Danfoss ISD 510 Design guide

ENGINEERING TOMORROW

Design Guide

VLT® Integrated Servo Drive ISD® 510 System

vlt-drives.danfoss.com

Contents Design Guide

Contents

1 Introduction

1.1 Purpose of the Design Guide

1.2 Additional Resources

1.3 Abbreviations and Conventions

1.3.1 Abbreviations 7

1.3.2 Conventions 7

1.4 Copyright

1.5 Approvals and Certications

1.5.1 Low Voltage Directive 8

1.5.2 EMC Directive 8

1.5.3 Machinery Directive 8

1.6 Safety

1.7 Terminology

2 System Overview

2.1 General Description of the Servo System

2.2 VLT® Integrated Servo Drive ISD® 510

2.3 System Wiring

2.3.1 Ethernet POWERLINK® without Redundancy 12

2.3.1.1 Standard Cabling Concept for 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

2.3.3.2 EtherCAT

2.4 EtherCAT® with Redundancy

2.5 Description of Operation

2.6 Sequence of Operation

2.6.1 VLT® Servo Access Box (SAB) 15

2.6.2 VLT® Integrated Servo Drive ISD 510 15

2.6.3 Switching on the VLT® Integrated Servo Drive ISD 510 System 15

2.7 Functional Safety Concept

2.7.1 Notes 16

2.7.2 Abbreviations and Conventions 16

2.7.3 Functional Description 16

2.7.4 Installation 17

2.7.5 Commissioning Test 17

2.7.6 Application Example 20

2.7.7 Safety Function Characteristic Data 21

Contents

VLT® Integrated Servo Drive ISD® 510 System

2.8 Communication

2.8.1 Fieldbus 21

2.8.1.1 EtherCAT

2.8.1.2 Ethernet POWERLINK

2.8.2 PC-Software 22

2.8.2.1 System Requirements 22

2.9 Operating Modes

2.10 Automated Operational Functions

2.10.1 Short Circuit Protection 24

2.10.1.1 Servo Access Box Features 24

2.10.1.2 ISD 510 Servo Drive Features 24

2.10.2 Ground Fault Protection 24

2.10.3 Temperature-controlled Fans 24

2.10.4 Thermal Protection 24

2.10.5 Additional Protection Features 24

2.10.5.1 Servo Access Box 24

2.10.5.2 VLT® Integrated Servo Drive ISD 510 25

2.11 Custom Application Functions

2.11.1 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

2.11.2.2 Sensor 28

2.11.3 Relays 29

2.12 Faults, Warnings, and Alarm Functions

2.12.1 Overview 29

2.12.2 Operating LEDs on the VLT® Integrated Servo Drive ISD 510 29

2.12.3 Operating LEDs on the VLT® Servo Access Box 30

2.13 User Interfaces

2.13.1 Overview 31

2.13.2 DDS Toolbox Software 31

2.13.3 Overview 31

2.13.4 TwinCAT® NC Axis 31

3 Application Examples

3.1 Intended Applications

4 System Integration

4.1 Operating Environment: VLT® Integrated Servo Drive ISD 510

Contents Design Guide

4.1.1 Humidity 33

4.1.2 Ambient Temperature 33

4.1.3 Cooling 33

4.1.4 Motor-generated Overvoltage 33

4.1.5 Acoustic Noise 34

4.1.6 Vibration and Shock 34

4.2 Operating Environment: SAB

4.2.1 Humidity 34

4.2.2 Ambient Temperature 34

4.2.3 Cooling 34

4.2.3.1 Cooling Fans 34

4.2.3.2 Calculation of Airow Required for Cooling the SAB 35

4.2.4 Acoustic Noise 35

4.2.5 Vibration and Shock 35

4.3 Operating Environment: General

4.3.1 Aggressive Atmospheres 35

4.3.1.1 Gases 35

4.3.1.2 Exposure to Dust 36

4.3.2 Electromagnetic 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 Earth Leakage Current 39

4.3.2.7 Touch Current 40

4.3.3 IP Ratings 41

4.3.3.1 Denitions 41

4.3.3.2 IP Ratings for SAB and Servo Drive 41

4.3.4 Radio Frequency Interference 41

4.3.5 PELV and Galvanic Isolation Compliance 41

4.3.5.1 Discharge Time 42

4.3.6 Maintenance 42

4.3.7 Storage 42

4.4 Mains Input

4.4.1 General Requirements 43

4.4.2 Harmonics 43

4.4.2.1 Mains Conguration and EMC eects 43

4.4.2.2 Mains Transients 43

4.5 System Concepts

Contents

VLT® Integrated Servo Drive ISD® 510 System

4.5.1 Auxiliary Power Supply Selection 44

4.5.1.1 Shell Diagram 44

4.5.1.2 Auxiliary Power 45

4.5.1.3 24 V Supply 45

4.5.1.4 48 V Supply 46

4.5.2 Communication Topology 47

4.6 VLT® Integrated Servo Drive ISD 510

4.6.1 Motor Selection Considerations 47

4.6.2 Motor Grounding 47

4.6.3 Thermal Protection 48

4.7 VLT® Servo Access Box

4.7.1 Grounding 48

4.7.2 Eciency 48

4.8 Cables

4.9 Peripheral Components

4.9.1 AUX Power Supply 48

4.9.2 Sensors 49

4.9.3 Safety Supply Requirements 49

5 Typecode and Selection

5.1 Drive Congurator for VLT® Integrated Servo Drive ISD 510

5.2 VLT® Integrated Servo Drive ISD 510

5.2.1 Typecode and Denitions 50

5.3 Servo Access Box

5.4 Options

5.4.1 Mechanical Holding Brake 51

5.4.2 Feedback 51

5.4.2.1 Built-in Feedback Devices 51

5.4.3 Customized Flange 51

5.4.4 Shaft Seal 51

5.5 Accessories

5.5.1 Flexible Hybrid Cable 51

5.5.1.1 Feed-In Cable 51

5.5.1.2 Loop Cable 52

5.5.2 Fieldbus Cables 52

5.5.3 LCP Cable 52

5.5.4 LCP Mounting Kit 52

5.5.5 Blind Caps 52

5.5.6 Sensor Cable 52

6 Specications

Contents Design Guide

6.1 Servo Drive

6.1.1 Dimensions 53

6.1.2 Terminal Locations 55

6.1.2.1 Connectors on the Servo Drives 55

6.1.3 Characteristic Data 57

6.1.4 General Specications and Environmental Conditions 58

6.1.5 Motor Output and Data 58

6.1.5.1 Speed-Torque Characteristics: Size 1, 1.5 Nm at 25 °C Ambient Temperature

6.1.5.2 Speed-Torque Characteristics: Size 1, 1.5 Nm at 40 °C Ambient Temperature

6.1.5.3 Speed-Torque Characteristics: Size 2, 2.1 Nm at 25 °C Ambient Temperature

6.1.5.4 Speed-Torque Characteristics: Size 2, 2.1 Nm at 40 °C Ambient Temperature

6.1.5.5 Speed-Torque Characteristics: Size 2, 2.9 Nm at 25 °C Ambient Temperature

6.1.5.6 Speed-Torque Characteristics: Size 2, 2.9 Nm at 40 °C Ambient Temperature

6.1.5.7 Speed-Torque Characteristics: Size 2, 3.8 Nm at 25 °C Ambient Temperature

6.1.5.8 Speed-Torque Characteristics: Size 2, 3.8 Nm at 40 °C Ambient Temperature

6.1.6 Derating 61

6.1.6.1 Derating at High Altitude 61

6.1.6.2 Derating at High Ambient Temperature 61

6.1.6.3 Derating using Servo Drives with Shaft Seals 61

