Danfoss VLT Integrated Servo Drive ISD 510 System Design Manual Download

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ENGINEERING TOMORROW

Design Guide

VLT

Integrated Servo Drive ISD

510 System

vlt-drives.danfoss.com

Summary of Contents for VLT Integrated Servo Drive ISD 510 System

Page 1: ...ENGINEERING TOMORROW Design Guide VLT Integrated Servo Drive ISD 510 System vlt drives danfoss com...

Page 2: ......

Page 3: ...1 Line 12 2 3 1 2 Standard Cabling Concept for 2 Lines 12 2 3 2 Ethernet POWERLINK with Redundancy 13 2 3 3 Wiring with more than 1 SAB 13 2 3 3 1 Ethernet POWERLINK 13 2 3 3 2 EtherCAT 14 2 4 EtherCA...

Page 4: ...Brake Resistor 26 2 11 1 1 Mechanical Installation 26 2 11 1 2 Electrical Installation 26 2 11 1 3 Brake Resistor Calculation 26 2 11 2 External Encoder and Sensors 28 2 11 2 1 External Encoder 28 2 1...

Page 5: ...ic Compatibility 36 4 3 2 1 Emission Requirements 36 4 3 2 2 Immunity Requirements 37 4 3 2 3 Grounding for Electrical Safety 38 4 3 2 4 EMC Grounding 39 4 3 2 5 Motor Bearing Currents 39 4 3 2 6 Eart...

Page 6: ...rements 49 5 Typecode and Selection 50 5 1 Drive Configurator for VLT Integrated Servo Drive ISD 510 50 5 2 VLT Integrated Servo Drive ISD 510 50 5 2 1 Typecode and Definitions 50 5 3 Servo Access Box...

Page 7: ...Nm at 25 C Ambient Temperature 60 6 1 5 8 Speed Torque Characteristics Size 2 3 8 Nm at 40 C Ambient Temperature 60 6 1 6 Derating 61 6 1 6 1 Derating at High Altitude 61 6 1 6 2 Derating at High Amb...

Page 8: ...ues 73 6 3 Cable 74 6 3 1 Feed In Cable 74 6 3 1 1 Clearances 74 6 3 2 Loop Cable 75 6 3 3 Fieldbus Extension Cable 75 6 3 4 LCP Cable 76 6 3 5 Sensor and Encoder Cable 76 6 3 6 Ethernet Cable 76 7 Ap...

Page 9: ...D 510 servo system and detailed technical data VLT Integrated Servo Drive ISD 510 System Programming Guide Information about the programming of the ISD 510 servo system Table 1 1 Available Manuals for...

Page 10: ...e between apparatus does not hinder their performance The basic protection requirement of the EMC Directive 2014 30 EU states that devices that generate electromagnetic interference EMI or whose opera...

Page 11: ...ulations and the information in this manual WARNING HIGH VOLTAGE The ISD 510 servo system contains components that operate at high voltage when connected to the electrical supply network A hazardous v...

Page 12: ...lectronic circuitry Ensure that the mains supply is disconnected and the required discharge time for the DC link capacitors has elapsed before disconnecting or connecting the hybrid cables or disconne...

Page 13: ...TO signals NOTICE The ISD 510 servo drives cannot be used in servo systems from other manufacturers without changing the cabling infrastructure Contact Danfoss for further information Drives from othe...

Page 14: ...d in chapter 6 1 1 Dimensions 2 3 System Wiring 2 3 1 Ethernet POWERLINK without Redundancy 2 3 1 1 Standard Cabling Concept for 1 Line 130BE436 10 AUX 1 Status Hand On Reset Auto On OK Ba ck Ca nc el...

Page 15: ...510 130BF041 10 Real Time Ethernet A A B B PLC UDC Real Time Ethernet Bus STO UAUX A Fieldbus extension cable B 3rd party network cable Illustration 2 5 Ethernet POWERLINK with Redundancy via PLC 2 3...

