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).
Copyright
1.4
VLT®, ISD®, and SAB® are Danfoss registered trademarks.
11
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:
ManualContents
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
eciency.
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 Certications
1.5
The VLT® Integrated Servo Drive ISD® 510 System fullls
the standards listed in Table 1.2.
IEC/EN 61800-3Adjustable speed electrical power drive
systems.
Part 3: EMC requirements and specic 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 61508Functional safety of electrical/electronical/
programmable electronic safety-related
systems.
EN ISO 13849-1Safety of machinery – Safety-related parts of
control systems.
Part 1: General principles for design.
EN ISO 13849-2Safety of machinery – Safety-related parts of
IEC/EN 60204-1Safety of machinery – Electrical equipment of
machines.
Part 1: General requirements.
IEC/EN 62061Safety 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 508CUL 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 aected 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/ECMachinery Directive
CE
2014/30/EUEMC Directive
2014/35/EULow 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 specication.
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
classied as electronic components
consisting of an aggregate of interconnected components
Table 1.2 Approvals and Certications
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 classied 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.
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 qualied 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 decient
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.
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
specied 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.
NumberMinimum waiting time (minutes)
0–64 servo drives10
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 cableHybrid cable for connecting servo drives in
Feed-in cableHybrid 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.
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 oers a highly exible drive concept. Danfoss
oers libraries for various IEC 61131-3 programmable PLCs.
Due to the standardized and certiedeldbus 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.
oersbenets 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.
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
OK
Back
Cancel
Info
Quick
Menu
Main
Menu
Alarm
Log
AUX 2
SAFE 1
SAFE 2
Status
Hand
On
Off Reset
Auto
On
OK
Back
Cancel
Info
Quick
Menu
Main
Menu
Alarm
Log
LCP
SAB
400-480 V AC
ISD 510
. . .
. . .
130BF043.10
Real-Time Ethernet
PLC
Power
CH. 1
CH. 2
P1
A2 14 24
P2
S11 S12 S21 S22
A1 13 28
P1
S33 S34 Y36 Y37
P2
PNOZ X2P
QUINT POWER
1
2
3
5
4
UDC + Real-Time Ethernet Bus + STO + U
AUX
2
System Overview
VLT® Integrated Servo Drive ISD® 510 System
2.3.3.2
22
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
ComponentDescription
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 cableThere 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
st
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.
STOSafe 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
124/48 V power supply
2Encoder
3I/O
4Brake resistor
5
Safety relay
1)
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
Illustration 2.8 shows a simplied block diagram of the SAB.
1 Control logicUsed 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 rectier section, voltage passes to the
intermediate section. This rectied 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 rectier circuits.
5 SwitchFor enabling or disabling the UDC
6 Overvoltage/overcurrent
protection
7 LED indicatorsShow the presence of the AUX
8 LED indicatorsShow 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 circuitIf STO is activated, the STO circuit disables
the inverter.
2 DC bus and lterThe DC bus and lter smooth the voltage.
3 InverterIn the inverter section, once run
command and speed/position references
are present, the IGBTs begin switching to
create the output waveform.
4 MotorSynchronous permanent magnet motor.
5 Control circuitUsed for generating the PWM pattern and
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
22
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 satised.
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 ReferenceDescription
PFHEN 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.
PFDEN IEC 61508 Average probability of failure on
demand
This value is used for low demand
operation.
PLEN ISO
13849-1
SFFEN IEC 61508 Safe Failure Fraction [%]
SILEN IEC 61508
EN IEC 62061
STOEN 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 ReferenceDescription
Cat.EN ISO
13849-1
DC–Diagnostic coverage
FIT–Failure in time
HFTEN IEC 61508 Hardware fault tolerance
MTTF
D
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.
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 1IN 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.
22
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:
are enabled).
2Stop the application.–All servo drives are at speed 0 RPM.
3Disable all the servo drives.–All servo drives are disabled.
4Enable STO.Check that STO can be activated without
5Disable STO.Check that STO can be deactivated
6Run the application (all the servo drives
are enabled).
7Enable STO.Check that errors are generated correctly
8Try to run the application (enable 1 or
more servo drives).
9Disable STO.Check that the STO start is still inhibited
10Try to run the application (enable 1 or
more servo drives).
11Send a reset signal via the PLC.–Statusword bit 3 = 0 in all servo drives.
12Try 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.
22
Table 2.7 Commissioning Test using Bit-Wise Readout
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 aected. 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/1bISD 510 servo drive on line 18Line 2 emergency stop button
2a/2bISD 510 servo drive on line 29Line 2 safety device contacts
3Servo Access Box (SAB)10Line 1 hybrid cable
4Safety device on line 111Line 2 hybrid cable
5Line 1 emergency stop button12Feed-in cable
6Line 1 safety device contacts13Loop cable
7Safety device on line 21424 V DC supply
Illustration 2.11 Application Example: Safe Torque O Function with 2 Lines
Response time (from switching on the
input until torque generation is
disabled)
Lifetime20 years
Data for EN/ISO 13849-1
Performance level (PL)d
Category3
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 classicationType A
Proof test interval1 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 certied 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
Prole.
®
®
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.
22
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
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.
X4
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 certied according to
DS301 V1.1.0. The following features are supported for the
servo drive and the SAB:
Specic 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
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-specic 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.
ModeDescription
22
ISD Inertia measurement
mode
Prole velocity modeIn prole velocity mode, the servo drive is operated under velocity control and executes a movement with
Prole position modeIn prole position mode, the servo drive is operated under position control and executes absolute and
Prole torque modeIn prole torque mode, the servo drive is operated under torque control and executes a movement with
Homing modeIn homing mode, the application reference position of the servo drive can be set. Several homing methods,
CAM modeIn CAM mode, the servo drive executes a synchronized movement based on a master axis. The synchroni-
Gear modeIn 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 eects 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 prole 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.
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.
I
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-
specied 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 airow 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.
FunctionDescriptionLimits/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.
When the AUX
voltage rises above
a certain level, a
warning/error is
issued.
When the AUX
voltage drops
below a certain
level, a warning/
error is issued.
When the AUX
current rises above
a certain level, a
warning/error is
issued.
various brakerelated errors.
up to 2 inrush
cycles per minute.
The SAB detects
the mains phase
loss and issues a
warning/error when
limits are reached.
The SAB indicates
the presence of the
STO 1 & STO 2
voltage.
Warning: >53 V
•
Error: >56 V
•
Warning: <21.6 V
•
Error: <19 V
•
Warning: >90% of user-
•
dened limit
Error: >100% of user-
•
dened limit
The default value of
15 A is used if no limits
are dened by the user.
Shorted brake resistor
•
Shorted brake IGBT
•
Thermal overload
•
Disconnected brake
•
resistor
Error issued if >2 inrush
cycles occur per minute.
Warning: 3–10% mains
•
phase imbalance
Error:
•
->10% mains
phase
imbalance
-3–10% mains
phase
imbalance for
>10 minutes
LED on: STO deactivated
LED o: STO activated
VLT® Integrated Servo Drive
ISD 510
The VLT® Integrated Servo Drive ISD 510 has the additional
protection features detailed in Table 2.10.
FunctionDescriptionLimits/errors
UDC
overvoltage
UDC
undervoltage
Overcurrent at
output
Motor
position
Brake control The brake current is
Maximum
shaft speed
Torque limitThe application peak torque
When the DC-link voltage
rises above a certain level, a
warning/error is issued.
When the DC-link voltage
drops below a certain level, a
warning/error is issued.
To protect the servo drive
and any machinery attached
to the servo drive shaft, a
current limit protection is
implemented. The current
limit protection on the servo
drive is available for motor
phase current. All 3 phase
currents are constantly
monitored. If an overcurrent
occurs, the servo drive stops
the actual operation. The
servo drive stops the shaft
rotation, engages the brake
(if present), and an error is
issued.
CRC check of each encoder
value, resolver amplitude, and
consistency check.
controlled by the servo drive
rmware.
The shaft speed of each
servo drive type is limited to
protect the motor mechanical
parts.
limit [M
parameters 52-15, 52-23, and
52-36 Application Torque Limit
(0x2053).
The maximum torque per
servo drive is calculated as:
Maximum phase current x
torque factor
] can be set via
max
Warning:
•
>810 V
Error: >820 V
•
Warning:
•
<410 V
Error: <373 V
•
Size 1: >8 A
•
Size 2: >9 A
•
–
–
Maximum motor
speed:
Size 1, 1.5 Nm:
•
7000 RPM
Size 2, 2.1 Nm:
•
6000 RPM
Size 2, 2.9 Nm:
•
5000 RPM
Size 2, 3.8 Nm:
•
4000 RPM
Peak torque M
Size 1, 1.5 Nm:
•
6.1 Nm
Size 2, 2.1 Nm:
•
7.8 Nm
Size 2, 2.9 Nm:
•
10.7 Nm
Size 2, 3.8 Nm:
•
12.7 Nm
max
22
:
Table 2.11 Additional Protection Features for ISD 510
The temperature switch can be used as an overtemperature protection feature to prevent damage to the
2.11.1 Brake Resistor
22
When the servo drives are decelerating, the motors act like
a generator. This means that the energy coming back from
the servo drives is collected in the DC-link. The function of
the brake resistor is to provide a load on the DC-link
during braking, thereby ensuring that the brake power is
absorbed by the brake resistor. If no brake resistor is used
and the servo drives are decelerating, the DC-link voltage
will rise to a dangerous level. The SAB disconnects the ISD
lines when the DC-link voltage is too high. A DC-link
overvoltage will result in damage to the SAB and the servo
drives.
brake resistor caused by overtemperature.
The temperature switch can also be used to disable the
mains supply to the SAB by a contactor.
1.Connect the built-in thermal switch on the brake
resistor to the K1 input contactor.
2.Connect the start and stop push buttons in series
with the thermal switch.
3.Connect to a contactor in the mains supply on
the front of the SAB.
Thermal overheating in the brake resistor disables the
mains supply of the SAB.
2.11.1.1 Mechanical Installation
The brake resistors are cooled by natural convection.
The ventilation must be ecient enough to dispatch the
regenerative power in the brake resistor.
2.11.1.2 Electrical Installation
EMC precautions
The following EMC precautions are recommended to
achieve interference-free operation of eldbus cables, and
digital and analog inputs and outputs.
Observe any relevant national and local regulations, for
example regarding protective earth connection.
Keep the eldbus cables away from the brake resistor
cables to avoid coupling of high frequency noise from one
cable to the other. The minimum distance of 200 mm is
Illustration 2.14 Temperature Switch Disconnecting the Mains
from the SAB
sucient, however a greater distance between the cables
is recommended, especially where the cables run in
parallel over long distances. When crossing is unavoidable,
the eldbus cables must cross the brake cable at an angle
of 90°.
