18
DIAS-Drive
SDD310-23
3 x 230 V
-10%
– 480 V 10% , 45 – 65 Hz
2.5
14
290 – 680
450 – 900
22 – 30
35
25 – 27
2
Max. 1 (at 3 x 2 A Holding brake current)
100
10
7
10
7
10
7
20
20
20
20
10
8
250
0
250
50
15
8
16
01.06.2021
Brake Unit
Capacitance of the intermediate circuit voltage
External regen resistor
Internal regen resistor
Rated power of the internal regen resistor
G-VMAINS = 230 (rated supply voltage = 230 V)
Start-up limit
Switch-off level
Over voltage protection
Max. rated power of the external regen resistor
Peak internal regen resistor power (max. 1 s)
G-VMAINS = 400 (rated supply voltage = 400 V)
Start-up limit
Switch-off level
Over voltage protection
Max. rated power of the external regen resistor
Peak internal regen resistor power (max. 1 s)
G-VMAINS = 480 (rated supply voltage = 480 V)
Start-up limit
Switch-off level
Over voltage protection
Max. rated power of the external regen resistor
Peak internal regen resistor power (max. 1 s)
Internal fuse
24 V auxiliary supply voltage (+24 V to BGND)
Holding brake supply 24 V-BR
(+24 V-BR to BGND)
Regen resistor
Resolver specification
Exciter frequency f err
Exciter voltage U
Ref
Number of poles m
Resolver voltage U sin/cos, max
Connector types
Internal auxiliary power supply (X1A)
Power Supply (X1B)
Feedback (X6, X7, X8)
Motor (X3, X4, X5)
Dimensions
Height with/without connector plugs
Width
Depth
Weight
µF
Ω
Ω
W kHz
U eff
-
U eff mm mm mm kg
-
-
-
-
V
DC
V
DC
V
DC
W kW
V
DC
V
DC
V
DC
W kW
V
DC
V
DC
V
DC
W kW
-
-
-
DIAS-DRIVE 310-23
730
690
800
1200
21
850
810
900
1500
27
700
25 - 50
25
200
420
400
450
750
6.5
Electronic fuse
Electronic fuse
Electronic protection
8
4
2, 4, 6 … 32
2.2
Combicon 5, 3-pole, 2.5 mm²
Power Combicon 7.62, 8-pole, 4 mm²
Sub-D 25-pole (female)
Power Combicon 7.62, 6-pole, 4 mm²
472 / 378
158
240
10
01.06.2021 Page 19
DIAS-DRIVE 310-23
General
Article number
09-501-101-23
09-501-101-23X (Printed circuit board with protective lacquer)
UL 508C, E336350 Standard
1.9 Environmental Conditions, Ventilation and Mounting
Storage conditions
Transport conditions
Environmental temperatures in operation
Air humidity in operation
Installation altitude above sea level
Pollution degree
Overvoltage category
Servo amplifier protection class
Mounting position
Ventilation
1.10 Auxiliary Supply Voltage
0 … +45 °C (32 … 113 °F) at rated values
+45 … 55 °C (113 … 131 °F) with power reduction by
2.5 % / K
0-95 %, non-condensing
0-2000 m without derating
> 2000 m with derating of the maximum environmental temperature by 0.5 °C per 100 m
2
III
IP 20
Forced ventilation by controlled internal fan
The power supply mounted in the switchgear cabinet and used for the +24 V auxiliary supply voltage and holding brake supply (+24V-BR), must output a galvanically isolated protected extra-low voltage (PELV) according to EN60950. Due to the start current at the power-up moment, the rated current must be at least 5 A.
Page 20 01.06.2021
2 Installation
2.1 Important Instructions
DIAS-DRIVE 310-23
•
When using a ground fault interrupter in the circuit, a Type B FI-switch must be used. If an FI switch of Type A is used, a DC ground fault could cause it to malfunction. High-frequency leakage currents occur, which must be taken into consideration when selecting the FI (e.g. Schrack ID-B
4/XX/XX-B).
Trigger diagram:
01.06.2021
•
The servo amplifier and motor must be grounded according to the guidelines. Uncoated mounting plates must be used in the control cabinet.
•
The DIAS-Drive must be connected to ground via the grounding terminal using a wire with a cross section of at least 10 mm² (8 AWG).
•
The main voltage supply for the DIAS-Drive requires a fixed connection. If the servo amplifier is mounted with a connector terminal to a moving machine part, the ground connection must have a cross section of at least
10 mm² (8 AWG) to avoid the high residual current (> 3.5 mA).
•
Before installation, the servo amplifier must be mechanically tested. If damage from transportation is determined, for example, the amplifier cannot be used. Electronic components cannot be handled.
Page 21
DIAS-DRIVE 310-23
•
The rated voltage and current of the servo motor and servo amplifier must match. The
electrical connection must correspond to the schematic on page 23.
•
The main supply can under no circumstances exceed the rated values for the servo amplifier. “Voltage Supply Options”
•
The external fuse for the main supply, the +24 V auxiliary and holding brake supply must meet the specifications for
“External fusing”
•
The motor and control cable should be routed with a minimum clearance of 100 mm.
This improves the effect of noise in the control cable, which is caused by the high noise generation of the motor cable. A shielded motor and feedback cable must be used, by which the shielding on both cable ends is applied.
•
As described on page 25, the correct mounting position is vertical.
•
The ventilation in the control cabinet must provide sufficient cool and filtered air.
Information on the
“Environmental conditions, ventilation and mounting”
can be
•
Any subsequent changes to a servo amplifier will render the warranty void , with exception of the parameter settings.
•
During the initial start-up of the servo amplifier, the peak current must be tested. small motors can be damaged quickly, especially if the servo amplifier settings are to high
(e.g. a 1 A motor with a 10 A amplifier without being limited to 1 A).
•
Note: The mass symbol found in all schematic plans means that the electric connection between the indicated device and the mounting panel in your control cabinet must be made over the largest possible surface. This connection should enable the dissipation of HF noise and should not be confused with the PE symbol .
(Protective measure according to EN 60204)
•
Storage time:
< 1 year: no limitations
≥ 1 year:
The intermediate circuit capacitors of the servo amplifier must be reformed before the initial startup. In addition, all electrical connections must be removed and the servo amplifier supplied with 230 V AC, single phase at terminals L1 / L2 for 30 minutes.
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2.2 Construction of the Control Cabinet
2.2.1 Wiring Diagram and Pin Assignment
DIAS-DRIVE 310-23
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DIAS-DRIVE 310-23
2.2.1.1 SDD 310-23
Amplifier type
Cable
SDD310-23
Page 24
Motor
Axis 1
Feedback
X3 X6
Motor
Axis 2
Feedback
X4 X7
Motor
Axis 3
Feedback
X5 X8
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2.2.2 Mechanical Construction and Mounting
DIAS-DRIVE 310-23
158
The drawing shows the servo amplifier dimensions.
