Danfoss ISD 510 Design guide

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ENGINEERING TOMORROW

Design Guide

VLT® Integrated Servo Drive ISD® 510 System

vlt-drives.danfoss.com

Contents Design Guide

Contents

1 Introduction

1.1 Purpose of the Design Guide

1.2 Additional Resources

1.3 Abbreviations and Conventions

1.3.1 Abbreviations 7

1.3.2 Conventions 7

1.4 Copyright

1.5 Approvals and Certications

1.5.1 Low Voltage Directive 8

1.5.2 EMC Directive 8

1.5.3 Machinery Directive 8

1.6 Safety

1.7 Terminology

2 System Overview

2.1 General Description of the Servo System

2.2 VLT® Integrated Servo Drive ISD® 510

2.3 System Wiring

2.3.1 Ethernet POWERLINK® without Redundancy 12

2.3.1.1 Standard Cabling Concept for 1 Line 12

2.3.1.2 Standard Cabling Concept for 2 Lines 12

2.3.2 Ethernet POWERLINK® with Redundancy 13

2.3.3 Wiring with more than 1 SAB 13

2.3.3.1 Ethernet POWERLINK

2.3.3.2 EtherCAT

2.4 EtherCAT® with Redundancy

2.5 Description of Operation

2.6 Sequence of Operation

2.6.1 VLT® Servo Access Box (SAB) 15

2.6.2 VLT® Integrated Servo Drive ISD 510 15

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

2.7 Functional Safety Concept

2.7.1 Notes 16

2.7.2 Abbreviations and Conventions 16

2.7.3 Functional Description 16

2.7.4 Installation 17

2.7.5 Commissioning Test 17

2.7.6 Application Example 20

2.7.7 Safety Function Characteristic Data 21

Contents

VLT® Integrated Servo Drive ISD® 510 System

2.8 Communication

2.8.1 Fieldbus 21

2.8.1.1 EtherCAT

2.8.1.2 Ethernet POWERLINK

2.8.2 PC-Software 22

2.8.2.1 System Requirements 22

2.9 Operating Modes

2.10 Automated Operational Functions

2.10.1 Short Circuit Protection 24

2.10.1.1 Servo Access Box Features 24

2.10.1.2 ISD 510 Servo Drive Features 24

2.10.2 Ground Fault Protection 24

2.10.3 Temperature-controlled Fans 24

2.10.4 Thermal Protection 24

2.10.5 Additional Protection Features 24

2.10.5.1 Servo Access Box 24

2.10.5.2 VLT® Integrated Servo Drive ISD 510 25

2.11 Custom Application Functions

2.11.1 Brake Resistor 26

2.11.1.1 Mechanical Installation 26

2.11.1.2 Electrical Installation 26

2.11.1.3 Brake Resistor Calculation 26

2.11.2 External Encoder and Sensors 28

2.11.2.1 External Encoder 28

2.11.2.2 Sensor 28

2.11.3 Relays 29

2.12 Faults, Warnings, and Alarm Functions

2.12.1 Overview 29

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

2.12.3 Operating LEDs on the VLT® Servo Access Box 30

2.13 User Interfaces

2.13.1 Overview 31

2.13.2 DDS Toolbox Software 31

2.13.3 Overview 31

2.13.4 TwinCAT® NC Axis 31

3 Application Examples

3.1 Intended Applications

4 System Integration

4.1 Operating Environment: VLT® Integrated Servo Drive ISD 510

Contents Design Guide

4.1.1 Humidity 33

4.1.2 Ambient Temperature 33

4.1.3 Cooling 33

4.1.4 Motor-generated Overvoltage 33

4.1.5 Acoustic Noise 34

4.1.6 Vibration and Shock 34

4.2 Operating Environment: SAB

4.2.1 Humidity 34

4.2.2 Ambient Temperature 34

4.2.3 Cooling 34

4.2.3.1 Cooling Fans 34

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

4.2.4 Acoustic Noise 35

4.2.5 Vibration and Shock 35

4.3 Operating Environment: General

4.3.1 Aggressive Atmospheres 35

4.3.1.1 Gases 35

4.3.1.2 Exposure to Dust 36

4.3.2 Electromagnetic Compatibility 36

4.3.2.1 Emission Requirements 36

4.3.2.2 Immunity Requirements 37

4.3.2.3 Grounding for Electrical Safety 38

4.3.2.4 EMC Grounding 39

4.3.2.5 Motor Bearing Currents 39

4.3.2.6 Earth Leakage Current 39

4.3.2.7 Touch Current 40

4.3.3 IP Ratings 41

4.3.3.1 Denitions 41

4.3.3.2 IP Ratings for SAB and Servo Drive 41

4.3.4 Radio Frequency Interference 41

4.3.5 PELV and Galvanic Isolation Compliance 41

4.3.5.1 Discharge Time 42

4.3.6 Maintenance 42

4.3.7 Storage 42

4.4 Mains Input

4.4.1 General Requirements 43

4.4.2 Harmonics 43

4.4.2.1 Mains Conguration and EMC eects 43

4.4.2.2 Mains Transients 43

4.5 System Concepts

Contents

VLT® Integrated Servo Drive ISD® 510 System

4.5.1 Auxiliary Power Supply Selection 44

4.5.1.1 Shell Diagram 44

4.5.1.2 Auxiliary Power 45

4.5.1.3 24 V Supply 45

4.5.1.4 48 V Supply 46

4.5.2 Communication Topology 47

4.6 VLT® Integrated Servo Drive ISD 510

4.6.1 Motor Selection Considerations 47

4.6.2 Motor Grounding 47

4.6.3 Thermal Protection 48

4.7 VLT® Servo Access Box

4.7.1 Grounding 48

4.7.2 Eciency 48

4.8 Cables

4.9 Peripheral Components

4.9.1 AUX Power Supply 48

4.9.2 Sensors 49

4.9.3 Safety Supply Requirements 49

5 Typecode and Selection

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

5.2 VLT® Integrated Servo Drive ISD 510

5.2.1 Typecode and Denitions 50

5.3 Servo Access Box

5.4 Options

5.4.1 Mechanical Holding Brake 51

5.4.2 Feedback 51

5.4.2.1 Built-in Feedback Devices 51

5.4.3 Customized Flange 51

5.4.4 Shaft Seal 51

5.5 Accessories

5.5.1 Flexible Hybrid Cable 51

5.5.1.1 Feed-In Cable 51

5.5.1.2 Loop Cable 52

5.5.2 Fieldbus Cables 52

5.5.3 LCP Cable 52

5.5.4 LCP Mounting Kit 52

5.5.5 Blind Caps 52

5.5.6 Sensor Cable 52

6 Specications

Contents Design Guide

6.1 Servo Drive

6.1.1 Dimensions 53

6.1.2 Terminal Locations 55

6.1.2.1 Connectors on the Servo Drives 55

6.1.3 Characteristic Data 57

6.1.4 General Specications and Environmental Conditions 58

6.1.5 Motor Output and Data 58

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

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

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

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

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

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

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

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

6.1.6 Derating 61

6.1.6.1 Derating at High Altitude 61

6.1.6.2 Derating at High Ambient Temperature 61

6.1.6.3 Derating using Servo Drives with Shaft Seals 61

6.1.6.4 Derating using Servo Drives with Mechanical Holding Brake 61

6.1.7 Connection Tightening Torques 61

6.1.8 Installation 62

6.1.8.1 Allowed Forces 62

6.1.8.2 Bearing Load Curves 62

6.1.8.3 Installation Safety and Warnings 64

6.2 SAB

6.2.1 Dimensions 65

6.2.2 Clearance 68

6.2.3 Terminal Locations 68

6.2.3.1 STO Connectors 70

6.2.3.2 Mains Connectors 70

6.2.3.3 Brake Connector 71

6.2.3.4 Relay Connectors 71

6.2.3.5 Encoder Connectors 71

6.2.3.6 Ethernet Connectors 72

6.2.3.7 AUX Connectors 72

6.2.3.8 24/48 V IN Connector 72

6.2.3.9 UDC Connectors 72

6.2.3.10 Hybrid Cable PE 72

6.2.4 Characteristic Data 73

Contents

VLT® Integrated Servo Drive ISD® 510 System

6.2.5 General Specications and Environmental Considerations 73

6.2.6 Mains Supply 73

6.2.7 Derating 73

6.2.8 Connection Tightening Torques 73

6.3 Cable

6.3.1 Feed-In Cable 74

6.3.1.1 Clearances 74

6.3.2 Loop Cable 75

6.3.3 Fieldbus Extension Cable 75

6.3.4 LCP Cable 76

6.3.5 Sensor and Encoder Cable 76

6.3.6 Ethernet Cable 76

7 Appendix

7.1 Glossary

Index

Introduction Design Guide

1 Introduction

1.1 Purpose of the Design Guide

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

Project and systems engineers.

•

Design consultants.

•

Application and product specialists.

•

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

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

Also included are:

Safety features.

•

Fault condition monitoring.

•

Operational status reporting.

•

Serial communication capabilities.

•

Programmable options and features.

•

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

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

1.3 Abbreviations and Conventions

1.3.1 Abbreviations

All abbreviations can be found in chapter 7.1 Glossary.

1.3.2 Conventions

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

gures.

Italicized text indicates:

Cross-reference.

•

Link.

•

