Danfoss VLT Integrated Servo Drive ISD 510 System Operating Instructions Manual Download Page 1

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MAKING MODERN LIVING POSSIBLE

Operating Instructions

VLT

Integrated Servo Drive ISD

510 System

vlt-drives.danfoss.com

Summary of Contents for VLT Integrated Servo Drive ISD 510 System

Page 1: ...MAKING MODERN LIVING POSSIBLE Operating Instructions VLT Integrated Servo Drive ISD 510 System vlt drives danfoss com...

Page 2: ......

Page 3: ...oreseeable Misuse 12 2 9 Service and Support 12 3 System Description 13 3 1 Overview 13 3 2 Servo Drive 13 3 2 1 Servo Drive Types 14 3 2 2 Motor Components 14 3 2 2 1 Shaft 14 3 2 2 2 Brake Optional...

Page 4: ...2 Ethernet POWERLINK 28 4 Mechanical Installation 29 4 1 Transport and Delivery 29 4 1 1 Items Supplied 29 4 1 2 Transport 29 4 1 3 Inspection on Receipt 29 4 2 Safety Measures during Installation 29...

Page 5: ...6 4 1 Programming with Automation Studio 44 6 4 1 1 Requirements 44 6 4 1 2 Creating an Automation Studio Project 44 6 4 1 3 Connecting to the PLC 48 6 4 2 Programming with TwinCAT 48 6 4 2 1 ISD Deli...

Page 6: ...y Concept 68 8 7 1 Statusword 68 8 7 2 Error Codes 69 8 8 Fault Reset 69 8 9 Commissioning Test 69 8 10 Application Example 72 8 11 Safety Function Characteristic Data 73 8 12 Maintenance Security and...

Page 7: ...tions 85 11 1 Servo Drive 85 11 1 1 Nameplate 85 11 1 2 Characteristic Data 85 11 1 3 Dimensions 86 11 1 4 Permitted Forces 88 11 1 5 General Specifications and Environmental Conditions 88 11 2 Servo...

Page 8: ...terature for Danfoss drives is also available online at vlt drives danfoss com Support Technical Documen tation 1 3 Copyright VLT ISD and SAB are Danfoss registered trademarks 1 4 Approvals and Certif...

Page 9: ...n the same casing There are 2 versions of the ISD 510 servo drive Standard With 2 hybrid connectors M23 that connect power and communication signals from a hybrid cable Advanced As standard plus 3 add...

Page 10: ...pdates to the firmware ISD Toolbox software and PLC libraries may be available When updates are available they can be downloaded from the danfoss com website The ISD Toolbox software or the PLC librar...

Page 11: ...omply with the specified ambient conditions For further information see chapter 11 1 5 General Specifications and Environmental Conditions and chapter 11 2 4 General Specifications and Environ mental...

Page 12: ...SAB the ISD 510 servo system has other supply voltage inputs including external auxiliary voltage Before commencing repair work check that all supply voltage inputs have been switched off and that th...

Page 13: ...instructions it contains The product markings and identification markings applied to the components as well as safety and warning instructions are not removed and are always kept in a legible conditi...

Page 14: ...lso applies to failure to comply with the specified operating conditions and applications Danfoss assumes no liability of any sort for damage attrib utable to improper use 2 9 Service and Support Cont...

Page 15: ...Ethernet UAUX and STO signals 3 2 Servo Drive ISD is the abbreviation of integrated servo drive which is a compact drive with an integrated permanent magnet synchronous motor PMSM This means the enti...

Page 16: ...voltage F138 138 mm1 39 40 Surface coating 15 17 Drive enclosure 31 32 Flange type SX Standard E54 IP54 SX Standard CX Customized E67 IP67 shaft IP65 C0 Customized version 18 20 Drive feedback FRX Res...

Page 17: ...feedback variants available Resolver 17 Bit single turn encoder 17 Bit multi turn encoder Table 3 4 summarizes the characteristic data of each variant Data type Resolver Single turn encoder Multi tur...

Page 18: ...PE PE PE connector 15 A 2 STO Safety supply 24 V DC 10 1 A 3 STO Safety supply ground 1 A 5 TD Positive Ethernet transmit According to standard 100BASE T 6 RD Positive Ethernet receive 7 TD Negative...

Page 19: ...6 SSI CLK Positive SSI BiSS clock out 7 Input 2 Analog Digital input Digital input Nominal voltage 0 24 V Bandwidth 100 kHz Analog input Nominal voltage 0 10 V Input impedance 5 46 k Bandwidth 25 kHz...

