Keba D3-DA 3 Series Project Engineering Manual Download Page 2

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Document: V 1.07 / Document No.: 1008665
Filename: da3xx_pjen.pdf
Pages: 120

© KEBA
Specifications are subject to change due to further technical developments. Details presented may be
subject to correction.

KEBA AG Headquarters:

Gewerbepark Urfahr, 4041 Linz, Austria, Phone: +43 732 7090-0,
Fax: +43 732 7309-10, [email protected]

For information about our subsidiaries please look at www.keba.com.

Summary of Contents for D3-DA 3 Series

Page 1: ...KeDrive D3 DA 3xx x Axis module Project engineering manual V 1 07 Translation of the original manual ...

Page 2: ...bject to change due to further technical developments Details presented may be subject to correction All rights reserved KEBA AG Headquarters Gewerbepark Urfahr 4041 Linz Austria Phone 43 732 7090 0 Fax 43 732 7309 10 keba keba com For information about our subsidiaries please look at www keba com ...

Page 3: ...asl 1 02 10 2016 Various chapter Several corrections and additions hasl ekt 1 03 12 2016 Various chapter Several corrections and additions swb 1 04 05 2017 Various chapter Several corrections and additions UL added swb hasl 1 05 07 2017 EG directives and standards UL added hasl 1 06 04 2018 Various chapter Several corrections Type plate Mounting tech data hasl 1 07 10 2018 Various chapter Several ...

Page 4: ...D3 DA 3xx x Project engineering manual V1 07 4 KEBA ...

Page 5: ...ons for personal safety 18 2 4 Safety instructions for device maintenance 18 2 5 ESD information 19 3 Description of module 20 3 1 Front view 20 3 2 Bottom view 20 3 3 Type plate 21 3 4 Overview D3 DA 3xx x variants 22 3 5 Accessories 23 3 5 1 Connector set 23 4 Displays and operating elements 25 4 1 Status LEDs of the axis 25 4 2 EtherCAT LEDs RJ45 25 5 Mounting and installation instructions 27 5...

Page 6: ... motor cable 64 6 9 Specification of EtherCAT connection interface 65 6 9 1 Pin assignment 65 6 10 Encoder connections 66 6 10 1 Matching motor encoder cables 66 6 10 2 Connection for high resolution encoder 67 6 11 Operation on special systems 68 6 12 DIP Switch S ADR 68 7 Configuration 69 8 Safety functions 70 8 1 STO Safe Torque OFF 70 8 1 1 Configuration of STO safety function 71 8 2 SBC Safe ...

Page 7: ...3 1 Current data D3 DA 320 x 16xx 92 12 3 2 Current data D3 DA 310 x 18xx 92 12 4 D3 DA 310 x 24xx D3 DA 310 x 32xx 93 12 4 1 Current data D3 DA 310 x 24xx 94 12 4 2 Current data D3 DA 310 x 32xx 94 12 5 General safety specifications 95 12 6 Ambient conditions 95 12 7 Safe digital inputs 97 12 8 Digital inputs 98 12 9 Dimensions weight 99 13 EC directives and standards 103 13 1 EC directives 103 1...

Page 8: ...111 16 1 1 Cooling Element D3 XM 310 055 111 16 1 2 Cooling plate D3 XM 300 060 112 16 1 3 Cooling plate D3 XM 300 080 113 16 2 Accessories 113 16 3 Connection technology 114 16 3 1 Connection cable XW P0x xxx 114 16 3 2 Connection cable XW H0x xxx 115 16 3 3 Signal cable XW E10 xxx 116 16 3 4 Signal cable XW R10 xxx 117 16 3 5 Signal cable XW 020 117 16 3 6 Signal cable XW 021 118 Index 120 ...

Page 9: ... engineer training or corresponding professional experience Knowledge about principles of functional safety relevant standards and safety regulations for the machine system particularly knowledge about validation according to EN ISO 13849 2 special risk potential of the machine system and the pro duction process specific protective measures to avert machine specific haz ards based on hazard and ri...

Page 10: ...neer training or corresponding professional experience Knowledge about current valid safety regulations fundamental validation concepts according to EN ISO 13849 the method of operation of the machine or system fundamental functions of the application system analysis and troubleshooting setting options on the operating devices Service technician Basic technical training technical college engineer ...

Page 11: ...levant control tasks in combination with axis module D3 DA 3xx x it is recommended to use the control module D3 DU 3xx x in the variant D3 DU 3x5 x Caution Also take care of the information in the safety manual Functional safety provided by KEBA Information The compliance of EMC directives can only be assumed under attention of chapter CE Certification as well as the information of cahpter Connect...

Page 12: ...es used by you 1 4 1 Content of this document Description of the module Mounting and installation instructions Description of interfaces including EMC directives Diagnostics functions Maintenance Technical data 1 4 2 Not contained in this document Programming instruction Application diagnosis Firmware description General functional safety information Examples for safety applications 1 5 Documentat...

Page 13: ...rammer Start up operator Service technician Onlinehelp DriveManager Programmer Start up operator Service technician DE 1008643 EN 1008666 D3 DP 3xx x Project engi neering manual Project engineer Electrician Start up operator Service technician Information This project engineering manual exclusively describes the D3 DA 3xx x You can find information about further components in the respective projec...

Page 14: ... bodily injury if the corresponding precautions are not taken CAUTION means that if the corresponding safety measures are not taken a potentially hazardous situation can occur that may result in slight bodily injury Caution means that damage to property can occur if the corresponding safety mea sures are not taken ESD This symbol reminds you of the possible consequences of touching electro statica...

Page 15: ...ng inappropriate use incor rect installation or operation causes the risk of severe personal injuries material damage or even fatal injuries Further information can be found in the product documentation Com missioning is not permitted if the product documentation is missing In this case you should immediately ask for a new product documentation Commissioning is only permitted for persons who under...