Cable connection
To comply with the EMC emission and immunity specication, the use of shielded/armored cables is mandatory.
Brake cable
Maximum length: 20 m shielded cable
Ensure that the connection cable to the brake resistor is
shielded. Use cable clamps to connect the shielding 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 (PELV) that is closed
under normal operating conditions and opens if the brake
resistor overheats.
In addition, the brake power monitor function enables
readouts of the momentary power and the mean power
for a selected period. A brake power limit can be set and if
the brake power exceeds the set limit, the SAB issues a
warning or an error. When the SAB issues a warning, the
UDC output remains enabled. However, when an error is
issued, the UDC output to the servo drives is disconnected.
The brake is protected against short-circuiting of the brake
resistor, and the brake transistor is monitored to ensure
that short-circuiting of the transistor is detected.
2.11.1.3 Brake Resistor Calculation
To select the most suitable brake resistor for a given
application, the following information is required:
The number of servo drives in the application.
•
The inertia connected to the servo drives.
•
The braking/accelerating prole.
•
130BF780.10
AUX 1
Status
Hand
On
Reset
Auto
On
OK
Back
Cancel
Info
Quick
Menu
Main
Menu
Alarm
Log
AUX 2
SAFE 1
SAFE 2
SAB
400-480 V AC
Real-Time Ethernet
UDC
2
ISD 510
3
. . .
. . .
1
4
R
brake
P
peak brake
=
UDC
2
P
peak brake
UDC
2
R
brake min
778 V x 778 V
54.6 Ω
===11086 W
P
peak ISD
=
η
ISD x ωStart
x j x
Δt
Δω
P
peak ISD
=
η
ISD x nStart
x
x
j
x
60
2 x π
Δt
Δn
()
System OverviewDesign Guide
Brake set-up
Illustration 2.15 shows the brake set-up in the VLT
Integrated Servo Drive ISD 510 System.
®
Calculation of brake power
When calculating the brake power, ensure that the brake
resistor is scaled for the average power as well as for the
peak power.
The peak brake power depends on the number of
•
22
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 example the length of the
braking time in relation to the process period
time.
Calculation of brake resistor peak power
The brake active voltage for the SAB is 778 V. When using
the minimal brake resistance of 54.6 Ω, a current of
14.25 A will ow at 778 V.
The brake resistor peak power is then calculated as follows:
1 I
brake
2 P
Line
3 P
ISD
4 Brake resistor R
: Absorbs brake power P
brake
Illustration 2.15 Brake Set-up
brake
.
If the application does not require braking with the
maximum current, a higher brake resistance can be
selected. A higher brake resistance results in a lower brake
peak power.
When the servo drives are accelerating, P
When the servo drives are decelerating, P
If the sum of all P
connected to the SAB results in a
ISD
is positive.
ISD n
is negative.
ISD n
negative value, the energy must be absorbed in the brake
resistor.
Brake resistance
To prevent the SAB from cutting out for protection when
the servo drives are braking, select brake resistor values on
the basis of the peak braking power.
If the sum of all P
is positive, energy from the mains is
ISD n
converted into rotation energy and the brake resistor does
not need to absorb energy.
To calculate the peak brake power, select the moment
where the most servo drives are decelerating and the
fewest servo drives are accelerating.
The peak power of a decelerating servo drive can be
The SAB starts braking when the UDC voltage exceeds
calculated as:
778 V.
The brake resistor can range from 54.6–200 Ω. Brake
resistors within this range are detected by the congurable
brake check. The brake check is executed each time before
the SAB enters the state Operation enabled and when
mains is powered up. The brake check activates the brake
and checks if the DC-link voltage drops.
The minimum brake resistance is 54.6 Ω. When higher
brake resistor resistance is selected, the maximum braking
torque cannot be reached, and there is a risk that the SAB
will cut out due to DC-link overvoltage protection.
Danfoss oers brake resistors with a duty cycle of
maximum 10% and 40%. If a 10% duty cycle is applied, the
brake resistors are able to absorb P
period time. The remaining 90% of the period is used on
deecting excess heat.
2.11.2 External Encoder and Sensors
Illustration 2.16 Decelerating Servo Drive
2.11.2.1 External Encoder
for 10% of the
peak
The peak power connected to line 1 can be calculated as:
The calculation for line 2 can be done in the same way.
The maximum peak brake power is the sum of the peak
brake power on both lines when the result is a negative
value.
With P
, the optimal resistance value can be
peak brake
calculated using the formula for brake resistance.
Calculation of brake resistor average power
The average power is determined by the length of the
braking time in relation to the process period.
An external encoder can be connected to the X4
connector on the advanced servo drive or the encoder
connector on the SAB. The encoder value can be used as
guide value provider.
Further information on external encoders and sensors can
be found in the VLT
®
Integrated Servo Drive ISD® 510
Operating Instructions.
2.11.2.2 Sensor
The M12 I/O and/or encoder connector (X4) is available of
the advanced servo drive. See chapter 6.1.2.1 Connectors onthe Servo Drives for pin assignment.
T
Process period time in s.
p
T
Braking time in s.
b
Illustration 2.17 Relation between Average Power and Peak
Relays are used for customer-dened reactions. For
example, the relay can be triggered if the SAB issues a
warning.
-Use the LCP to read out the error or
warning that occurred last on either the
servo drive or the SAB.
-Use the DDS Toolbox to read out the
error or warning that occurred last on
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 VLT
Integrated Servo Drive ISD 510 System
Programming Guide for details on how to use the
mentioned functions and the list of fault codes.
22
Illustration 2.18 Relay Outputs 1 and 2
See chapter 6.2.3.4 Relay Connectors for further information.
Faults, Warnings, and Alarm Functions
2.12
2.12.1 Overview
For diagnostic purposes, there are several possibilities to
obtain information:
Current status
•
-The LEDs on the ISD 510 servo drive
(see Illustration 2.19) show the current
status of the servo drive.
-The LEDs on the SAB (see
Illustration 2.20) show the current status
of the SAB.
Readout of errors/warnings
•
2.12.2
Operating LEDs on the VLT
®
Integrated Servo Drive ISD 510
Illustration 2.19
drive.
Illustration 2.19 Operating LEDs on the Servo Drive
The LCP is the graphical user interface on the SAB for
diagnostic and operating purposes. It is included as
standard with the SAB but can also be connected to the
advanced version servo drives using an optional cable
(M8 to LCP SUB-D extension cable).
The LCP display provides the operator with a quick view of
the state of the servo drive or SAB, depending on which
device it is connected to. The display shows parameters
and alarms/errors and can be used for commissioning and
troubleshooting. It can also be used to perform simple
functions, for example activating and deactivating the
output lines on the SAB.
2.13.2 DDS Toolbox 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. 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™ (Version 3.0.90 and 4.x, supported
platform SG4) environment to easily integrate the
functionality without the need of special motion run-time
on the controller. The provided function blocks conform to
the PLCopen® standard. Knowledge of the underlying
eldbus communication and/or the CANopen® CiA DS 402
prole is not necessary.
The library contains:
Function blocks for controlling and monitoring
•
the servo drive and the SAB.
Function blocks for all available motion
•
commands of the servo drive.
Function blocks and structures for creating Basic
•
CAM
proles.
Function blocks and structures for creating
•
Labeling CAMproles.
2.13.4
The VLT® Integrated Servo Drive ISD 510 can be operated
with the built-in NC functionality of TwinCAT®. This means
that the trajectory calculations are all done within the PLC.
The servo drive can be used with cyclic synchronous
position mode or cyclic synchronous velocity mode to
follow the setpoints given by the controller. The features
are provided by the TwinCAT® library. To use this
functionality, the controller must have an NC-PTP-Runtime
system installed.
TwinCAT® NC Axis
22
The LCP can be mounted on the front of the control
cabinet and then connected to the SAB via SUB-D cables
(available as an accessory).
NOTICE
Do not permanently connect the LCP to the servo drive.
Doing so will reduce the IP-rating.
Although the VLT® Integrated Servo Drive ISD 510 can
operate properly at high humidity, avoid condensation.
There is a specic risk of condensation when the servo
drive is colder than moist ambient air. Moisture in the air
can also condense on the electronic components and
cause short circuits. Condensation occurs in units without
power. Avoid installation in areas subject to frost. Alternatively, operating the servo drive in standby mode (with the
servo drives connected to the auxiliary power supply via
the SAB) reduces the risk of condensation. Ensure that the
power dissipation is sucient to keep the servo drive
circuitry free of moisture.
4.1.2 Ambient Temperature
Minimum and maximum ambient temperature limits are
specied for the VLT® Integrated Servo Drive ISD 510 (see
chapter 6.1.4 General Specications and Environmental
Conditions). Avoiding extreme ambient temperatures
prolongs the life of the equipment and maximizes the
overall system reliability. Follow the recommendations
listed for maximum performance and equipment longevity.
4.1.3 Cooling
The servo drives are self-cooling. Cooling (heat dispersal) is
primarily via the ange, with a small amount dispersed by
the housing. The following recommendations are necessary
for eective cooling of the units.
Maximum air temperature to enter enclosure
•
must never exceed 55 °C (131 °F).
Day/night average temperature must not exceed
•
35 °C (95 °F).
Mount the unit to allow for free cooling airow.
•
Provide minimum front and rear clearance
•
requirements for cooling airow.
It is possible to install 2 or more servo drives next to each
other, however the surfaces of the servo drives must not
be in contact with each other. Ensure that there is a
minimum gap of 1.2 mm between the servo drives to
provide adequate ventilation of the servo drives and to
allow sucient heat transfer to take place in the
surrounding areas.
44
Although the servo drive can operate at temper-
•
atures as low as 0 °C, proper operation at rated
load is only guaranteed at ≥5 °C.
Do not exceed the maximum temperature limit.
•
The lifetime of electronic components decreases
•
by 50% for every 10 °C operated above the
design temperature.
Devices with IP54, IP65, or IP67 protection ratings
•
must also adhere to the
temperature ranges.
Additional air conditioning of the cabinet or
•
installation site may be required.
specied ambient
Illustration 4.1 Example of Servo Drive Installation on the
Same Flange
4.1.4 Motor-generated Overvoltage
The DC voltage in the intermediate circuit (DC bus)
increases when the servo drive acts as a generator. This
can occur in 2 ways:
The load drives the servo drive when it is
•
operated at a constant speed. This is referred to
as an overhauling load.