6.1.6.4 Derating using Servo Drives with Mechanical Holding Brake 61

6.1.7 Connection Tightening Torques 61

6.1.8 Installation 62

6.1.8.1 Allowed Forces 62

6.1.8.2 Bearing Load Curves 62

6.1.8.3 Installation Safety and Warnings 64

6.2 SAB

6.2.1 Dimensions 65

6.2.2 Clearance 68

6.2.3 Terminal Locations 68

6.2.3.1 STO Connectors 70

6.2.3.2 Mains Connectors 70

6.2.3.3 Brake Connector 71

6.2.3.4 Relay Connectors 71

6.2.3.5 Encoder Connectors 71

6.2.3.6 Ethernet Connectors 72

6.2.3.7 AUX Connectors 72

6.2.3.8 24/48 V IN Connector 72

6.2.3.9 UDC Connectors 72

6.2.3.10 Hybrid Cable PE 72

6.2.4 Characteristic Data 73

Contents

VLT® Integrated Servo Drive ISD® 510 System

6.2.5 General Specications and Environmental Considerations 73

6.2.6 Mains Supply 73

6.2.7 Derating 73

6.2.8 Connection Tightening Torques 73

6.3 Cable

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 Appendix

7.1 Glossary

Index

Introduction Design Guide

1 Introduction

1.1 Purpose of the Design Guide

This design guide for Danfoss VLT® Integrated Servo Drive ISD® 510 System is intended for:

Project and systems engineers.

•

Design consultants.

•

Application and product specialists.

•

The design guide provides technical information to understand the capabilities of the VLT® Integrated Servo Drive ISD® 510 System, and to provide design consider-

ations and planning data for integration of the system into an application.

Also included are:

Safety features.

•

Fault condition monitoring.

•

Operational status reporting.

•

Serial communication capabilities.

•

Programmable options and features.

•

Design details, such as site requirements, cables, fuses, control wiring, the size and weight of units, and other important information necessary to plan for system integration are also provided.

Technical literature for Danfoss drives is also available online at drives.danfoss.com/knowledge-center/technical- documentation/.

1.3 Abbreviations and Conventions

1.3.1 Abbreviations

All abbreviations can be found in chapter 7.1 Glossary.

1.3.2 Conventions

Numbered lists indicate procedures. Bullet lists indicate other information and descriptions of

gures.

Italicized text indicates:

Cross-reference.

•

Link.

•

Footnote.

•

Parameter name, parameter group name,

•

parameter option.

All dimensions in drawings are in mm (inch).

1.4

VLT®, ISD®, and SAB® are Danfoss registered trademarks.

1 1

The design guide caters for the selection of ISD 510 servo system components and options for a diversity of applications and installations. Reviewing the detailed product information in the design stage enables the development of a well-conceived system with optimal functionality and

Additional Resources

1.2

Available manuals for the VLT® Integrated Servo Drive ISD® 510 System:

Manual Contents

VLT® Integrated Servo Drive ISD® 510 System Operating Instructions

VLT® Integrated Servo Drive ISD® 510 System Design Guide

VLT® Integrated Servo Drive ISD® 510 System Programming Guide

Table 1.1 Available Manuals for the ISD 510 Servo System

eciency.

Information about the installation, commissioning, and operation of the ISD 510 servo system.

Information about the set-up of the ISD 510 servo system and detailed technical data.

Information about the programming of the ISD 510 servo system.

Approvals and Certications

1.5

The VLT® Integrated Servo Drive ISD® 510 System fullls the standards listed in Table 1.2.

IEC/EN 61800-3 Adjustable speed electrical power drive

systems. Part 3: EMC requirements and specic test methods.

IEC/EN 61800-5-1 Adjustable speed electrical power drive

systems. Part 5-1: Safety requirements – Electrical, thermal, and energy.

IEC/EN 61800-5-2 Adjustable speed electrical power drive

systems. Part 5-2: Safety requirements – Functional.

IEC/EN 61508 Functional safety of electrical/electronical/

programmable electronic safety-related systems.

EN ISO 13849-1 Safety of machinery – Safety-related parts of

control systems. Part 1: General principles for design.

EN ISO 13849-2 Safety of machinery – Safety-related parts of

control systems. Part 2: Validation.

Introduction

VLT® Integrated Servo Drive ISD® 510 System

IEC/EN 60204-1 Safety of machinery – Electrical equipment of

machines. Part 1: General requirements.

IEC/EN 62061 Safety of machinery – Functional safety of

safety-related electrical, electronic, and programmable electronic control systems.

IEC/EN 61326-3-1 Electrical equipment for measurement,

control, and laboratory use – EMC requirements. Part 3-1: Immunity requirements for safetyrelated systems and for equipment intended to perform safety-related functions (functional safety) – General industrial applications.

UL 508C UL Standard for Safety for Power Conversion

Equipment.

1.5.2 EMC Directive

Electromagnetic compatibility (EMC) means that electromagnetic interference 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 operation could be aected by EMI, must be designed to limit the generation of electromagnetic interference and must have a suitable degree of immunity to EMI when properly installed, maintained, and used as intended.

Devices used as standalone or as part of a system must bear the CE mark. Systems must not be CE marked but must comply with the basic protection requirements of the EMC directive.

2006/42/EC Machinery Directive CE

2014/30/EU EMC Directive 2014/35/EU Low Voltage Directive RoHS (2011/65/EU)

EtherCAT

Ethernet POWERLINK

PLCopen

Restriction of hazardous substances.

Ethernet for Control Automation Technology. Ethernet-based eldbus system. Ethernet-based eldbus system.

Technical specication. Function blocks for motion control (formerly Part 1 and Part 2) Version 2.0 March 17, 2011.