Page 16: ...diations Use in non stationary applications Usage in environments with constant vibrations Direct use on a DC motor The module is defined as open type equipment UL 508 or as open equipment EN 61131 2 and must therefore be installed in a control cabinet The D3 DA 3xx x contains safety relevant functions e g STO For safety relevant control tasks and personnel security a control of KEBA in the varian...

Page 17: ...e inputs and possibly the relay outputs of the safety control KEBA shall assume no liability or warranty for consequential losses which may arise of Disregard of directives and standards Illegal changes Improper use Disregard of instructions in this document Information If information about potentially dangerous incidents of the machine or sys tem is obtained in the course of product monitoring ob...

Page 18: ...us voltage WARNING Dangerous voltage may be applied to the device even if the device does not emit any visual or audible signals indications CAUTION Protection against magnetic and or electromagnetic fields during in stallation and operation Persons fitted with heart pacemakers metallic implants and hearing aids etc must not be allowed access to the following areas Areas where drive systems are in...

Page 19: ...any handling with open electronics is only permissible with the application of effective ESD protection When handling open electronics please follow the following ESD measures Only touch open electronics if this is absolutely necessary Wear a conductive ESD wristband Use conductive mats Establish a conductive connection between device system mat wrist band and grounding connection Cotton work clot...

Page 20: ... graphic shows the full expansion of each size depending on variant less interfaces can be on the module Fig 3 1 Front side D3 DA 3xx x 1 D3 DA 3xx x size 1 2 D3 DA 3xx x size 2 3 Status LEDs of axis 4 EtherCAT interface 5 Digital inputs 6 Encoder interface 7 Digital inputs safety function 3 2 Bottom view The following graphic shows the full expansion of each size depending on variant less interfa...

Page 21: ...an 5 DIP switch S ADR 3 3 Type plate The D3 DA 3xx x has two type plates one on the left side of the module and one on the top side of cover flap Type plate on left side of module Fig 3 3 Type plate 1 1 Manufacturer and manufacturer ad dress 2 Product group 3 Material name 4 Technical data 5 Material number revision number 6 Serial number 7 Country of origin ...

Page 22: ...vision number 3 cURus marking 4 Serial number 5 CE marking of convormity 6 Data matrics code 7 Production date month year Variant with cold plate Fig 3 5 Typenschild 2 1 Material name 2 Material number revision number 3 cURus marking 4 Serial number 5 CE marking of convormity 6 Data matrics code 7 Production date month year 3 4 Overview D3 DA 3xx x variants Example DA 3 1 0 A 01 0 0 00 Products an...

Page 23: ...0 maximum output frequency 600 Hz 20 Classification number of axis rated current and size Axis module with Size 1 Rated current Inenn eff A Size 2 Rated current Inenn eff A 1 axis 1 5 A 3 A 6 A 12 A 18 A 24 A 32 2 axis 2 x 1 5 A 2 x 3 A 2 x 6 A 2 x 12 A 2 x 16 A 3 axis 3 x 1 5 A 3 x 3 A 3 x 6 A 3 x 12 A 3 5 Accessories 3 5 1 Connector set Caution Only compatible mating connectors that are approved...

Page 24: ...BA Connector set Connector set suitable for Order number KEBA D3 XT 230 A For control cable X25 A X26 A 94801 D3 XT 231 A Motor connector X31 x 94503 The connector set fits for single axis module For double axis or tripple axis the connector set must ordered proportionally ...

Page 25: ... assigned to axis 1 to axis 3 from top to bottom The significance of the LEDs is the same for each axis and is as follows Fig 4 6 Status LEDs Axis 1 2 3 Indication of which axis is accessed via the display on the control module assembly ERR Error indication using flash ing code RUN Ready power stage active 4 2 EtherCAT LEDs RJ45 At the EtherCAT connectors are the following LEDs Fig 4 7 EtherCAT co...

Page 26: ...flashing slow Indication of the EtherCAT operating state PRE OPERA TIONAL Green flashing Indication of the EtherCAT operating state SAFE OPERA TIONAL Green flashing fast Indication of the EtherCAT operating state BOOTSTRAP Green Indication of the EtherCAT operating state OPERATIONAL ERR LED Indication Meaning Dark No EtherCAT error Red flashing Indication of an EtherCAT error according to ETG 1300...

Page 27: ...ign on the device see front of device Information For installing the axis module within a system also note the project manu als of the control module and the supply module Control cabinet The module is designed only for installation in an stationary control cabinet The control cabinet must be conform with IP code IP44 By usage of safety functions of the axis module or of D3 DU 3x5 x the control ca...

Page 28: ...s must be added in the specified order side by side Any other order is not permitted otherwise problems with busbars and reciprocal ther mal influcence are occured Fig 5 8 Mounting order 1 D3 DU 3xx x control module 2 D3 DP 3xx x supply module 3 D3 DA 3xx x axis module 4 Further D3 DA 3xx x axis module ...

Page 29: ...ng the device to the power supply you must wait until the device temperature is the same as the room temperature and the moisture has evaporated again 5 1 EMC requirements The essential EMC measures are already implemented in the design of the devices in the form of optimised housing shielding printed circuit board lay out filter measures and selection of suitable connectors with shield plate In a...

Page 30: ... Requirements to the connectors The following connections are available in the system RT Ethernet RJ45 connectors Encoder connections Connections for motor Connections brake resistor Connections power supply Voltage equalizing cable RT Ethernet RJ45 connectors If an RT Ethernet cable is led outside of the cabinet the isolation of the ca ble must be opened after the RJ45 plug and the cable shield m...

Page 31: ...e the break resistor with a shield clamp on the base plate as close as possible to the break resistor All available break re sistors from KEBA are listed in the appendix Supply connectors The supply connector X01A Line IN of the supply module must have an ap propriate filter Appropriate filters are listed in the appendix For demension ing on the one hand supply current and on the other hand the su...

Page 32: ... bounding lines If the cabinet is not mounted directly on the machine or severals metres away from the machine it is recommended to install a equipotential bound ing line parallel to the cables which are lead from the cabinet to the ma chine The reason for this is that because of switching processes and indi rect lightning strikes low frequency high compensating currents can be cre ated which may ...