Footnote.

•

Parameter name, parameter group name,

•

parameter option.

All dimensions in drawings are in mm (inch).

1.4

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

1 1

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

Additional Resources

1.2

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

Manual Contents

VLT® Integrated Servo Drive ISD® 510 System Operating Instructions

VLT® Integrated Servo Drive ISD® 510 System Design Guide

VLT® Integrated Servo Drive ISD® 510 System Programming Guide

Table 1.1 Available Manuals for the ISD 510 Servo System

eciency.

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

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

Information about the programming of the ISD 510 servo system.

Approvals and Certications

1.5

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

IEC/EN 61800-3 Adjustable speed electrical power drive

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

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

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

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

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

IEC/EN 61508 Functional safety of electrical/electronical/

programmable electronic safety-related systems.

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

control systems. Part 1: General principles for design.

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

control systems. Part 2: Validation.

Introduction

VLT® Integrated Servo Drive ISD® 510 System

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

machines. Part 1: General requirements.

IEC/EN 62061 Safety of machinery – Functional safety of

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

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

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

UL 508C UL Standard for Safety for Power Conversion

Equipment.

1.5.2 EMC Directive

Electromagnetic compatibility (EMC) means that electromagnetic interference between apparatus does not hinder their performance. The basic protection requirement of the EMC Directive 2014/30/EU states that devices that generate electromagnetic interference (EMI), or whose operation could be aected by EMI, must be designed to limit the generation of electromagnetic interference and must have a suitable degree of immunity to EMI when properly installed, maintained, and used as intended.

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

2006/42/EC Machinery Directive CE

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

EtherCAT

Ethernet POWERLINK

PLCopen

Restriction of hazardous substances.

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

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

1.5.3 Machinery Directive

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

Machinery Directive 2006/42/EC covers a machine

classied as electronic components

consisting of an aggregate of interconnected components

Table 1.2 Approvals and Certications

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

1.5.1 Low Voltage Directive

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

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

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

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

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

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

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

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

Introduction Design Guide

1.6 Safety

The following symbols are used in this guide:

WARNING

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

CAUTION

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

NOTICE

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

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

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

WARNING

HAZARDOUS SITUATION

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

Always comply with the instructions in this

•

manual and national and local safety regulations.

WARNING

GROUNDING HAZARD

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

For reasons of operator safety, ground the

•

components of the ISD 510 servo system correctly in accordance with national or local electrical regulations and the information in this manual.

WARNING

HIGH VOLTAGE

The ISD 510 servo system contains components that operate at high voltage when connected to the electrical supply network. A hazardous voltage is present on the servo drives and the SAB whenever they are connected to the mains network. There are no indicators on the servo drive or SAB that indicate the presence of mains supply. Incorrect installation, commissioning, or maintenance can lead to death or serious injury.

Installation, commissioning, and maintenance

•

must only be performed by qualied personnel.

WARNING

UNINTENDED START

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

Take suitable measures to prevent unintended

•

starts.

WARNING

UNINTENDED MOVEMENT

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

When changing parameters, take suitable

•

measures to ensure that unintended movement cannot pose any danger.

1 1

Introduction

VLT® Integrated Servo Drive ISD® 510 System

WARNING

DISCHARGE TIME

The servo drives and the SAB contain DC-link capacitors that remain charged for some time after the mains supply is switched o at the SAB. Failure to wait the specied time after power has been removed before performing service or repair work could result in death or serious injury.

To avoid electrical shock, fully disconnect the

•

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

Number Minimum waiting time (minutes)

0–64 servo drives 10

Table 1.3 Discharge Time

NOTICE

Never connect or disconnect the hybrid cable to or from the servo drive when the ISD 510 servo system is connected to mains or auxiliary supply, or when voltage is still present. Doing so damages the electronic circuitry. Ensure that the mains supply is disconnected and the required discharge time for the DC-link capacitors has elapsed before disconnecting or connecting the hybrid cables or disconnecting cables from the SAB.

NOTICE

Full safety warnings and instructions are detailed in the

VLT® Integrated Servo Drive ISD 510 System Operating Instructions.

1.7 Terminology

VLT® Integrated Servo Drive ISD 510

VLT® Servo Access

Box SAB

PLC

Loop cable Hybrid cable for connecting servo drives in

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

Table 1.4 Terminology

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

Integrated servo drive

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

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

daisy-chain format.

the 1st servo drive.

, Real-Time Ethernet, UDC,

AUX

130BE385.10

System Overview Design Guide

2 System Overview

2.1 General Description of the Servo System

2.2

VLT® Integrated Servo Drive ISD® 510

2 2

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

It comprises:

A central power supply: VLT® Servo Access Box

•

(SAB®).

VLT® Integrated Servo Drives ISD® 510.

•

Cabling infrastructure.

•

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

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

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

oers benets in

, and STO

AUX

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

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

NOTICE

The ISD 510 servo drives cannot be used in servo systems from other manufacturers without changing the cabling infrastructure. Contact Danfoss for further information. Drives from other manufacturers cannot be used in the ISD 510 servo system when using Danfoss hybrid cables.

