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DIAS-DRIVE 335-23 

 

 

 

Page 48 

27.09.2017 

 

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. 

 
 
 
 
 
 
 
 
 

Summary of Contents for DIAS-Drive 335-23

Page 1: ...DIAS Drive 335 23 Date of creation 01 10 2013 Current version 27 09 2017 Article No 10 501 351 23E...

Page 2: ...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 res...

Page 3: ...nterface description Setup of the servo amplifier Accessories Transport storage maintenance disposal Abbreviations used in this manual Abbreviation Definition AWG American Wire Gauge American cable co...

Page 4: ...Hardware 16 1 8 2 DIAS Drive Concept 17 1 8 3 Software Functions 18 1 9 Technical Data 19 1 10 Environmental Conditions Ventilation and Mounting 21 1 11 Auxiliary Supply Voltage 21 2 Installation 22 2...

Page 5: ...egen Resistor X1B 38 3 5 Motor Connection X3 X4 X5 39 3 5 1 Standard configuration 39 3 5 2 Classic Emergency Stop Functions Stop Category 0 40 3 5 3 Personnel Safe Holding Brake Control 41 3 6 Feedba...

Page 6: ...Data 62 7 1 1 General 62 7 1 2 Electrical Requirements 62 7 1 3 Input Specifications 62 7 1 4 Relay Specifications 63 7 1 5 Safety Conformity 63 7 1 6 Miscellaneous 63 7 1 7 Environmental Conditions 6...

Page 7: ...27 09 2017 Page 5 7 8 2 Wiring Outside of the Control Cabinet 87 7 8 3 Shielding for Wiring within the Control Cabinet 88 7 8 4 Connecting Noise Generating Components 89 7 8 5 Shielding Between Two Co...

Page 8: ...eral 1 1 Symbols used in this manual Danger Electric shock Danger to personal from electricity and its effects Caution General Danger to machines General warning Caution Hot surface Hot surface more t...

Page 9: ...s 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...

Page 10: ...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 dam...

Page 11: ...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 ope...

Page 12: ...DIAS DRIVE 335 23 Page 10 27 09 2017 1 3 Servo Amplifier Components...

Page 13: ...tage 2006 95 EG 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 Ene...

Page 14: ...r 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 pa...

Page 15: ...ons 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 cauti...

Page 16: ...DIAS DRIVE 335 23 Page 14 27 09 2017 1 7 Nameplate The name plate is attached to the side of the amplifier heat sink The information in the individual fields depends on the various amplifier types...

Page 17: ...DIAS DRIVE 335 23 27 09 2017 Page 15 1 8 Block Diagram...

Page 18: ...ent 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...

Page 19: ...r 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 supp...

Page 20: ...speed controller update time 62 5 s Spline interpolation and position controller update time 62 5 s Full synchronisation up to the output stage to the control frequency with cycle times of 250 s 500...

Page 21: ...l current for axis 1 starting from 500 ms Arms 7 Rated current for axis 2 rms 3 Arms 10 Max standstill current for axis 2 starting from 500 ms Arms 7 Rated current for axis 3 rms 3 Arms 15 Max standst...

Page 22: ...G VMAINS 480 rated supply voltage 480 V Start up limit VDC 850 Switch off level VDC 810 Over voltage protection VDC 900 Max rated power of the external regen resistor W 1500 Peak internal regen resis...

Page 23: ...tional altitude Up to 1000 m above sea level at rated data 1000 to 2500 m above sea level with a 1 5 100 m reduction Pollution degree 2 Servo amplifier protection class IP 20 Mounting position page 26...

Page 24: ...lines 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 mm 8 AWG The m...

Page 25: ...filtered air Information on the Environmental conditions ventilation and mounting can be found on page 21 Any subsequent changes to a servo amplifier will render the warranty void with exception of th...

Page 26: ...DIAS DRIVE 335 23 Page 24 27 09 2017 2 2 Construction of the Control Cabinet 2 2 1 Wiring Diagram and Pin Assignment...

Page 27: ...DIAS DRIVE 335 23 27 09 2017 Page 25 2 2 1 1 SDD 335 23 Drive type Axis 1 Axis 2 Axis 3 Cable Motor Feedback Motor Feedback Motor Feedback SDD335 23 X3 X6 X4 X7 X5 X8...

Page 28: ...DIAS DRIVE 335 23 Page 26 27 09 2017 2 2 2 Mechanical Construction and Mounting 378 472 without with connectors 240 158 The drawing shows the servo amplifier dimensions...

Page 29: ...Page 27 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 to DIN 912...

Page 30: ...2017 2 2 3 Laying the Motor and Control Cables 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 l...

Page 31: ...5 mm 21 24 AWG solder or crimp Ground bolt M5 10 mm 8 AWG 3 5 Nm 31 inch lb 2 2 5 Cable Types According to EN 60204 for AWG table 310 16 of the NEC 60 C or 75 C column is recommended Signal Cable rati...

Page 32: ...pable 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 conne...

Page 33: ...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 w...

Page 34: ...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...

Page 35: ...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...

Page 36: ...ivated 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...

Page 37: ...olding 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...

Page 38: ...e 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 a...

Page 39: ...e 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...

Page 40: ...External Regen Resistor X1B If the power of the internal brake resistor is insufficient an external resistor can be added Here the connection to Rint terminal 4 of X1B and Rtr terminal 5 of X1B must b...

Page 41: ...27 09 2017 Page 39 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 out...

Page 42: ...required Note The KEM 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 REM re...

Page 43: ...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 th...

Page 44: ...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 en...

Page 45: ...k 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 conta...

Page 46: ...44 27 09 2017 3 6 2 EnDAT Signal Encoder 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 thr...

Page 47: ...DIAS DRIVE 335 23 27 09 2017 Page 45 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 48: ...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 frequenc...