Page 33: ...ow 130 mm and 150 mm or 200 mm stated in the figure applies to all devices The clearance above is im portant to prevent the build up of heat the clearance underneath to permit correct cable laying Fig 5 11 Mounting clearances in mm The bend radius of the connecting cables must be taken into account Up to 3 x 10 mm2 ca 48 98 mm depending on the cable version ...

Page 34: ... Fig 5 12 Mounting clearances in mm The bend radius of the connecting cables must be taken into account Up to 3 x 16 mm2 ca 150 200 mm depending on the cable version KeDrive D3 example with control module with safety functionality and with supply module Example with one axis module size 1 BG1 ...

Page 35: ...ting and installation instructions Project engineering manual V1 07 35 KEBA Fig 5 13 Dimension with size 1 Dimensions Height 310 mm Width 165 mm Depth 241 mm Example with one axis module size 1 BG1 and size 2 BG2 each ...

Page 36: ...A Fig 5 14 Dimension with size 2 Dimensions Height 310 mm Width 273 mm Depth 241 mm 5 3 Mounting the module The D3 DA 3xx x is exclusively intended for the vertical installation on a plane stable conductive and grounded mounting plate by means of bolted connections Position of mounting holes ...

Page 37: ...ounting plate Drill holes in the mounting plate and cut a thread for each fixing screw in the mounting plate The bend radius of the connecting cables must be taken into account 3 Mount the modules vertically abutting on the mounting plate Make sure the surface of the cooler is free of drill chippings or other soiling The D3 DA 3xx x is now mounted and ready for cabling see chap Connec tions and wi...

Page 38: ...ure cooling plate Device 85 C Surface of the cooler2 max roughness RZ 6 3 1 Thermal resistance between active cooling surface on the device and cooler 2 In this case the cooled rear panel for mounting the module is called as cooler 5 3 2 1 Sizing the cooler D3 DA 3xx x size BG1 D3 DA 3xx x size BG2 Thermal resistance RthK 1 0 02 K W 0 01 K W Thermal capacity of the cool ing plate on the device 390...

Page 39: ...ounding bracket if existing 3 Unfasten the fixing screws be careful that the screws remain in the mounting plate 4 Lift and pull out the moduel The module is disassembled 5 5 Air conditioning and ventilation Cooling air must be able to flow through the device without restriction For in stallation in cabinets with convection heat loss is discharged to the out side via the cabinet walls always fit a...

Page 40: ...d The following layout plan shows the layout of the D3 DA 3xx x axis module with the corresponding positions of connectors and terminals To aid orienta tion the connectors and terminals are labelled by abbreviations X The following pages contain detailed layout diagrams on the D3 DA 3xx x single axis double axis and triple axis modules Fig 6 15 Overview D3 DA 3xx x axis modules 1 Status axis 1 2 S...

Page 41: ...A Encoder interface See 6 10 Encoder connec tions X48B Encoder interface X48C Encoder interface X48D Encoder interface X26A Digital inputs safety function See 6 7 2 Safe digital input terminal X26A S ADR DIL switch bank for the con figuration of the SD0 func tionality See 8 Safety functions X31A Power connection motor 1 With integrated connections for motor brake and motor temperature monitoring F...

Page 42: ... Digital inputs safety function X40B EtherCAT OUT output field bus Axis 1 LED yellow X25A Digital inputs ERR LED red State axis 1 ERR LED red X48A Encoder connection 1 axis 1 RUN LED green X48B Additional encoder connection axis 1 For informations about the status LEDs of the axes see 4 1 Status LEDs of the axis Single axis module encoder axis 1 Fig 6 17 Pin assignment connector X48A single axis m...

Page 43: ... A COS S1 COS A 3 max 5 4 V max 250 mA Vcc 4 R Data SD 5 R Data SD 6 B REFSIN S4 SIN B 7 10 V 110 mA 8 GND GND 9 R2 resolver excit 10 R1 resolver excit 11 B SIN S2 SIN B 12 Safety Sense 13 Safety Sense 14 CLK 15 CLK Fig 6 18 Pin assignment connector X48B single axis module Pin SinCos and TTL 1 A 2 A 3 max 5 4 V max 250 mA 4 R 5 R 6 B 7 8 GND 9 10 11 B ...

Page 44: ...tal inputs safety function X40B EtherCAT OUT output field bus Axis 1 LED yellow X25A Digital inputs ERR LED red State axis 1 ERR LED red X48A Encoder connection 1 axis 1 RUN LED green X48B Additional encoder connection axis 1 Axis 2 LED yellow X48C Encoder connection 1 axis 2 ERR LED red State axis 2 ERR LED red X48D Additional encoder connection axis 2 RUN LED green For informations about status ...

Page 45: ...in SinCos and TTL EnDat SSI Hiperface Resolver Nikon 1 A REFCOS S3 COS A 2 A COS S1 COS A 3 max 5 4 V max 250 mA Vcc 4 R Data SD 5 R Data SD 6 B REFSIN S4 SIN B 7 10 V 110 mA 8 GND GND 9 R2 resolver excit 10 R1 resolver excit 11 B SIN S2 SIN B 12 Safety Sense 13 Safety Sense 14 CLK 15 CLK Fig 6 21 Pin assignment connector X48B double axis module Pin SinCos and TTL 1 A ...

Page 46: ...D 9 10 11 B 12 13 14 15 Double axis module encoder axis 2 Fig 6 22 Pin assignment connector X48C double axis module Pin SinCos and TTL EnDat SSI Hiperface Resolver Nikon 1 A REFCOS S3 COS A 2 A COS S1 COS A 3 max 5 4 V max 250 mA Vcc 4 R Data SD 5 R Data SD 6 B REFSIN S4 SIN B 7 10 V 110 mA 8 GND GND 9 R2 resolver excit 10 R1 resolver excit ...