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240
Page 25
DIAS-DRIVE 310-23
The cable channels below and above the servo amplifier must have the specified distances.
This will ensure the sufficient air reaches the heat sink.
Material: 4 x M5 socket head screws DIN 912
Tool required: 4 mm Allen key
Page 26 01.06.2021
2.2.3 Laying the Motor and Control Cables
DIAS-DRIVE 310-23
01.06.2021
Note: The motor and control cable must absolutely be kept separate.
The voltage connection to X1B should also be laid mainly in the cable channels on the left side of the control cabinet.
Page 27
DIAS-DRIVE 310-23
2.2.4 Connector Models
All connections to the servo amplifier are connector plugs (except: grounding bolt). With this method, the cable connection is simplified and the amplifier can be more easily exchanged.
Additionally, it also provides the possibility to manufacture pre-assembled cable sets for large machine quantities.
The following is the technical data for the applicable connectors:
Connector Type Allowable cross section Max. tightening torque
X1A Phoenix MSTB 2,5
HC/3-ST
1-2.5 mm² (14-18 AWG) 0.3 Nm (2.25 inch lb)
X1B
X3, X4, X5
X6, X7, X8
Ground bolt
2.2.5 Cable Types
Phoenix PC5/8-ST2-7,62
Phoenix PC5/6-ST2-7,62
D-Sub 25 with metal housing
M5
1-4 mm² (12-18 AWG)
1-2.5 mm² (14-18 AWG)
0.25-0.5 mm²
(21-24 AWG)
10 mm² (8 AWG)
1.3 Nm (12 inch lb)
1.3 Nm (12 inch lb)
Solder or crimp
3.5 Nm (31 inch lb)
According to EN 60204 (for AWG: table 310-16 of the NEC 60 °C or 75 °C column), is recommended:
Signal Cable rating
Alternating current
DC-link voltage
Maximum 4 mm² (12 AWG)
Maximum 4 mm² (12 AWG)
600 V,105 °C (221 °F)
1000 V,105 °C (221 °F)
Regen resistor
Motor cable
Holding brake
Resolver with thermo contact
EnDAT ® signal encoder
+24 V and +24 V-BR input
2.5 mm² (14 AWG)
Maximum 2.5 mm² (14 AWG), shielded, max. 25 m, cable capacitance <150 pF/m
Min. 0.75 mm² (18 AWG), component of the motor cable, shielded separately, note voltage loss
1000 V,105 °C (221 °F)
600 V,105 °C (221 °F)
600 V,105 °C (221 °F)
4x2x0.25 mm² (24 AWG), twisted pairs, shielded, max. 25 m, cable capacitance <120 pF/m
7x2x0.25 mm² (24 AWG), twisted pairs, shielded, max. 25 m, cable capacitance <120 pF/m
Maximum 2.5 mm² (14 AWG) (check voltage drop)
Note: Use 60/75 °C Copper conductors only!
Page 28 01.06.2021
2.2.6 External Fusing
DIAS-DRIVE 310-23
The AC-mains and 24 V fuses are designed according to the customer requirements for the circuit.
Signal Fuses, time delay
AC voltage supply (L1-L3)
Suitable for use on a circuit capable of delivering not more than
5000 rms symmetrical amperes,
528 volts maximum when protected by RK5 class fuses rated
20 A
The size of the fuse depends on the average power consumption of the connected amplifier. Max. 20 A with 4 mm²
(12 AWG) (FRS-25)
24 V DC input
(24 V, 24 V-BR to BGnd)
16 A slow-blow at 2.5 mm² (14 AWG) for the control
External regen resistor 10 A time delayed, 1200 V (e.g. SIBA 10 022 01,
3-pin-D-Fuse-Link) or FRS-10
UL Requirement:
Suitable for use on a circuit capable of delivering not more than 5000 rms symmetrical amperes, 528 volts maximum when protected by RK5 class fuses rated 20A.
Integral solid state short circuit protection does not provide branch circuit protection. Branch circuit protection must be provided in accordance with the Manufacturer Instructions,
National Electrical Code and any additional local codes.
01.06.2021 Page 29
DIAS-DRIVE 310-23
2.2.7 Voltage Supply Options
The main voltage supply for the DIAS-Drive requires a fixed connection. If the servo amplifier is mounted on a moveable machine part with connector plug, the ground connection has to have a minimum wire size of greater than 10 mm² (8 AWG) because of the high leakage current of the servo amplifier
(> 3.5 mA).
When using a ground fault interrupter in the circuit, a Type B FI switch must be used. If an FI switch of Type A is used, a DC ground fault could cause it to malfunction.
Main voltage supply
(grounded)
Main voltage supply
(non-grounded)
The servo amplifier can be connected directly to a voltage supply with a grounded neutral point without galvanic isolation.
If the servo amplifier is operated in a non-grounded system (IT grid), the danger of over voltage or damage exists. The following measures can be taken to provide protection against over voltage:
•
Use of a galvanically insolating transformer with a grounded neutral point on the secondary side. This offers the highest protection.
•
Installation of over voltage protection in the voltage supply of the control cabinet.
The servo amplifier is tested according to EN 61800-3 as follows:
•
Periodic over voltage between phase conductors (L1, L2,
L3) and the amplifier housing cannot exceed 1000 V
(amplitude).
•
According to EN61800, the peak voltages (< 50 µs) between the phase conductors cannot exceed 1000 V.
Peak voltages (< 50 µs) between the phase conductors and the housing cannot exceed 2000 V..
High voltage supply
Note: Non-grounded mains supplies always require additional surge protection in the mains input.
If the input supply voltage exceeds the specified maximum value, a suitable transformer is required to reduce it.
Page 30 01.06.2021
2.2.8 Usage of Cooling Devices
DIAS-DRIVE 310-23
The servo amplifier functions up to an ambient temperature of 45 °C (55 °C with reduced power). Under some circumstances, a cooling device is required.
Note: A cooling device always produces condensation water. Important points must therefore be observed:
•
Cooling units must be mounted in such a way that no condensation water can drip into the control cabinet.
•
Cooling units must be mounted so that condensation water is not distributed over electrical or electronic components.
Cooling device mounted in the top of the control cabinet
Cooling device mounted in the cabinet door
01.06.2021 Page 31
DIAS-DRIVE 310-23
Condensation water can also be avoided as follows
•
The switch point of the temperature regulator should be just below the building temperature.
•
In damp environments, the proper seals should be used in the control cabinet.
If electronic components are colder than the air in the control cabinet, condensation water can accumulate; especially when the cabinet door is opened during servicing.
Page 32 01.06.2021
2.2.9 Turn on/off Response of the Servo Amplifier
The turn on/off response of the servo amplifier is shown below.
DIAS-DRIVE 310-23
Five seconds after turning on the 24 V auxiliary supply (start time of the micro controller), the "Drive ready" signal is set to high.