During deceleration, if the inertia of the servo
•
drives is high and the deceleration of the servo
drives is set to a high value.
The SAB cannot regenerate energy back to the grid. It is
possible to connect and congure a brake resistor to the
SAB that can consume some power if the DC-link voltage
becomes too high (see chapter 2.11.1 Brake Resistor). If this
is unsuccessful, or if the load drives the servo drive, the
SAB shuts down and shows a fault when a critical DC bus
voltage level is reached.
The servo drive cannot regenerate energy back to the
44
input. Therefore, it limits the energy accepted from the
motor. If this is unsuccessful, or if the load drives the
motor, the servo drive shuts down and displays a fault
when a critical DC bus voltage level is reached.
4.1.5 Acoustic Noise
Acoustic noise from the servo drive comes from the
following sources:
Shaft seal
•
Ball bearings
•
Speed
•
Brake
•
4.1.6 Vibration and Shock
The VLT® Integrated Servo Drive ISD 510 is tested
according to a procedure based on IEC 60068-2-64.
The servo drive is intended for use on rotary parts/
machines.
Operating Environment: SAB
4.2
4.2.1 Humidity
Follow the recommendations listed for maximum
performance and equipment longevity.
Although the SAB can operate at temperatures
•
down to 0 °C, proper operation at rated load is
only guaranteed at ≥5 °C.
Do not exceed the maximum temperature limit.
•
The lifetime of electronic components decreases
•
by 50% for every 10 °C operated above the
design temperature.
Additional air conditioning of the cabinet or
•
installation site may be required.
4.2.3 Cooling
The SAB dissipates power in the form of heat. Cooling
(heat dispersal) is primarily via the integrated fans. The
following recommendations are necessary for eective
cooling of the units.
Maximum air temperature to enter enclosure
•
must never exceed 50 °C (122 °F).
Day/night average temperature must not exceed
•
45 °C (113 °F).
Mount the unit to allow for free cooling airow
•
through the cooling ns. See
chapter 6.2.2 Clearance for correct mounting
clearances.
Provide minimum front and rear clearance
•
requirements for cooling airow. See the VLT
Integrated Servo Drive ISD 510 System Operating
Instructions for the installation requirements.
®
4.2.3.1 Cooling Fans
Although the SAB can operate properly at high humidity,
avoid condensation. There is a specic risk of condensation
when the SAB is colder than moist ambient air. Moisture in
the air can also condense on the electronic components
and cause short circuits. Condensation occurs in units
without power. It is recommended to install a cabinet
heater when condensation is possible due to ambient
conditions. Avoid installation in areas subject to frost.
Alternatively, operating the SAB in standby mode (with the
unit connected to the mains) reduces the risk of condensation. Ensure that the power dissipation is sucient to
keep the SAB circuitry free of moisture.
The SAB has built-in fans to ensure optimum cooling. The
main fan forces the airow along the cooling ns on the
heat sink, ensuring cooling of the internal air. The SAB has
a small secondary fan on the power control board,
ensuring that the internal air is circulated to avoid hot
spots. The main fan is controlled by the internal
temperature in the SAB and the speed gradually increases
along with temperature. This reduces noise and energy
consumption when the need is low, and ensures maximum
cooling when needed.
In case of overtemperature inside the SAB, an alarm or
warning is issued and a coast and trip lock occurs.
4.2.2 Ambient Temperature
Minimum and maximum ambient temperature limits are
specied for the SAB (see chapter 6.2.5 General Speci-
cations and Environmental Considerations). Avoiding
extreme ambient temperatures prolongs the life of the
equipment and maximizes the overall system reliability.
4.2.3.2 Calculation of Airow Required for
Cooling the SAB
The airow required to cool the SAB (or multiple SABs in 1
cabinet) can be calculated as follows:
1.Determine the power loss at maximum output for
all SABs.
2.Add the power loss values of all SABs that can
operate at same time. The resulting sum is the
heat Q to be transferred. Multiply the result with
the factor f, read from Table 4.2.
For example, f = 3.1 m3 x K/Wh at sea level.
3.Determine the highest temperature of the air
entering the enclosure. Subtract this temperature
from the required temperature inside the
enclosure, for example 45 °C (113 °F).
4.Divide the total from step 2 by the total from
step 3.
The calculation is expressed by the following formula:
V
f
QHeat to be transferred in W
T
i
T
A
Airow in m3/h
Factor in m3 x K/Wh (calculated as: cp x ρ (specic
heat of air x density of air))
Temperature inside the enclosure in °C
Ambient temperature in °C
Example
How to calculate the airow 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 installation altitude of 500 m:
1.The sum of the heat losses of both frequency
converters (295 + 150 W) = 445 W.
2.
Multiply 445 W by 3.3 m3 x K/Wh = 1468.5 m3 x
K/h.
3.
Subtract 37 °C from 45 °C = 8 °C (=8 K).
4.
Divide 1468.5 m3 x K/h by 8 K = 183.56 m3/h.
airow is required in CFM (cubic feet per minute),
If the
use the conversion 1 m3/h = 0.589 CFM. For this example,
183.56 m3/h = 108.1 CFM.
4.2.4 Acoustic Noise
Acoustic noise from the SAB comes from 3 sources:
DC-link (intermediate circuit) coils
•
RFI lter choke
•
Internal fans
•
The acoustic noise ratings shown in Table 4.3 were
measured 1 m from the unit.
50% fan speed [dBA]Full fan speed [dBA]
SAB5160
Table 4.3 Acoustic Noise Ratings
44
Table 4.1 Formula Abbreviations
NOTICE
Specic heat of air (cp) and density of air (ρ) are not
constants, but depend on temperature, humidity, and
atmospheric pressure. Therefore, they depend on the
altitude above sea level.
Table 4.2 shows typical values of the factor f, calculated
for dierent altitudes.
Table 4.2 Factor f, Calculated for Various Altitudes
Specic heat of air (cp)
[kJ/kgK]
Density of air (p)
[kg/m3]
Factor (f)
[m3K/Wh]
4.2.5 Vibration and Shock
The SAB is tested according to a procedure based on the
IEC 60068-2-6. The SAB complies with requirements that
correspond to these conditions when the unit is wall or
oor-mounted, as well as when mounted within panels, or
bolted to walls or oors.
Operating Environment: General
4.3
4.3.1 Aggressive Atmospheres
4.3.1.1 Gases
Aggressive gases, such as hydrogen sulphide, chlorine, or
ammonia can damage SAB electrical and mechanical
components. Contamination of the cooling air can also
cause the gradual decomposition of PCB tracks and door
seals. Aggressive contaminants are often present in sewage
treatment plants or swimming pools. A clear sign of an
aggressive atmosphere is corroded copper.
In aggressive atmospheres, restricted IP enclosures of
cabinet are recommended.
Installation of the SAB in environments with high dust
exposure is often unavoidable. Dust aects wall- or framemounted units and also cabinet-mounted devices with
IP20 protection ratings. Consider the 2 aspects described in
this section when the SAB is installed in such
environments.
Reduced cooling
Dust forms deposits on the surface of the device and
inside on circuit boards and the electronic components.
These deposits act as insulation layers and hamper heat
transfer to the ambient air, reducing the cooling capacity.
The components become warmer. This causes accelerated
aging of the electronic components, and the service life of
the SAB decreases. Dust deposits on the heat sink at the
back of the SAB also decrease the service life.
Ozonemg/m³0.01 0.050.10.10.3
Cooling fans
The airow for cooling the SAB is produced by cooling fans
Nitrogen mg/m³0.10.51.03.09.0
on the top and bottom of the SAB. The fan rotors have
small bearings into which dust can penetrate and act as an
Table 4.4 Conformal Coating Values
1) Maximum values are transient peak values not to exceed 30
minutes per day.
abrasive. This leads to bearing damage and fan failure.
Periodic maintenance:
Under the conditions described above, it is recommended
to clean the SAB during periodic maintenance. Remove
4.3.1.2 Exposure to Dust
dust from the heat sink and fans.
Servo drive:
Installation of the servo drives in environments with high
dust exposure is often unavoidable. Dust aects the servo
drives with IP54, IP65, and IP67 protection ratings. Consider
the 2 aspects described in this section when servo drives
are installed in such environments.
Reduced cooling
Dust forms deposits on the surface of the device and
inside on circuit boards and the electronic components.
These deposits act as insulation layers and hamper heat
transfer to the ambient air. This reduces the cooling
capacity, resulting in the components becoming warmer.
This causes accelerated aging of the electronic
components, and the service life of the servo drive
decreases.
Shaft seal
Dust can form deposits on the shaft and can lead to
abrasion on the shaft seal. This can lead to a reduced
lifetime of the shaft seal.
Periodic maintenance
Under the conditions described above, it is recommended
to clean the servo drive during periodic maintenance.
Remove dust from the housing and the shaft.
4.3.2 Electromagnetic Compatibility
4.3.2.1 Emission Requirements
The EMC product standard for frequency converters
denes 4 categories (C1, C2, C3, and C4) with specied
requirements for emission and immunity. Table 4.5 states
the denition of the 4 categories and the equivalent classication from EN 55011.
The VLT® Integrated Servo Drive ISD 510 System complies
with the emission limits Class A Group 1 according to EN
55011 and Category C2 according to EN 61800-3.
installed in the rst
environment (home and
oce) with a supply voltage
less than 1000 V.
C2Frequency converters
installed in the rst
environment (home and
oce) with a supply voltage
less than 1000 V, which are
not plug-in or movable and
are intended to be installed
and commissioned by a
professional.
C3Frequency converters
installed in the second
environment (industrial) with
a supply voltage lower than
1000 V.
C4Frequency converters
installed in the second
environment with a supply
voltage equal to or above
1000 V or rated current
equal to or above 400 A or
intended for use in complex
systems.
in EN 55011
Class B
Class A Group 1
Class A Group 2
No limit line. Make an
EMC plan.
EN 61000-4-4 (IEC 61000-4-4): Burst transients:
•
Simulation of interference brought about by
switching a contactor, relay, or similar devices.
EN 61000-4-5 (IEC 61000-4-5): Surge transients:
•
Simulation of transients brought about for
example by lightning that strikes near installations.
EN 61000-4-6 (IEC 61000-4-6): RF Common mode:
•
Simulation of the eect from radio-transmission
equipment joined by connection cables.
44
Table 4.5 Correlation between IEC 61800-3 and EN 55011
4.3.2.2 Immunity Requirements
The immunity requirements for the servo drives and SAB
depend on the environment where they are installed. The
requirements for the industrial environment are higher
than the requirements for the home and oce
environment. All servo drives and the SABs comply with
the requirements for the industrial environment and
consequently also comply with the lower requirements for
home and oce environment with a large safety margin.