Page 16: ...e STO Component Description ISD 510 servo drive Motors with integrated signal and power electronics They are mounted decentrally in the application and have advanced motion control functionality on bo...

Page 17: ...mplified block diagram of the ISD 510 servo drive 1 2 3 4 5 6 7 8 STO STO UDC UDC AUX AUX Advanced servo drive Ethernet 130BF743 10 1 STO circuit If STO is activated the STO circuit disables the inver...

Page 18: ...mode or in continuous operating mode where the frequency of demands for operation made on a safety related system occurs more than once per year PFD EN IEC 61508 Average probability of failure on dema...

Page 19: ...e Illustration 2 10 Route the wires for STO 1 and STO 2 separately and not in a single multicore cable 130BE690 10 SAB STO 1 IN STO STO 1 IN STO STO 2 IN STO STO 2 IN STO Illustration 2 10 Safety Rela...

Page 20: ...rqueOff True and MC_ReadStatus_ISD51x output ErrorStop True and MC_ReadAxisError_ISD51x output AxisErrorID 0xFF80 on all enabled servo drives Motors are torque free Motors coast and stop after some ti...

Page 21: ...when STO is activated while the servo drives are running Motors are torque free Motors coast and stop after some time Statusword bit 3 1 bit 14 1 and object 0x603F shows fault 0xFF80 in all servo dri...

Page 22: ...ves on line 2 Select the safety switch devices in accordance with the requirements of the application 24 V DC GND 130BE689 11 8a 8b 9a 9b 4 2 3 1 X1 X2 X1 X2 X1 X2 X1 X2 6 6 7 5 1a 1b ISD 510 servo dr...

Page 23: ...Studio Using the NC axis functionality of TwinCAT for the servo drives Using the CANopen CiA DS 402 standard by reading and writing to objects The servo drives and the SABs can be operated with the fo...

Page 24: ...the SAB and can also be used to operate the devices in a non productive environment The DDS Toolbox contains several functionalities called sub tools which in turn provide various functionalities The...

Page 25: ...e the servo drive is operated under torque control and executes a movement with constant torque Linear ramps are used Additional parameters such as torque ramp and maximum velocity can be parameterize...

Page 26: ...nts are constantly monitored If an overcurrent occurs an error is issued and the servo drive coasts to stop as default For servo drives with the mechanical brake option the brake engages 2 10 2 Ground...

Page 27: ...n the DC link voltage rises above a certain level a warning error is issued Warning 810 V Error 820 V UDC undervoltage When the DC link voltage drops below a certain level a warning error is issued Wa...

Page 28: ...lding to the conductive decoupling plate of the SAB and to the brake resistor metal cabinet Protective functions The VLT Brake Resistor MCE 101 is equipped with a galvanic isolated temperature switch...

Page 29: ...number of servo drives that are in acceleration mode and deceleration mode The torque used to accelerate and decelerate is also important The average power is determined by the process period time for...

Page 30: ...erage power is calculated as follows Pave Ppeak x Tp Tb The duty cycle is calculated as follows Duty cycle Tp x 100 Tb Danfoss offers brake resistors with a duty cycle of maximum 10 and 40 If a 10 dut...

Page 31: ...either the servo drive or the SAB or to read out a history of errors that occurred Use the Danfoss VLT Servo Motion library on the PLC to read out the error or warning that occurred last Refer to the...

Page 32: ...tate machine is in state UAUX disabled or Fault Auxiliary voltage is not applied to line 1 Aux 2 Green State of the auxiliary voltage on line 2 On State machine is in state Standby Power up or Operati...

Page 33: ...B See chapter 2 8 2 PC Software for further details 2 13 3 Overview The libraries provided for the VLT Integrated Servo Drive ISD 510 System can be used in TwinCAT V2 and in the Automation Studio Vers...

Page 34: ...ng Filling PET blow moulding Digital bottle printing Food and beverage packaging machines Flow wrapping Bag maker Tray sealing Shrink wrapping Industrial and pharmaceutical packaging machines Palletiz...