Page 20: ...ating LEDs on the Servo Access Box for further information NOTICE The SAB has an IP rating of IP20 It is only designed for use within a control cabinet The SAB may be damaged if exposed to fluids All...

Page 21: ...clamp for encoder cable 11 ISD Line 1 STO 1 STO output to hybrid cable line 1 STO 28 X1 Ethernet input line 1 RJ45 connector not included 12 ISD Line 1 NET 1 X3 Ethernet output to hybrid cable line 1...

Page 22: ...ISD Line 1 STO 1 Underside Used for STO output voltage 1 130BE394 10 STO Pins left to right STO STO Nominal voltage 24 V DC 10 Nominal current Depends on the number of servo drives in the application...

Page 23: ...rent 2 A Maximum cross section 2 5 mm2 Table 3 10 Relay Connectors 3 3 1 5 Encoder Connectors Item Description Drawing pins Ratings Encoder connector Used to connect SSI or BiSS encoders 130BE392 10 G...

Page 24: ...ns Ratings 24 48 V IN Connector Used for 24 48 V DC input to the SAB 130BE397 10 AUX Pins left to right AUX AUX Nominal voltage 24 48 V DC 10 Nominal current Depends on the number of servo drives in t...

Page 25: ...P Layout The local control panel is divided into 4 functional groups see Illustration 3 10 A Display area B Display menu keys C Navigation keys and indicator lights LEDs D Operation keys and reset A D...

Page 26: ...cursor and provide operation control in local operation There are also 3 status LEDs in this area Key Function 10 Back Reverts to the previous step or list in the menu structure 11 Cancel Cancels the...

Page 27: ...gn Guide for further information Both ends of the loop cable are fitted with M23 connectors The feed in cable is fitted with an M23 connector at the output end for connection to the 1st servo drive At...

Page 28: ...undancy that can be used to connect 1 or 2 lines each with up to 32 servo drives in an application NOTICE For cabling with redundancy see the VLT Integrated Servo Drive ISD 510 System Design Guide 3 6...

Page 29: ...ng and writing to objects The servo drives and the SABs can be operated with the following cycle times for both fieldbuses 400 s and multiples of it for example 800 s 1200 s and so on 500 s and multip...

Page 30: ...1 Ports always connected internally in the SAB Illustration 3 16 EtherCAT Port Assignment for the SAB in Line Topology Mode default 3 8 2 Ethernet POWERLINK The ISD drive and the SAB are certified acc...

Page 31: ...performed by qualified personnel see chapter 2 5 Qualified Personnel Installation must be performed with due care and attention All safety regulations and protective measures must be complied with and...

Page 32: ...surface before fixing the servo drive Misalignment shortens the life of the bearing and the coupling components and reduces heat transfer from the servo drive 3 Provide contact protection according to...

Page 33: ...ing screws according to the template All dimensions are in mm 130BE423 10 130 8 6 2 5 5 11 10 110 10 110 6 5 7 5 2 Illustration 4 1 SAB Mounting Template Mechanical Installation Operating Instructions...

Page 34: ...vanced servo drive is delivered additionally with M8 and M12 blind caps These blind caps prevent contamination of the servo drive and are necessary to achieve the relevant IP protection rating Always...

Page 35: ...lists the tightening torque values for the fixing screws Always tighten the fixing screws uniformly and crosswise Servo drive size Thread type hole size Maximum thread length Tightening torque Size 1...

Page 36: ...nto the holding screws on the backplate of the control cabinet Tighten the holding screws Tighten the screws at the bottom of the SAB NOTICE A remote mounting kit is available to mount the LCP in the...

Page 37: ...5 8 Connecting the Components 5 4 Grounding Grounding for electrical safety Ground the ISD servo drive with the PE wire of the feed in cable see chapter 5 8 Connecting the Components Ensure that the...

Page 38: ...ly the SAB with a power supply unit with an output range of 24 48 V DC 10 The output ripple of the power supply unit must be 250 mVpp Only use supply units that conform to the PELV specification Refer...

Page 39: ...ponding terminal block on the SAB 2 Secure the feed in cable 6 using the cable clamp 5 ensuring that the shield is positioned exactly under the clamp 3 Secure the STO cable using the cable clamp 3 ens...

Page 40: ...mains cable using the cable clamp 5 5 If using a brake resistor decouple the cable using the brake cable clamp 4 6 If using a relay decouple the cable with a cable tie to the fixing 3 Step 4 Connect t...