NOTICE

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

1 Operating LEDs 2 Connectors

Illustration 2.1 ISD 510 Servo Drive

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

130BE436.10

AUX 1

Status

Hand

Reset

Auto On

Back

Cancel

Info

Quick Menu

Main Menu

Alarm Log

AUX 2 SAFE 1 SAFE 2

Status

Hand On

Reset

Auto On

Back

Cancel

Info

Quick Menu

Main Menu

Alarm Log

LCP

SAB

400-480 V AC

Real-Time Ethernet

ISD 510

. . .

130BE437.10

AUX 1

Status

Hand

Reset

Auto On

Back

Cancel

Info

Quick Menu

Main Menu

Alarm Log

AUX 2 SAFE 1 SAFE 2

Status

Hand On

Reset

Auto On

Back

Cancel

Info

Quick Menu

Main Menu

Alarm Log

LCP

SAB

400-480 V AC

Real-Time Ethernet

ISD 510

. . .

System Overview

VLT® Integrated Servo Drive ISD® 510 System

Interface Description

Shaft Mechanical interface.

2.3.1.2 Standard Cabling Concept for 2 Lines

Operating LEDs Provides the status of the servo

drive.

M23 hybrid input connector Input connector for power and

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

Output connector for power and

communication signals.

Input connector for eldbus

devices.

Input connector for external

encoder or I/Os.

Input connector for LCP. (advanced servo drive only)

Table 2.1 External Interfaces on the ISD 510 Servo Drive

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

Size 1,

1.5 Nm

Flange size 76 mm 84 mm

Table 2.2 Motor and Flange Sizes

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

System Wiring

2.3

Size 2,

2.1 Nm

Size 2,

2.9 Nm

Size 2,

3.8 Nm

1 M23 Feed-in cable 2 M23 Loop cable

Illustration 2.3 Standard Cabling Concept for 2 Lines

2.3.1

Ethernet POWERLINK® without Redundancy

2.3.1.1 Standard Cabling Concept for 1 Line

1 M23 Feed-in cable 2 M23 Loop cable

Illustration 2.2 Standard Cabling Concept for 1 Line

AUX 1

Status

Hand

Oﬀ

Reset

Auto On

Back

Cancel

Info

Quick Menu

Main Menu

Alarm

Log

AUX 2 SAFE 1 SAFE 2

Status

Hand On

Oﬀ Reset

Auto On

Back

Cancel

Info

Quick Menu

Main Menu

Alarm

Log

LCP

SAB

400-480 V AC

ISD 510

UDC + Real-Time Ethernet Bus + STO + U

AUX

. . .

130BF040.10

Real-Time Ethernet

AUX 1

Status

Hand On

Oﬀ

Reset

Auto

Back

Cancel

Info

Quick Menu

Main Menu

Alarm Log

AUX 2 SAFE 1 SAFE 2

Status

Hand

Oﬀ Reset

Auto On

Back

Cancel

Info

Quick Menu

Main Menu

Alarm

Log

LCP

SAB

400-480 V AC

ISD 510

. . .

130BF041.10

Real-Time Ethernet

PLC

UDC + Real-Time Ethernet Bus + STO + U

AUX

130BF042.10

AUX 1

Status

Hand On

Oﬀ

Reset

Auto On

Back

Cancel

Info

Quick Menu

Main Menu

Alarm Log

AUX 2 SAFE 1 SAFE 2

Status

Hand

Oﬀ Reset

Auto On

Back

Cancel

Info

Quick Menu

Main Menu

Alarm Log

LCP

SAB

400-480 V AC

ISD 510

UDC + Real-Time Ethernet Bus + STO + U

AUX

. . .

Real-Time Ethernet

PLC

AUX 1

Status

Hand On

Oﬀ

Reset

Auto On

Back

Cancel

Info

Quick Menu

Main

Alarm Log

AUX 2 SAFE 1 SAFE 2

SAB

400-480 V AC

ISD 510

UDC + Real-Time Ethernet Bus + STO + U

AUX

. . .

Real-Time Ethernet

System Overview Design Guide

2.3.2

Ethernet POWERLINK® with Redundancy

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

eldbus extension cable

Via a

•

Via the PLC

•

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

A Fieldbus extension cable B

3rd party network cable

2 2

A Fieldbus extension cable B

3rd party network cable

Illustration 2.4 Ethernet POWERLINK® with Redundancy via

Fieldbus Extension Cable

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

Illustration 2.5 Ethernet POWERLINK® with Redundancy via

PLC

2.3.3 Wiring with more than 1 SAB

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

3rd party network cable

Illustration 2.6 Wiring with >1 SAB

2.3.3.1

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

Ethernet POWERLINK

AUX 1

Status

Hand On

Oﬀ

Reset

Auto On

Back

Cancel

Info

Quick Menu

Main Menu

Alarm Log

AUX 2 SAFE 1 SAFE 2

Status

Hand On

Oﬀ Reset

Auto On

Back

Cancel

Info

Quick Menu

Main

Alarm Log

LCP

SAB

400-480 V AC

ISD 510

. . .

130BF043.10

Real-Time Ethernet

PLC

Power

CH. 1

CH. 2

A2 14 24

S11 S12 S21 S22

A1 13 28

S33 S34 Y36 Y37

PNOZ X2P

QUINT POWER

UDC + Real-Time Ethernet Bus + STO + U

AUX

System Overview

VLT® Integrated Servo Drive ISD® 510 System

2.3.3.2

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

EtherCAT

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

2.4

EtherCAT® with Redundancy

Component Description

ISD 510 servo drive

Motors with integrated signal and power electronics. They are mounted decentrally in the application and have advanced motion control

functionality on board. Servo Access Box (SAB)

Central supply and access unit for mounting

inside a control cabinet. The SAB is the power

supply for the ISD 510 servo drives and is the

central access point for the eldbus.

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

2.5 Description of Operation

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

Hybrid cable There are 2 types of hybrid cable:

Feed-in cable: Connects the SAB to the 1

•

servo drive.

Loop cable: Connects the servo drives in an

•

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

Local Control Panel (LCP)

Graphical user interface for diagnostic and

operating purposes. The LCP is mounted on the

SAB but can be removed and connected to the

servo drive via connector X5 (advanced version

only). The LCP can be used for the ID

assignment of the advanced servo drives. The ID

assignment is started via LCP and the LCP also

indicates if the procedure is nished. External encoder PLC

An external encoder can be connected to each

SAB and servo drive in the system.

PLC with Ethernet POWERLINK® and EtherCAT

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

external safety circuits. Analog/Digital

Connection to the servo drives is possible. Sensor

3rd party eldbus device

Connection to the M8 4-pole eldbus port on

the servo drive (advanced servo drive only)

Illustration 2.7 Overview of the ISD 510 Servo System and

Table 2.4 ISD 510 System Components

Components

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

Safety relay

Table 2.3 Legend to Illustration 2.7

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

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

STO.

Ethernet X1

Ethernet X2

AC mains supply

24/48 V IN

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

ISD Line 2: STO 2

ISD Line 2: AUX 2

ISD Line 1: AUX 1

ISD Line 2: UDC 2

ISD Line 1: UDC 1

Ethernet X4

Ethernet X3

STO 2 IN: STO 2

130BF744.10

2 3

6 7 8

STO+ STO–

UDC+

UDC–

AUX+

AUX–

Advanced servo drive

Ethernet

130BF743.10

System Overview Design Guide

2.6 Sequence of Operation

2.6.1

VLT® Servo Access Box (SAB)

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

1 Control logic Used for communication and

monitors the status of the SAB.