Page 35: ...rature Devices with IP54 IP65 or IP67 protection ratings must also adhere to the specified ambient temperature ranges Additional air conditioning of the cabinet or installation site may be required 4...

Page 36: ...ions and Environmental Considerations Avoiding extreme ambient temperatures prolongs the life of the equipment and maximizes the overall system reliability Follow the recommendations listed for maximu...

Page 37: ...ample How to calculate the airflow required to cool 2 SABs with heat losses of 295 W and 1430 W running simultaneously mounted in an enclosure with an ambient temperature peak of 37 C and an installat...

Page 38: ...vo Access Box Installation of the SAB in environments with high dust exposure is often unavoidable Dust affects wall or frame mounted units and also cabinet mounted devices with IP20 protection rating...

Page 39: ...drives and the SABs comply with the requirements for the industrial environment and consequently also comply with the lower requirements for home and office environment with a large safety margin The...

Page 40: ...tion to the flange of the servo drive because this is the main PE connection Use the front side flange surface Ensure PE connection on that part of the machine Ensure that the ground connections are t...

Page 41: ...hine Standard mitigation strategies 1 Apply rigorous installation procedures 1a Ensure that the motor and motor load are aligned 1b Strictly follow the EMC Installation guideline 1c Reinforce the PE s...

Page 42: ...power drive system is less than 3 5 mA AC or 10 mA DC If the leakage current is below or equal to 3 5 mA AC or 10 mA DC no special measures relating to the PE connection are required The leakage curre...

Page 43: ...tings 130BE724 10 IM B5 IM V1 IM V3 Mounting position of servo drive according to DIN 42950 IP rating according to EN 60529 Housing All positions IP67 Shaft without shaft seal IM B5 IM V1 IP54 IM V3 I...

Page 44: ...he ISD is largely maintenance free Only the shaft seal if used is subject to wear Component Maintenance task Maintenance interval Instruction Servo drive Carry out a visual inspection Every 6 months C...

Page 45: ...load maintain harmonic currents at a low level to avoid overload of the transformer and high temperature in the cables NOTICE Some of the harmonic currents might disturb communi cation equipment conne...

Page 46: ...servo drives without sensors connected 8 9 6 W and only with a feed in cable length of 10 m The 1st step is that the power consumption of each servo drive is set to 8 W Then the number of servo drives...

Page 47: ...that can be connected per line is 32 The maximum cable length is 100 m per line 100 120 80 60 40 20 0 0 5 10 15 20 25 30 35 1 n 130BF827 10 I total m 1 Connected ISD servo drives Illustration 4 8 48...

Page 48: ...5 42 41 8 1 0 5 45 0 42 47 8 2 0 5 50 0 42 58 8 4 0 4 56 0 33 75 8 6 0 4 64 0 33 88 10 0 5 4 42 0 42 39 10 1 0 4 44 0 42 44 10 2 0 4 48 0 42 54 10 4 0 3 52 0 31 5 10 6 0 3 58 0 32 59 13 8 0 5 3 41 5...

Page 49: ...ielded Brake cable 20 m shielded Fieldbus extension cable 2 m2 24 48 V IN connector cable 3 m Table 4 14 Maximum Cable Lengths 1 Maximum total length for each line 100 m 2 Maximum length to next port...

Page 50: ...servo drive stops operation and an error is issued Table 4 16 Thermal Protection 4 7 VLT Servo Access Box 4 7 1 Grounding See chapter 4 3 2 3 Grounding for Electrical Safety and chapter 4 3 2 4 EMC G...

Page 51: ...95 3 kHz 1 SPI Interface from ADC to FPGA PELV functional isolated 12 5 MHz Digital output Switchable output voltage controlled over fieldbus 0 V 10 24 V 10 Maximum output current 150 mA Maximum switc...

Page 52: ...B K S C X 0 2 C 9 F M 1 P N F 1 0 8 N 2 9 C 0 3 C 8 E N F 1 3 8 N 2 4 Table 5 1 Type Code 01 03 Product group 21 22 Bus system 33 35 Motor speed ISD VLT Integrated Servo Drive PL Ethernet POWERLINK N4...