The VLT® Integrated Servo Drive ISD 510 System complies
with the immunity requirements for 2nd environment
according to EN 61800-3.
To document immunity against electrical interference, the
following immunity tests have been made in accordance
with following basic standards:
EN 61000-4-2 (IEC 61000-4-2): Electrostatic
•
discharges (ESD): Simulation of electrostatic
discharges from human beings.
EN 61000-4-3 (IEC 61000-4-3): Incoming electro-
•
magnetic eld radiation, amplitude modulated
simulation of the eects of radar and radio
communication equipment as well as mobile
communications equipment.
LCP cable––––10 V
SAB
Encoder
cable
Ethernet
cable
U
AUX
supply
cable
U
safe
supply
cable
Feed-in
cable
Loop cable2 kV/
M8 LCP
cable
rd
M8 3
Ethernet
cable
M12
Sensor
cable
Enclosure
2 kV/
5 kHz
2 kV/
5 kHz
2 kV/
5 kHz
2 kV/
5 kHz
2 kV/
5 kHz
5 kHz
–––10 V
1 kV
1)
––10 V
–––10 V
1 kV
1 kV
1 kV
1)
1)
1)
––10 V
––10 V
––10 V
––––10 V
2 kV/
5 kHz
2 kV/
5 kHz
–––10 V
–––10 V
80 MHz –
RF
common
mode
voltage
IEC
61000-4-6
RMS
RMS
RMS
RMS
RMS
RMS
RMS
RMS
RMS
RMS
RMS
RMS
RMS
4.3.2.3 Grounding for Electrical Safety
Ground the servo drive with the PE wire of the
•
feed-in cable.
Ensure that the machine frame has a proper
•
electrical connection to the ange of the servo
drive because this is the main PE connection. Use
the front side ange surface. Ensure PE
connection on that part of the machine.
Ensure that the ground connections are tight and
•
free of oxidation for the lifetime of the machine.
Use a dedicated ground wire for input power and
•
control wiring.
Do not ground 1 SAB to another in daisy-chain
•
format.
Keep the ground wire connections as short as
•
possible.
Follow the wiring requirements in this manual.
•
Ensure a minimum ground wire cross-section of
•
10 mm2 on the SAB, or 2 separate ground wires,
both complying with the dimensioning rules.
See EN/IEC 61800-5-1 for further information on
•
grounding.
1 GHz:
10 V/m
1.4 GHz –
2.7 GHz:
3 V/m
–
––
4 kV CD
8 kV AD
2.0 GHz –
2.7 GHz:
1 V/m
Table 4.6 EMC Immunity Form
1) Injection on cable shield.
1 Servo Access Box
(SAB)
7
Equalizing minimum 16 mm
(AWG 5)
2 Control cabinet8 Feed-in cable
3 Servo drive9 Grounding rail (PE)
4 Machine frame10 Grounding of feed-in cable
5 Flange11 Mains, 3-phase, and reinforced PE
6 Shaft– –
Illustration 4.2 Recommended Installation for Electrical Safety
are used, mount them on a common metal
mounting plate to improve EMC performance.
NOTICE
If necessary, use washers for fastening bolts, for example,
in case of painted parts.
Grounding for EMC-compliant installation
Establish electrical contact between the cable
•
shield and the SAB enclosure by using metal
cable glands, or by using the clamps provided on
the SAB.
Use high-strand wire to reduce electrical
•
interference.
Do not use pigtails.
•
Ensure a minimum distance of 200 mm between
•
signal and power cables.
Only cross cables at 90°.
•
NOTICE
POTENTIAL EQUALIZATION
There is a risk of electrical interference when the ground
potential between the servo system and the machine is
dierent. Install equalizing cables between the system
components. The recommended cable cross-section is
16 mm2.
NOTICE
EMC INTERFERENCE
Use shielded cables for control wiring and separate
cables for power and control wiring. Failure to isolate
power and control wiring can result in unintended
behavior or reduced performance. Ensure a minimum
clearance of 200 mm between signal and power cables.
4.3.2.5 Motor Bearing Currents
To minimize bearing and shaft currents, ground the
following to the driven machine:
SAB
•
Servo drive
•
Driven machine
•
Standard mitigation strategies:
1.Apply rigorous installation procedures:
1aEnsure that the motor and motor load
are aligned.
1bStrictly follow the EMC Installation
guideline.
1cReinforce the PE so the high frequency
impedance is lower in the PE than the
input power leads.
1dProvide a good high frequency
connection between the system
components, for instance, by using
shielded cable.
1eMake sure that the impedance from the
VLT® Integrated Servo Drive ISD 510
System to building ground is lower that
the grounding impedance of the
machine.
1fMake a direct ground connection
between the motor and load motor.
2.Install a shaft grounding system or use an
isolating coupling.
3.Apply conductive lubrication.
4.Use minimum speed settings if possible.
5.Try to ensure that the line voltage is balanced to
ground.
4.3.2.6 Earth Leakage Current
Follow national and local codes regarding protective
earthing of equipment where leakage currents are
>3.5 mA. High frequency switching at high power
generates a leakage current in the ground connection.
The earth leakage current is made up of several contributions and depends on various system congurations,
including:
RFI ltering.
•
Cable length.
•
Cable shielding.
•
Frequency converter power.
•
Compliance with EN/IEC61800-5-1 (power drive system
product standard) requires special care if the leakage
current is >3.5 mA. Reinforce grounding with the following
protective earth connection requirements:
Ground wire (terminal 95) of at least 10 mm
•
cross-section.
2 separate ground wires, both complying with
•
the dimensioning rules.
See EN/IEC 61800-5-1 and EN 50178 for further
information.
Where residual current devices (RCDs), also known as earth
leakage circuit breakers (ELCBs), are used, comply with the
following:
Only use type B RCDs, as they are capable of
•
detecting AC and DC currents.
Use RCDs with a delay to prevent faults due to
•
transient ground currents.
Dimension RCDs according to the system congu-
44
•
ration and environmental considerations.
The leakage current includes several frequencies
originating from both the mains frequency and the
switching frequency. Whether the switching frequency is
detected depends on the type of RCD used.
The purpose of the touch current is to test if the leakage
current in the protective earth (PE) of the 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 current of the VLT® Integrated Servo Drive
ISD 510 System is greater than 3.5 mA AC or 10 mA DC,
therefore a xed connection is required and 1 or more of
the following conditions must be satised when installing
the DUT:
1.A cross-section of the protective earthing
conductor of at least 10 mm² Cu or 16 mm² Al.
2.Automatic disconnection of the supply in case of
discontinuity of the protective earthing
conductor.
3.Provision of an additional terminal for a
protective earthing conductor of the same crosssectional area as the original protective earthing
conductor.
The amount of leakage current detected by the RCD
depends on the cut-o frequency of the RCD.
Illustration 4.3 Main Contributions to Leakage Current
WARNING
LEAKAGE/GROUNDING CURRENT HAZARD
Leakage/grounding currents are >3.5 mA. Failure to
ground the SAB and the servo drives properly could
result in death or serious injury.
Ensure the correct grounding of the SAB and
•
servo drives by a certied electrical installer in
accordance with applicable national and local
electrical standards and directives, and the
instructions contained in this manual.
Illustration 4.4 Inuence of RCD Cut-o Frequency on Leakage
0 (not protected)(not protected)
1 ≥50 mm diameterBack of hand
2 12.5 mm diameterFinger
3 2.5 mm diameterTool
4 ≥1.0 mm diameterWire
5 Dust protectedWire
6 Dust-tightWire
Second
digit
First letter –Additional information
Additional
letter
Table 4.7 IEC 60529 Denitions for IP Ratings
Against water
penetration with
harmful eect
0 (not protected)–
1 Drops falling vertically–
2 Drops at 15° angle–
3 Spraying water–
4 Splashing water–
5 Water jets–
6 Powerful water jets–
x7 Temporary immersion–
8 Long-term immersion–
9 High pressure and
temperature water jet
A –Back of hand
B –Finger
C –Tool
D –Wire
Additional information –
H High voltage device–
M Device moving during
water test
S Device stationary
during water test
W Weather conditions–
Against access to
hazardous parts by:
–
–
–
–
4.3.3.2 IP Ratings for SAB and Servo Drive
SAB
The SAB is available with the following protection rating:
IP20 for cabinet installation (UL rating: Open
•
type).
Servo drive
The servo drive is available with the following protection
rating:
IP54 (without shaft sealing)
•
IP65 (with shaft sealing)
•
The protection rating is reduced from IP54 to IP50 and
from IP65 to IP60 if the shaft is mounted upwards. The IP
rating of the electronic housing of the servo drive is IP67
((UL rating: Type 4X indoor use).
Protection ratings
Mounting position of
servo drive
(according to DIN 42950)
HousingAll positionsIP67
Shaft without shaft
seal
Shaft with shaft
seal
Illustration 4.5 Mounting Positions
IM B5 & IM V1IP54
IM V3IP50
IM B5 & IM V1IP65
IM V3IP60
IP rating
(according to
EN 60529)
4.3.4 Radio Frequency Interference
The main objective is to obtain systems that operate stably
without radio frequency interference between components.
The SAB is therefore equipped with an RFI lterspecied
in EN 61800-3, which conforms to the Class A limits of the
general standard EN 55011.
Filters that are built in to the equipment take up space in
the cabinet, but eliminate additional costs for tting,
wiring, and material. However, the most important
advantage is the perfect EMC conformance and cabling of
integrated lters.
4.3.5 PELV and Galvanic Isolation
Compliance
PELV (Protective Extra Low Voltage) oers protection by
using extra low voltage. Protection against electric shock is
ensured when the electrical supply is PELV and the installation complies with local and national PELV regulations.
To maintain PELV at the control terminals, all connections
must be PELV, such as thermistors being reinforced/double
insulated. All SAB control and relay terminals comply with
PELV.
Galvanic (ensured) isolation is obtained by fullling
requirements for higher isolation and by providing the
relevant creepage/clearance distances. These requirements
are described in EN 61800-5-1.
Electrical isolation is provided and the components comply
with both PELV and galvanic isolation requirements. The
components also comply with the requirements for higher
isolation and the relevant test as described in
EN 61800-5-1.
All control terminals and relay terminals 01-03/04-06
comply with PELV.
44
Installation at high altitude
Component Maintenance
task
Servo drive Carry out a
visual
inspection.
Shaft sealCheck the
condition and
check for
leakage.