2 SMPS (Switch mode power

supply)

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

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

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

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

5 Switch For enabling or disabling the UDC

6 Overvoltage/overcurrent

protection

7 LED indicators Show the presence of the AUX

8 LED indicators Show the presence of the STO

Used to generate the control voltage from the intermediate bus.

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

voltage at the outputs of the SAB.

voltage.

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

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

command and speed/position references

are present, the IGBTs begin switching to

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

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

and/or encoder connector (advanced servo drive only)

7 X5: LCP connector

(advanced servo drive only)

8 X3: Ethernet

connector (advanced servo drive only)

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

Drive

2.6.3

Switching on the VLT® Integrated

This interface can be used to connect

digital inputs/outputs. It can also be used

for analog values. SSI/BISS encoders can

be connected to this interface.

An LCP can be connected to read out

parameters and set-up of the servo drive.

This interface can be used to connect

external real-time Ethernet devices.

Servo Drive ISD 510 System

2 2

Illustration 2.8 Simplied Block Diagram of the Servo Access

Box

2.6.2

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

VLT® Integrated Servo Drive ISD 510

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

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

If the SAB is supplied with mains and U

•

AUX

, communication to the SAB internal controller is established and U

is automatically passed on

AUX

to the connected servo drives.

If the SAB is only powered by U

•

, then the SAB

AUX

and servo drive control units are running.

System Overview

VLT® Integrated Servo Drive ISD® 510 System

If the SAB is only supplied with mains power,

•

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

drives.

Procedure for switching on the ISD 510 servo system

1. Switch U

power on to enable communication

AUX

to the SAB and servo drives.

2. Switch the mains on.

3. Set the SAB to state Operation Enabled.

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

2.7 Functional Safety Concept

2.7.1 Notes

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

The integrated STO function complies with the following standards:

EN 60204-1: 2006 Stop Category 0 – uncontrolled

•

stop

IEC/EN 61508: 2010 SIL 2

•

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

•

IEC/EN 62061: 2005 SIL CL2

•

EN ISO 13849-1: 2015

•

The VLT® Integrated Servo Drive ISD 510 System has been

Abbreviation Reference Description

PFH EN IEC 61508 Probability of dangerous failures

per hour Take this value into account if the safety device is operated in high demand mode or in continuous operating mode, where the frequency of demands for operation made on a safety-related system occurs more than once per year.

PFD EN IEC 61508 Average probability of failure on

demand This value is used for low demand operation.

PL EN ISO

13849-1

SFF EN IEC 61508 Safe Failure Fraction [%]

SIL EN IEC 61508

EN IEC 62061

STO EN IEC

61800-5-2

Table 2.5 Abbreviations and Conventions

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

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

Safe Torque O

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

2.7.3 Functional Description

2.7.2 Abbreviations and Conventions

Abbreviation Reference Description

Cat. EN ISO

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

HFT EN IEC 61508 Hardware fault tolerance

MTTF

EN ISO

13849-1

Category, level B, 1–4

Failure rate: 1E-9/hour

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

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

NOTICE

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

130BE690.10

SAB

STO 1 IN: + STO

STO 1 IN: – STO

STO 2 IN: + STO

STO 2 IN: – STO

System Overview Design Guide

NOTICE

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

NOTICE

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

NOTICE

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

2.7.4 Installation

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

NOTICE

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

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

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

Illustration 2.10 Safety Relay with Plus and Minus Switching

Output

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

2 2

2.7.5 Commissioning Test

NOTICE

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

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

Using the Danfoss Library or the TwinCAT® Library.

•

Bit-wise readout of the status.

•

Commissioning test using libraries

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

Danfoss Library

•

- MC_ReadAxisInfo_ISD51x

- MC_ReadStatus_ISD51x

- MC_ReadAxisError_ISD51x

- MC_Reset_ISD51x

TwinCAT® Library

•

- MC_ReadStatus

- MC_ReadAxisError

- MC_Reset

System Overview

VLT® Integrated Servo Drive ISD® 510 System

Test steps Reason for the test step Expected result for Danfoss

library

1 Run the application (all the

servo drives are enabled).

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

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

5 Disable STO. Check that STO can be

6 Run the application (all the

servo drives are enabled).

7 Enable STO. Check that errors are

8 Try to run the application

(enable 1 or more servo drives).

9 Disable STO. Check that the STO start is

10 Try to run the application

(enable 1 or more servo drives).

11 Send a reset signal via

MC_Reset(_ISD51x).

12 Try to run the application (all

servo drives are enabled).

Check that the application can run.

activated without error.

deactivated without error. No reset is required.

– Application runs as expected. Application runs as expected.

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

Checks that the STO function is working correctly.

still inhibited by the error signal.

Check whether reset is required.

– MC_ReadAxisInfo_ISD51x output

– Application runs as expected. Application runs as expected.

Application runs as expected. Application runs as expected.

RPM.

MC_ReadAxisInfo_ISD51x output

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

MC_ReadAxisInfo_ISD51x output

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

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

MC_ReadAxisInfo_ISD51x output

SafeTorqueO = True and

MC_ReadStatus_ISD51x output ErrorStop = True

and

MC_ReadAxisError_ISD51x output AxisErrorID = 0xFF80 on

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

MC_ReadAxisInfo_ISD51x output

SafeTorqueO = False and

MC_ReadStatus_ISD51x output ErrorStop = True

Application does not run. Application does not run.

SafeTorqueO = False and

MC_ReadStatus_ISD51x output ErrorStop = False

Expected result for TwinCAT

library

All servo drives are at speed 0 RPM.

–

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

MC_ReadStatus output ErrorStop

= True and

MC_ReadAxisError output AxisErrorID = 0xFF80 on all

enabled servo drives.

MC_ReadStatus output ErrorStop

= True

MC_ReadStatus output ErrorStop

= False

Table 2.6 Commissioning Test using Libraries

System Overview Design Guide

Commissioning test using bit-wise readout

Test steps Reason for the test step Expected result

1 Run the application (all the servo drives

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

5 Disable STO. Check that STO can be deactivated

6 Run the application (all the servo drives

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

8 Try to run the application (enable 1 or

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

10 Try to run the application (enable 1 or

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

are enabled).

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

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

error.

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

when STO is activated while the servo drives are running.

Checks that the STO function is working correctly.

by the error signal.

Check whether reset is required. Application does not run.

– Application runs as expected.

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

Motors are torque free. Motors coast and stop after some time. Statusword bit 3 = 1, bit 14 = 1 and object 0x603F shows fault 0xFF80 in all servo drives. Application does not run.

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

2 2

Table 2.7 Commissioning Test using Bit-Wise Readout

+24 V DC

GND

130BE689.11

System Overview

2.7.6 Application Example

VLT® Integrated Servo Drive ISD® 510 System

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

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

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

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

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

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

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

EtherCAT

Slave Controller

(ESC)

OUT

Port 1 (B)

OUT

Port 2 (C)

Port 0 (A)

X2X1

130BE695.10

System Overview Design Guide

2.7.7 Safety Function Characteristic Data

General information

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

Data for EN/ISO 13849-1

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

Diagnostic coverage (DC) 60%

Data for EN/IEC 61508 and EN/IEC 62061

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

Table 2.8 Safety Function Characteristic Data

<100 ms

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

<5 x 10-8/h

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

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

•

1200 µs, and so on).