1.5.3 Machinery Directive

The VLT® Integrated Servo Drive ISD® 510 System components are subject to the Low Voltage Directive, however components or systems with an integrated safety function must comply with the machinery directive 2006/42/EC. Components or systems without a safety function do not fall under the machinery directive. If components are integrated into a machinery system, Danfoss provides information on safety aspects relating to them.

Machinery Directive 2006/42/EC covers a machine

classied as electronic components

consisting of an aggregate of interconnected components

Table 1.2 Approvals and Certications

or devices, of which at least 1 is capable of mechanical movement. The directive mandates that the equipment

1.5.1 Low Voltage Directive

design must ensure the safety and health of people and livestock are not endangered and the preservation of

The VLT® Integrated Servo Drive ISD® 510 System components are classied as electronic components and

material worth so long as the equipment is properly installed, maintained, and used as intended.

must be CE labeled in accordance with the Low Voltage Directive. The directive applies to all electrical equipment in the 50–1000 V AC and the 75–1600 V DC voltage ranges.

When servo system components are used in machines with at least 1 moving part, the machine manufacturer must provide a declaration stating compliance with all relevant statutes and safety measures. Danfoss CE-labels comply

The directive mandates that the equipment design must ensure the safety and health of people and livestock are not endangered and the preservation of material worth so

with the machinery directive for drives with an integrated safety function. Danfoss provides a declaration of conformity on request.

long as the equipment is properly installed, maintained, and used as intended. Danfoss CE-labels comply with the Low Voltage Directive. Danfoss provides a declaration of conformity on request.

Introduction Design Guide

1.6 Safety

The following symbols are used in this guide:

WARNING

Indicates a potentially hazardous situation that could result in death or serious injury.

CAUTION

Indicates a potentially hazardous situation that could result in minor or moderate injury. It can also be used to alert against unsafe practices.

NOTICE

Indicates important information, including situations that can result in damage to equipment or property.

The following safety instructions and precautions relate to the VLT® Integrated Servo Drive ISD® 510 System.

Read the safety instructions carefully before starting to work in any way with the ISD 510 servo system or its components. Pay particular attention to the safety instructions in the relevant sections of this manual.

WARNING

HAZARDOUS SITUATION

If the servo drive, SAB, or the bus lines are incorrectly connected, there is a risk of death, serious injury, or damage to the unit.

Always comply with the instructions in this

•

manual and national and local safety regulations.

WARNING

GROUNDING HAZARD

The ground leakage current is >3.5 mA. Improper grounding of the ISD 510 servo system components may result in death or serious injury.

For reasons of operator safety, ground the

•

components of the ISD 510 servo system correctly in accordance with national or local electrical regulations 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 voltage is present on the servo drives and the SAB whenever they are connected to the mains network. There are no indicators on the servo drive or SAB that indicate the presence of mains supply. Incorrect installation, commissioning, or maintenance can lead to death or serious injury.

Installation, commissioning, and maintenance

•

must only be performed by qualied personnel.

WARNING

UNINTENDED START

The ISD 510 servo system contains servo drives and the SAB that are connected to the electrical supply network and can start running at any time. This may be caused by a eldbus command, a reference signal, or clearing a fault condition. Servo drives and all connected devices must be in good operating condition. A decient operating condition may lead to death, serious injury, damage to equipment, or other material damage when the unit is connected to the electrical supply network.

Take suitable measures to prevent unintended

•

starts.

WARNING

UNINTENDED MOVEMENT

Unintended movement may occur when parameter changes are carried out immediately, which may result in death, serious injury, or damage to equipment.

When changing parameters, take suitable

•

measures to ensure that unintended movement cannot pose any danger.

1 1

Introduction

VLT® Integrated Servo Drive ISD® 510 System

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 o at the SAB. Failure to wait the specied time after power has been removed before performing service or repair work could result in death or serious injury.

To avoid electrical shock, fully disconnect the

•

SAB from the mains and wait for at least the time listed in Table 1.3 for the capacitors to fully discharge before carrying out any maintenance or repair work on the ISD 510 servo system or its components.

Number Minimum waiting time (minutes)

0–64 servo drives 10

Table 1.3 Discharge Time

NOTICE

Never connect or disconnect the hybrid cable to or from the servo drive when the ISD 510 servo system is connected to mains or auxiliary supply, or when voltage is still present. Doing so damages the electronic 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 disconnecting cables from the SAB.

NOTICE

Full safety warnings and instructions are detailed in the

VLT® Integrated Servo Drive ISD 510 System Operating Instructions.

1.7 Terminology

VLT® Integrated Servo Drive ISD 510

VLT® Servo Access

Box SAB

PLC

Loop cable Hybrid cable for connecting servo drives in

Feed-in cable Hybrid cable for connection from the SAB to

Table 1.4 Terminology

An explanation of all terminology and abbreviations can be found in chapter 7.1 Glossary.

Integrated servo drive

Unit that generates the DC-link voltage and passes the U and STO signals to the servo drives via a hybrid cable.

External device for controlling the VLT Integrated Servo Drive ISD® 510 System.

daisy-chain format.

the 1st servo drive.

, Real-Time Ethernet, UDC,

AUX

130BE385.10

System Overview Design Guide

2 System Overview

2.1 General Description of the Servo System

2.2

VLT® Integrated Servo Drive ISD® 510

2 2

The VLT® Integrated Servo Drive ISD® 510 System is a highperformance decentral servo motion solution.

It comprises:

A central power supply: VLT® Servo Access Box

•

(SAB®).

VLT® Integrated Servo Drives ISD® 510.

•

Cabling infrastructure.

•

The decentralization of the drive unit mounting, installation, and operation. Depending on the application, the SAB can power up to 64 servo drives in a servo drive system when using 2 hybrid lines. It generates a DC-link voltage of 565–680 V DC ±10% and guarantees high power density. It has a removable local control panel (LCP), and is based on the proven quality of a Danfoss frequency converter. The motion control is integrated into the servo drive so that the motion sequences can take place independently. This reduces the required computing power of the central PLC and oers a highly exible drive concept. Danfoss oers libraries for various IEC 61131-3 programmable PLCs. Due to the standardized and certied eldbus interfaces of

the ISD devices, any PLC with an EtherCAT® master functionality, or Ethernet POWERLINK® managing node

functionality according to the standards can be used. Hybrid cables are used to connect the servo drives, making installation fast and simple. These hybrid cables contain the DC-link supply, the Real-Time Ethernet, U signals.

oers benets in

, and STO

AUX

ISD is the abbreviation of integrated servo drive, which is a compact drive with an integrated permanent magnet synchronous motor (PMSM). This means that the entire power drive system consisting of motor, position sensor, mechanical brake, and also power and control electronics is integrated into 1 housing. Additional circuits, such as low voltage supply, bus drivers, and functional safety are implemented within the servo drive electronics. All servo drives have 2 hybrid connectors (M23) that connect power and communication signals from a hybrid cable. The advanced version has 3 additional interfaces for external encoder or I/Os, eldbus devices, and for the local control panel (LCP) to be connected directly.