Page 41: ...t for the discharge time to elapse WARNING DISCHARGE TIME The servo drives and the SAB contain DC link capacitors that remain charged for some time after the mains supply is switched off at the SAB Fa...

Page 42: ...daisy chain format connect the male connector of the loop cable to the female connector X2 of the 1st servo drive 7 Connect the female connector of the loop cable to the male connector X1 of the next...

Page 43: ...for the X1 and X2 connectors Mount the blind caps after removing the corresponding connector 5 8 2 2 Connecting Disconnecting Cables from Ports X3 X4 and X5 Cable routing 1 Avoid mechanical tension f...

Page 44: ...Ethernet connector marked X3 on the servo drive 2 Press the connector towards the electronic housing of the servo drive and tighten the threaded ring by turning it clockwise 130BE668 10 Illustration...

Page 45: ...egrated Servo Drive ISD 510 System Programming Guide for more information Setting an ID to a device can also be done via the LCP Setting the node ID directly on a servo drive or on the SAB All IP rela...

Page 46: ...erlying fieldbus communi cation and or the CANopen CiA DS 402 profile is not necessary The library contains Function blocks for controlling and monitoring the servo drive and the SAB Function blocks f...

Page 47: ...se the ISD libraries will not work Inside the library the following lists of constants are defined AxisErrorCodes Constants for error codes of the axis Error codes can be read using the function block...

Page 48: ...nitializing each instance with its node number and the slot name for example IF3 it is connected to Each instance of SAB_REF is the logical representation of 1 physical SAB Import fieldbus device and...

Page 49: ...ects 1 Right click on the entry of the ISD 510 and select Open I O Configuration 2 In the Channels section change the Cyclic transmission of the following objects 2a All subindexes of object 0x5050 Li...

Page 50: ...Automation Studio 1 Right click CPU Open Software Configuration in the Physical View 2 Ensure that the PLC cycle time is the same as the Ethernet POWERLINK cycle time 6 4 1 3 Connecting to the PLC Inf...

Page 51: ...functionality for the SAB The names of the POUs that target the SAB all end with _SAB When integrating the ISD 510 library some standard libraries are integrated automatically unless they are already...

Page 52: ...information for the TwinCAT System Manager Illustration 6 10 Instantiation of AXIS_REF_ISD51x Append a PLC Project into TwinCAT System Manager To create a link between the TwinCAT PLC Control project...

Page 53: ...elect Danfoss GmbH VLT ISD Series VLT ISD 510 Integrated Servo Drive 11 Click on OK 12 Answer the question if the drive is used as an NC axis with No If the drive should be used as an NC axis see chap...

Page 54: ...Correct I O Configu ration Attach the input and output variables of the PLC program to the physical inputs and outputs of the device This is done inside the TwinCAT System Manager so that the library...

Page 55: ...sAddr and select Change Link 18 In the Attach Variable netId Input window select PLC Configuration MyFirstIsd510Project Standard myAxis AmsNetId 19 Click on OK 20 Right click on port via I O Configura...

Page 56: ...In addition to the Danfoss_VLT_ISD_510 lib file include the TcMC2 lib file the Danfoss_VLT_ISD_510 lib file is still needed for the SAB to be operated 2 Create 1 instance of AXIS_REF instead of AXIS_R...

Page 57: ...the function block MC_Power_ISD51x for every axis in order to control its power stage Call up this function block in every PLC cycle It is recommended to have 1 instance of the function block DD_Power...

Page 58: ...llow the on screen instructions to complete the installation process 6 5 4 ISD Toolbox Communication This chapter describes the Ethernet specific network interface settings needed by the ISD Toolbox T...

Page 59: ...spective and does not reflect the actual physical topology of the network 6 5 4 1 Network Settings for Indirect Communication Any network interface can be used to communicate through a PLC and a dedic...

Page 60: ...ter in the Windows IP Routing section 6 Reboot the PLC for the changes to take effect Set the IP address of the EtherCAT slave servo drive or SAB 1 Open the TwinCAT System Manager 2 Click on Advanced...

Page 61: ...on and select Properties 4 Click on Internet Protocol Version 4 TCP IPv4 the checkbox must be checked and then click on Properties 5 Select Use the following IP address and use 192 168 100 240 as the...

Page 62: ...Window is the basis for all ISD Toolbox functionalities It consists of the following components 130BE311 10 1 2 3 4 5 7 8 9 6 Illustration 6 24 Main Window Commissioning VLT Integrated Servo Drive IS...