Page 47: ...KEBA Pin SinCos and TTL EnDat SSI Hiperface Resolver Nikon 11 B SIN S2 SIN B 12 Safety Sense 13 Safety Sense 14 CLK 15 CLK Fig 6 23 Pin assignment connector X48D double axis module Pin SinCos and TTL 1 A 2 A 3 max 5 4 V max 250 mA 4 R 5 R 6 B 7 8 GND 9 10 11 B 12 13 14 15 ...

Page 48: ... bus RUN LED gree X25A Digital inputs Axis 2 LED yellow X48A Encoder connection 1 axis 1 ERR LED red State axis 2 X48B Additional encoder connection axis 1 RUN LED green X48C Encoder connection 1 axis 2 Axis 3 LED yellow X48D Encoder connection 1 axis 3 ERR LED red State axis 3 X26A Digital inputs safety function RUN LED green Axis 1 LED yellow For informations about the status LEDs of the axes se...

Page 49: ...perface Resolver Nikon 1 A REFCOS S3 COS A 2 A COS S1 COS A 3 max 5 4 V max 250 mA Vcc 4 R Data SD 5 R Data SD 6 B REFSIN S4 SIN B 7 10 V 110 mA 8 GND GND 9 R2 resolver excit 10 R1 resolver excit 11 B SIN S2 SIN B 12 Safety Sense 13 Safety Sense 14 CLK 15 CLK Fig 6 26 Pin assignment connector X48B triple axis module Pin SinCos and TTL 1 A 2 A 3 max 5 4 V max 250 mA ...

Page 50: ...axis module encoder axis 2 Fig 6 27 Pin assignment connector X48C triple axis module Pin SinCos and TTL EnDat SSI Hiperface Resolver Nikon 1 A REFCOS S3 COS A 2 A COS S1 COS A 3 max 5 4 V max 250 mA Vcc 4 R Data SD 5 R Data SD 6 B REFSIN S4 SIN B 7 10 V 110 mA 8 GND GND 9 R2 resolver excit 10 R1 resolver excit 11 B SIN S2 SIN B 12 Safety Sense ...

Page 51: ...solver Nikon 1 A REFCOS S3 COS A 2 A COS S1 COS A 3 max 5 4 V max 250 mA Vcc 4 R Data SD 5 R Data SD 6 B REFSIN S4 SIN B 7 10 V 110 mA 8 GND GND 9 R2 resolver excit 10 R1 resolver excit 11 B SIN S2 SIN B 12 Safety Sense 13 Safety Sense 14 CLK 15 CLK 6 4 Grounding 1 Ground each device Connect the PE connections screw socket M4 on the supply module the axis modules and the controller in series with ...

Page 52: ...be doubled or a copper cable with a minimum cross section 10 mm2 is to be laid 2 Also connect the PE conductor terminals of all other components such as main filters etc in a star configuration with the PE bar main earth in the cabinet These further components are only required for the D3 DP 3xx x supply module Information Material of the cooler or cold plate aluminium with high conductive trans p...

Page 53: ... and national regulations and conditions WARNING The protective earth conductor connection is a safety feature Therefore make sure that all connections have good contact and are sufficiently se cure that they cannot come loose Protective earth conductor with mains cable crosssection 10 mm Fig 6 30 Double protective earth conductor 1 D3 DU 3xx x control module 2 D3 DP 3xx x supply module 3 D3 DA 3x...

Page 54: ...ption Potential Acronym Busbars 24 V DC Power supply control module Protective extra low voltage circuit 3 PELV D c link circuit supply DC Link Power supply d c link Low voltage 1 ZK X40A EtherCAT IN field bus connection Protective extra low voltage circuit 3 PELV X40B EtherCAT OUT field bus connection Protective extra low voltage circuit 3 PELV X25A Digital control inputs Protective extra low vol...

Page 55: ...upply 11 D3 DA 3xx x axis module 12 Control cabinet 13 Field 14 Braking resistor 15 EtherCAT connection 16 Conductive mounting plate 17 PE connection 18 Conductive mounting plate PELV Protective extra low voltage circuit BI Basic isolation VI Strenghten isolation ZK Low voltage d c link NV Low voltage Information The electrical isolation method correspond to EN 61800 5 1 The following conditions a...

Page 56: ...s necessary to unscrew the screws slightly 3 Only connect the DC link supply for the axis modules when you want to place the axis modules in operation If you want to use several axis mod ules all DC Link connections and all DC Link connections must be connected together For this purpose also use the pre assembled busbar elements To be able to rotate the busbar elements it is necessary to unscrew t...

Page 57: ...iable isolation in re lation to the mains acc to EN 61131 2 or EN 61800 5 1 Tightening torque for the busbar fittings 2 1 Nm 18 5 lb in 6 6 2 D c link Caution Busbars The busbars supplied are to be used for the electrical coupling of the de vices On the usage of connection elements that do not meet the require ments KEBA does provide any guarantee for stable reliable operation Fig 6 33 D c link D ...

Page 58: ...ide protection against physical contact with bare and live parts Death or serious injuries may occur if these protective mea sures are not taken 6 7 Control connections 6 7 1 Digital inputs on X25A standard functions The digital inputs are provided for axis related tasks e g limit switches They can be programmed individually via the EtherCAT bus system The in puts DI09 and DI10 are suitable for to...

Page 59: ...igital input DI01 DI07 Digital input DI02 DI08 Digital input DI03 DI09 Fast digital input Touch Probe TP1 DI09 DI10 DI08 DI10 Fast digital input Touch Probe TP2 DI10 DI08 DI09 GND GND Reference ground All axis Digital inputs are galvanic isolated from GND rail of 24 V supply GND must be connected with the reference mass of the sensors Information At the digital inputs only PNP sensors are allowed ...

Page 60: ......