Page 49: ...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...

Page 50: ...ier 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 f...

Page 51: ...o 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 informe...

Page 52: ...imitations 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...

Page 53: ...s 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 Red On On Controller in boot mode Firmware damaged or not...

Page 54: ...otor spins through The motor torque is too low or different in the directions M ROFF is not set to the right value Motor and or feedback is connected incorrectly Check the M ROFF parameter Check the m...

Page 55: ...is loaded 2 reserved 3 DC over voltage Internal External regen resistor not connected Internal regen resistor defective External regen resistor defective connect regen resistor replace amplifier repla...

Page 56: ...ition Wrong wiring of motor or feedback cable Check M ROFF Check motor connection 14 Motor over speed Incorrect motor phase position Incorrect motor connection or wrong feedback cable Over shoot great...

Page 57: ...gen resistor limit reached Regen resistor power is insufficient Brake resistance power has been reached and the resistor was deactivated An external regen resistor must be used to adjust the value of...

Page 58: ...DIAS DRIVE 335 23 Page 56 27 09 2017 29 Total power limit reached The power of all axes has exceeded the maximum load Reduce the load Drive is insufficiently dimensioned 30 reserved 31 reserved...

Page 59: ...e 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 In...

Page 60: ...IAS Drive in the switchgear cabinet By doing so the amplifier s fan block is located outside of the switchgear cabinet better ventilation An appropriate recess in the switchgear cabinet must be provid...

Page 61: ...ructions Mounting on the upper side of the amplifier Place the mounting bracket in the provided slots and secure it with both screws Mounting on the lower side of the amplifier Place the mounting brac...

Page 62: ...DIAS DRIVE 335 23 Page 60 27 09 2017 6 2 2 Dimensions incl Mounting Set...

Page 63: ...s 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...

Page 64: ...Supply voltage 5 V DC supplied by the DIAS Drive Current consumption Supply voltage Typically 400 mA Maximum 500 mA 7 1 3 Input Specifications Number Digital inputs D IN1 to D IN4 Safety inputs ENABLE...

Page 65: ...5 A Switching power Max 42 V AC min 100 A max 0 5 A 7 1 5 Safety Conformity Safety integration level according to IEC EN 62061 SIL 3 Performance Level according to EN ISO 13849 1 PLe Probability of f...

Page 66: ...tal Conditions Storage temperature 20 85 C Environmental temperature 0 60 C Humidity 0 95 uncondensed EMC stability Tested in the DIAS Drive according to EN61800 3 Shock resistance EN 60068 2 27 150 m...

Page 67: ...DIAS DRIVE 335 23 27 09 2017 Page 65 7 2 Mechanical Dimensions Integrated into the SDD3xx servo amplifier...

Page 68: ...7 3 Connector Layout X1 VARAN In X2 VARAN Out Further information about the VARAN bus can be found in the VARAN bus specifications Pin Function 1 TX RX 2 TX RX 3 RX TX 4 5 6 RX TX 7 8 Pin Function 1 T...

Page 69: ...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 Pin Function 1 ENABLE_L 2 ENABLE_H 3 Reserved 4 Rese...

Page 70: ...en LINK Lights when the connection between the two PHYs is established Yellow ACTIVE Lights when data is received or sent over the VARAN bus VARAN OUT Green LINK Lights when the connection between the...

Page 71: ...ined 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...

Page 72: ...ions 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...

Page 73: ...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 f...

Page 74: ...tions 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...

Page 75: ...TR 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...

Page 76: ...pen 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 When the servo amp...

Page 77: ...de 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...

Page 78: ...pplication is running Motor s running 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...

Page 79: ...ive 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...

Page 80: ...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...

Page 81: ...DIAS DRIVE 335 23 27 09 2017 Page 79 2 Two channel error proof relay output with which the output is connected to ENABLE_H and the output to ENABLE_L...

Page 82: ...DIAS DRIVE 335 23 Page 80 27 09 2017...

Page 83: ...ue 00000000 0008 4 r w Value 1 00000000 000C 4 r w Value 2 00000000 0010 4 r w Value 3 00000000 0014 4 r w Value 4 00000000 0018 4 r w Value 5 00000000 001C 4 r w Reserved 00000000 0020 1 r w Receive...

Page 84: ...004C 4 r w Value 2 00000000 0050 4 r w Value 3 00000000 0054 4 r w Value 4 00000000 0058 4 r w Value 5 00000000 005C 4 r w Reserved 00000000 0060 1 r w Receive Status Register Bit 0 1 Executed Object...

Page 85: ...008C 4 r w Value 2 00000000 0090 4 r w Value 3 00000000 0094 4 r w Value 4 00000000 0098 4 r w Value 5 00000000 009C 4 r w Reserved 00000000 00A0 1 r w Receive Status Register Bit 0 1 Executed Object...

Page 86: ...ue 3 00000000 00C8 4 w Value 4 00000000 00CC 4 w Value 5 00000000 00D0 16 reserved 00E0 1 r w reserved 00 00E1 1 r w reserved 00 00E2 1 r w Digital In Out Byte 00 00E3 1 r w Transmit Control Byte 00 0...

Page 87: ...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 nex...

Page 88: ...nal 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 cabi...

Page 89: ...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 mo...

Page 90: ...c 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...

Page 91: ...nnecting 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 plac...

Page 92: ...tween Two Control Cabinets 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 f...

Page 93: ...added 30 04 2015 45 Sine Cosine TTL Encoder feedback changed 08 05 2015 34 main input DC link 25 11 2015 1 VAC 013 note 08 02 2016 Document AWG corrected Shielding Plate extended VAC 013 documentation...

Page 94: ...DIAS DRIVE 335 23 Page 92 27 09 2017...

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