Page 63: ...ment window lists all available sub tools for each added device See the VLT Integrated Servo Drive ISD 510 System Programming Guide for further information on the sub tools 6 Workspace This is the spa...

Page 64: ...d comply with this standard PLCopen Technical Specification Function blocks for motion control Formerly Part 1 and Part 2 Version 2 0 March 17 2011 Additionally specific ISD function blocks provide th...

Page 65: ...r home switch are available CAM mode In CAM mode the servo drive executes a synchronized movement based on a master axis The synchroni zation is done by means of a CAM profile that contains slave posi...

Page 66: ...Link A CT X2 Green Link activity status of Hybrid Out X2 On Ethernet link established Flashing Ethernet link established and active Off No link LED Color Flash status Description Link A CT X31 Green L...

Page 67: ...s in state Fault Flashing Mains is not applied at the input NET STAT Green red Fieldbus dependent Network status of the device see corresponding fieldbus standard Link A CT X1 Green Link activity stat...

Page 68: ...ortion of safe failures and detected dangerous failures of a safety function or a subsystem as a percentage of all possible failures SIL EN IEC 61508 EN IEC 62061 Safety Integrity Level STO EN IEC 618...

Page 69: ...iting the length of time specified in chapter 2 Safety Failure to isolate the mains voltage supply and waiting the time specified could result in death or serious injury Do not use the STO function to...

Page 70: ...itching Output Signals with test pulses must not have test pulses of 1 ms Longer pulses may lead to reduced availability of the servo system The external supply must be a SELV PELV supply 8 7 Operatio...

Page 71: ...ce 8 8 Fault Reset Change bit 7 of the controlword from 0 to 1 to reset faults See the VLT Integrated Servo Drive ISD 510 System Programming Guide for further information 8 9 Commissioning Test NOTICE...

Page 72: ...not run Application does not run 9 Disable STO Check that the STO start is still inhibited by the error signal MC_ReadAxisInfo_ISD51x output SafeTorqueOff False and MC_ReadStatus_ISD51x output ErrorS...

Page 73: ...that the STO function is working correctly Application does not run 9 Disable STO Check that the STO start is still inhibited by the error signal Statusword bit 3 1 bit 14 0 and object 0x603F shows fa...

Page 74: ...ine 2 Select the safety switch devices in accordance with the requirements of the application 24 V DC 24 V DC 130BE689 10 1a 1b 2a 2b 3 4 5 6 7 8 9 11 12 14 X1 X2 X1 X2 X1 X2 X1 X2 13 13 11 10 1a 1b I...

Page 75: ...2 Probability of failure per hour PFH for maximum system size of 32 servo drives on each STO line 5 x 10 8 h Safe Failure Fraction SFF 95 Hardware fault tolerance H 0 Subsystem classification Type A...

Page 76: ...adjust the contrast Display is defective Replace the faulty LCP or connection cable Fault Possible cause Possible solution Servo drive overheats high surface temperature Excessive load Check the torq...

Page 77: ...pplication error Error Generic application error generic err 0x2310 Overcurrent on output Error Overcurrent on output overcurr out Code Name Severity Warning Error Trip lock Description LCP name 0x239...

Page 78: ...Package description mismatch Trip lock Firmware found does not match the package description FW pack err 0xFF71 Firmware Power cycle needed Warning error Firmware update transfer is completed but a p...

Page 79: ...t The sum of the servo drive current exceeds the maximum rating of the SAB Check the servo drive current consumption Avoid simultaneous acceleration of all servo drives Fault Possible cause Possible s...

Page 80: ...approximately 200 of the rated current is exceeded DC1 overcurr 0x2398 DC 2 overcurrent Error Overcurrent on DC Line 2 The SAB peak current limit approximately 200 of the rated current is exceeded DC2...

Page 81: ...ning Error SAB card overtemperature The cutout temperature of the SAB card is 80 C overtemp SC 0x4293 Inrush overtemperature SAB card Error Inrush fault Too many transitions into state Normal operatio...

Page 82: ...ing The minimum off time required to protect the internal hardware has not been met AUX2 min off 0xFF51 Internal error 1 Trip lock Internal error 1 contact Danfoss PM int err 1 0xFF52 Internal error 2...

Page 83: ...tasks listed in Table 10 2 can be performed by qualified personnel see chapter 2 5 Qualified Personnel No other tasks are required Component Maintenance task Maintenance interval Instruction Servo dr...