Page 61: ...n using DriveManager The motor cables from KEBA have a shielded wire pair for temperature evaluation integrated and the shield has contact with the connectors on both sides 4 If fitted connect the motor brake to X31 A X31 B X31 C 1 2 The mo tor cables from KEBA have a shielded wire pair for motor brake inte grated and the shield has contact with the connectors on both sides Motor cable All motor c...

Page 62: ...tor holding brake Information Recommended connection of the motor holding brake up to max 2 A motor brake current Fig 6 38 Connection of a servomotor with motor holding brake 1 Control motor brake 2 Brake 3 Brake 4 Supply for brake The temperature sensor connection is shown in the version with standard encoder interface ...

Page 63: ...otor connecting cable one cable solution in 16 3 Connection tech nology WARNING Electric shock Isolation of temperatur sensors to motor winding must have a double or strengthened isolation 6 8 2 Monitoring output motor holding brake The motor brake output BRK_Out and BRK GND is continuously monitored independently of the usage SBC The monitoring uses shut down pulses that are sent with a maximum t...

Page 64: ...nsor or Hiperface DSL Control terminals Crioss section 0 25 1 mm2 or AWG 26 16 IN 10 A 3 BRK_OUT 4 BRK_GND Connection motor brake IBR max 2 A U V W Connection motor phase Connectable cross section with out ferrule max 6 mm2 PE symbol Connection PE of motors M4 screw with serrated washer connection using ring lug S Connection cable shield 6 8 4 Switching in the motor cable Caution Switching in the ...

Page 65: ...field bus interface can also be used as a service and diag nostics interface However it is then only suitable for the connection of a PC for commissioning service and diagnostics using the software DriveMan ager Technical specification Transfer rate 10 100 MBits s BASE T Transfer profile IEEE802 3 compliant For shielded connection up to a length of 20 m the following tested cable or an equivalent ...

Page 66: ...ly module and the axis modules of an axis block 6 10 Encoder connections All encoder connections are located on the front of the device All encoder cables must be shielded The cables available from KEBA are listed in chap ter 16 3 Connection technology Equivalent shielded cables must be used for the connection of motors from other manufacturers 6 10 1 Matching motor encoder cables Compare the rati...

Page 67: ... ERN1381 ROD486 Heidenhain SinCos encoder with EnDat in terface EnDat 2 1 and EnDat 2 2 13 Bit singleturn encoder ECN1313 En Dat01 and 25 Bit multiturn encoder EQN1325 EnDat01 SinCos encoder with SSI interface 13 Bit singleturn and 25 Bit multiturn en coder ECN413 SSI EQN425 SSI Sick Stegmann SinCos encoder with HIPER FACE Interface Single and multiturn encoder e g SRS50 SRM50 The usage of encoder...

Page 68: ...the supply system conforms to the maximum overvoltage category III as per EN 61800 5 1 at a system voltage external conductor star point of maximum 277 V IT system The operation is only possible for three phase supply with 3 x 230 V The compliance of EMC directives 2014 30 EC has to be ensured by the user The operation for three phase supply with 3 x 400 V or 3 x 480 V is not per mitted Otherwise ...

Page 69: ... The configuration of the D3 DA 3xx x is done via configuration tools inte grated in the delivery For information to configuration see online help of D3 DA 3xx x For informa tion of parametrization of a drive see functional description KeDrive D3 Firmware for axis controller devices ...

Page 70: ... diagnosis 8 1 STO Safe Torque OFF The axis module supports the safety function STO safe torque off in ac cordance with EN 61800 5 2 EN ISO 13849 1 PL e category 4 and EN 61508 EN 62061 SIL 3 For the safety function STO the supply to the drive is interrupted safe no galvanic isolation The drive must not create torque and therefore dangerous movements The stand still position is not monitored The f...

Page 71: ...O e g due to a suspended load this movement must be safely pre vented by additional measures e g by means of two brakes locking de vice or clamping device with brake Despite correct shutdown in the case of a short circuit in two offset branches of the power section an axis movement of max 180 may be triggered electrically 8 1 1 Configuration of STO safety function Via DIP switch S ADR the desired ...

Page 72: ...s ing two channel technology Depending on the pre selection of the DIP switch S ADR the SBC will be automatically activated in case of release parallely with STO1 The function SBC always effects to all brake outputs of the axis module The function SBC is used in conjunction with the functions STO to prevent the movement of an axis in the torque free state e g due to gravity The axis module support...

Page 73: ...to account during the design of the brake s and the validation The failure Brake does not engage must be excluded by one of the follow ing measures Usage of a safety brake with a manufacturer s specification that ex cludes this failure with the necessary safety integrity Definition and validation of a second means of braking in the application For instance this feature can be achieved by using two...

Page 74: ...tion to an error message and the system changes into safe state 8 3 Diagnosis via cross circuit test To detect short circuits and cross circuits in the wiring of safe digital inputs terminal X26A via DIP switch S ADR a cross circuit test can be activated In this case the testoutputs of the D3 DP 3xx x must be used or own testout puts which meet the signal format of the following table Settings Des...

Page 75: ...e with EN ISO 13849 1 or SIL in accordance with EN 61508 EN 62061 In addition the following points must be noted The safety regulations and EMC directives must be met In relation to the failure exclusions assumed reference is made to the table in annex D of EN ISO 13849 2 The examples shown in the following and their characteristic architecture de fine the allocation to a category in accordance wi...

Page 76: ... door a reset button start test on switching module is activated is implemented In the shown DIP switch configuration it is configured to use STO1 for all axes and SBC is released simultaneously with STO1 Fig 8 43 STO and SBC control 1 D3 DU 3x5 x 2 D3 DA 3xx x Should safety functions STO and SBC of the single axis modules controlled via same outputs of the safety control the wiring can be copied ...

Page 77: ...rts a separate STO controlling of the axes STO1 is fix assigned to the first axis the both other axes can be assigned to STO1 or STO2 depending on the DIP switch setting If sperated STO controlling is used the safety function SBC may not be activated because it is always as signed to STO1 Fig 8 45 STO without SBC control 1 D3 DU 3x5 x 2 D3 DA 3xx x Caution By usage of STO1 and STO2 on an axis modu...