The above image shows when the 24 V auxiliary supply activates the system through turning on the main switch and the main supply is engaged later. This, however, is not absolutely necessary. The main supply can also be activated with the 24 V auxiliary supply at the same time.
Since the servo amplifier has a volatile memory, received parameters must be stored in the host controller. The advantage here is in the automatic download of program data when an amplifier is changed.
If the main supply is turned on, the capacitors in the intermediate circuit are loaded.
Approximately 0.7 seconds are needed.
If the main supply is turned off, the current of intermediate circuit is maintained and can be used for controlled braking of the motor. If the motor is slowed, the energy is returned to the intermediate circuit.
If the motor is stopped, the "enable" signal can be removed. After 5 minutes, the intermediate circuit is discharged.
01.06.2021 Page 33
DIAS-DRIVE 310-23
2.2.10 Holding Brake Control
The figure above shows the holding brake function.
A standard holding brake with 24 volts DC and a maximum of 2 Amps can be used on the servo amplifier.
The circuit has a high level of functional safety, but no personnel safety .
Page 34 01.06.2021
01.06.2021
3 Connections
3.1 Main Power supply (X1B)
DIAS-DRIVE 310-23
The connection to the main supply voltage is designed for voltages from 230 V AC to
480 V AC. When using a non-earthed supply, over voltage protection must be built into the main power supply of the control cabinet.
Note: If within a group of amplifiers, the intermediate circuit is bridged, the input voltage in this group must also be bridged.
3-phase connection:
Page 35
DIAS-DRIVE 310-23
3.2 24 V Auxiliary supply – Holding Brake supply (X1A)
If a 24 V supply is used in the control cabinet to power the relays, coils or other devices, it can also be used for the servo amplifier (the maximum current of the supply must be taken into consideration).
To deactivate the stop brake independently from the 24 V auxiliary voltage, the amplifier has an additional input +24 V-BR.
Note: The mass of the 24 V power supply must be connected to ground near the supply.
Page 36 01.06.2021
3.3 DC-link (X1B)
DIAS-DRIVE 310-23
To bridge the DC-link voltage with other servo amplifiers, the X1B/2 (+DC) and 3 (-DC) connectors can be used.
The intermediate circuit power can be distributed to different servo amplifiers with this method.
Note: If the intermediate circuit is bridged within a group of amplifiers, the main power supply in this group must also be bridged.
3.4 External Regen Resistor (X1B)
If the power of the internal brake resistor is insufficient, an external resistor can be added.
Here, the connection to R int
(terminal 4 of X1B) and R tr
(terminal 5 of X1B) must be removed. The external resistor is connected to terminal 2 and 5 of X1B. The fuse on both connections of the external brake resistor is mandatory. 1000 VDC fuses with slow trigger characteristics must be used.
Note: The brake resistor fuse does not protect the resistor, rather the connected cable in the event of a short circuit. The amplifier has electronic protection for the brake resistor.
01.06.2021 Page 37
DIAS-DRIVE 310-23
3.5 Motor Connection (X3, X4, X5)
3.5.1 Standard configuration
The cable length for the motor is limited to 25 m. If a longer cable is used, additional suppression coils in the motor output are required.
Page 38 01.06.2021
3.5.2 Classic Emergency Stop Functions (Stop Category 0)
DIAS-DRIVE 310-23
The cable length for the motor is limited to 25 m. If a longer cable is used, additional suppression coils in the motor output are required.
Note: The K
EM
coil must be turned on before the amplifier is enabled and can be turned off after at least 1 ms after the amplifier is disabled.
The resistance value and the power of the R
EM
resistor are calculated using the following formulas:
R
EM
= max SPEED
I max
0 .
8
K
Erms P
EM
=
( I max
0 .
8 )²
10
R
EM maxSPEED
I max
K
Erms maximum revolutions [rpm] maximum motor current allowed [A] voltage constant of the motor [V*min]
01.06.2021 Page 39
DIAS-DRIVE 310-23
3.5.3 Personnel-Safe Holding Brake Control
The servo amplifier has a high reliability in the brake control.
If a personnel-safe holding brake control is required, an additional safety contact in the
+24V-BR voltage path in keeping with the safety standards is needed.
Despite this, the danger of injury and/or damage to the machine still exists with a mechanical defect in the holding brake.
Page 40 01.06.2021
3.6 Feedback (X6, X7, X8)
DIAS-DRIVE 310-23
The servo amplifier has various feedback inputs for different feedback devices.
•
Resolver Feedback with thermo contact
•
EnDAT ® encoder (single and multi-turn)
•
Hiperface® encoder (single and multi-turn)
•
Sin/Cos & TTL Encoder
For EnDAT, Hiperface, Sin/Cos and TTL encoder systems, the current maximum number of feedback signals of 8192 per mechanical turn is supported (M-RPULSE).
01.06.2021 Page 41
DIAS-DRIVE 310-23
3.6.1 Resolver Feedback
A resolver is used as the standard feedback. The servo amplifier supports the analysis of single-speed (2-pin) and multi-speed resolvers (up to 32 pins). The maximum cable length is 50 m. If a thermo contact is used, the signal is also wired into the resolver cable.
Page 42 01.06.2021
3.6.2 EnDAT ® Signal Encoder
DIAS-DRIVE 310-23
The EnDAT ® encoder is a high-resolution feedback system for motors. The cable length is limited to 25 m. If a thermo contact is used, the signal is transmitted through the feedback cable.
01.06.2021 Page 43
DIAS-DRIVE 310-23
3.6.3 Hiperface ® Signal Encoder
The signal encoder with a Hiperface ® interface is a high-resolution feedback system for motors. The cable length is limited to 25 m.
Page 44 01.06.2021
3.6.4 Sine/Cosine & TTL Encoder Feedback
DIAS-DRIVE 310-23
A sine encoder is a high-resolution feedback system, used with linear or torque servomotors. The maximum cable length is 10 m. If a thermo contact is used, the signal is wired into the resolver cable.
The upper frequency limit for TTL encoders is 100 kHz. The reference signal is not evaluated in the amplifier.
01.06.2021 Page 45
DIAS-DRIVE 310-23
4 Maintenance
The servo amplifier is maintenance-free.
Note: Opening the housing invalidates the warranty.
Dirt on the housing can be removed with isopropyl alcohol or similar products.
•
Contamination in the device must be removed by the manufacturer.
•
Dirty fan grates can be cleaned with a dry brush.
•
Spraying or submersion is not allowed.
4.1 Replace and Repair
Repair: Repair of the servo amplifier must be performed by the manufacturer.
Replace: If a servo amplifier must be replaced, the following checklist must be observed (no special mounting tools are required):
Turn off the control cabinet supply and remove the servo amplifier fuses.
After disconnecting the servo amplifier from the main voltage supply, a waittime of 5 minutes is required before current-conducting components in the amplifier (e.g. contacts) can be touched or connectors removed. Capacitors can contain dangerous voltages for up to 5 minutes after the supply voltage is removed. It is necessary to wait until the DC-link voltage is below 40 V.