LEDs on the top of the servo drive show the current status. Data transfer takes place via Real-Time Ethernet.

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 other manufacturers cannot be used in the ISD 510 servo system when using Danfoss hybrid cables.

NOTICE

Only the components described in this manual may be tted or installed. Third-party devices and equipment may be used only in consultation with Danfoss.

1 Operating LEDs 2 Connectors

Illustration 2.1 ISD 510 Servo Drive

Illustration 2.1 and Table 2.1 show the external interfaces on the ISD 510 servo drive.

130BE436.10

AUX 1

Status

Hand

Reset

Auto On

Back

Cancel

Info

Quick Menu

Main Menu

Alarm Log

AUX 2 SAFE 1 SAFE 2

Status

Hand On

Reset

Auto On

Back

Cancel

Info

Quick Menu

Main Menu

Alarm Log

LCP

SAB

400-480 V AC

Real-Time Ethernet

ISD 510

. . .

130BE437.10

AUX 1

Status

Hand

Reset

Auto On

Back

Cancel

Info

Quick Menu

Main Menu

Alarm Log

AUX 2 SAFE 1 SAFE 2

Status

Hand On

Reset

Auto On

Back

Cancel

Info

Quick Menu

Main Menu

Alarm Log

LCP

SAB

400-480 V AC

Real-Time Ethernet

ISD 510

. . .

System Overview

VLT® Integrated Servo Drive ISD® 510 System

Interface Description

Shaft Mechanical interface.

2.3.1.2 Standard Cabling Concept for 2 Lines

Operating LEDs Provides the status of the servo

drive.

M23 hybrid input connector Input connector for power and

communication signals. M23 hybrid output connector M8 4-pole connector (advanced servo drive only) M12 8-pole connector (advanced servo drive only) M8 6-pole connector

Output connector for power and

communication signals.

Input connector for eldbus

devices.

Input connector for external

encoder or I/Os.

Input connector for LCP. (advanced servo drive only)

Table 2.1 External Interfaces on the ISD 510 Servo Drive

The ISD 510 servo drive has the ange sizes shown in Table 2.2.

Size 1,

1.5 Nm

Flange size 76 mm 84 mm

Table 2.2 Motor and Flange Sizes

All dimensions of the servo drive are listed in chapter 6.1.1 Dimensions.

System Wiring

2.3

Size 2,

2.1 Nm

Size 2,

2.9 Nm

Size 2,

3.8 Nm

1 M23 Feed-in cable 2 M23 Loop cable

Illustration 2.3 Standard Cabling Concept for 2 Lines

2.3.1

Ethernet POWERLINK® without Redundancy

2.3.1.1 Standard Cabling Concept for 1 Line

1 M23 Feed-in cable 2 M23 Loop cable

Illustration 2.2 Standard Cabling Concept for 1 Line

AUX 1

Status

Hand

Oﬀ

Reset

Auto On

Back

Cancel

Info

Quick Menu

Main Menu

Alarm

Log

AUX 2 SAFE 1 SAFE 2

Status

Hand On

Oﬀ Reset

Auto On

Back

Cancel

Info

Quick Menu

Main Menu

Alarm

Log

LCP

SAB

400-480 V AC

ISD 510

UDC + Real-Time Ethernet Bus + STO + U

AUX

. . .

130BF040.10

Real-Time Ethernet

AUX 1

Status

Hand On

Oﬀ

Reset

Auto

Back

Cancel

Info

Quick Menu

Main Menu

Alarm Log

AUX 2 SAFE 1 SAFE 2

Status

Hand

Oﬀ Reset

Auto On

Back

Cancel

Info

Quick Menu

Main Menu

Alarm

Log

LCP

SAB

400-480 V AC

ISD 510

. . .

130BF041.10

Real-Time Ethernet

PLC

UDC + Real-Time Ethernet Bus + STO + U

AUX

130BF042.10

AUX 1

Status

Hand On

Oﬀ

Reset

Auto On

Back

Cancel

Info

Quick Menu

Main Menu

Alarm Log

AUX 2 SAFE 1 SAFE 2

Status

Hand

Oﬀ Reset

Auto On

Back

Cancel

Info

Quick Menu

Main Menu

Alarm Log

LCP

SAB

400-480 V AC

ISD 510

UDC + Real-Time Ethernet Bus + STO + U

AUX

. . .

Real-Time Ethernet

PLC

AUX 1

Status

Hand On

Oﬀ

Reset

Auto On

Back

Cancel

Info

Quick Menu

Main

Alarm Log

AUX 2 SAFE 1 SAFE 2

SAB

400-480 V AC

ISD 510

UDC + Real-Time Ethernet Bus + STO + U

AUX

. . .

Real-Time Ethernet

System Overview Design Guide

2.3.2

Ethernet POWERLINK® with Redundancy

There are 2 methods to use Ethernet POWERLINK® with redundancy:

eldbus extension cable

Via a

•

Via the PLC

•

Illustration 2.4 shows Ethernet POWERLINK® with redundancy via a eldbus extension cable.

A Fieldbus extension cable B

3rd party network cable

2 2

A Fieldbus extension cable B

3rd party network cable

Illustration 2.4 Ethernet POWERLINK® with Redundancy via

Fieldbus Extension Cable

Illustration 2.5 shows Ethernet POWERLINK® with redundancy via the PLC.

Illustration 2.5 Ethernet POWERLINK® with Redundancy via

PLC

2.3.3 Wiring with more than 1 SAB

Illustration 2.6 shows how to wire the servo system using >1 SAB.

3rd party network cable

Illustration 2.6 Wiring with >1 SAB

2.3.3.1

To connect additional SAB units in the same Ethernet POWERLINK® network, use an RJ45 to RJ45 network cable from the Ethernet X2 connection on the 1st SAB to the Ethernet X1 connection on the 2nd SAB, and so on.

Ethernet POWERLINK

AUX 1

Status

Hand On

Oﬀ

Reset

Auto On

Back

Cancel

Info

Quick Menu

Main Menu

Alarm Log

AUX 2 SAFE 1 SAFE 2

Status

Hand On

Oﬀ Reset

Auto On

Back

Cancel

Info

Quick Menu

Main

Alarm Log

LCP

SAB

400-480 V AC

ISD 510

. . .