Page 78: ...agnosis measurements and then changed into safe state The failure Simultaneous short circuit of both outputs to 24 V must be excluded by suitable wiring 8 4 4 Example STO and SBC control directly via supply module It is for example possible to control the safety functions STO and SBC via safety door without using the safety control Therefore the door switch must be supplied via testoutputs of the ...

Page 79: ... against the safety requirements from the application in the following cases During commissioning After changes of the application After repair or device replacement The following table shows the test steps to be undertaken The table has to be worked through from top to bottom Designation State Event Expected result Initial state System is switched on Torque is enabled STO input is active Axis mod...

Page 80: ...nd there is no error message Test step 2 STO1 input becomes active Brake s is are released 8 8 Validate cross circuit test If monitoring of STO inputs is undertaken by means of usage of testoutputs e g usage of testoutputs of the supply module this has to be validated in the following cases During commissioning After changes to the application After repair or device replacement The following table...

Page 81: ...D3 DA 3xx x Safety functions Project engineering manual V1 07 81 KEBA Information A restart is necessary to start the system again ...

Page 82: ...On On On Restart Start or loading firmware update Initialisation during starting device Off 1 x 1 x Not ready to switch on Off 2 x 2 x Axis switch on disabled Off 3 x 3 x Axis ready to switch on Off 4 x 4 x Axis switched on Off On On Operation enabled Off 6 x 6 x Quickstop Error code 7 x 7 x Fault reaction active Error code 8 x 8 x Error Fault 1 LED green long Operation with real motor 2 LED green...

Page 83: ...case of er ror replace the device It is asked to send back defect devices to KEBA 10 1 Update firmware The firmware can be updated via the tool DriveManager included in the de livery For more information see online help of DriveManager Information All D3 DA 3xx x of an axis group need to have the same version of the firmware For information see functional description KeDrive D3 Firmware for axis c...

Page 84: ...d electronic devices The symbol with the crossed out waste container means that electrical and electronic devices including their accessories must not be disposed of in the household garbage The materials are recyclable in accordance with their labeling You can make an important contribution to protecting our envi ronment by reusing renewing and recycling materials and old appliances ...

Page 85: ...brake driver D3 DA 310 x max 2 A D3 DA 320 x max 2 x 2 A D3 DA 330 x max 3 x 2 A Current consumption fan 400 mA D c link Capacity 165 μF DC resistance in DC to DC 146 kΩ Power section Ambient temperature 5 40 C upt o 50 C with derating Permissible switching frequencies 2 4 8 12 16 kHz without motor holding brake with 10 m motor cable 3 8 kV μs Recommended output frequency range 2 4 kHz 0 400 Hz 8 ...

Page 86: ...nformation Current data per axis in the axis module 230 400 480 V AC refers to the supply voltage for the supply module The value in the following table is output current and specified for each axis of the respective product variant see 3 4 Overview D3 DA 3xx x variants At Usupply 230 V und 400 V FS 2 kHz 4 kHz 8 kHz 12 kHz 16 kHz Nominal current 1 5 A 1 5 A 1 5 A 1 0 A 0 8 A Maximum current for 1...

Page 87: ...2 9 A Maximum current for 500 ms 9 A 9 A 6 25 A 4 85 A 3 8 A Maximum current at FM 0 Hz 7 35 A 6 15 A 4 A 3 1 A 2 4 A At Usupply 480 V FS 2 kHz 4 kHz 8 kHz 12 kHz 16 kHz Nominal current 3 A 3 A 2 6 A 1 35 A 0 6 A Maximum current for 10 s 6 A 6 A 5 2 A 2 7 A 1 2 A Maximum current for 500 ms 9 A 8 A 5 2 A 3 6 A 2 75 A Maximum current at FM 0 Hz 6 2 A 5 1 A 3 3 A 2 3 A 1 75 A 12 2 D3 DA 3x0 x 06xx D3...

Page 88: ...erature 5 40 C upt o 50 C with derating Permissible switching frequencies 2 4 8 12 16 kHz without motor holding brake with 10 m motor cable 3 8 kV μs Recommended output frequency range 2 4 kHz 0 400 Hz 8 kHz 0 800 Hz 16 kHz 0 1600 Hz For Variants with limitation of output frequency the max output frequency is limited to 599 Hz Axis module Dissipation 400 V 4 kHz Inom in the interior D3 DA 310 A 06...

Page 89: ...he respective product variant see 3 4 Overview D3 DA 3xx x variants At Usupply 230 V and 400 V FS 2 kHz 4 kHz 8 kHz 12 kHz 16 kHz Nominal current 6 A 6 A 6 A 4 A 2 9 A Maximum current for 10 s 12 A 12 A 12 A 8 A 5 8 A Maximum current for 500 ms 18 A 18 A 12 5 A 9 7 A 7 6 A Maximum current at FM 0 Hz 14 7 A 12 3 A 8 A 6 2 A 4 8 A At Usupply 480 V FS 2 kHz 4 kHz 8 kHz 12 kHz 16 kHz Nominal current 6...

Page 90: ... current for 2 s 24 A 24 A 17 6 A 12 4 9 4 A Maximum current for 500 ms 36 A 27 2 A 17 6 A 12 4 9 4 A Maximum current at FM 0 Hz 21 A 17 3 A 11 2 A 15 1 6 A D3 DA 320 x 12xx D3 DA 330 x 12xx size BG2 At Usupply 230 V and 400 V FS 2 kHz 4 kHz 8 kHz 12 kHz 16 kHz Nominal current 12 A 12 A 10 A 6 4 A 5 1 A Maximum current for 10 s 24 A 24 A 20 A 12 8 A 10 2 A Maximum current for 500 ms 36 A 36 A 29 3...