Page 53: ...ic data of each variant Data type Resolver Single turn encoder Multi turn encoder Signal Sin cos BiSS B BiSS B Accuracy 10 arcmin 1 6 arcmin 1 6 arcmin Resolution 14 bit 17 bit 17 bit Maximum number o...

Page 54: ...on Length m Ordering number LCP Cable SUB D to M8 3 175G8942 SAB LCP cable 3 175Z0929 Table 5 9 LCP Cable Ordering Numbers 5 5 4 LCP Mounting Kit Description Ordering number LCP remote mounting kit IP...

Page 55: ...5 55 4 2 18 2 5 0 09 123 4 84 78 3 07 14 0 55 76 2 99 76 2 99 70 2 76 5 8 0 23 X4 44 5 1 75 30 1 18 130BE438 10 Illustration 6 1 Dimensions of ISD 510 Size 1 1 5 Nm 252 9 92 83 5 3 29 1 0 0 3 9 4 55...

Page 56: ...ion 6 3 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 5 39 92 3 62 19 0 75 84 3 31 84 3 31 80 3 15 7 0 28 X4 40 1 57 74 2 91 130BE441 10 Illustration 6 4 Dim...

Page 57: ...thernet cable minimum CAT5 shielded X4 advanced version only M12 I O and or encoder cable shielded X5 advanced version only M8 LCP cable shielded Illustration 6 5 Connectors on the Servo Drive X1 and...

Page 58: ...n Assignment of X3 3rd Ethernet Connector M8 4 pole X4 M12 I O and or encoder connector M12 8 pole The M12 I O and or encoder connector is available on the advanced servo drive and can be used or conf...

Page 59: ...ply for LCP 5 V 10 at 120 mA maximum load Illustration 6 10 Pin Assignment of X5 LCP Connector M8 6 pole 6 1 3 Characteristic Data Table 6 3 and Table 6 4 provide a summary of typical servo drive char...

Page 60: ...ng maximum 55 C 24 hour average maximum 35 C Transport 25 to 70 C Storage 25 to 55 C Installation elevation Maximum 1000 m above sea level EMC standard for emission and immunity EN 61800 3 Table 6 5 G...

Page 61: ...erformance at 40 C Ambient Temperature Size 1 1 5 Nm 6 1 5 3 Speed Torque Characteristics Size 2 2 1 Nm at 25 C Ambient Temperature 0 00 1 00 2 00 3 00 4 00 5 00 6 00 7 00 8 00 9 00 M Nm 0 1000 2000 3...

Page 62: ...at 40 C Ambient Temperature Size 2 2 9 Nm 6 1 5 7 Speed Torque Characteristics Size 2 3 8 Nm at 25 C Ambient Temperature 0 00 2 00 4 00 6 00 8 00 10 00 12 00 14 00 M Nm 0 500 1000 1500 2000 2500 3000...

Page 63: ...laims any liability for damage to person or property caused by the products due to the product being installed at altitudes above 2000 m above sea level 6 1 6 2 Derating at High Ambient Temperature Se...

Page 64: ...hanical device connected to the shaft must not exceed the values shown in Table 6 11 The shaft must be loaded slowly and in a constant manner Avoid pulsating loads NOTICE The bearing could be permanen...

Page 65: ...RPM 4 3000 RPM 5 4000 RPM Illustration 6 24 Size 2 2 1 Nm Size 2 2 9 Nm 0 100 200 300 400 500 600 700 800 900 1000 1100 1200 0 200 400 600 800 1000 1200 1400 Fa N Fr N 130BF948 10 2 3 4 1 1 500 RPM 2...

Page 66: ...scharge time see chapter 1 6 Safety to elapse Mount the protection caps for any servo drive connectors that are not in use Warnings and notes for servo drive with optional brake Use an additional exte...