130BF043.10

Real-Time Ethernet

PLC

Power

CH. 1

CH. 2

A2 14 24

S11 S12 S21 S22

A1 13 28

S33 S34 Y36 Y37

PNOZ X2P

QUINT POWER

UDC + Real-Time Ethernet Bus + STO + U

AUX

System Overview

VLT® Integrated Servo Drive ISD® 510 System

2.3.3.2

To connect additional SAB units in the same EtherCAT network, use an RJ45 to RJ45 network cable from the

EtherCAT

Ethernet X2 connection on the 1st SAB to the Ethernet X1 connection on the 2nd SAB, and so on.

2.4

EtherCAT® with Redundancy

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 board. Servo Access Box (SAB)

Central supply and access unit for mounting

inside a control cabinet. The SAB is the power

supply for the ISD 510 servo drives and is the

central access point for the eldbus.

Ring redundancy can be achieved using a special cabling scheme. Connect the eldbus extension cable to the last servo drive on the line and connect the other end of the cable with an Ethernet CAT5 cable. Settings must also be made in the engineering environment; see the corresponding online help for further information.

2.5 Description of Operation

Illustration 2.7 shows the VLT® Integrated Servo Drive ISD® 510 System and components.

Hybrid cable There are 2 types of hybrid cable:

Feed-in cable: Connects the SAB to the 1

•

servo drive.

Loop cable: Connects the servo drives in an

•

application in daisy-chain format. Speed connectors minimize installation time, cost, and risk of failures.

Local Control Panel (LCP)

Graphical user interface for diagnostic and

operating purposes. The LCP is mounted on the

SAB but can be removed and connected to the

servo drive via connector X5 (advanced version

only). The LCP can be used for the ID

assignment of the advanced servo drives. The ID

assignment is started via LCP and the LCP also

indicates if the procedure is nished. External encoder PLC

An external encoder can be connected to each

SAB and servo drive in the system.

PLC with Ethernet POWERLINK® and EtherCAT

eldbus master functionality. STO Safe torque o feature can be provided via

external safety circuits. Analog/Digital

Connection to the servo drives is possible. Sensor

3rd party eldbus device

Connection to the M8 4-pole eldbus port on

the servo drive (advanced servo drive only)

Illustration 2.7 Overview of the ISD 510 Servo System and

Table 2.4 ISD 510 System Components

Components

1 24/48 V power supply 2 Encoder 3 I/O 4 Brake resistor 5

Safety relay

Table 2.3 Legend to Illustration 2.7

1) Safety relays that have a plus and minus switching output signal

can be directly connected to the ISD 510 servo system to activate

STO.

Ethernet X1

Ethernet X2

AC mains supply

24/48 V IN

STO 1 IN: STO 1 ISD Line 1: STO 1

ISD Line 2: STO 2

ISD Line 2: AUX 2

ISD Line 1: AUX 1

ISD Line 2: UDC 2

ISD Line 1: UDC 1

Ethernet X4

Ethernet X3

STO 2 IN: STO 2

130BF744.10

2 3

6 7 8

STO+ STO–

UDC+

UDC–

AUX+

AUX–

Advanced servo drive

Ethernet

130BF743.10

System Overview Design Guide

2.6 Sequence of Operation

2.6.1

VLT® Servo Access Box (SAB)

Illustration 2.8 shows a simplied block diagram of the SAB.

1 Control logic Used for communication and

monitors the status of the SAB.

2 SMPS (Switch mode power

supply)

3 When power is rst applied to the SAB, it enters through the

input terminals (L1, L2, and L3) and on to the RFI lter.

4 Following the rectier section, voltage passes to the

intermediate section. This rectied voltage is smoothed by a sine-wave lter circuit, consisting of the DC bus inductor and the DC bus capacitor bank. The DC bus inductor provides series impedance to changing current. This aids the ltering process while reducing harmonic distortion to the input AC current waveform normally inherent in rectier circuits.

5 Switch For enabling or disabling the UDC

6 Overvoltage/overcurrent

protection

7 LED indicators Show the presence of the AUX

8 LED indicators Show the presence of the STO

Used to generate the control voltage from the intermediate bus.

output lines. Inrush current limitation for the servo drives is also done within this section. For the auxiliary line.

voltage at the outputs of the SAB.

voltage.

1 STO circuit If STO is activated, the STO circuit disables

the inverter. 2 DC bus and lter The DC bus and lter smooth the voltage. 3 Inverter In the inverter section, once run

command and speed/position references

are present, the IGBTs begin switching to

create the output waveform. 4 Motor Synchronous permanent magnet motor. 5 Control circuit Used for generating the PWM pattern and

monitoring the status of the ISD. 6 X4: M12 I/O

and/or encoder connector (advanced servo drive only)

7 X5: LCP connector

(advanced servo drive only)

8 X3: Ethernet

connector (advanced servo drive only)

Illustration 2.9 Simplied Block Diagram of the ISD 510 Servo

Drive

2.6.3

Switching on the VLT® Integrated

This interface can be used to connect

digital inputs/outputs. It can also be used

for analog values. SSI/BISS encoders can

be connected to this interface.

An LCP can be connected to read out

parameters and set-up of the servo drive.

This interface can be used to connect

external real-time Ethernet devices.

Servo Drive ISD 510 System

2 2

Illustration 2.8 Simplied Block Diagram of the Servo Access

Box

2.6.2

Table 2.1 shows a simplied block diagram of the ISD 510 servo drive.

VLT® Integrated Servo Drive ISD 510

The cabling in the ISD 510 servo system provides the supply voltage and the communication signals. This is a fundamental requirement for operation of the servo drives.

The ISD 510 servo system can be switched on in 3 ways:

If the SAB is supplied with mains and U

•

AUX

, communication to the SAB internal controller is established and U

is automatically passed on

AUX

to the connected servo drives.

If the SAB is only powered by U

•

, then the SAB

AUX

and servo drive control units are running.

System Overview

VLT® Integrated Servo Drive ISD® 510 System

If the SAB is only supplied with mains power,

•

then only the SAB control unit is running and power is not passed on to the connected servo

drives.

Procedure for switching on the ISD 510 servo system

1. Switch U

power on to enable communication

AUX

to the SAB and servo drives.

2. Switch the mains on.

3. Set the SAB to state Operation Enabled.

4. The SAB and servo drives are now ready for operation.

2.7 Functional Safety Concept

2.7.1 Notes

Use of the STO function requires that all provisions for safety, including relevant laws, regulations, and guidelines, are satised.