Installations exceeding high altitude limits may not comply
with PELV requirements. The insulation between
components and critical parts could be
is a risk of overvoltage. Reduce the risk of overvoltage
using external protective devices or galvanic isolation.
NOTICE
For installations at high altitude, contact Danfoss
regarding PELV compliance.
4.3.5.1 Discharge Time
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
specied time after power has been removed before
Maintenance
interval
Every 6 months Check for any
Recommended
every 4500 hrs.
A shorter or
longer interval
is possible
depending on
the application.
Every 6 months If damaged or
Every 6 months Ensure that the
Every 12
months
months
Instruction
abnormalities on
the surface of
the servo drive.
If damaged,
replace the shaft
seal.
worn, replace
the hybrid cable.
brake can
achieve the
holding torque.
Activate the STO
and check the
status with the
PLC.
Check that the
fan can turn and
remove any dust
or dirt.
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
Table 4.9 Maintenance Tasks
4.3.7 Storage
time listed in Table 4.8 for the capacitors to fully
discharge before carrying out any maintenance
or repair work on the ISD 510 servo system or
its components.
Like all electronic equipment, SABs and servo drives must
be stored in a dry, dust-free location with low vibration
(ve≤0.2 mm/s). Do not store the packaged system
components on top of each other. The storage location
must be free from corrosive gases. Avoid sudden
NumberMinimum waiting time (minutes)
0–64 servo drives10
Table 4.8 Discharge Time
4.3.6 Maintenance
temperature changes.
Keep the equipment sealed in its packaging until installation. Periodic forming (capacitor charging) is necessary
once per year during storage.
The SAB is mainly maintenance free. A maintenance
interval for the cooling fans (approximately 3 years) is
recommended in most environments.
The ISD is largely maintenance free. Only the shaft seal (if
used) is subject to wear.
NOTICE
To recondition the electrolytic capacitors, servo drives
and SABs not in service must be connected to a supply
source once per year to allow the capacitors to charge
and discharge. Otherwise the capacitors could suer
permanent damage.
Ensure that the supply has the following properties:
Grounded 3-phase mains network, 400–480 V AC
•
3-phase frequency: 47–63 Hz
•
3-phase lines and PE line
•
Mains supply: 400–480 V ±10%
•
Continuous input current SAB: 12.5 A
•
Intermittent input current SAB: 20 A
•
NOTICE
Use fuses and/or circuit breakers on the supply side of
the SAB to comply with CE or UL as detailed in
Table 4.10.
CE Compliance (IEC 60364)UL Compliance
(NEC 2014)
Recommended
fuse size
gG-16Eaton/Moller
Table 4.10 Fuses and Circuit Breakers
Maximum imbalance
temporary between
mains phase
True power factor [λ] ≥0.9 at rated current
Switching on input
supply
Environment
according to
EN60664-1
Mains drop outDuring low mains or a mains drop-out,
Table 4.11 Additional Specications
4.4.2 Harmonics
The VLT® Integrated Servo Drive ISD 510 System takes up
non-sinusoidal current from the mains, which increases the
input current IRMS. A non-sinusoidal current is transformed
by means of a Fourier analysis and split up into sine-wave
Recommended
circuit breaker
PKZM0-16
Maximum
trip level
in [A]
16
Recommended
maximum fuse
•
•
3% of the rated supply voltage
Maximum 2 times per minute
Overvoltage category III
•
Pollution degree 2
•
the SAB and the servo drives keep
running until the DC-link voltage drops
below 373 V. Full torque of the servo
drives cannot be expected at mains
voltage 10% below the rated supply
voltage.
size
Littelfuse
KLSR015
Littelfuse
FLSR015
®
®
currents with dierent frequencies, that is dierent
harmonic currents IN with 50 Hz as the basic frequency.
The harmonics do not aect the power consumption
directly, but increase the heat losses in the installation
(transformer, cables). Consequently, in plants with a high
percentage of rectier 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 communication equipment connected to the same transformer or
cause resonance in connection with power factor
correction units.
To ensure low harmonic currents, the SAB is equipped with
intermediate circuit coils as standard. DC-coils reduce the
total harmonic distortion (THD) to 40%.
4.4.2.1 Mains Conguration and EMC
eects
Only TN mains systems are allowed for powering the VLT
Integrated Servo Drive ISD 510 System.
TN-S: A 5-wire system with separate neutral (N)
•
and protective earth (PE) conductors. It provides
the best EMC properties and avoids transmitting
interference.
TN-C: A 4-wire system with a common neutral
•
and protective earth (PE) conductor throughout
the system. The combined neutral and protective
earth conductor results in poor EMC characteristics.
IT mains systems and AC mains systems with a grounded
mains are not allowed.
4.4.2.2 Mains Transients
Transients are brief voltage peaks in the range of a few
thousand volts. They can occur in all types of power distribution systems, including industrial and residential
environments.
Lightning strikes are a common cause of transients.
However, they are also caused by switching large loads on
line or o, or switching other mains transients equipment,
such as power factor correction equipment. Transients can
also be caused by short circuits, tripping of circuit breakers
in power distribution systems, and inductive coupling
between parallel cables.
EN 61000-4-1 describes the forms of these transients and
how much energy they contain. Their harmful eects can
be limited by various methods. Gas-lled surge arresters
and spark gaps provide rst-level protection against highenergy transients. For second-level protection, most
electronic devices, use voltage-dependent resistors
(varistors) to attenuate transients.
4.5 System Concepts
4.5.1 Auxiliary Power Supply Selection
4.5.1.1 Shell Diagram
44
The allowed number of servo drives on a hybrid line is
limited by the fact that voltage drops occur on the hybrid
cable. These voltage drops involve the auxiliary voltage
(24/48 V DC). The voltage drops on the cable depend on
the power consumption of the servo drives on the hybrid
line. The dierences in power consumption are due to
servo drives with integrated holding brake, servo drives
without integrated holding brake, and ISD standard and
ISD advanced servo drive versions.
The number of ISD servo drives connected on 1 line
depends on several conditions. The most important
conditions are:
Power required by the servo drives on the
•
auxiliary supply
Auxiliary voltage
•
Cable length
•
10 ISD servo drives with brake
23 ISD servo drives with brake
36 ISD servo drives with brake
4Example 1
The shell diagram is only calculated for servo drives
without sensors connected (8–9.6 W) and only with a feed-
Illustration 4.6 24 V and 10 m Feed-in Cable
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 with brake (9.6 W) is increased
step-by-step. The servo drives with brake must be
connected at the beginning of the output line to lower the
voltage drop for all servo drives.
Example I: 7 servo drives are possible with a cable length
of 38 m, and 6 of them can be equipped with a brake.
The graphs are very close together because there is only a
slight dierence between the AUX power consumption of
the servo drives with and without brake. The graphs are
calculated with the servo drives with brake connected at
the beginning of the line.
10 ISD servo drives with brake
26 ISD servo drives with brake
3Example 2
4Example 1
Illustration 4.7 24 V and 10 m Feed-in Cable - 6 Servo Drives
with Brake
Illustration 4.7 shows 2 examples:
Example I: 7 servo drives are possible with a
•
cable length of 38 m, and 6 of them can be
equipped with a brake.
Example II: 11 servo drives are possible with a
•
cable length of 21 m. No brakes are employed.
At 48 V AUX supply, the voltage drop is not the limiting
factor. The maximum number of servo drives that can be
connected per line is 32. The maximum cable length is
100 m per line.
1Connected ISD servo drives
Illustration 4.8 48 V and 10 m Feed-in Cable - Servo Drives
Connected
4.5.1.2 Auxiliary Power
4.5.1.3 24 V Supply
When 24 V AUX supply is used, the power losses on the
cable are limited because only a limited number of servo
drives can be connected. The maximum power loss on the
cable is 6.4 W (when the servo drive draws 13.8 W and 8
servo drives are connected with 0.5 m loop cables). The
nominal power of the servo drives is 8 x 13.8 W = 116.8 W.
The AUX power supply has to provide ≈6% more than the
nominal power.
When 48 V AUX supply is used, the power losses on the
cable can be higher because up to 32 servo drives can be
connected. The power losses of the feed-in cable have a
higher inuence. Therefore, the losses are calculated at
10 m, 25 m, or 40 m cable length.
The maximum power loss on the cable is 260.4 W when
40 m feed-in cable is used (the servo drives draw 13.8 W
and 27 servo drives are connected with 2 m loop cables).
The nominal power of the servo drives is 27 x 13.8 W
= 372.6 W. The AUX power supply must provide 70% more
than the nominal power.
4.5.2 Communication Topology
The maximum cable lengths are dened in Table 4.14.
CableMaximum length
Feed-in cable
Loop cable
Encoder cable25 m (shielded)
Brake cable20 m (shielded)
Fieldbus extension cable
24/48 V IN connector cable3 m
Table 4.14 Maximum Cable Lengths
1) Maximum total length for each line: 100 m.
2) Maximum length to next por t: 100 m.
4.6
VLT® Integrated Servo Drive ISD 510
40 m (shielded)
25 m (shielded)
2)
2 m
1)
1)
4.6.1 Motor Selection Considerations
Danfoss oers 128 dierent servo variants, allowing
selection of the most appropriate servo drive for the
application. Table 4.15 shows the available options. Refer to
chapter 5 Typecode and Selection and chapter 6 Specications for the ordering code and a detailed explanation of
the available options.
Motor option
Torque/speed range
•
Mechanical holding
•
brake
Feedback
•
Shaft seal
•
Table 4.15 Available Options for the Servo Drive
Control
electronics
Fieldbus
•
Servo drive version
Standard servo
•
drive
Advanced servo
•
drive
4.6.2 Motor Grounding
To ensure electrical safety, minimize EMC disturbances and
ensure good thermal behavior, the servo drive must be
grounded properly using the following 2 methods:
Via the PE wire of the feed-in or loop cable.
•
Via the servo drive ange.
•
Ensure that the machine frame has a proper electrical
connection to the ange of the servo drive. Use the front
side ange surface. Ensure PE connection on that part of
the machine.
44
Refer to chapter chapter 4.3.2.3 Grounding for Electrical
Safety for more information.
Leakage/grounding currents are >3.5 mA. Failure to
ground the SAB and the servo drives properly could
result in death or serious injury.
Ensure the correct grounding of the devices by
•
a certied electrical installer in accordance with
44
Potential equalization
There is a risk of electrical interference when the ground
potential between the VLT® Integrated Servo Drive ISD 510
System and the machine is
cables between the system components. The
recommended cable cross-section is 16 mm2.