Page 67: ...mensions All dimensions are in mm in Front view 190 5 7 50 268 10 55 371 5 14 63 130BE312 10 Illustration 6 27 Dimensions Front View Specifications Design Guide MG36C102 Danfoss A S 08 2017 All rights...

Page 68: ...de view246 4 9 70 11 5 0 45 218 7 8 61 130BE313 10 Illustration 6 28 Dimensions Side View Specifications VLT Integrated Servo Drive ISD 510 System 66 Danfoss A S 08 2017 All rights reserved MG36C102 6...

Page 69: ...Mounting plate 130BE423 10 130 8 6 2 5 5 11 10 110 10 110 6 5 7 5 2 Illustration 6 29 Dimensions Mounting Plate Specifications Design Guide MG36C102 Danfoss A S 08 2017 All rights reserved 67 6 6...

Page 70: ...mm space between the SAB decoupling plate and the cable duct for connecting cables 6 2 3 Terminal Locations 1 3 4 2 5 6 7 8 9 10 11 12 13 14 17 16 15 18 19 20 21 22 24 23 25 26 27 28 29 30 33 31 32 13...

Page 71: ...to hybrid cable line 2 AUX 26 Fixture for Ethernet inputs 10 ISD Line 2 UDC 2 UDC output to hybrid cable line 2 UDC 27 Decoupling clamp for encoder cable 11 ISD Line 1 STO 1 STO output to hybrid cabl...

Page 72: ...4 V Front 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 ap...

Page 73: ...al current 2 A Maximum cross section 2 5 mm2 Table 6 17 Relay Connectors 6 2 3 5 Encoder Connectors Item Description Drawing pins Ratings Encoder connector Used to connect SSI or BiSS encoders 130BE39...

Page 74: ...4 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 the applicati...

Page 75: ...1 14 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 and stationary use 5 93 non condensing Ambient temper...

Page 76: ...it for discharge time to elapse see chapter 1 6 Safety The interlocking of the hybrid feed in cable and loop cable with the servo drive is indicated by the marking OPEN on the cable connector The adva...

Page 77: ...Straight connector The minimum distance for the straight connector is calculated as follows 0 5 x cable diameter connector height Rmin 7 8 mm 112 mm 78 mm 197 8 mm 200 mm 200 min 37 112 Rmin 130BF955...

Page 78: ...e chapter 6 2 3 6 Ethernet Connectors for pin assignment Specification Ethernet standard Standard Ethernet in accordance with IEEE 802 3 100Base TX Fast Ethernet Cable type S FTP shielded foiled twist...

Page 79: ...own DC link consisting of capacitors DC link voltage A DC voltage shared by several servo drives connected in parallel DC voltage A direct constant voltage DDS Toolbox A Danfoss pc software tool used...

Page 80: ...dent worldwide association that defines a standard for industrial control programming POU Program organization unit This can be a program function block or function PWM Pulse width modulation Radial f...

Page 81: ...DS Toolbox 22 EtherCAT 21 Ethernet POWERLINK 22 Fieldbus 21 Connectors on the ISD 510 servo drive 55 Connectors on the Servo Access Box AUX 72 Brake 71 Encoder 71 Ethernet X1 X4 72 Mains 70 PE 72 Rela...

Page 82: ...nce 42 Motor and flange sizes 12 Motor grounding 47 Motor output and data 58 Motor selection considerations 47 Operating environment 33 Options 47 Overvoltage 33 Speed torque characteristics 58 Termin...

Page 83: ...Instructions and precautions 9 Unintended start 9 Sensor cable 52 Sensors 49 Servo Access Box Acoustic noise 35 Ambient temperature 34 AUX connectors 72 Block diagram 15 Brake connector 71 Characteri...

Page 84: ...V Voltage warning 9 74 W Warnings Discharge time 10 High voltage 9 74 Unintended start 9 Weight Brake 58 Servo Access Box 73 Servo drive 58 Wiring 12 X X1 X2 hybrid connectors 55 X3 3rd Ethernet conne...

Page 86: ...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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