Page 84: ...cables 1 Disconnect the SAB from its power source mains network and all auxiliary supplies 2 Wait for the necessary discharge time to elapse 3 Disconnect any cables connected to the X3 X4 or X5 ports...

Page 85: ...servo drive of the same type See the VLT Integrated Servo Drive ISD 510 System Design Guide for part numbers 10 4 2 Fitting and Commissioning The procedure for fitting and commissioning the servo dri...

Page 86: ...mper disposal Furthermore foreign materials or third party components cannot be included with the returned product Ship the products free on board to the local Danfoss sales company 10 8 Recycling and...

Page 87: ...torque 4 Maximum torque 10 Rated speed 5 Ambient temperature range 11 Maximum speed 6 Protection rating Illustration 11 1 Servo Drive Nameplate 11 1 2 Characteristic Data Table 11 1 and Table 11 2 pr...

Page 88: ...rque derating 8 6 7 Table 11 2 Characteristic Data for Servo Drive with Brake 11 1 3 Dimensions Flange Servo drive Flange thickness Size 1 1 5 Nm 7 mm Size 2 2 1 Nm Size 2 2 9 Nm 8 mm Size 2 3 8 Nm 8...

Page 89: ...3 0 12 137 5 39 92 3 62 19 0 75 84 3 31 84 3 31 80 3 15 7 0 28 X4 45 1 77 40 1 57 130BE440 10 Illustration 11 4 Dimensions of ISD 510 Size 2 2 9 Nm 310 12 20 83 5 3 29 1 0 0 3 9 4 55 4 2 18 3 0 12 137...

Page 90: ...tion 7 54 g 2h axis according to EN 60068 2 64 Sinusoidal vibration 0 7 g 2h axis according to EN 60068 2 6 Maximum relative humidity Storage transport 5 93 non condensing Stationary use 15 85 non con...

Page 91: ...y legible 11 2 2 Characteristic Data Definition Value and unit Input Input voltage 400 480 V 10 Efficiency 98 5 at 400 V Input current 12 5 A continuous 20 A intermittent Output Output voltage ISD Lin...

Page 92: ...ions are in mm in Front view 190 5 7 50 268 10 55 371 5 14 63 130BE312 10 Illustration 11 9 Dimensions Front View Specifications VLT Integrated Servo Drive ISD 510 System 90 Danfoss A S 12 2015 All ri...

Page 93: ...Side view246 4 9 70 11 5 0 45 218 7 8 61 130BE313 10 Illustration 11 10 Dimensions Side View Specifications Operating Instructions MG75K102 Danfoss A S 12 2015 All rights reserved 91 11 11...

Page 94: ...th xxxx Ordering no 175Gxxxx Rev x 1 7 5 G 8 9 X X Specification no 175Rxxxx Rev xxx Signal rating Ethernet 2 x 2 x AWG24 300V yy mm dd Power rating 5 x 2 5mm 1000V 18A 2 Signal rating 2 x 0 5mm 300V...

Page 95: ...ting of capacitors DC link voltage A DC voltage shared by several servo drives connected in parallel DC voltage A direct constant voltage EPSG Ethernet POWERLINK Standardization Group ETG EtherCAT Tec...

Page 96: ...LCopen PLCopen is a vendor and product independent worldwide association which defines a standard for industrial control programming POU Program organization unit This can be a program function block...

Page 97: ...x AUX 22 Brake 21 Encoder 21 Ethernet 22 Mains 20 PE 22 Relay 21 UDC 22 Connectors on the servo drive 15 Control system 66 Cooling 15 Creating a TwinCAT 48 Creating an Automation Studio Project 44 Cyc...

Page 98: ...s 56 ISD touch probe 63 L LCP Cable 25 Display area 23 Menu key 23 Navigation key 23 Operation key 23 Overview 23 Reset 23 LEDs on LCP 24 LEDs on the SAB Aux 1 64 Aux 2 65 Link ACT X1 65 Link ACT X2 6...

Page 99: ...recautions 9 Symbols 9 Unintended start 10 Warnings 10 Safety concept Abbreviations and conventions 66 Application example 72 Characteristic data 73 Commissioning test 69 Error codes 69 Fault reset 69...

Page 100: ...pply requirements Auxiliary 36 Mains 36 Safety power 36 Support 12 Switching on the ISD 510 servo system 44 System overview 7 T Template for programming 62 Terminology 8 Thermal protection 15 Tighteni...

Page 102: ...ucts already on order provided that such alterations can be made without subsequential changes being necessary in specifications already agreed All trademarks in this material are property of the resp...

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