The integrated STO function complies with the following standards:

EN 60204-1: 2006 Stop Category 0 – uncontrolled

•

stop

IEC/EN 61508: 2010 SIL 2

•

IEC/EN 61800-5-2: 2007 SIL 2

•

IEC/EN 62061: 2005 SIL CL2

•

EN ISO 13849-1: 2015

•

The VLT® Integrated Servo Drive ISD 510 System has been

Abbreviation Reference Description

PFH EN IEC 61508 Probability of dangerous failures

per hour Take this value into account if the safety device is operated in high demand 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

demand This value is used for low demand operation.

PL EN ISO

13849-1

SFF EN IEC 61508 Safe Failure Fraction [%]

SIL EN IEC 61508

EN IEC 62061

STO EN IEC

61800-5-2

Table 2.5 Abbreviations and Conventions

Performance level A discrete level used to specify the capability of safety-related parts of a system to perform safetyoriented functions under foreseeable conditions. Levels: a–e.

Proportion of safe failures and detected dangerous failures of a safety function or a subsystem as a percentage of all possible failures. Safety Integrity Level

Safe Torque O

tested for higher EMC immunity as described in EN 61800-5-2:2017.

2.7.3 Functional Description

2.7.2 Abbreviations and Conventions

Abbreviation Reference Description

Cat. EN ISO

13849-1 DC – Diagnostic coverage FIT – Failure in time

HFT EN IEC 61508 Hardware fault tolerance

MTTF

EN ISO

13849-1

Category, level B, 1–4

Failure rate: 1E-9/hour

H = n means that n + 1 faults may lead to a loss of the safety function. Mean time to failure – dangerous Unit: years

The STO function in the VLT® Integrated Servo Drive ISD 510 System features a separate STO function for each line of servo drives in daisy-chain format. The function is activated by inputs on the SAB. Using the STO function activates the STO for all servo drives on that line. Once the STO is activated, no torque is generated on the axes. Reset of the safety function and diagnostics can be carried out via the PLC.

NOTICE

The ISD 510 servo system does not implement a manual reset function as required by ISO 13849-1. The standard failure reset from the PLC cannot be used for this purpose. For automatic restart without manual reset, observe the requirements detailed in paragraph 6.3.3.2.5 of ISO 12100:2010 or equivalent standard.

130BE690.10

SAB

STO 1 IN: + STO

STO 1 IN: – STO

STO 2 IN: + STO

STO 2 IN: – STO

System Overview Design Guide

NOTICE

Carry out a risk assessment to select the correct stop category for each stop function in accordance with EN 60204-1.

NOTICE

When designing the machine application, consider timing and distance for coast to stop (Stop Category 2 or STO). See EN 60204-1 for further information.

NOTICE

All signals connected to the STO must be supplied by a SELV or PELV supply.

2.7.4 Installation

Only Danfoss cables may be used for the installation of the servo system, however cables from other suppliers may be used for the user connection to the STO terminals (STO 1 IN and STO 2 IN) on the SAB.

NOTICE

If the application does not require the Safe Torque O (STO) functionality, build a bridge by connecting +24 V from the connector STO 1 IN: +24V to STO 1 IN: +STO, and from STO 1 IN: –24 V to STO 1 IN: –STO. Repeat this process for STO line 2 if used.

Safety relays that have a plus and minus switching output signal can be directly connected to the VLT® Integrated

Servo Drive ISD 510 System to activate STO (see Illustration 2.10). Route the wires for STO 1 and STO 2 separately and not in a single multicore cable.

Illustration 2.10 Safety Relay with Plus and Minus Switching

Output

Signals with test pulses must not have test pulses of >1 ms. Longer pulses may lead to reduced availability of the servo system.

2 2

2.7.5 Commissioning Test

NOTICE

Perform a commissioning test after installation of the STO function, after every change to the installed function, or after a safety fault. Perform the test for each STO line.

There are 2 ways to implement the commissioning test depending on the method used to program the PLC, however the steps of the test are the same:

Using the Danfoss Library or the TwinCAT® Library.

•

Bit-wise readout of the status.

•

Commissioning test using libraries

Depending on the application, 1 or both of the following libraries are required to program the commissioning test:

Danfoss Library

•

- MC_ReadAxisInfo_ISD51x

- MC_ReadStatus_ISD51x

- MC_ReadAxisError_ISD51x

- MC_Reset_ISD51x

TwinCAT® Library

•

- MC_ReadStatus

- MC_ReadAxisError

- MC_Reset

System Overview

VLT® Integrated Servo Drive ISD® 510 System

Test steps Reason for the test step Expected result for Danfoss

library

1 Run the application (all the

servo drives are enabled).

2 Stop the application. – All servo drives are at speed 0

3 Disable all the servo drives. – All servo drives are disabled. All servo drives are disabled. 4 Enable STO. Check that STO can be

5 Disable STO. Check that STO can be

6 Run the application (all the

servo drives are enabled).

7 Enable STO. Check that errors are

8 Try to run the application

(enable 1 or more servo drives).

9 Disable STO. Check that the STO start is

10 Try to run the application

(enable 1 or more servo drives).

11 Send a reset signal via

MC_Reset(_ISD51x).

12 Try to run the application (all

servo drives are enabled).

Check that the application can run.

activated without error.

deactivated without error. No reset is required.

– Application runs as expected. Application runs as expected.

generated correctly when STO is activated while the servo drives are running.

Checks that the STO function is working correctly.

still inhibited by the error signal.

Check whether reset is required.

– MC_ReadAxisInfo_ISD51x output

– Application runs as expected. Application runs as expected.

Application runs as expected. Application runs as expected.

RPM.

MC_ReadAxisInfo_ISD51x output

SafeTorqueO = True for all servo drives on the corresponding line.

MC_ReadAxisInfo_ISD51x output

SafeTorqueO = False for all servo drives on the corresponding line.

Motors are torque free. Motors coast and stop after some time.

MC_ReadAxisInfo_ISD51x output

SafeTorqueO = True and

MC_ReadStatus_ISD51x output ErrorStop = True

and

MC_ReadAxisError_ISD51x output AxisErrorID = 0xFF80 on

all enabled servo drives. Application does not run. Application does not run.

MC_ReadAxisInfo_ISD51x output

SafeTorqueO = False and

MC_ReadStatus_ISD51x output ErrorStop = True

Application does not run. Application does not run.

SafeTorqueO = False and

MC_ReadStatus_ISD51x output ErrorStop = False

Expected result for TwinCAT

library

All servo drives are at speed 0 RPM.

–

Motors are torque free. Motors coast and stop after some time. For enabled motors:

MC_ReadStatus output ErrorStop

= True and

MC_ReadAxisError output AxisErrorID = 0xFF80 on all

enabled servo drives.