Page 91: ...405 μF D3 DA 310 x 18xx 275 μF DC resistance in d c link DC to DC 146 kΩ Power section Ambient temperature 5 40 C upt o 50 C with derating Permissible switching frequencies 2 4 8 12 16 kHz without motor holding brake with 10 m motor cable 3 8 kV μs Recommended output frequency range 2 4 kHz 0 400 Hz 8 kHz 0 800 Hz 16 kHz 0 1600 Hz For Variants with limitation of output frequency the max output fre...

Page 92: ... 36 A 29 5 A 20 2 A 13 7 A 10 1 A At Usupply 480 V FS 2 kHz 4 kHz 8 kHz 12 kHz 16 kHz Nominal current 16 A 16 A 11 A 8 2 A 6 3 A Maximum current for 2 s 32 A 32 A 21 A 15 5 A 10 4 A Maximum current for 500 ms 40 A 36 A 20 9 A 15 5 A 12 4 A Maximum current at FM 0 Hz 36 A 26 A 14 4 A 10 7 A 8 5 A 12 3 2 Current data D3 DA 310 x 18xx Information Current data per axis in the axis module 230 400 480 V...

Page 93: ...ncoder D3 DA 310 x 0 9 A Current output output motor holding brake D3 DA 310 x 24xx max 2 A D3 DA 310 x 32xx max 2 x 2 A Current consumption fan 700 mA D c link Capacity 675 μF DC resistance in d c link DC to DC 146 kΩ Power section Ambient temperature 5 40 C upt o 50 C with derating Permissible switching frequencies 2 4 8 12 16 kHz without motor holding brake with 10 m motor cable 3 8 kV μs Recom...

Page 94: ... A Maximum current at FM 0 Hz 53 9 A 39 2 A 26 8 A 18 2 A 13 4 A At Usupply 480 V FS 2 kHz 4 kHz 8 kHz 12 kHz 16 kHz Nominal current 24 A 24 A 17 1 A 10 1 A 8 2 A Maximum current for 10 s 48 A 48 A 32 6 A 24 1 A 19 3 A Maximum current for 500 ms 72 A 59 A 32 6 A 24 1 A 19 3 A Maximum current at FM 0 Hz 52 5 A 34 6 A 19 1 A 14 2 A 11 3 A 12 4 2 Current data D3 DA 310 x 32xx Information Current spec...

Page 95: ...p to SIL 3 to EN 62061 and EN 61508 System structure 2 channel PFH 5 29 x 10 11 for each axis according to EN 62061 EN 61508 DCavg High Proof test interval 20 years Dimensioning the operating mode high demand according to EN 61508 high demand rate Reaction time 2 5 ms SBC Safety category up to category 3 PL d to EN ISO 13849 1 up to SIL 2 to EN 62061 and EN 61508 System structure 2 channel PFH 3 5...

Page 96: ...eight To 1 000 m over NN with overvoltage cate gory III above with performance reduction 1 per 100 m max 2 000 m over NN 5 Contamination level 2 1 Performance reduction D3 DA 3x0 A 01xx D3 DA 3x0 A 03xx D3 DA 3x0 A 06xx 3 4 per C D3 DA 310 A 12xx D3 DA 310 A 18xx 1 6 per C D3 DA 320 A 12xx D3 DA 330 A 12xx 2 per C D3 DA 320 A 16xx 2 6 per C D3 DA 310 A 24xx 2 3 per C D3 DA 310 A 32xx 3 0 per C 2 T...

Page 97: ...they must be complied also in the control cabinet 12 7 Safe digital inputs Quantity 4 Type Type 1 to EN 61131 2 Nominal voltage 24 V DC PELV Input current Max 15 mA Low level range 3 V DC to 5 V DC High level range 15 V DC to 30 V DC Electrical isolated Yes Cross circuit detection Yes via test outputs OSSD compatible Yes Effect by incorrectly connected inputs Potential defect OSSD Output Signal Sw...

Page 98: ...the control elec tronics Yes Galvanic isolation of the inputs No Cycle time processing time 1 ms Filter Digital inputs 500 Hz Wiring Sink Interrupt driven inputs Input type Type 1 according to EN 61131 2 2007 Voltage range for HIGH 18 V UH 28 8 V Voltage range for LOW 0 V UL 5 V Galvanic isolation toward the control elec tronics Yes Galvanic isolation of the inputs No Reaction time HIGH 0 75 us Re...

Page 99: ...D3 DA 3xx x Technical data Project engineering manual V1 07 99 KEBA 12 9 Dimensions weight Size 1 Dimensions with cooling element Fig 12 48 Dimensional drawing measures in mm ...

Page 100: ...D3 DA 3xx x Technical data Project engineering manual V1 07 100 KEBA Dimensions with cold plate Fig 12 49 Dimensional drawing measures in mm ...

Page 101: ...D3 DA 3xx x Technical data Project engineering manual V1 07 101 KEBA Size 2 Dimensions with cooling element Fig 12 50 Dimensional drawing measures in mm ...

Page 102: ... drawing measures in mm Dimensions weight Height 310 mm Width Baugröße 1 55 mm Baugröße 2 110 mm Depth D3 DA 3x0 A with without cover flap 241 mm 222 mm D3 DA 3x0 B with without cover flap 188 5 mm 170 mm Weight D3 DA 3x0 A Size 1 2 650 g D3 DA 3x0 B Size 1 2 300 g D3 DA 3x0 A Size 2 5 100 g D3 DA 3x0 B Size 2 3 700 g ...

Page 103: ...2 2007 Functional Safety requirements of adjustable speed electrical power drive systems IEC 61508 1 7 2010 Functional safety of electrical electronic pro grammable electronic safety related systems 13 2 2 EMC directives EN 61800 3 2004 A1 2012 Adjustable speed electrical power drive sys tems Part 3 EMC requirements and spe cific test methods EN 61326 3 1 2008 Electrical equipment for measurement ...

Page 104: ... allowed axes and max allowed complete cable length for all axes must be considered 13 4 UL certification Information The following requirements must be observed for a valid UL mark Common terms to comply with the UL certification UL 61800 5 1 for all the sizes of D3 DA 3xx x Multiple rated equipment Operation only within the technical ratings of the drive details see Technical data Ensure that su...