4.6.3 Thermal Protection
IGBT
overtemperature
PCB 1
overtemperature
PCB 2
overtemperature
Motor
winding
overtemperature
Maximum
winding
energy
Table 4.16 Thermal Protection
applicable national and local electrical
standards and directives and the instructions
contained in this manual.
dierent. Install equalizing
During the operation of the servo drive, the power
loss on the IGBT causes a temperature rise on the
IGBT. The servo drive monitors the IGBT
temperature constantly and, in case of overtemperature, stops operation and shows an IGBT
overtemperature error.
To protect the servo drive electronics from thermal
destruction, the temperature inside the electronic
housing is monitored. The servo drive shuts down
if the threshold level is reached.
To protect the servo drive electronics from thermal
destruction, the temperature inside the electronic
housing is monitored. The servo drive shuts down
if the threshold level is reached.
The motor winding temperature is protected
against thermal runaway by constantly monitoring
its temperature. The servo drive stops operation if
the limit of winding temperature is reached.
Another method to prevent motor wire damage is
to monitor the power ow into the motor wire
and its time duration. After reaching a certain
energy level, the servo drive stops operation and
an error is issued.
4.7.2 Eciency
The eciency of the SAB is >98% at the nominal current of
15 A.
4.8 Cables
The VLT® Integrated Servo Drive ISD 510 System uses pre-congured hybrid cables to connect the SAB to the 1
servo drive on each line. This hybrid cable combines the
DC link supply, the auxiliary voltage, the STO signal, and
the bus communication. The hybrid cables pass these
signals on to further servo drives connected in daisy-chain
concept.
There are 2 types of hybrid cables available with both
angled and straight M23 connectors:
Feed-in cable:
•
For connecting the 1st servo drive of a line to the
connection point on the SAB.
-Input end: Pigtailed with individual
connectors for connection to the
corresponding terminals on the SAB
-Output end: M23 connector (for
connection to the 1st servo drive on the
line)
Loop cable:
•
For connecting the servo drives in daisy-chain
format in an application.
-Input end: M23 connector
-Output end: M23 connector
Both these cables are provided by Danfoss and are
available in various lengths.
See chapter 5.5.1 Flexible Hybrid Cable for cable
cations.
Peripheral Components
4.9
st
speci-
4.9.1 AUX Power Supply
Supply the SAB with a power supply unit with an output
range of 24–48 V DC ±10%. The output ripple of the
power supply unit must be <250 mVpp. Only use supply
units that conform to the PELV specication.
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 Grounding for information on
grounding the SAB.
Use a supply that is CE-marked according to the
standards EN 61000-6-2 and EN 61000-6-4 or similar for
industrial use.
The power supply unit must be dedicated to the VLT
Integrated Servo Drive ISD 510 System, meaning that the
supply is used exclusively for powering the servo system.
®
System IntegrationDesign Guide
The maximum cable length between the supply unit and
the SAB is 3 m.
4.9.2 Sensors
Digital input Input range nominal0–24 V
Input range absolute maximum
rating
Bandwidth (-3 dB, simulation
results)
Switching threshold high10 V
Switching threshold low5 V
Delay including ADC conversion:
Rising edge 0–24 V
Falling edge 24–0 V
Input impedance 0–10.5 V
Input impedance 10.5–24 V
ADC resolution12-bit
ADC accuracy
Analog input Input range nominal0–10 V
Input range absolute maximum
rating
Bandwidth (-3 dB, simulation
results)
Input impedance 0–10 V
ADC resolution12-bit
ADC accuracy
Sample rate for each channel
SPI Interface from ADC to FPGA
(PELV), functional isolated
Digital output Switchable output voltage,
controlled over eldbus
Maximum output current150 mA
Maximum switching period100 Hz
Maximum switching delay100 µs
-5 to +30 V
100 kHz
<8 us
<12 us
5.46 kΩ±1%
4.8–5.46 kΩ
±250 mV
–5 to +30 V
25 kHz
5.46 kΩ±1%
±25 mV
195.3 kHz ±1%
12.5 MHz
0 V ±10%
24 V ±10%
4.9.3 Safety Supply Requirements
Supply the STO line with a 24 V DC supply with the
following properties:
Output range: 24 V DC ±10%
•
Maximum current: 1 A
•
NOTICE
Use a 24 V supply unit that is CE marked according to
the standards EN 61000-6-2 and EN 61000-6-4 or similar
for industrial use. The supply must only be used for the
ISD 510 safety input. The supply must fulll the PELV
specication.
It is possible to use the auxiliary supply for the STO
function if the following conditions are met:
Drive Congurator for VLT® Integrated Servo Drive ISD 510
The Danfoss Drive Congurator (vltcong.danfoss.com) is an advanced but easy-to-use tool to congure the Danfoss VLT
®
Integrated Servo Drive ISD 510 that exactly matches your requirements.
NOTICE
The Drive Congurator shows the valid conguration of servo drive variants. Only valid combinations are shown.
Therefore, not all variants detailed in the type code (see chapter 5.2.1 Typecode and Denitions) are visible.
55
The Drive Congurator generates a unique code number for the servo drive required, preventing errors during order entry.
Decoding is also available: Enter a typecode and the Drive
ration of the servo drive.
VLT® Servo Access Box (SAB®) with Ethernet
POWERLINK
VLT® Servo Access Box (SAB®) with EtherCAT
Table 5.3 SAB Ordering Numbers
®
5.4 Options
5.4.1 Mechanical Holding Brake
The optional mechanical holding brake is designed as a
single-disc brake. The emergency stop function can be
initiated at most once every 3 minutes and up to 2000
times in total, depending on the load.
The eective holding torque is:
Size 1: 2.5 Nm
•
Size 2: 5.3 Nm
•
The brake operates as a holding brake according to the
fail-safe principle closed when no current. It is powered
from the 24–48 V DC auxiliary supply. This enables lowbacklash load holding when no current is present.
Power consumption:
Size 1: 2.0 W
•
Size 2: 2.5 W
•
NOTICE
Do not misuse the holding brake as a working brake
because this causes increased wear, resulting in
premature failure.
5.4.2 Feedback
5.4.2.1 Built-in Feedback Devices
The built-in feedback device measures the rotor position.
There are 3 feedback variants available:
Resolver
•
17-bit single-turn encoder
•
17-bit multi-turn encoder
•
Table 5.4 summarizes the characteristic data of each
variant.
Data/typeResolverSingle-turn
encoder
SignalSin/cosBiSS-BBiSS-B
Accuracy
Resolution14 bit17 bit17 bit
Maximum
number of turns
±10 arcmin ±1.6 arcmin±1.6 arcmin
––4096 (12 bit)
Multi-turn
encoder
5.4.3 Customized Flange
A customized ange is available on request. Contact
Danfoss for further information.
5.4.4 Shaft Seal
The servo drives can be sealed by a shaft seal (optional) to
achieve up to IP65 on the A-side of the motor.
DescriptionOrdering
number
Shaft seal set for size 1 servo drive (10 pieces) 175G8192
Shaft seal set for size 2 servo drive (10 pieces) 175G8191
Table 5.5 Shaft Seal Ordering Numbers
See chapter 4.5.1.3 24 V Supply for further information on IP
ratings.
LCP remote mounting kit (IP21) including LCP,
fasteners, 3 m cable, and gasket.
LCP remote mounting kit (IP21) without LCP, but
including fasteners, 3 m cable, and gasket.
Table 5.10 LCP Mounting Kit Ordering Numbers
130B1170
130B1117
5.5.5 Blind Caps
DescriptionOrdering number
Blind cap for M23 connector, IP67175G8805
Blind cap for M23 connector, IP40175G8183
Blind cap for M12 connector175G7162
Blind cap for M8 connector175G8785
Table 5.11 Blind Caps Ordering Numbers
5.5.6 Sensor Cable
Other than the LCP cable (see chapter 5.5.3 LCP Cable), the
cables for the sensor interface (X4) on the advanced
version of the servo drive are not supplied by Danfoss.
5.5.2 Fieldbus Cables
DescriptionLength [m] Ordering
number
Fieldbus extension cable, M23
angled to M12 straight
Fieldbus extension cable, M23
straight to M12 straight
Table 5.8 Fieldbus Cable Ordering Numbers
2175G8940
2175G8941
The M8 Ethernet cable for the 3rd Ethernet port (X3) is not
supplied by Danfoss.
5.5.3 LCP Cable
DescriptionLength [m]Ordering number
LCP Cable (SUB-D to M8)3175G8942
SAB LCP cable3175Z0929
This chapter details all possible connections for the
standard and advanced servo drive. Refer to the tables in
this chapter for maximum cable lengths, ratings, and other
limits.
There are 5 connectors on the servo drives.
X1 and X2: Hybrid connector (M23)
The hybrid cable provides the supply (mains and auxiliary),
the communication lines, and the safety supply for each
line of servo drives. Input and output connectors are
connected inside the servo drive.
Illustration 6.6 X1: Male Hybrid Connector (M23)
6
6
ConnectorDescription
X1M23 Feed-in or loop hybrid cable input
X2M23 Loop hybrid cable output or eldbus
extension cable
X3 (advanced version
only)
X4 (advanced version
M8 Ethernet cable (minimum CAT5,
shielded)
M12 I/O and/or encoder cable (shielded)
only)
X5 (advanced version
Switched 24 V as
digital output or
supply (24 V/150 mA)
clock out
in
out
Nominal voltage
24 V ±15%
Maximum current
150 mA
Maximum switching
frequency 100 Hz
Nominal voltage 0–
24 V
Bandwidth: ≤100 kHz
Analog input:
Nominal voltage 0–
10 V
Input impedance
5.46 kΩ
Bandwidth: ≤25 kHz
SSI:
Bus Speed: 0.5 Mbit
with 25 m cable
BiSS:
Fullls the RS485
specication.
Maximum cable length
(SSI & BiSS): 25 m
Nominal voltage 0–
24 V
Bandwidth: ≤100 kHz
Analog input:
Nominal voltage 0–
10 V
Input impedance
5.46 kΩ
Bandwidth: ≤25 kHz
130BE434.10
1
2
3
4
5
6
SpecicationsDesign Guide
Pin Description NotesRating/parameter
8/SSI DATNegative SSI/BiSS datainSSI:
Bus Speed: 0.5 Mbit
with 25 m cable
BiSS:
Fullls the RS485
specication.
Maximum cable length
(SSI & BiSS): 25 m
Illustration 6.9 Pin Assignment of X4 M12 I/O and/or Encoder
Connector (M12)
X5: LCP connector (M8, 6 pole)
The X5 connector is used to connect the LCP directly to
the advanced servo drive via a cable.