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

•

1 ms, and so on).

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

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

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

2.8.1.1

EtherCAT

Prole.

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

CANopen over EtherCAT® (CoE)

•

File Access over EtherCAT® (FoE)

•

Ethernet over EtherCAT® (EoE)

•

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

2 2

Communication

2.8

2.8.1 Fieldbus

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

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

Programming Guide for further information.

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

Using the Danfoss VLT® Servo Motion library

•

(available for TwinCAT® and Automation Studio™).

Using the NC axis functionality of TwinCAT® for

•

the servo drives.

Using the CANopen® CiA DS 402 standard by

•

reading and writing to objects.

The EtherCAT® port assignment for the servo drive and SAB is shown in Illustration 2.12 and Illustration 2.13.

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

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

Illustration 2.12 EtherCAT® Port Assignment for the ISD 510

Servo Drive

ESC SAB L1

Main EtherCAT

slave

OUT

Port 2 (C)

OUT

Port 1 (B)

Port 0 (A)

ESC SAB L2

AL emulated

junction slave

Port 0 (A)

OUT

Port 1 (B)

OUT

Port 2 (C)

130BE696.10

System Overview

VLT® Integrated Servo Drive ISD® 510 System

CAM editor for designing CAM proles for the

•

servo drives.

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

Integrated Servo Drive ISD® 510 System Programming Guide.

2.8.2.1 System Requirements

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

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

•

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

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

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

Illustration 2.13 EtherCAT® Port Assignment for the SAB in

Line Topology Mode (default)

Supported operating systems: Microsoft

•

Windows XP Service Pack 3, Windows 7, Windows

8.1.

.NET framework version: 3.5 Service Pack 1.

•

Minimum hardware requirements: 512 MB RAM,

•

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

Recommended hardware requirements: Minimum

•

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

2.8.1.2

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

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

Ethernet POWERLINK

Work as controlled node.

•

Can be operated as multiplexed stations.

•

Support of cross-communication.

•

Ring redundancy is supported for media

•

redundancy.

2.8.2 PC-Software

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

The most important sub-tools are:

Scope for visualization of the tracing functionality

•

of the servo drives and SAB.

•

Parameter list for reading/writing parameters.

Firmware update

ISD 500 Drive control/SAB control to operate the

servo drives and/or SAB for testing purposes.

System Overview Design Guide

2.9 Operating Modes

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

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

Guide.

Mode Description

2 2

ISD Inertia measurement mode

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

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

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

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

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

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

Cyclic synchronous position mode Cyclic synchronous velocity mode

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

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

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

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

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

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

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

Table 2.9 Operating Modes

System Overview

VLT® Integrated Servo Drive ISD® 510 System

2.10 Automated Operational Functions

2.10.1 Short Circuit Protection

2.10.1.1 Servo Access Box Features

The SAB has several protection functions for limiting the current:

IN 100% (15 A

•

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

•

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

IDC protection (UDC)

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

•

nected within 1.5 s.

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

•

disconnected within 500 μs.

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

•

disconnected within 10 μs.

protection

AUX

Software limit range: 0–15 A

•

- A warning and alarm is issued at

These software limits are disabled by default. See

•

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

Drive ISD 510 System Programming Guide.

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

•

to avoid unintended warnings or alarms due to inrush currents.

2.10.1.2 ISD 510 Servo Drive Features

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

Current limit protection is implemented on the servo drive and the currents are constantly monitored. If an overcurrent occurs, an error is issued and the servo drive coasts to stop as default. For servo drives with the mechanical brake option, the brake engages.

), no limitation.

RMS

user-

specied levels. A warning is issued at

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

2.10.2 Ground Fault Protection

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

2.10.3 Temperature-controlled Fans

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

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

2.10.4 Thermal Protection

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

2.10.5 Additional Protection Features

2.10.5.1 Servo Access Box

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

Function Description Limits/errors

UDC overvoltage

UDC undervoltage

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

Brake active: >778 V

•

Warning: >810 V

•

Error: >820 V

•

Warning: <410 V

•

Error: <373 V

•

System Overview Design Guide

Function Description Limits/errors

AUX overvoltage

AUX undervoltage

AUX overcurrent

Brake error The SAB reports

Inrush fault The SAB can handle

Mains phase loss

STO 1 & STO 2 indicators

Table 2.10 Additional Protection Features for SAB

2.10.5.2

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-

•

dened limit

Error: >100% of user-

•

dened limit The default value of 15 A is used if no limits are dened 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.

Function Description Limits/errors

UDC overvoltage

UDC undervoltage

Overcurrent at output

Motor position

Brake control The brake current is

Maximum shaft speed

Torque limit The 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

2 2

Table 2.11 Additional Protection Features for ISD 510

Servo Drive

91 92 93 95

L1 L2 L3 PE

Line1Line

SAB

MCE 101

Brake resistor

T1 T2

RB1 RB2

R–81 R+82 PE99

L1 L2 L3

S1 K1

130BF779.10

System Overview

VLT® Integrated Servo Drive ISD® 510 System

2.11 Custom Application Functions

The temperature switch can be used as an overtemperature protection feature to prevent damage to the

2.11.1 Brake Resistor

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 ecient 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

sucient, 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 specication, 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 prole.

•

130BF780.10

AUX 1

Status

Hand On

Reset

Auto On

Back

Cancel

Info

Quick Menu

Main

Alarm Log

AUX 2 SAFE 1 SAFE 2

SAB

400-480 V AC

Real-Time Ethernet

UDC

ISD 510

. . .

brake

peak brake

UDC

peak brake

UDC

brake min

778 V x 778 V

54.6 Ω

=== 11086 W

peak ISD

ISD x ωStart

x j x

Δt

Δω

peak ISD

ISD x nStart

2 x π

Δt

Δn

( )

System Overview Design 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

•

2 2

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 congurable 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.

j: Shaft inertia n

: Eciency of the servo drive (typically 0.88)

ISD

ω Start

ω Stop

∆t

∆ω/∆t

175ZA863.11

peak ISD line 1

Peak ISD 1.1

+ P

Peak ISD 1.2 + PPeak ISD 1.n + . . .

peak brake

Peak ISD line 1

+ P

Peak ISD line 2

P [W]

peak

avg

t [s]

175ZA094.13

ave

peak x

Duty cycle [%]

p x 100

System Overview

VLT® Integrated Servo Drive ISD® 510 System

The duty cycle is calculated as follows:

Danfoss oers 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 deecting 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 on the Servo Drives for pin assignment.

Process period time in s.

Braking time in s.

Illustration 2.17 Relation between Average Power and Peak

Power

The average power is calculated as follows:

Relay1

Relay2

240 V AC, 2 A

400 V AC, 2 A

130BA047.11

DRIVE STAT X1

NET STAT

LINK/ACT

DRIVE STAT X1

X2NET STAT

LINK/ACT

Advanced Standard

130BE677.10

System Overview Design Guide

2.11.3 Relays

Relays are used for customer-dened 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.

2 2

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

LED Color Flash status Description

DRIVE STAT

NET STAT

shows the operating LEDs on the servo

Green On Servo drive is in state

Operation enabled.

Flashing Auxiliary voltage is

applied.