During operation, the heat sink of the servo amplifier can reach temperatures of over 80 °C (176 °F). The heat sink temperature should be checked before handling and it may be necessary to wait until it is below 40 °C (104 °F).
Page 46 01.06.2021
DIAS-DRIVE 310-23
Disconnect the contact plug.
The connectors should be labeled to avoid confusing them later.
The servo amplifier can be dismantled.
The replacement unit must be compared with the original amplifier; only identical amplifiers can be used!
Reestablish the connection. The connectors must not be crossed.
Insert the fuses for the servo amplifier, turn on the main switch in the control cabinet.
Check whether the correct parameters were loaded into the amplifier.
01.06.2021 Page 47
DIAS-DRIVE 310-23
5 Appendix
5.1 Transport, Storage and Disposal
Transport:
•
For transport, the original recyclable packaging from the manufacturer must be used.
•
During transport dropping should be avoided.
•
The storage temperature must be between –25 and +70 °C (-13 ... 158 °F), max. change 20 K/h.
•
The maximum humidity is 95 %, non-condensing
•
The servo amplifier contains electrostatic-sensitive components, which can be damaged by improper handling. Before touching the servo amplifier, the user must discharge their body by touching a grounded object with a conductive surface. Contact with highly insulated material (synthetic fibre, plastic foil etc.) must be avoided. The servo amplifier must be placed on a conductive surface.
•
If the packaging is damaged, the amplifier must be visually inspected for damage. If damaged, the transport company and the manufacturer must be informed. The amplifier should not be installed and operated if damaged.
Packaging:
•
Recyclable cardboard with liner
•
Dimensions: 500 mm x 300 mm x 400 mm (width, height, depth)
•
Labelling: nameplate on the outer side of the box
Storage :
•
Only the original recyclable packaging from the manufacturer can be used
•
The servo amplifier contains electrostatic-sensitive components, which can be damaged by improper handling. Before touching the servo amplifier, the user must discharge their body by touching a grounded object with a conductive surface. Contact with highly insulated material (synthetic fibre, plastic foil etc.) must be avoided. The servo amplifier must be placed on a conductive surface.
Page 48 01.06.2021
DIAS-DRIVE 310-23
•
A maximum of 6 servo amplifiers can be stacked on top of one another.
•
The storage temperature must be between
–25 and +70 °C (-13 ... 158 °F), max. change 20 K/h.
•
The maximum humidity 95 %, non-condensing.
•
Storage time:
< 1 year: without limitations
≥ 1 year:
The intermediate circuit capacitors of the servo amplifier must be reformed before the initial startup. In addition, all electrical connections must be removed and the servo amplifier supplied with 230 V AC, single phase at terminals L1 / L2 for 30 min.
Disposal:
•
The servo amplifier can be disassembled by removing the screws in its main components (heat sink, steel housing, circuit boards).
•
Disposal should be carried out by certified companies.
01.06.2021 Page 49
DIAS-DRIVE 310-23
5.2 Correcting Errors
Errors and warnings are displayed via LED and over the bus system. On page 52 under
"Status Register", the various errors that can occur are described.
5.2.1 LED Display
The DIAS-
Drive has two LED’s, which display the status of the amplifier.
LED Description
Green
On
1 Hz flashing
8 Hz flashing
On
On
Off
Red
On
Off
Controller in boot mode (Firmware damaged or not available)
Ready to start
Off
Off
Output current is limited by the I2T value (one or more axes)
Operation
1 Hz flashing Warning
On Error
Page 50 01.06.2021
5.2.2 Amplifier Malfunctions
Malfunction of the drive
When the motor is turning in the clockwise direction (observe the motor shaft), I-FPOS decreases
Possible Causes
Resolver not functioning correctly
Resolver connected incorrectly
Motor is not connected correctly
DIAS-DRIVE 310-23
Solution
Check resolver
Connect the resolver according to the
wiring diagram (see page 41 et seq.)
Check connections on motor terminal board
U, V, W
Motor does not rotate
Motor current has reached limit, however, without torque
The motor "spins through"
The motor torque is too low or different in the directions
Motor stops at certain positions
The motor oscillates
M-ROFF is not set to the right value
Motor and/or feedback is connected incorrectly
The setting of M-POL and/or M-
RPOL is incorrect
The motor cable has a wire break
The motor cable is not connected to all wires
Control gain too high
Shielding of the feedback cable has a defect
Check the M-ROFF parameter
Check the motor and feedback connection
Check the M-POL and M-RPOL parameters corresponding to the motor data.
Replace motor cable (especially for drag chains)
Check motor cable connections
Reduce V-KP and/or P-KV
Check the feedback cable and exchange it if needed (especially with drag chains)
01.06.2021 Page 51
DIAS-DRIVE 310-23
5.2.3 Status Register
With I-STATUS , the status of the DIAS-Drive can be read. All error and status information is contained in a 32-bit variable. The amplifier function can be changed by setting the appropriate bits via using the G-MASKE1 , G-MASKE2 , G-MASKW and G-MASKD commands.
According to the mask settings the amplifier detects errors, warnings or does not respond.
The individual bits have different values and limitations in the mask assignment.
Bit Error Cause Solution
0 Single-phase operation
The main supply voltage is single phase only
1
2
3
4
5
6
7
Error in the main voltage supply reserved
DC over voltage
DC under voltage reserved
Holding brake error
Brake switch error
Amplifier is "enabled" without the applied main voltage supply
Internal / External regen resistor not connected
Internal regen resistor defective
External regen resistor defective
The main voltage supply for the enabled amplifier is too low
No holding brake connected with parameter M-BRAKE = 1
Short circuit in holding brake cables
Short circuit in the holding brake
Defective internal stop brake switch
No holding brake connected in parameters
M-BRAKE = 1
Check the amplifier fuse
Check electrical connection check fuses in the mains supply check electrical supply
Amplifier is enabled before the DC-link voltage is loaded connect regen resistor replace amplifier replace external regen resistor disable amplifier before the DC-link voltage crosses the under-voltage threshold set by G-VBUSM
Use motor with holding brake
Check holding brake cable
Change M-BRAKE parameter to 0 as long as a motor without brakes is used.
Check connector and motor cable
Check holding brake
Replace amplifier
Use motor with holding brake
Change M-BRAKE parameter to 0 as long as a motor without brakes is used.