PinDescriptionNotesRating/
parameter
1Not connected ––
2/LCP RSTResetActive at
<0.5 V
3LCP RS485Positive RS485
signal
4/LCP RS485Negative RS485
signal
5GNDGND–
6VCC5 V Supply for
LCP
Speed:
38.4 kBd
The levels
fulll the
RS485 speci-
cation.
5 V ±10% at
120 mA
maximum load
6
6
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 characteristics.
SpecicationsUnitSize 1
1.5 Nm
Rated speed n
Rated torque M
Rated current I
Rated power P
Standstill (Stall)
torque M
Standstill (Stall)
current I
Peak torque M
Peak current (rms
value) I
Rated VoltageV DC560/680
Inductance L 2 phmH18.526.832.633.9
Resistance R 2 ph
Voltage constant
EMK
Illustration 6.18 Performance at 40 °C Ambient Temperature:
Size 2, 3.8 Nm
i_ph_out / I_ph_out_cont [%]
Installation altitude [m]
0%
05001000 15002000 25003000 3500 4000
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
130BF924.10
130BE670.10
SpecicationsDesign Guide
6.1.6 Derating
6.1.6.3 Derating using Servo Drives with
Shaft Seals
6.1.6.1 Derating at High Altitude
Illustration 6.19 shows the derating factor when using the
servo drives above 1000 m.
Illustration 6.19 Derating of Phase Output Current versus
Installation Altitude
NOTICE
The components of the VLT® Integrated Servo Drive
ISD 510 System are only approved for installation at
altitudes up to 2000 m above sea level. Products used at
altitudes above 2000 m above sea level means that such
products are accepted “as is”, and that Danfoss disclaims
all warranties of quality, whether express or implied,
including the warranties of merchantability and tness
for particular purpose. For any such products, Danfoss
has no obligation to repair any damage to or defect in
the products, replace the products, or otherwise remedy
the products. Furthermore, Danfoss disclaims 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.
The xing screws are not supplied and must be selected
according to the machine xings.
Illustration 6.22 shows the maximum allowed forces on the
motor shaft.
The maximum axial and radial load while assembling the
motor and for any mechanical 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 permanently damaged if the
maximum allowed forces are exceeded.
Motor sizeRadial Force (Fr) in NAxial Force (Fa) in N
Size 14501050
Size 29001700
Table 6.11 Permitted Forces
The maximum radial load ratings are based on the
following assumptions:
The servo drives are operated with peak torque
•
of the longest member of the frame size.
Fully reversed load is applied to the end of the
•
smallest diameter standard mounting shaft
extension.
Innite life with standard 99% reliability.
•
Safety factor = 2
•
6.1.8.2 Bearing Load Curves
This section shows the bearing load curves (L10h – 10%
failure) for each servo drive variant, which are calculated
based on DIN ISO281. The curves show the maximum
allowed radial force versus the maximum allowed axial
force on the shaft end for dierent speeds. The estimated
life-span of the bearing with this condition is 20000 h.
the servo drive ange must be unpainted to
guarantee good thermal behavior of the servo
drive, and to minimize EMI disturbance in the
servo system.
Do not machine the shaft.
•
Do not use the servo drive if the shaft does not
•
match the coupling arrangement.
Do not hammer the servo and do not use a
•
hammer for tting because this will damage the
equipment.
Ensure that the machinery is at a complete
•
standstill before installing the servo drive.
Ensure that the machinery is at a complete
•
standstill and secured against unintended start
before doing any work on the servo drive, for
example dismounting the servo drive.
During operation, the surface of both motor and
•
electronic housing could reach temperatures of
>100 °C. Ensure that the surface has cooled down
before dismounting the servo drive.
Avoid brute force while dismounting the servo
•
drive and follow the instructions in the VLT
Integrated Servo Drive ISD® 510 System Operating
Instructions.
Before working on the power connector
•
(connecting and disconnecting the M23
connector), disconnect the mains supply and wait
for the discharge 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, external, mechanical brake to
•
ensure personal safety in case of hanging loads
(vertical axes). If the brake is released, then the
rotor can be moved without remanent torque.
The holding brakes are designed as standstill
•
brakes and are not suitable for repeated
operational braking. Frequent operational braking
results in premature wear and failure of the
holding brake.
Warnings and notes for servo drive with optional shaft
seal
Do not apply any axial load to the shaft seal.
•
Prevent the seal from becoming dry by using
•
adequate lubrication.
®
Harsh environmental conditions, for example
•
frictional heat, dirt, dust, or chemical substances,
can reduce the lifetime of the shaft seal.
Therefore the lifetime depends on the specic
application.
The maintenance task for the shaft seal is
•
explained in Table 6.12.
Maintenance taskMaintenance intervalInstruction
Check the
condition and
check for leakage
Table 6.12 Maintenance Task: Shaft Seal
Recommended every
4500 hours. A shorter or
longer interval is possible
depending on the
application.
connectors can
only be used
to make a
bridge to STO
1 IN: STO and
STO 2 IN: STO
if the STO
function is not
required in the
application.
This connector
cannot be
used for any
other function.
output voltage
1.
output voltage
2.
pins
Pins (left
to right):
STO+
STO-
Pins (left
to right):
24+
24-
Pins (left
to right):
STO+
STO-
Ratings
Nominal voltage:
24 V DC ±10%
Nominal current:
Depends on the
number of servo
drives in the
application.
Maximum current:
1 A
Maximum crosssection:
2
1.5 mm
Nominal voltage:
24 V DC ±10%
Nominal current:
1 A
Maximum crosssection:
2
1.5 mm
Nominal voltage:
24 V DC ±10%
Nominal current:
Depends on the
number of servo
drives in the
application.
Maximum current:
1 A
Maximum crosssection:
2
0.5 mm
6.2.3.2 Mains Connectors
ItemDescriptionDrawing/
pins
AC mains
supply
Mains PE
(terminal
95)
Table 6.15 Mains Connectors
1PE screw (terminal 95)
Illustration 6.31 PE Screw
Used to connect
L1/L2/L3
The PE screw is used
to connect the
protective earth, see
Illustration 6.31.
The maximum length of the X1 and X2 shielded Ethernet
cables is 30 m.
6.2.3.7 AUX Connectors
Connector
name
ISD Line 1:
AUX 1
ISD Line 2:
AUX 2
DescriptionDrawing/
pins
Used to connect
the AUX output
from the SAB to
the hybrid cable.
Pins (left to
right):
AUX+
AUX–
Ratings
Nominal voltage:
24–48 V DC±10%
Nominal current:
Depends on the
number of servo
drives in the
application
Maximum current:
15 A
Maximum crosssection: 2.5 mm
2
NOTICE
The maximum cable length is 3 m.
6.2.3.9 UDC Connectors
Connector
name
ISD Line 1:
UDC 1
ISD Line 2:
UDC 2
Table 6.23 UDC Connectors
6.2.3.10 Hybrid Cable PE
ItemDescriptionDrawing/pinsRatings
Hybrid
cable PE
Table 6.24 Hybrid Cable PE
DescriptionDrawing/
Used to connect
the DC-link
voltage from the
SAB to the
hybrid cable.
Used to connect the
PE wire from the
hybrid cable to the
decoupling plate.
Ratings
pins
Nominal voltage:
565–778 V DC
Nominal current:
Pins (left to
right):
UDC+
UDC–
Depends on the
number of servo
drives in the
application
Maximum current:
15 A
Maximum crosssection:
Nominal voltage: 24–
48 V DC ±10%
Nominal current:
Depends on the
number of servo
drives in the
application
Maximum current:
34 A
Maximum crosssection:
2
4 mm
Maximum
I
out
(%)
a
t
T
A
MB
, M A X
Altitude (km)
T
a
t 100% I
out
D
100%
91%
82%
0 K
–5 K
–9 K
1 k m 2 k m 3 k
m
A
MB
, M A X
(K
)
SpecicationsDesign Guide
6.2.4 Characteristic Data
DenitionValue and unit
Input
Input voltage
Eciency98.5% at 400 V
Input current12.5 A continuous
Output
Output voltage
ISD Line 1: UDC 1 & ISD Line 2: UDC 2
Output voltage
ISD Line 1: STO 1 & ISD Line 2: STO 2
Output voltage
ISD Line 1: AUX 1 & ISD Line 2: AUX 2
Output current
ISD Line 1: AUX 1 & ISD Line 2: AUX 2
Output current UDC
Output current
ISD Line 1: STO 1 & ISD Line 2: STO 2
Output power8 kW at 400 V
Housing
Dimensions (W x H x D)130 x 268 x 80 mm
Weight8.3 kg
400–480 V ±10%
20 A intermittent
565–679 V ±10%
24 V ±10%
24–48 V ±10%
1)
15 A
1)
15 A
1)
1 A
9.7 kW at 480 V
6.2.7 Derating
The cooling capability is decreased at lower air pressure.
Below 1000 m altitude no derating is necessary. Above
1000 m, the ambient temperature or the maximum output
current has to be derated.
2)
6
6
Illustration 6.32 Derating SAB
6.2.8 Connection Tightening Torques
Decoupling plate screws: 2 Nm
Table 6.25 Servo Access Box Characteristic Data
1) Depends on the number of servo drives connected in the
application. The current per servo drive is 6.7 mA.
6.2.5 General Specications and
Environmental Considerations
Protection ratingIP20 (UL rating: Open type)
Vibration testRandom vibration: 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
Ambient
temperature range
Installation elevation Maximum 1000 m above sea level
EMC standard for
emission and
immunity
Table 6.26 General Specications and Environmental Conditions
SAB
Storage/transport and stationary use:
5–93% (non-condensing)
5–50 °C operating temperature
(24-hour average maximum 45 °C)
Transport: -25 to +70 °C
Storage: -25 to +55 °C
EN 61800-3
6.2.6 Mains Supply
Refer to chapter 4.4 Mains Input for information on the
mains supply for the SAB.
All cables supplied by Danfoss have a nameplate as per
the example in Illustration 6.33.
1Cable type
2Ordering code
3Revision of specication
4Manufacturing date
5Length
6Power rating
7Signal rating
8Signal rating for Ethernet
9Barcode
10Manufacturer logo
Illustration 6.33 Example of a Cable Nameplate
WARNING
HIGH VOLTAGE
The VLT® Integrated Servo Drive ISD 510 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 qualied personnel.
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 advanced servo drive is delivered with M8, M12, and
M23 caps. These caps protect the servo drive connectors
during transportation and storage. Furthermore, they are a
part of the IP protection (IP67 for M8 and M12 covers; IP40
for M23 covers) and must remain tted if the respective
connectors are not used. To achieve IP67 on the M23
connector, use the M23 blind cap.