Page 105: ...Ratings and fuse classes refer to chapter UL certification in project engineering manual of D3 DP 3xx x Overload protection D3 DA 3xx x 01 D3 DA 3xx 12 200 10 sec D3 DA 3xx x 16 D3 DA 3xx 32 200 2 sec Max ambient temperature 45 C Certification D3 DA 3xx A c UL us D3 DA 3xx B c UR us Information Valid for all variants with firmware version V1 40 13 or higher 13 5 Loads on the mains due to harmonics...

Page 106: ...D3 DA 3xx x Declaration of conformity Project engineering manual V1 07 106 KEBA 14 Declaration of conformity 14 1 With safety ...

Page 107: ...D3 DA 3xx x Declaration of conformity Project engineering manual V1 07 107 KEBA ...

Page 108: ...D3 DA 3xx x Declaration of conformity Project engineering manual V1 07 108 KEBA ...

Page 109: ...wer output at the DC link permanently if the sum of all DC link ca pacities is 1 000 μF Module Power DC link capacity Supply module 10 kW 330 μF Single axis module 24 A 675 μF Triple axis module 12 A 405 μF 330 405 675 1 410 The available DC link capacity of the axis group in this example is 1 410 µF Therefore the available effective power of the DC link is 10 kW All axis can not take more than in...

Page 110: ... is 7 2 kW The available power output for an axis with 12 A with a maximal motor volt age of 326 V depending on the modulation type is calculated as shown be low 326 x 12 x 3 6 78 kW The available power output for one axis is 6 78 kW Reduction of the effective power Supply voltage 3 x 230 V AC For supply modules which can be supplied with 3 x 230V AC the effective permanently available power of th...

Page 111: ...late and cooling element The following cooling plates and cooling elements are available Designation Material number Cooling element D3 XM 310 055 95179 Cooling plate D3 XM 300 060 95521 Cooling plate D3 XM 300 080 102204 16 1 1 Cooling Element D3 XM 310 055 Fig 16 52 Dimensions of cooling element D3 XM 310 055 dimensions in mm ...

Page 112: ...A 3xx x Appendix Further components Project engineering manual V1 07 112 KEBA 16 1 2 Cooling plate D3 XM 300 060 Fig 16 53 Dimensions of cooling plate D3 XM 300 060 dimensions in mm 1 all thread M4 passage ...

Page 113: ...assembled encoder cable Data cables for fieldbus and communication with supply module Connector sets PE connection plate PC usersoftware e g KeStudioDriveManager Mains filter reduces conducted high frequency interference of the D3 DA 3xx x axis module For use on the D3 DP 3xx x supply module Mains choke reduces the voltage distortions THD in the system and prolongs the life of the D3 DA 3xx x axis...

Page 114: ...ty is possible In this case the user has to ensure that the requirements of the EMC directive are met 16 3 1 Connection cable XW P0x xxx Fig 16 55 Structure of the connection cable XW P0x xxx S1 Connector motor sided S2 Connector drive control system sided 1 Outer and inner shields connected to copper strip 2 Shrinking tube overlaps the copper strip 5 mm 3 Shield is fixed at the mounting plate 4 C...

Page 115: ... the motor If intermediate sockets are required ensure that a continuous shielding of the Hiperface DSL elements from the axis module to the motor is retained The existing M23 connector may need to be replaced by an other suitable connector Fig 16 56 Structure of the connection cable XW H0x xxx S1 Connector motor sided S2 Connector axis module sided 1 Outer and inner shields connected to copper st...

Page 116: ...e 6 4 16 3 3 Signal cable XW E10 xxx Fig 16 57 Structure of the signal cable XW E10 xxx S1 Connector motor sided S2 Connector HDSUB 1 Cable of length L 2 Outer shield connected with copper strip to housing Pin assignment at signal cable XW E10 xxx Signal Connector S1 Motor sided Color of wires identification Connector S2 Drive control system sided Us 1 White 7 GND 2 Brown 8 Ref Sin 3 Blue 6 Ref Co...

Page 117: ... with copper strip to housing Pin assignment at signal cable XW R10 xxx Signal Connector S1 Motor sided Color of wires identification Connector S2 Drive control system sided S2 1 Black 11 S1 2 Green 2 S3 3 Yellow 1 n c 4 n c n c 5 n c S4 6 Brown 6 R1 7 Brown Red 10 n c 8 n c n c 9 n c n c 10 n c R2 11 Brown Blue n c 12 n c 16 3 5 Signal cable XW 020 The signal cable XW 020 serves as connection wit...

Page 118: ... Data 2 Orange 2 Re Data 3 White green 3 Bi Data 4 Blue 4 Bi Data 5 White Blue 5 Re Data 6 Green 6 Bi Data 7 White Brown 7 Bi Data 8 Brown 8 16 3 6 Signal cable XW 021 The signal cable XW 021 serves as connection between drive blocks D3 DU 3xx x D3 DA 3xx x D3 DP 3xx x It is to connect the last axis module of the drive block with the supply module of the next drive block Fig 16 60 Structure of the...

Page 119: ...omponents Project engineering manual V1 07 119 KEBA Signal Connector S1 Color of wires identification Connector S2 Tr Data 1 White Orange 1 Tr Data 2 Orange 2 Re Data 3 White green 3 n c 4 4 n c 5 5 Re Data 6 Green 6 n c 7 7 n c 8 8 ...

Page 120: ...on Position 20 DIP switch S ADR Position 21 Disassembly 38 E Encoder interface Position 20 EtherCAT interface Pin assignment 65 Position 20 F Fan Position 21 L LEDs ERR LED 26 Link Activity LED 25 RUN LED 26 M Motor cable Position 21 Mounting Cold plate 37 Wall mounting 37 P Pin assignment EtherCAT interface 65 S Status LED axis Position 20 ...

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