Check connector and motor cable
Check holding brake
8 reserved
Page 52 01.06.2021
DIAS-DRIVE 310-23
9
10
11
12
13
14
15
16
17
18
Motor temperature Motor temperature switch is triggered
Break in feedback cable or connectors
Internal temperature too high
Check cause (Motor underdimensioned; poor environmental conditions)
Check feedback cable and connector, exchange if necessary
Environmental temperature
Heat sink temperature
Feedback error
Commutation error
Motor over speed
Drag error
Trajectory error
Heat sink temperature too high
Feedback cable broken feedback device defective
Bad feedback connection
Incorrect motor phase position
Wrong wiring of motor or feedback cable
Incorrect motor phase position
Incorrect motor connection or wrong feedback cable
Over shoot (greater than
1.2 * V-NMAX)
P-PEMAX lag window too small improve ventilation in the cabinet and check mounting position according to this manual
Improve ventilation in the cabinet and check mounting position according to this manual
Check feedback cable and replace if necessary
Replace feedback device
Check feedback connection
Check M-ROFF
Check motor connection
Check M-ROFF
Check motor connection
Check feedback cable
Optimize control loop
The speed setting, which was calculated using the change in the position setting by the host, is higher than 10000 r/min -1
Increase P-PEMAX and/or optimize control loops
Check P-PSCALE and
P-SSCALE parameters and the reference value of the controller
Host communication
Amplifier error E2
(I-DERROR)
No new preset values were transmitted for two successive cycles
Internal communication error with the interface
Various internal errors
Synchronization is not engaged;
check A-CTIME and the cycle time of the control
Check A-STIME
Communication disrupted, check see also I-DERROR see also I-DERROR
Contact manufacturer
01.06.2021 Page 53
DIAS-DRIVE 310-23
19
20
21
22
23
24
25
26
27
28
Amplifier Error E1
(I-DERROR)
"Enable locked" error
Driver voltage error regen resistor limit reached.
DC over voltage and
Various internal errors
Power output error:
Motor cable has a ground fault
Motor has a ground fault
Output stage defective
Ballast circuit error regen resistor cable has ground fault regen resistor has ground fault regen output stage is defective
The amplifier is "enabled" via the software when one of safety inputs still has a "low" signal.
The amplifier is "enabled" via the software when LOCK still has a
"low" signal.
Regen resistor power is insufficient. Brake resistance power has been reached and the resistor was deactivated. see also I-DERROR
Contact manufacturer
Check motor cable, replace if necessary replace motor
Replace amplifier replace regen resistor cable replace regen resistor
Replace amplifier
Enable amplifier only if ENABLE and
EN-BRAKE are "high".
Enable the amplifier only if the LOCK signal is "high".
An external regen resistor must be used to adjust the value of G-MBAL .
Brake supply voltage error reserved
I2T Error
Motor temperature warning
Motor parameter error
Multi-turn error
Holding brake supply 24 V-BR missing.
Holding brake switch is defective
I-I2T exceeds the warning value
A-I2TERR
I-TEMPM exceeds the warning value A-TEMPMW
M parameters were not found in the encoder when using motors with an EnDAT
®
or HIPERFACE
® encoder
When using an EnDAT ® or
HIPERFACE ® multi-turn encoder, an error has occurred at the extension at > 4096 turns
If the motor has a holding brake, the amplifier can only be "enabled" when
24 V-BR is applied to the brake.
Replace amplifier
Increase
Increase
A-I2TERR
A-TEMPMW
M parameters were not loaded into the encoder
Encoder defective
Defective signal lines or connectors, faulty wiring or broken cables
Motor with multi-turn encoder was replaced
Encoder defect
Page 54 01.06.2021
29
30
31
Total power limit reached reserved reserved
The power of all axes has exceeded the maximum load.
DIAS-DRIVE 310-23
Reduce the load
Drive is insufficiently dimensioned
01.06.2021 Page 55
DIAS-DRIVE 310-23
6 DIAS Drive 300 Accessories
6.1 Shielding Plate with Strain Relief
(Article number: 09-501-101-Z1)
The shielding plate with strain relief is used to secure the DIAS Drive cables.
Included in delivery are:
1 pcs. Strain relief
(mounting on the upper side of the DIAS
Drive)
2 pcs. Allen screws
Type M5
6.1.1 Mounting Instructions
Remove the appropriate connector. Insert the strain relief into the slots provided.
The reconnected plug holds the strain relief in position.
Run the cable through the clamps and secure it to the strain relief using the two screws.
Page 56 01.06.2021
6.2 Mounting Set
DIAS-DRIVE 310-23
(Article number: 09-501-101-Z2)
The fixing (mounting) set serves for mounting the DIAS Drive in the switchgear cabinet. By d oing so, the amplifier’s fan block is located outside of the switchgear cabinet (better ventilation). An appropriate recess in the switchgear cabinet must be provided.
Included in delivery are:
2 pcs. Mounting Bracket
(mounting on the upper or lower side of the DIAS Drive)
4 pcs. Allen screws
Type M5
01.06.2021 Page 57
DIAS-DRIVE 310-23
6.2.1 Mounting Instructions
Mounting on the upper side of the amplifier.
Place the mounting bracket in the provided slots and secure it with both screws.
Page 58
Mounting on the l ower side of the amplifier.
Place the mounting bracket in the provided slots and secure it with both screws.
01.06.2021
6.2.2 Dimensions incl. Mounting Set
DIAS-DRIVE 310-23
01.06.2021 Page 59
DIAS-DRIVE 310-23
7 VARAN Interface for DIAS Drive 3xx (VAC 013)
This VARAN interface module is used for communication between a DIAS drive and control over the VARAN bus. It is integrated into the DIAS Drive.
It contains the safety functions SS1 (Safe Stop 1) (stop category 1 according to EN60204) for safely shutting down the amplifier and the "safe restart" STO (Safe Torque Off).
In addition, it contains the interface for digital inputs that can be used as a fast positionlatch input.
Through the VARAN-Out port, the VARAN bus can be configured in a linear structure.