Red On Servo drive is in Fault

or Fault reaction active state.

Flashing DC-link voltage is not

applied.

Green/

Fieldbus dependent Network status of the

red

device (see corresponding eldbus standard).

130BE733.11

Aux 1

Aux 2

Safe 1

Safe 2

SAB STAT

NET STAT

LINK ACT

System Overview

VLT® Integrated Servo Drive ISD® 510 System

LED Color Flash status Description

Link/A

Green – Link/activity status of

CT X1

On Ethernet link

Hybrid In (X1)

established.

Flashing Ethernet link

established and active.

O No link.

Link/A

Green – Link/activity status of

CT X2

Hybrid Out (X2)

On Ethernet link

established.

Flashing Ethernet link

established and active.

O No link.

Link/A

Green – Link/activity status of CT X3

On Ethernet link

the Ethernet port (X3).

established.

Flashing Ethernet link

established and active.

O No link.

Table 2.12 Legend to Illustration 2.19

1) Advanced version only

2.12.3

Operating LEDs on the VLT® Servo Access Box

LED Color Flash status Description

Aux 1 Green – State of the auxiliary

voltage on line 1.

On State machine is in

state Standby, Power

up, or Operation enabled. Auxiliary

voltage is applied to the output connectors on line 1.

O State machine is in

state U

disabled or

AUX

Fault. Auxiliary voltage

is not applied to line 1.

Aux 2 Green – State of the auxiliary

voltage on line 2.

On State machine is in

state Standby, Power

up, or Operation enabled. Auxiliary

voltage is applied to the output connectors on line 2.

O State machine is in

state U

disabled or

AUX

Fault. Auxiliary voltage

is not applied to line 2.

Safe 1 Green On 24 V for STO is present

on line 1.

O 24 V for STO is not

present on line 1.

Safe 2 Green On 24 V for STO is present

on line 2.

O 24 V for STO is not

present on line 2.

SAB

Green On SAB is in state

STAT

Operation enabled.

Flashing Auxiliary voltage is

applied at the input.

O No auxiliary voltage is

applied at the input.

Red On The SAB is in state

Fault.

Flashing Mains is not applied at

the input.

device (see corresponding eldbus standard).

In.

Illustration 2.20 Operating LEDs on the SAB

NET

Green/

Fieldbus dependent. Network status of the

STAT

red

Link/A

Green – Link/activity status of

CT X1

On Ethernet link

established.

Flashing Ethernet link

established and active.

O No link.

System Overview Design Guide

LED Color Flash status Description

Link/A

Green – Link/activity status of CT X2

On Ethernet link

Flashing Ethernet link

O No link.

Link/A

Green – Link/activity status of CT X3

On Ethernet link

Flashing Ethernet link

O No link.

Link/A

Green – Link/activity status of CT X4

On Ethernet link

Flashing Ethernet link

O No link.

Table 2.13 Legend to Illustration 2.20

User Interfaces

2.13

Out.

established.

established and active.

line 1.

established.

established and active.

line 2.

established.

established and active.

2.13.1 Overview

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 prole 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

proles.

Function blocks and structures for creating

•

Labeling CAM proles.

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

2 2

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.

For details on how to congure the servo drive to use this functionality, refer to the VLT® Integrated Servo Drive ISD

510 System Programming Guide.

NOTICE

A servo drive can either be controlled by the Danfoss

VLT® Servo Motion library, or operated as a TwinCAT® NC axis. However, it is possible to mix both types of operation within 1 application.

Application Examples

3 Application Examples

3.1 Intended Applications

VLT® Integrated Servo Drive ISD® 510 System

There are numerous possible applications for the VLT Integrated Servo Drive ISD® 510 system as per the

following examples.

Beverage machines:

Labelling

•

Capping

•

Filling

•

PET blow-moulding

•

Digital bottle printing

•

Food and beverage packaging machines:

Flow wrapping

•

Bag maker

•

Tray sealing

•

Shrink wrapping

•

Industrial and pharmaceutical packaging machines:

Palletization

•

Top loader

•

Cartoning

•

Tube lling

•

Blister machine

•

Liquid lling

•

Solid dosing

•

12°

1.2

Ø960

130BF956.10

System Integration Design Guide

4 System Integration

4.1

Operating Environment: VLT

Integrated Servo Drive ISD 510

4.1.1 Humidity

Although the VLT® Integrated Servo Drive ISD 510 can operate properly at high humidity, avoid condensation. There is a specic 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 sucient to keep the servo drive circuitry free of moisture.

4.1.2 Ambient Temperature

Minimum and maximum ambient temperature limits are specied for the VLT® Integrated Servo Drive ISD 510 (see

chapter 6.1.4 General Specications 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 eective 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 airow.

•

Provide minimum front and rear clearance

•

requirements for cooling airow.

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 sucient heat transfer to take place in the surrounding areas.

4 4

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.

specied 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.

System Integration

VLT® Integrated Servo Drive ISD® 510 System

The SAB cannot regenerate energy back to the grid. It is possible to connect and congure 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

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 eective 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 airow

•

through the cooling ns. See chapter 6.2.2 Clearance for correct mounting clearances.

Provide minimum front and rear clearance

•

requirements for cooling airow. 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 specic 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 sucient to keep the SAB circuitry free of moisture.

The SAB has built-in fans to ensure optimum cooling. The main fan forces the airow along the cooling ns on the heat sink, ensuring cooling of the internal air. 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

specied 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.

– T

f x Q

System Integration Design Guide

4.2.3.2 Calculation of Airow Required for Cooling the SAB

The airow 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:

Q Heat to be transferred in W T

Airow in m3/h

Factor in m3 x K/Wh (calculated as: cp x ρ (specic heat of air x density of air))

Temperature inside the enclosure in °C Ambient temperature in °C

Example

How to calculate the airow 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.

Multiply 445 W by 3.3 m3 x K/Wh = 1468.5 m3 x K/h.

Subtract 37 °C from 45 °C = 8 °C (=8 K).

Divide 1468.5 m3 x K/h by 8 K = 183.56 m3/h.

airow 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] SAB 51 60

Table 4.3 Acoustic Noise Ratings

4 4

Table 4.1 Formula Abbreviations

NOTICE

Specic 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 dierent altitudes.

Altitude

[m]

0 0.9480 1.225 3.1 500 0.9348 1.167 3.3 1000 0.9250 1.112 3.5 1500 0.8954 1.058 3.8 2000 0.8728 1.006 4.1 2500 0.8551 0.9568 4.4 3000 0.8302 0.9091 4.8 3500 0.8065 0.8633 5.2

Table 4.2 Factor f, Calculated for Various Altitudes

Specic 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.

System Integration

VLT® Integrated Servo Drive ISD® 510 System

Class

Gas type Unit

Sea salt n/a 0.1 0.3 1.0 5.0 10.0 Sulphur oxides Chlorine mg/m³0.01 0.1 0.03 0.3 1.0

3C1 3C2 (SAB) 3C3 (ISD)

Average

value

mg/m³0.01 0.1 0.5 3.0 10.0

Maximum

value

Average

value

Maximum

value

Hydrogen chloride Hydrogen

uoride

Ammonia mg/m³0.3 1.0 3.0 10.0 35.0

mg/m³0.01 0.1 0.5 1.0 5.0

mg/m³0.003 0.01 0.03 0.1 3.0

Servo Access Box:

Installation of the SAB in environments with high dust exposure is often unavoidable. Dust aects 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.