ConnectorTightening torque [Nm]
M80.2
M120.4
M230.8
Table 6.27 Tightening Torques
6.3.1 Feed-In Cable
Shielded/
unshielded
Shielded
Table 6.28 Feed-In Cable
1) Maximum 100 m total length for each line of servo drives.
There are 2 types of connector for the feed-in cable:
•
•
See chapter 5.5.1.1 Feed-In Cable for ordering numbers.
Maximum
cable length
1)
40 m
Description
Hybrid cable (overall shield with
additional eldbus and safety
section shield).
M23 angled connector
M23 straight connector
6.3.1.1 Clearances
Illustration 6.35 and Illustration 6.36 show the dimensions of
2 types of M23 cable connectors installed on the servo
drive. A size 2 servo drive is used in this example and the
dimensions of other sizes dier.
The M23 angled connector can be adjusted or tilted up to
120°, as illustrated in Illustration 6.34.
NOTICE
Do not use force to connect or t the connector. This
causes permanent damage to connector and cables.
Before working on the power connector (connecting and
disconnecting M23), disconnect the mains supply and wait
for discharge time to elapse (see chapter 1.6 Safety).
Illustration 6.34 Adjustable Angle of the Angled Connector
200 min
37
112
Rmin
130BF955.10
51.4
Rmin
65.5
80
140 min
130BF951.10
130BE383.10
SpecicationsDesign Guide
Each connector type requires specic installation spaces or
area in order to ease the installation and to meet the
minimum allowable bending radius of cable.
NOTICE
Exceeding the minimum allowable bending radius of
cable causes damage on connectors on both the servo
drive and the cable itself.
There are 2 possible types of cable installation. The
minimum allowable bending radius R
lation type is:
Permanently exible: 12 x cable diameter =
•
187.2 mm
Permanently installed: 5 x cable diameter =
•
78 mm
The maximum number of bending cycles is 5 million at 7.5
x cable diameter (15.6 mm).
Illustration 6.35 shows the servo drive with the straight
connector installed on a size 2 servo drive. Illustration 6.36
shows the servo drive with the angled connector installed
on a size 2 servo drive. The illustrations show the
minimum distance from the servo drive to next object, and
the minimum allowable bending radius R
permanently installed cable.
For cable installation, allow the height of the connector
plus an additional 30 mm for the cable.
Required installation distances
The minimum distance is measured from the electronic
housing as this is the same for all motor variants.
Straight connector
The minimum distance for the straight connector is
calculated as follows:
0.5 x cable diameter + connector height + R
+ 112 mm + 78 mm = 197.8 mm ≈ 200 mm
for each instal-
min
for
min
= 7.8 mm
min
Angled connector
The minimum distance for the angled connector is
calculated as follows:
0.5 x cable diameter + connector length measured from
electronic housing + R
= 7.8 mm + 51.4 mm + 78 mm =
min
137.8 mm ≈ 140 mm
Illustration 6.36 Required Installation Distance and Minimum
Bending Radius for M23 Angled Connector
6.3.2 Loop Cable
Shielded/
unshielded
Shielded
Table 6.29 Loop Cable
1) Maximum 100 m total length for each line of servo drives.
Illustration 6.37 Loop Cable
Maximum
cable length
1)
25 m
Description
Hybrid cable (overall shield with
additional eldbus and safety
section shield).
6
6
See chapter 5.5.1.2 Loop Cable for ordering numbers.
See chapter 6.1.2.1 Connectors on the Servo Drives for pin
assignment.
6.3.3 Fieldbus Extension Cable
There are 2 types of eldbus extension cable for ring
redundancy:
M23 angled connector to M12 straight connector
Illustration 6.35 Required Installation Distance and Minimum
See chapter 5.5.2 Fieldbus Cables for ordering numbers.
Specications
VLT® Integrated Servo Drive ISD® 510 System
6.3.4 LCP Cable
There are 2 types of cable for the LCP module:
To connect the LCP to the servo drive.
•
To connect the LCP to the SAB.
•
See chapter 5.5.3 LCP Cable for ordering numbers.
6.3.5 Sensor and Encoder Cable
Contact Danfoss for further information regarding cables
for connection to the M8 and M12 connectors. The pin
assignment can be found in chapter 6.1.2.1 Connectors onthe Servo Drives. Always use shielded cables.
6
Maximum length: 25 m (shielded)
•
Maximum cross-section: 0.5 mm
•
2
6.3.6 Ethernet Cable
See chapter 6.2.3.6 Ethernet Connectors for pin assignment.
Specication
Ethernet standard Standard Ethernet (in accordance with IEEE
802.3), 100Base-TX (Fast Ethernet)
Cable typeS/FTP (shielded foiled twisted pair), ISO
(IEC 11801 or EN 50173), CAT 5e or 6
Damping23.2 dB (at 100 Mhz and 100 m each)
Crosstalk damping 24 dB (at 100 Mhz and 100 m each)
Return loss10 dB (100 m each)
Surge impedance
Maximum cable
length
Table 6.30 Ethernet Cable Recommendations
100 Ω
100 m between switches or network devices
NOTICE
Ground the Ethernet cable through the RJ45 connector.
Do not ground it on the strain relief.
The temperature in the immediate vicinity of the servo
system or component.
Automation Studio™
Automation Studio™ is a registered trademark of B&R. It is
the integrated software development environment for B&R
controllers.
Axial force
The force in newton acting on the rotor axis in the axial
direction.
Bearings
The ball bearings of the servomotor.
Beckho
Beckho® is a registered trademark of and licensed by
Beckho Automation GmbH, Germany.
B&R
Multi-national company, specializing in factory and process
automation software and systems for a wide range of
industrial applications.
B side
The rear side of the servo drive with the plug-and-socket
connectors.
Brake
Mechanical holding brake on the servo drive.
CANopen
CANopen® is a registered community trademark of CAN in
Automation e.V.
CE
European test and certication mark.
CiA DS 402
Device prole for drives and motion control.
CiA® is a registered community trademark of CAN in
Automation e.V.
Clamping set
A mechanical device, which, for example, can be used to
secure gears to a motor shaft.
Connector (M23)
Servo drive hybrid connector.
Cooling
The servo drives are cooled by natural convection (without
fans).
DC-link
Each servo drive has its 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 for parameter setting and
diagnostics of the servo drives and the SAB.
EPSG
Ethernet POWERLINK® Standardization Group.
ETG
EtherCAT® Technology Group
EtherCAT
EtherCAT® (Ethernet for Control Automation Technology) is
an open high-performance Ethernet-based
EtherCAT® is registered trademark and patented
technology, licensed by Beckho Automation GmbH,
Germany.
Illustration 7.1 EtherCAT
Ethernet POWERLINK
Ethernet POWERLINK® is a deterministic real-time protocol
for standard Ethernet. It is an open protocol managed by
the Ethernet POWERLINK® Standardization Group (EPSG). It
was introduced by Austrian automation company B&R in
2001.
Feed-in cable
Hybrid connection cable between the SAB and servo drive.
Feedback system
The feedback system measures the rotor position.
Fieldbus
Communication bus between controller and servo axis and
SAB; in general between controller and eld nodes.
Firmware
Software in the unit; runs on the control board.
Function block
Device functionalities are accessible via the engineering
environment software.
IGBT
The insulated-gate bipolar transistor is a 3-terminal
semiconductor device, primarily used as an electronic
switch to combine high eciency and fast switching.
Installation elevation above normal sea level, typically
associated with a derating factor.
ISD
Integrated servo drive.
ISD devices
Refers to both the servo drives and the SAB.
ISD servomotor
Designates the ISD servomotor (without the drive
electronics).
LCP
Local control panel.
Loop cable
Hybrid connection cable between 2 servo drives, with 2
M23 connectors.
M8 connectors
77
Fully functional real-time Ethernet port (X3) on the B side
of the advanced servo drive.
Connector (X5) for connection of the LCP to the B side of
the advanced servo drive.
M12 connector
Connector (X4) for connecting I/O and/or encoder on the B
side of the advanced servo drive.
M23 connectors
Connectors (X1 & X2) for connecting the hybrid feed-in
and loop cables on the B side of the standard and
advanced servo drive.
Motor shaft
Rotating shaft on the A side of the servo motor, typically
without a key groove.
Multi-turn encoder
Describes a digital absolute encoder, in which the absolute
position remains known after several revolutions.
PLC
A programmable logic controller is a digital computer used
for automation of electromechanical processes, such as
control of machinery on factor assembly lines.
PELV
Protected extra low voltage is an electricity supply voltage
in a range which carries a low risk of dangerous electrical
shock.
PLCopen
®
Radial force
The force in newton acting at 90° to the longitudinal
direction of the rotor axis.
RCCB
Residual current circuit breaker.
Resolver
A feedback device for servomotors, typically with 2 analog
tracks (sine and cosine).
Safety (STO)
A servo drive safety circuit that switches o the voltages of
the driver components for the IGBTs.
Scope
Is part of the DDS Toolbox software and is used for
diagnosis. It enables internal signals to be depicted.
Servo Access Box (SAB)
Generates the DC-link supply for the VLT® Integrated Servo
Drive ISD 510 System and can host up to 64 servo drives.
SIL 2
Safety Integrated Level II.
Single-turn encoder
Describes a digital absolute encoder, in which the absolute
position for 1 revolution remains known.
SSI
Synchronous serial interface.
Standstill (servo drive)
Power is on, there is no error in the axis, and there are no
motion commands active on the axis.
STO
Safe Torque
O function. On activation of STO, the servo
drive is no longer able to produce torque in the motor.
TwinCAT
®
TwinCAT® is a registered trademark of and licensed by
Beckho Automation GmbH, Germany. It is the integrated
software development environment for controllers from
Beckho.
U
AUX
Auxiliary supply, provides power to the control electronics
of the servo drives and SAB.
Wireshark
®
Wireshark® is a network protocol analyzer released under
the GNU General Public License version 2.
The name PLCopen® is a registered trademark and,
together with the PLCopen® logos, is owned by the
association PLCopen®. PLCopen® is a vendor and product-
independent worldwide association, that
denes a
standard for industrial control programming.
POU
Program organization unit. This can be a program, function
block, or function.
Danfoss can accept no responsibility for possible errors in catalogues, brochures and other printed material. Danfoss reserves the right to alter its products without notice. This also applies to
products already on order provided that such alterations can be made without subsequential changes being necessary in specications already agreed. All trademarks in this material are property
of the respective companies. Danfoss and the Danfoss logotype are trademarks of Danfoss A/S. All rights reserved.