Page 60 01.06.2021
7.1 Technical Data
7.1.1 General
DIAS-DRIVE 310-23
Interfaces 1 x VARAN-In (RJ45) (maximum length: 100 m)
1 x VARAN-Out (RJ45) (maximum length: 100 m)
1 x DIAS-Drive interface (26-pin blade terminal)
4 fast digital inputs
2 safety inputs for the SSI (SAFE Stop 1) and
STO (SAFE Torque Off) safety functions
1 relay output for indicating the safety function status
7.1.2 Electrical Requirements
Supply voltage +5 V DC
(supplied by the DIAS-Drive)
Typically 400 mA Maximum 500 mA Current consumption
Supply voltage
7.1.3 Input Specifications
Number
Input voltage
Signal level
Switching threshold
Input current
Input delay
Digital inputs
(D-IN1 to D-IN4)
Typically +24 V, maximal +30 V
Safety inputs
(ENABLE_L and ENABLE_H)
Differential voltage between
ENABLE_H (+) and ENABLE_L (-) typically 24 V, maximum 30 V
Low: ≤+5 V, High: ≥+15 V
Typically +9 V
-
Differential voltage between
ENABLE_H (+) and ENABLE_L (-) typically 24 V, maximum 30 V
Low < +6 V, High > +14 V
10 mA at +24 V
Typically 0,1 ms Turn-on circa 20 ms,
Turn-off 0.5 s to 1 s
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DIAS-DRIVE 310-23
7.1.4 Relay Specifications
Number of relays
Relay types
Power supply
Switching time
Switching range
Switching power
7.1.5 Safety Conformity
Safety integration level according to IEC EN 62061
Performance Level according to
EN ISO 13849-1
Probability of failure per hour
Mean time until a dangerous error occurs
Confirmation Test Interval
[Years]
7.1.6 Miscellaneous
Article number
Hardware version
Standardization
1 x Relay output (contacts S3, S4)
1 x normally open
+24 V DC
<10 ms
Max. 30 V DC/ min. 100 µA, max. 0.5 A
Max. 42 V AC / min. 100 µA, max. 0.5 A
PFH
D
[10 -9 ]
MTTF
D symmetrized [Years]
SIL 3
PLe
20
16-059-013
2.x
UL (336350)
0.3
High
Page 62 01.06.2021
7.1.7 Environmental Conditions
Storage temperature
Environmental temperature
Humidity
EMC stability
Shock resistance
Protection Type
Pollution degree
DIAS-DRIVE 310-23
-20 … +85 °C
0 … +60 °C
0 - 95 %, uncondensed
Tested in the DIAS Drive according to EN61800-3
EN 60068-2-27 150 m/s²
EN 60529 IP 20
2
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DIAS-DRIVE 310-23
7.2 Mechanical Dimensions
Integrated into the SDD3xx servo amplifier
Page 64 01.06.2021
7.3 Connector Layout
DIAS-DRIVE 310-23
X1: VARAN-In
Pin
1
2
3
4 – 5
6
7 – 8
Function
TX/RX+
TX/RX-
RX/TX+
-
RX/TX-
-
X2: VARAN-Out
Pin
1
2
3
4 - 5
6
7 - 8
Function
TX/RX+
TX/RX-
RX/TX+
-
RX/TX-
-
Further information about the VARAN bus can be found in the VARAN bus specifications!
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DIAS-DRIVE 310-23
X3: IO
Pin
1
2
3
4
9
10
11
12
5
6
7
8
13
14
15
16
Function
ENABLE_L
ENABLE_H
Reserved
Reserved
Not used
Not used
S3
S4
Reserved
Reserved
Reserved
Ext. GND
D-IN 1
D-IN 2
D-IN 3
D-IN 4
Applicable connectors
X3: 2 x 8-pin Phoenix plug with spring terminal FMC1, 5/8-ST-3.5
For the cable strain relief, it is important to ensure that the minimum bend radius
(eight times the cable diameter) of the cable is not undercut!
Page 66 01.06.2021
7.4 Status Displays
DIAS-DRIVE 310-23
LED
VARAN IN
VARAN OUT
LED color
Green
Yellow
Green
Yellow
LINK
Definition
Lights when the connection between the two PHYs is established
ACTIVE Lights when data is received or sent over the VARAN bus.
LINK Lights when the connection between the two PHYs is established.
ACTIVE Lights when data is received or sent over the VARAN bus.
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DIAS-DRIVE 310-23
7.5 Additional Safety Information
The safety module "Safe Restart Lock" in an integral component of the DIAS Drive 3xx and is already installed with delivery; it meets the conditions required for safe operation according to SIL 3 in compliance with IEC 62061 and according to PL e in compliance with
EN 13849-1.
Safety modules can only be powered by supplies that meet the requirements for
PELV in compliance with EN60294.
Installation, mounting, programming, initial start-up, operation, maintenance and discarding of safety modules can only be performed by qualified personnel .
Qualified personnel in this context are people, who have completed training or have trained under supervision of qualified personnel and have been authorized to operate and maintain safety-related equipment, systems and facilities in compliance with the strict guidelines and standards of safety technology.
For your own safety and the safety of others, use safety modules for their designated purpose only.
Correct EMC installation is also included under designated use.
Non-designated use consists of
•
Any changes made to the Safety modules or the use of damaged modules
•
The use of the Safety modules inconsistent with the technical margins described in these operating instructions
•
The use of the Safety modules inconsistent with the technical data described in these operating instructions (see the "Technical data" sections of the respective production).
In addition, observe the warnings in the other sections of these instructions. These instructions are visibly emphasized by symbols.
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DIAS-DRIVE 310-23
•
Only qualified personnel are authorized to install the "safe restart" STO
(Safe Torque off) and set the parameters.
•
All control devices (switches, relays, PLC, etc.) and the control cabinet must meet the requirements for EN 13849. This consists of:
➢ Door switches, etc. with at least IP54 protection
➢
Control cabinet with at least IP54 protection
•
The proper cables and end-sleeves must be used
•
All cables that affect safety (e.g. control cables for the ENABLE_L and
ENABLE_H inputs) must be laid in a conduit outside of the control cabinet.
Short or crossed circuits in the signal lines must be avoided! See EN
ISO 13849
•
The terminal connections X3/Pin 2, Pin 4, Pin 10 and Pin 12 are labelled as “reserved” and cannot be used externally!
•
When using the SS1 (Safe Stop 1) safety function, the typical turn-off delay is 0.5 seconds. Subsequent actions that require the STO (Safe
Torque Off) function (e.g. manual access to the machine), can only be released after 1 second.
•
If external forces influence axes that are used with the STO safety function (e.g. hanging load), additional measures must be taken (such as an electromagnetic double-surface spring brake, instead of a permanent magnet brake).
Failure to follow the above safety measures can lead to severe injuries.
The main power supply for the servo amplifier must be disconnected using the main switch for the following instances:
•
Cleaning, maintenance or repairs
•
Extended still-stand periods
Failure to follow the above safety measures can lead to severe injuries.
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7.6 Additional Information
7.6.1 "Safe Restart Lock" STO (Safe Torque Off)
The DIAS Drive, in combination with the optional VARAN interface, supports the safety functions SS1 (Safe Stop 1) and STO (Safe Torque Off), and meets the requirements for
Category 4 Performance Level "e" according to EN ISO 13849-1 and SIL3 according to EN
62061.
For his purpose, the servo amplifier has two safe inputs ENABLE_L und ENABLE_H.
The relay output S1/S2 can be used to provide the status of the safety function. It is not safety-relevant, but can be used to test the safety function.
The holding brake control is not a component of the safety function. If a safe shutdown of the holding brake is required, the +24 V-BR brake supply must also be shut down externally.
For the 24 V supply, only PELV/SELV supplies can be used.
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7.6.1.1 Implementation
The block diagram below shows an overview of the internal switching circuits.
REL 01
G 01
TR
IN
OPTO 01
AMV
Astable Multivibrator
OPTO 02
CONTR 01
Super visor
1
AMP 01
U_Treiber
0.5s
Super visor
2
CONTR 02
AMP 02
Control
U_Treiber
U_Treiber
OPTO 03
U_Treiber
µ P
Digital I/O potential Electronic potential
Mains potential
Block diagram for safe restart lock
The blocks in the diagram above have the following functions:
Block IN
The input block IN generates the supply voltage for the AMV block. This is formed from the voltage difference between ENABLE_H and ENABLE_L. Power is therefore available shortly after the appropriated signal is applied to ENABLE_H and ENABLE_L. The voltage difference between ENABLE_H and ENABLE_L must exceed the minimum HIGH level.