MC_ReadStatus output ErrorStop

= True

MC_ReadStatus output ErrorStop

= False

Table 2.6 Commissioning Test using Libraries

System Overview Design Guide

Commissioning test using bit-wise readout

Test steps Reason for the test step Expected result

1 Run the application (all the servo drives

are enabled). 2 Stop the application. – All servo drives are at speed 0 RPM. 3 Disable all the servo drives. – All servo drives are disabled. 4 Enable STO. Check that STO can be activated without

5 Disable STO. Check that STO can be deactivated

6 Run the application (all the servo drives

are enabled). 7 Enable STO. Check that errors are generated correctly

8 Try to run the application (enable 1 or

more servo drives). 9 Disable STO. Check that the STO start is still inhibited

10 Try to run the application (enable 1 or

more servo drives). 11 Send a reset signal via the PLC. – Statusword bit 3 = 0 in all servo drives. 12 Try to run the application (all servo drives

are enabled).

Check that the application can run. Application runs as expected.

Statusword bit 3 = 0 and bit 14 =1 in all

error.

without error. No reset is required. – Application runs as expected.

when STO is activated while the servo drives are running.

Checks that the STO function is working correctly.

by the error signal.

Check whether reset is required. Application does not run.

– Application runs as expected.

servo drives. Statusword bit 3 = 0 and bit 14 =0 in all servo drives.

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 drives. Application does not run.

Statusword bit 3 = 1, bit 14 = 0 and object 0x603F shows fault 0xFF80 in all servo drives.

2 2

Table 2.7 Commissioning Test using Bit-Wise Readout

+24 V DC

GND

130BE689.11

System Overview

2.7.6 Application Example

VLT® Integrated Servo Drive ISD® 510 System

Illustration 2.11 shows an example of an installation for 2 lines that can be put in Safe Torque O mode by separate safety circuits for each line.

The safety circuits may be remote from each other and are not supplied from the VLT® Integrated Servo Drive ISD 510 System.

The 2 lines in the example are controlled separately. If the Safe Torque normal operation and the servo drives on this line are not aected. There may still be a hazard from the servo drives on line 2.

Select the safety switch devices in accordance with the requirements of the application.

O function is triggered on line 1, line 2 remains in

1a/1b ISD 510 servo drive on line 1 8 Line 2 emergency stop button 2a/2b ISD 510 servo drive on line 2 9 Line 2 safety device contacts 3 Servo Access Box (SAB) 10 Line 1 hybrid cable 4 Safety device on line 1 11 Line 2 hybrid cable 5 Line 1 emergency stop button 12 Feed-in cable 6 Line 1 safety device contacts 13 Loop cable 7 Safety device on line 2 14 24 V DC supply

Illustration 2.11 Application Example: Safe Torque O Function with 2 Lines

EtherCAT

Slave Controller

(ESC)

OUT

Port 1 (B)

OUT

Port 2 (C)

Port 0 (A)

X2X1

130BE695.10

System Overview Design Guide

2.7.7 Safety Function Characteristic Data

General information

Response time (from switching on the input until torque generation is disabled) Lifetime 20 years

Data for EN/ISO 13849-1

Performance level (PL) d Category 3 Mean time to dangerous failure (MTTFd) for maximum system size of 32 servo drives on each STO line

Diagnostic coverage (DC) 60%

Data for EN/IEC 61508 and EN/IEC 62061

Safety integrity level (SIL) 2 Probability of failure per hour (PFH) for maximum system size of 32 servo drives on each STO line Safe failure fraction (SFF) >95% Hardware fault tolerance (H) 0 Subsystem classication Type A Proof test interval 1 year

Table 2.8 Safety Function Characteristic Data

<100 ms

233 years (limited to 100 years if the VLT Integrated Servo Drive ISD 510 System forms an entire safety channel)

<5 x 10-8/h

The servo drives and the SABs can be operated with the following cycle times (for both eldbuses):

400 µs and multiples of it (for example, 800 µs,

•

1200 µs, and so on).

500 µs and multiples of it (for example, 500 µs,

•

1 ms, and so on).

When the cycle time is a multiple of 400 µs and 500 µs, the time base of 500 µs is used.

The servo drive and the SAB are certied for both eldbuses according to the corresponding rules and

regulations. The servo drive conforms to the CANopen CiA DS 402 Drive

2.8.1.1

EtherCAT

Prole.

The servo drive and the SAB support the following EtherCAT® protocols:

CANopen over EtherCAT® (CoE)

•

File Access over EtherCAT® (FoE)

•

Ethernet over EtherCAT® (EoE)

•

The servo drive and the SAB support distributed clocks. To compensate for the failure of a communication cable section in the system, cable redundancy is available for both eldbuses.

2 2

Communication

2.8

2.8.1 Fieldbus

The VLT® Integrated Servo Drive ISD 510 System has an open system architecture realized by fast Ethernet (100BASE-T) based communication. The system supports

both EtherCAT® and Ethernet POWERLINK® eldbuses. See the VLT® Integrated Servo Drive ISD® 510 System

Programming Guide for further information.

In productive environments, communication to the devices always takes place via a PLC that acts as a master. The servo drives and the SABs can be controlled by these communication methods:

Using the Danfoss VLT® Servo Motion library

•

(available for TwinCAT® and Automation 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 EtherCAT® port assignment for the servo drive and SAB is shown in Illustration 2.12 and Illustration 2.13.

X1 M23 hybrid cable connector to SAB or previous servo drive. X2 M23 hybrid cable connector to the next servo drive. X3

M8 Ethernet cable connector to other EtherCAT® slaves, for example EtherCAT® encoder. The connector is only available on the advanced servo drive.

Illustration 2.12 EtherCAT® Port Assignment for the ISD 510

Servo Drive

ESC SAB L1

Main EtherCAT

slave

OUT

Port 2 (C)

OUT

Port 1 (B)

Port 0 (A)

ESC SAB L2

AL emulated

junction slave

Port 0 (A)

OUT

Port 1 (B)

OUT

Port 2 (C)

130BE696.10

System Overview

VLT® Integrated Servo Drive ISD® 510 System

CAM editor for designing CAM proles for the

•

servo drives.

The detailed description of the DDS Toolbox functionality and the full parameter lists can be found in the VLT

Integrated Servo Drive ISD® 510 System Programming Guide.

2.8.2.1 System Requirements

To install the DDS Toolbox software, the PC must meet the following requirements:

Supported hardware platforms: 32-bit, 64-bit.

•

1 Ports always connected internally in the SAB. X1 RJ45 cable connector to the PLC or previous slave. X2 RJ45 cable connector to the PLC or next slave. X3

M23 feed-in cable to the 1st servo drive on line 1 with RJ45 connector.

M23 feed-in cable to the 1st servo drive on line 2 with RJ45 connector.