Ozone mg/m³0.01 0.05 0.1 0.1 0.3

Cooling fans

The airow for cooling the SAB is produced by cooling fans

Nitrogen mg/m³0.1 0.5 1.0 3.0 9.0

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 aects 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 denes 4 categories (C1, C2, C3, and C4) with specied requirements for emission and immunity. Table 4.5 states the denition of the 4 categories and the equivalent classication 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.

System Integration Design Guide

Categ

Denition Equivalent emission class

ory

C1 Frequency converters

installed in the rst environment (home and oce) with a supply voltage less than 1000 V.

C2 Frequency converters

installed in the rst environment (home and oce) 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.

C3 Frequency converters

installed in the second environment (industrial) with a supply voltage lower than 1000 V.

C4 Frequency 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 eect from radio-transmission equipment joined by connection cables.

4 4

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 oce 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 oce 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 eects of radar and radio communication equipment as well as mobile communications equipment.

130BF957.10

L1 L2 L3 PE

4 5

Aux 1 Aux 2 Safe 1 Safe 2

System Integration

VLT® Integrated Servo Drive ISD® 510 System

Radiated

electro-

magnetic

eld

IEC

Basic

standard

Burst

IEC

61000-4-4

Surge

IEC

61000-4-5

ESD

IEC

61000-4-2

61000-4-3

Acceptance Criterion Line 2 kV/

Brake 2 kV/

B B B A A

5 kHz

1 kV DM

2 kV CM

– – – 10 V

– – 10 V

Relay wires

2 kV/

5 kHz

2 kV

– – 10 V

LCP cable – – – – 10 V SAB Encoder cable Ethernet cable U

AUX

supply cable U

safe

supply cable Feed-in cable Loop cable 2 kV/

M8 LCP cable

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

– – – 10 V

1 kV

– – 10 V

– – – 10 V

1 kV

– – 10 V

– – – – 10 V

2 kV/

5 kHz

2 kV/

5 kHz

– – – 10 V

80 MHz –

common

mode

voltage

IEC

61000-4-6

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)

Equalizing minimum 16 mm

(AWG 5) 2 Control cabinet 8 Feed-in cable 3 Servo drive 9 Grounding rail (PE) 4 Machine frame 10 Grounding of feed-in cable 5 Flange 11 Mains, 3-phase, and reinforced PE 6 Shaft – –

Illustration 4.2 Recommended Installation for Electrical Safety

System Integration Design Guide

4.3.2.4 EMC Grounding

Proper EMC grounding practice:

Respect safety grounding.

•

The best EMC performance is achieved when the

•

ground connection is kept as short as possible.

Wires with a large cross-section have lower

•

impedance and better EMC grounding.

In cases where more devices with metal cabinets

•

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 dierent. 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:

1a Ensure that the motor and motor load

are aligned.

1b Strictly follow the EMC Installation

guideline.

1c Reinforce the PE so the high frequency

impedance is lower in the PE than the input power leads.

1d Provide a good high frequency

connection between the system components, for instance, by using shielded cable.

1e Make 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.

1f Make 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 congurations, 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.

4 4

130BB958.12

Cable

150 Hz

3rd harmonics

50 Hz

Mains

RCD with low f

cut-

RCD with high f

cut-

Leakage current

Frequency

130BB957.11

Leakage current [mA]

100 Hz

2 kHz

100 kHz

System Integration

VLT® Integrated Servo Drive ISD® 510 System

Using RCDs

4.3.2.7 Touch Current

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 congu-

•

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 satised 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 certied electrical installer in accordance with applicable national and local electrical standards and directives, and the instructions contained in this manual.

Illustration 4.4 Inuence of RCD Cut-o Frequency on Leakage

Current

130BE724.10

IM B5 IM V1 IM V3

System Integration Design Guide

4.3.3 IP Ratings

4.3.3.1 Denitions

First digit Against penetration by

solid foreign objects

0 (not protected) (not protected) 1 ≥50 mm diameter Back of hand 2 12.5 mm diameter Finger 3 2.5 mm diameter Tool 4 ≥1.0 mm diameter Wire 5 Dust protected Wire

6 Dust-tight Wire Second digit

First letter – Additional information

Additional letter

Table 4.7 IEC 60529 Denitions for IP Ratings

Against water

penetration with

harmful eect

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)

Housing All positions IP67 Shaft without shaft seal

Shaft with shaft seal

Illustration 4.5 Mounting Positions

IM B5 & IM V1 IP54 IM V3 IP50 IM B5 & IM V1 IP65 IM V3 IP60

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 lter specied 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) oers 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 fullling requirements for higher isolation and by providing the relevant creepage/clearance distances. These requirements are described in EN 61800-5-1.

4 4

System Integration

VLT® Integrated Servo Drive ISD® 510 System

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.

Installation at high altitude

Component Maintenance

task

Servo drive Carry out a

visual inspection.

Shaft seal Check 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

insucient. There

Hybrid cable Check for

damage and

wear. Mechanical holding brake (optional) Functional safety

SAB Check the fan. Every 12

Check the

brake.

Perform a

system power

cycle and

check the STO

function.

that remain charged for some time after the mains supply is switched o at the SAB. Failure to wait the specied time after power has been removed before

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

Number Minimum waiting time (minutes)

0–64 servo drives 10

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 suer permanent damage.

System Integration Design Guide

4.4 Mains Input

4.4.1 General Requirements

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-16 Eaton/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 out During low mains or a mains drop-out,

Table 4.11 Additional Specications

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]

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 dierent frequencies, that is dierent harmonic currents IN with 50 Hz as the basic frequency.

The harmonics do not aect the power consumption directly, but increase the heat losses in the installation (transformer, cables). Consequently, in plants with a high percentage of rectier 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 Conguration and EMC

eects

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 eects 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

4 4

100

0 2 4 6 8 10 12 14

130BF825.10

total

[m]

System Integration

VLT® Integrated Servo Drive ISD® 510 System

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

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 dierences 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

•

1 0 ISD servo drives with brake 2 3 ISD servo drives with brake 3 6 ISD servo drives with brake 4 Example 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 dierence 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.

100

0 2 4 6 8 10 12 14

130BF826.10

total

[m]

100

120

0 5 10 15 20 25 30 35

130BF827.10

total

[m]

System Integration Design Guide

4 4

1 0 ISD servo drives with brake 2 6 ISD servo drives with brake 3 Example 2 4 Example 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.