The level LOW ranges from 0 V to +5 V.
The level HIGH ranges from +15 V to +30 V.
If the input voltage is disconnected, the block maintains the supply voltage for the AMV block for approximately 400 ms. Because the differential voltage is supplied to the OPTO03 block without a delay, the motor can be actively slowed before the amplifier goes into the safe status by disabling U_Treiber.
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Blocks AMV, OPTO 01 and OPTO 02
As long as the AMV block is powered by the IN input block, it generates a pulse with a constant frequency that is transmitted to the sequential electronics through blocks OPTO 01 and OPTO 02.
Blocks CONTR 01, CONTR 02, AMP 01, AMP 02 and TR
These blocks form a safe switching power supply, which generates the driver voltage for
U_Treiber through the transformer TR. It is ensured that the switching supply cannot transmit energy if no control signal is sent from the AMV block via OPTO 01 and OPTO 02.
Blocks G01 and REL01
The relay output S1/S2 is closed when the servo amplifier is supplied with 24 V and the safety function is active. The two blocks are not safety-relevant.
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7.6.1.2 Function
The safety functions in the DIAS Drive are controlled over two safe digital inputs.
The following table shows the status that the ENABLE_L and ENABLE_H inputs must assume to enable normal operation or trigger the safety function.
Input Status Relay output S3/S4 Description
ENABLE_L
Open
ENABLE_H
Open When the servo amplifier is supplied with 24 V, the inputs are closed after a minimum delay 0.4 of seconds and a maximum of
1 seconds
Safe status of the drive system
Low
Low
Low
Open
When the servo amplifier is supplied with 24 V, the inputs are closed after a minimum delay 0.4 of seconds and a maximum of
1 seconds
•
Single channel safe status, only when using classic I/O technology
•
Safe status of the drive system , when a safe output is used by a Safety PLC. Also when ENABLE_L is connected to „Ext. GND“
Low High Open Drive system ready
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Timing Diagram
If the ENABLE_L and ENABLE_H are changed from any status to the "Drive Ready" status, the servo amplifier is not immediately enabled. In addition, in the software ( K-EN = 1) or the corresponding bit in the "control word" must be set so that the software "enable" can be set and the drive therefore switched to the operational mode.
7.6.1.3 Function Test
The safety function test is required to ensure correct operation. The entire safety circuit must be tested for full functionality.
Tests must be performed at the following times:
•
After installation
•
In regular intervals, or at least once a year
If the function test results in an invalid machine status, the error must be found and corrected before the safety function is retested. If the error reoccurs during the function test, the machine can no longer be operated.
Failure to follow the above safety measures can lead to severe injuries and damage.
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7.6.1.4 Test conditions
The entire safety circuit must be tested for functionality.
The function test is performed from the following start condition:
•
An operation-ready servo drive system
•
Safe input ENABLE_L is LOW and ENABLE_H is HIGH
•
Software application is running
•
Motor(s) running
DIAS-DRIVE 310-23
Depending on the wiring:
1. both the ENABLE_L and ENABLE_H inputs are opened or when ENABLE_L is connected to „Ext. GND“ and the safe output of a Safe PLC is used for ENABLE_H,
2. ENABLE_H is open or LOW (depending on the wiring).
The motor speed is expected to slow to null and the relay output S1/S2 to close after a minimum delay of 0.4 s and a maximum of 1 s when the servo drive is supplied with 24 V.
The servo drive system should go into safe mode.
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7.6.1.5 Example Connection with Switching Contacts
To meet the requirements of safety category 4, performance level "e" for EN 13849-1 and
SIL3 according to EN 62061, a two-channel control must be provided for the safety functions.
The wiring for both connections must be provided with protective insulation (to avoid the
"external voltage supply" error).
For ENABLE_H this means, the other signals that can have a 24 V potential must be led separately.
For ENABLE_L this means, the other signals that can have "Ext. GND" potential must be wired separately. Because the 24 V auxiliary voltage in the control cabinet is normally grounded, caution must be taken to avoid a short-circuit with PE. This can occur through, for example, wiring in a cable duct.
The schematic shows the possible wiring for use of conventional switch contacts.
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7.6.1.6 Example: Safety PLC Application
To meet the requirements of safety category 4, performance level "e" for EN 13849-1 and
SIL 3 according to EN 62061, an error-proof output of a safety PLC must be used.
There are two types of error-safe outputs.
1. A simple error-safe output, which functions based on "Ext. GND" only. This is then connected to the ENABLE_H input. The wiring for both connections must be provided with protective insulation (to avoid the "external voltage supply" error).
In this case, ENABLE_L is connected to "Ext. GND"
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2. Two-channel error-proof relay output, with which the “+” output is connected to
ENABLE_H and the
“–“ output to ENABLE_L.