Illustration 2.13 EtherCAT® Port Assignment for the SAB in

Line Topology Mode (default)

Supported operating systems: Microsoft

•

Windows XP Service Pack 3, Windows 7, Windows

8.1.

.NET framework version: 3.5 Service Pack 1.

•

Minimum hardware requirements: 512 MB RAM,

•

Intel Pentium 4 with 2.6 GHz or equivalent, 40 MB hard disk space.

Recommended hardware requirements: Minimum

•

1 GB RAM, Intel Core i5/i7 or compatible.

2.8.1.2

The servo drive and the SAB are certied according to DS301 V1.1.0. The following features are supported for the servo drive and the SAB:

Specic ports are not assigned for Ethernet POWERLINK®.

Ethernet POWERLINK

Work as controlled node.

•

Can be operated as multiplexed stations.

•

Support of cross-communication.

•

Ring redundancy is supported for media

•

redundancy.

2.8.2 PC-Software

The DDS Toolbox is a standalone PC software designed by Danfoss. It is used for parameterization and diagnostics of the servo drives and the SAB and can also be used to operate the devices in a non-productive environment. The DDS Toolbox contains several functionalities, called subtools, which in turn provide various functionalities.

The most important sub-tools are:

Scope for visualization of the tracing functionality

•

of the servo drives and SAB.

•

Parameter list for reading/writing parameters.

Firmware update

ISD 500 Drive control/SAB control to operate the

servo drives and/or SAB for testing purposes.

System Overview Design Guide

2.9 Operating Modes

The VLT® Integrated Servo Drive ISD 510 implements several modes of operation. The behavior of the servo drive depends on the activated mode of operation. It is possible to switch between the modes while the servo drive is enabled. The

supported modes of operation are according to CANopen® CiA DS 402 and there are also ISD-specic modes of operation. All supported modes of operation are available for EtherCAT® and Ethernet POWERLINK®. The various modes of operation are described in detail in the VLT® Integrated Servo Drive ISD® 510 System Programming

Guide.

Mode Description

2 2

ISD Inertia measurement mode

Prole velocity mode In prole velocity mode, the servo drive is operated under velocity control and executes a movement with

Prole position mode In prole position mode, the servo drive is operated under position control and executes absolute and

Prole torque mode In prole torque mode, the servo drive is operated under torque control and executes a movement with

Homing mode In homing mode, the application reference position of the servo drive can be set. Several homing methods,

CAM mode In CAM mode, the servo drive executes a synchronized movement based on a master axis. The synchroni-

Gear mode In gear mode, the servo drive executes a synchronized movement based on a master axis by using a gear

Cyclic synchronous position mode Cyclic synchronous velocity mode

This mode measures the inertia of an axis. It is used to measure the inertia of the servo drive and the external load, and to optimize the control loop settings. The friction eects are eliminated automatically.

constant speed. Additional parameters, such as acceleration and deceleration, can be parameterized.

relative movements. Additional parameters, such as velocity, acceleration, and deceleration, can be parameterized.

constant torque. Linear ramps are used. Additional parameters, such as torque ramp and maximum velocity, can be parameterized.

such as homing on actual position, homing on block, limit switch, or home switch are available.

zation takes place by means of a CAM prole that contains slave positions corresponding to master positions. CAMs can be designed graphically with the DDS Toolbox software, or can be parameterized via the PLC. The guide value can be provided by an external encoder, virtual axis, or the position of another axis.

ratio between the master and the slave position. The guide value can be provided by an external encoder, virtual axis, or the position of another axis. In cyclic synchronous position mode, the trajectory generator of the position is located in the control device, not in the servo drive. In cyclic synchronous velocity mode, the trajectory generator of the velocity is located in the control device, not in the servo drive.

Table 2.9 Operating Modes

System Overview

VLT® Integrated Servo Drive ISD® 510 System

2.10 Automated Operational Functions

2.10.1 Short Circuit Protection

2.10.1.1 Servo Access Box Features

The SAB has several protection functions for limiting the current:

IN 100% (15 A

•

100–200% current is limited by an I2t function. A

•

load of 160% is allowed for 1 minute. The RMS current must be lowered to ≤100% before a new overload is allowed. The time taken to reset the I2t function depends on the load current. A 2 A overload for 10 s (17 A) requires a nominal current of ≤13 A for 10 s to reset the I2t function.

IDC protection (UDC)

Imax0: At 200% RMS, the output will be discon-

•

nected within 1.5 s.

Imax1: At 51 A peak current, the output will be

•

disconnected within 500 μs.

Imax2: At 125 A peak current, the output will be

•

disconnected within 10 μs.

protection

AUX

Software limit range: 0–15 A

•

- A warning and alarm is issued at

These software limits are disabled by default. See

•

parameters AUX line 1 user current limit and AUX line 2 user current limit in the VLT® Integrated Servo

Drive ISD 510 System Programming Guide.

A low-pass lter is implemented in the rmware

•

to avoid unintended warnings or alarms due to inrush currents.

2.10.1.2 ISD 510 Servo Drive Features

To protect the servo drive and the machinery attached to the servo drive shaft, a current limit protection is implemented in the servo drive.

Current limit protection is implemented on the servo drive and the currents 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.

), no limitation.

RMS

user-

specied levels. A warning is issued at

90% of the selected value. An alarm is issued when the measured value has exceeded the software limit.

2.10.2 Ground Fault Protection

When a ground fault current of >3 A is present, a warning is issued immediately. The SAB issues an error if the warning is present for 10 s.

2.10.3 Temperature-controlled Fans

The SAB has 2 built-in forced air convection fans to ensure optimum cooling. The main fan forces the airow along the cooling ns on the heat sink, ensuring cooling of the internal air. A secondary fan cools the SAB power control board. Both fans are controlled by the internal temperature and speed increases. The fans not only ensure maximum cooling when required, but also reduce noise and energy consumption when the workload is low.

If overtemperature occurs in the SAB, an error/warning is issued, resulting in a coast and trip lock.

2.10.4 Thermal Protection

Thermal protection exists for both the servo drive and the SAB. See chapter 4.6.3 Thermal Protection for further information.

2.10.5 Additional Protection Features

2.10.5.1 Servo Access Box

The SAB has the additional protection features detailed in Table 2.10.

Function Description Limits/errors

UDC overvoltage

UDC undervoltage

When the DC-link voltage rises above a certain level, a warning/error is issued. A brake resistor can be connected to the SAB and activated via parameter 0x2030 in the DDS Toolbox software. When the DC-link voltage drops below a certain level, a warning/ error is issued.

Brake active: >778 V

•

Warning: >810 V

•

Error: >820 V

•

Warning: <410 V

•

Error: <373 V

•

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Danfoss ISD 510 Design guide

Specifications and Main Features

Frequently Asked Questions

User Manual