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7.7 Addressing
Description
Axis 1
0000
0001
0002
0003
0004
0008
000C
0010
0014
0018
001C
0020
0021
0022
0023
0024
0028
002C
0030
0034
0038
003C
1
1
1
1
4
4
4
4
4
4
4
1
4
4
4
4
4
4
1
1
1
4 r/w
Transmit Execution Register
Bit 0: 1 = Start Object Transfer
Bit 1: 1 = Repeat Object Transfer
Bit 2: 1 = Enable Value 3-5
Bit 3…7: Reserved r/w Reserved r/w Drive Control Byte r/w Object Address r/w Object Value r/w Value 1 r/w Value 2 r/w Value 3 r/w Value 4 r/w Value 5 r/w Reserved r/w
Receive Status Register
Bit 0: 1 = Executed Object Transfer
Bit 1: 1 = CRC Error
Bit 2…7: Reserved r/w Reserved r r r r r r/w Digital In/Out Byte r/w Transmit Control Byte r/w Object Value
Value 6
Value 7
Value 8
Value 9
Value 10 r/w Reserved
Page 80
Reset value
00
00
00
00
00
00000000
00000000
00000000
00000000
00000000
00000000
-
00
00
00
00000000
00000000
00000000
00000000
00000000
00000000
00000000
01.06.2021
Axis 2
0040
0041
0042
0043
0044
0048
004C
0050
0054
0058
005C
0060
0061
0062
0063
0064
0068
006C
0070
0074
0078
007C
1
4
4
4
1
1
1
4
4
4
4
1
4
4
4
4
1
1
1
4
4
4 r/w
Transmit Execution Register
Bit 0: 1 = Start Object Transfer
Bit 1: 1 = Repeat Object Transfer
Bit 2: 1 = Enable Value 3-5
Bit 3…7: Reserved r/w Reserved r/w Drive Control Byte r/w Object Address r/w Object Value r/w Value 1 r/w Value 2 r/w Value 3 r/w Value 4 r/w Value 5 r/w Reserved r/w
Receive Status Register
Bit 0: 1 = Executed Object Transfer
Bit 1: 1 = CRC Error
Bit 2…7: Reserved r/w Reserved r/w Digital In/Out Byte r/w Transmit Control Byte r/w Object Value r/w Value 6 r/w Value 7 r/w Value 8 r/w Value 9 r/w Value 10 r/w Reserved
DIAS-DRIVE 310-23
00
00
00
00
00000000
00000000
00000000
00000000
00000000
00000000
00000000
00
00
00
00
00000000
00000000
00000000
00000000
00000000
00000000
-
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Axis 3
0080 1 r/w
Transmit Execution Register
Bit 0: 1 = Start Object Transfer
Bit 1: 1 = Repeat Object Transfer
Bit 2: 1 = Enable Value 3-5
Bit 3 …7: Reserved
00A1
00A2
00A3
00A4
00A8
00AC
00B0
00B4
00B8
00BC
4
4
4
4
1
1
1
4
4
4
0081
0082
0083
0084
0088
008C
0090
0094
0098
009C
00A0
4
4
4
1
1
1
4
4
4
4
1 r/w Reserved r/w Drive Control Byte r/w Object Address r/w Object Value r/w Value 1 r/w Value 2 r/w Value 3 r/w Value 4 r/w Value 5 r/w Reserved r/w
Receive Status Register
Bit 0: 1 = Executed Object Transfer
Bit 1: 1 = CRC Error
Bit 2…7: Reserved r/w Reserved r/w Digital In/Out Byte r/w Transmit Control Byte r/w Object Value r/w Value 6 r/w Value 7 r/w Value 8 r/w Value 9 r/w Value 10 r/w Reserved
00
00
00
00
00000000
00000000
00000000
00000000
00000000
00000000
00000000
00
00
00
00
00000000
00000000
00000000
00000000
00000000
00000000
-
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00CC
00D0
00E0
00E1
00E2
00E3
00E4
Axis 3 – Telegram Type 2 (Fast Axis)
00C0 1 w*
Transmit Execution Register
Bit 4 : 1 = Enable Telegram Typ 2
Bit 5 : 1 = Direct Access
00C1
00C2
00C3
00C4
00C8
1
1
1
4
4 w* w* w* w* w* reserved
Drive Control Byte reserved
Value 3
Value 4
00E8
00EC
00F0
4
16
1
1
1
1
4
4
4
16 w*
- r/w
Value 5 reserved reserved r/w reserved r/w Digital In/Out Byte r/w Transmit Control Byte r/w Value 8 r/w r/w r/w
Value 9
Value 10 reserved
DIAS-DRIVE 310-23
00
00
00
00
00000000
00000000
00000000
-
00
00
00
00
00000000
00000000
00000000
-
For additional addressing, see the VARAN bus specifications
More addressing applications can be found in the DIAS drive parameter documentation.
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7.8 Recommended Shielding for VARAN
The real-time VARAN Ethernet bus system exhibits a very robust quality in harsh industrial environments. Using IEEE 802.3 standard Ethernet physics, the potentials between an
Ethernet line and sending/receiving components are separated. In the event of an error, the
VARAN Manager resends messages to a bus participant immediately. The shielding described below is principally recommended.
For applications in which the bus is run outside the control cabinet, the correct shielding is required. Especially when for structural reasons, the bus line must be placed next to strong electromagnetic interference sources.
SIGMATEK recommends the use of CAT5e industrial Ethernet bus cables.
For the shielding, an S-FTP cable should be used.
It is a symmetric, multi-wire cable with unshielded pairs. For the total shielding, a combination of foil and braiding is used. A non-laminated variant is recommended.
The VARAN cable must be secured at a distance of 20 cm from the connector to protect against vibration!
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7.8.1 Wiring from the Control Cabinet to an External VARAN Component
If the Ethernet lines are connected from a VARAN component to a VARAN node located outside the control cabinet, the shielding should be placed at the entry point to the control cabinet housing. All noise can then be dissipated before reaching the electronic components.
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7.8.2 Wiring Outside of the Control Cabinet
If a VARAN bus cable must be placed outside of the control cabinet only, no additional shield support is required. This requires that only IP67 modules and connectors be used.
These components have extremely robust and noise-resistant construction. The shielding for all sockets in IP67 modules are internally connected to common bus or electrically connected to the housing, whereas the dissipation of voltage spikes does not flow through the electronics.
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7.8.3 Shielding for Wiring within the Control Cabinet
DIAS-DRIVE 310-23
Sources of strong electromagnetic noise located within the control cabinet (drives,
Transformers, etc.) can induce interference in a VARAN bus line. Voltage spikes are dissipated over the metallic housing of a RJ45 connector. Noise is conducted over the control cabinet without additional measures needed on the circuit board of electronic components. To avoid error sources with data exchange, it is recommended that shielding be placed before any electronic components in the control cabinet.
Page 87
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7.8.4 Connecting Noise-Generating Components
When connecting power components to the bus that generate strong electromagnetic noise, it is also critical to ensure correct shielding. The shielding should be placed before a power component (or a group thereof).
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7.8.5 Shielding Between Two Control Cabinets
DIAS-DRIVE 310-23
If two control cabinets must be connected over a VARAN bus, it is recommended that the shielding be located at the entry points of each cabinet. Noise is therefore prevented from reaching the electronic components in both cabinets.
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Documentation Changes
Change date
27.05.2014
17.07.2014
30.04.2015
08.05.2015
25.11.2015
08.02.2016
23.05.2016
21.11.2016
31.05.2017
19.07.2017
27.09.2017
21.05.2019
19.02.2020
11.03.2020
25.01.2021
31.03.2021
01.06.2021
Affected page(s)
19
20
16
45
34
1
Document
Chapter Note
20
29
20
16
67, 69,
75, 76
16
18
9
7
Document
1
Nameplate
28
59
2.2.4 Connector Models
6.2.2 Dimensions incl.
Mounting Set
1.8 Technical Data
1.9 Environmental
Conditions, Ventilation and
Mounting
2.2.6 External Fusing
1.8 Technical Data
Added leakage currents notice
Added shelf life notice
Max. holding brake switching energy added
Sine/Cosine & TTL Encoder feedback changed main input → DC-link
VAC 013 note
AWG corrected
Shielding Plate extended
VAC 013 documentation added
Limitation 599 Hz
Removed EN / IEC 61508 max. standstill current added
Added note regarding the star-connection
Added warning regarding EMF
Standards updated
Picture exchanged
Chapter removed
2 connector types changed (X1B + X3, X4, X5)
Dimension corrected
PWM frequency and Regulator frequency added
Overvoltage category added
UL Requirement - paragraphs added
09-501-101-23X added
Page 90 01.06.2021
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