1 Connected 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.

System Integration

VLT® Integrated Servo Drive ISD® 510 System

AUX

voltage

(V)

Feed-

cable

(m)

24 10

24 25

Power

ISD

[W]

8 0.5 12 16.0 101.4 8 1.0 11 21.0 93.0 8 2.0 9 28.0 75.7 8 4.0 8 42.0 65.7 8 6.0 6 46.0 50.2 10 0.5 10 15.0 105.6 10 1.0 9 19.0 94.9 10 2.0 8 26.0 84.4 10 4.0 6 34.0 62.9 10 6.0 6 46.0 63.4

13.8 0.5 8 14.0 116.8

13.8 1.0 7 17.0 101.8

13.8 2.0 6 22.0 87.1

13.8 4.0 5 30.0 72.5

13.8 6.0 4 34.0 57.7 8 0.5 8 29.0 68.3 8 1.0 7 32.0 59.36 8 2.0 7 39.0 59.65 8 4.0 6 49.0 51 8 6.0 5 55.0 42.23 8 8.0 5 65.0 42.46 10 0.5 6 28.0 63.63 10 1.0 6 31.0 63.8 10 2.0 5 35.0 52.76 10 4.0 5 45.0 53.12 10 6.0 4 49.0 42.1 10 8.0 4 57.0 42.3

13.8 0.5 5 27.5 73.7

13.8 1.0 4 29.0 58.28

13.8 2.0 4 33.0 58.47

13.8 4.0 4 41.0 58.84

13.8 6.0 3 43.0 43.54

13.8 8.0 3 49.0 43.7

Cable

length

[m]

Number

of servo

drives

Overall

cable

length

[m]

Overall

power

(cable

losses

included)

[W]

AUX

voltage

(V)

Table 4.12 24 V Auxiliary Supply

Feed-

cable

(m)

24 40

Power

Cable

Number

ISD

length

of servo

[W]

[m]

drives

8 0.5 5 42.5 42.41 8 1.0 5 45.0 42.47 8 2.0 5 50.0 42.58 8 4.0 4 56.0 33.75 8 6.0 4 64.0 33.88 10 0.5 4 42.0 42.39 10 1.0 4 44.0 42.44 10 2.0 4 48.0 42.54 10 4.0 3 52.0 31.5 10 6.0 3 58.0 32.59

13.8 0.5 3 41.5 43.94

13.8 1.0 3 43.0 43.98

13.8 2.0 3 46.0 44.07

13.8 4.0 3 52.0 44.24

Overall

cable

length

[m]

Overall

power

(cable

losses

included)

[W]

4.5.1.4 48 V Supply

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 inuence. Therefore, the losses are calculated at 10 m, 25 m, or 40 m cable length.

AUX

voltage

(V)

Feed-

cable

(m)

48 10

Power

Cable

ISD

length

[W]

[m]

8 0.5 32 26.0 274.4 8 1.0 32 42.0 279.1 8 2.0 32 74.0 289.6 8 4.0 22 98.0 193.0 8 6.0 15 100.0 127.4 10 0.5 32 26.0 349.9 10 1.0 32 42.0 358.5 10 2.0 32 74.0 378.8 10 4.0 22 98.0 248.2 10 6.0 15 100.0 161.7

13.8 0.5 32 26.0 505.2

13.8 1.0 32 42.0 525.3

13.8 2.0 32 74.0 588.6

13.8 4.0 22 98.0 368.3

13.8 6.0 15 100.0 231.3

Number

of servo

drives

Overall

cable

length

[m]

Overall

power

(cable

losses

included)

[W]

System Integration Design Guide

AUX

voltage

(V)

Feed-

Power

ISD

cable

[W]

(m)

8 0.5 32 41.0 287.5 8 1.0 32 57.0 293.1 8 2.0 32 89.0 307.1 8 4.0 18 97.0 157.1 8 6.0 12 97.0 101.3 10 0.5 32 41.0 374.0

48 25

48 40

Table 4.13 48 V Auxiliary Supply

10 1.0 32 57.0 383.6 10 2.0 32 89.0 414.9 10 4.0 18 97.0 201.9 10 6.0 12 97.0 128.6

13.8 0.5 32 41.0 547.2

13.8 1.0 32 57.0 602.2

13.8 2.0 30 85.0 637.0 8 0.5 32 56.0 303.4 8 1.0 32 72.0 311.6 8 2.0 30 100.0 299.9 8 4.0 15 100.0 130.5 8 6.0 10 100.0 84.4 10 0.5 32 56.0 406.3 10 1.0 32 72.0 424.3 10 2.0 30 100.0 415.6 10 4.0 15 100.0 167.6

13.8 0.5 31 55.5 644.0

13.8 1.0 30 70.0 650.6

13.8 2.0 27 94.0 633.0

13.8 4.0 15 100.0 243.7

Cable

length

[m]

Number

of servo

drives

Overall

cable

length

[m]

Overall

power

(cable

losses

included)

[W]

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 dened in Table 4.14.

Cable Maximum length

Feed-in cable

Loop cable

Encoder cable 25 m (shielded) Brake cable 20 m (shielded) Fieldbus extension cable

24/48 V IN connector cable 3 m

Table 4.14 Maximum Cable Lengths

1) Maximum total length for each line: 100 m.

2) Maximum length to next por t: 100 m.

4.6

VLT® Integrated Servo Drive ISD 510

40 m (shielded)

25 m (shielded)

2 m

4.6.1 Motor Selection Considerations

Danfoss oers 128 dierent 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 Specications 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.

4 4

Refer to chapter chapter 4.3.2.3 Grounding for Electrical Safety for more information.

System Integration

VLT® Integrated Servo Drive ISD® 510 System

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 devices by

•

a certied electrical installer in accordance with

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.

dierent. 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 Eciency

The eciency 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- congured 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

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 specication.

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.

NOTICE

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 Integration Design Guide

The maximum cable length between the supply unit and the SAB is 3 m.

4.9.2 Sensors

Digital input Input range nominal 0–24 V

Input range absolute maximum rating Bandwidth (-3 dB, simulation results) Switching threshold high 10 V Switching threshold low 5 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 resolution 12-bit ADC accuracy

Analog input Input range nominal 0–10 V

Input range absolute maximum rating Bandwidth (-3 dB, simulation results) Input impedance 0–10 V ADC resolution 12-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 current 150 mA Maximum switching period 100 Hz Maximum switching delay 100 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 fulll the PELV

specication.

It is possible to use the auxiliary supply for the STO function if the following conditions are met:

Output range: 24 V DC ±10%

•

Maximum cable length: 3 m

•

4 4

Table 4.17 Sensors

Typecode and Selection

VLT® Integrated Servo Drive ISD® 510 System

5 Typecode and Selection

5.1

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

The Danfoss Drive Congurator (vltcong.danfoss.com) is an advanced but easy-to-use tool to congure the Danfoss VLT

Integrated Servo Drive ISD 510 that exactly matches your requirements.

NOTICE

The Drive Congurator shows the valid conguration 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 Denitions) are visible.

The Drive Congurator 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.

5.2

VLT® Integrated Servo Drive ISD 510

5.2.1 Typecode and Denitions

Pos. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

Fixed I S D 5 1 0 T D 6 Variant A 0 1 C 5 E 5 4 F R X P L S X X T F 0 7 6 S X N 4 6 X S X S X

S 0 2 C 1 E 6 7 F S 1 E C S C O F F 0 8 4 C 0 N 4 0 B K S C X 0 2 C 9 F M 1 P N F 1 0 8 N 2 9 C 0 3 C 8 E N F 1 3 8 N 2 4

Table 5.1 Type Code

Congurator decodes the conguration and show the congu-

[01–03] Product group [21–22] Bus system [33–35] Motor speed

ISD [04–06] Product variant EC 510 [07] Hardware conguration EN A Advanced [23–25] Firmware [36] Mechanical brake S Standard SXX Standard X Without brake [08] Drive torque SC0 Customized version B With brake T Torque [26] Safety [37] Motor shaft [09–12] Torque T Safe Torque O (STO) S Standard smooth shaft 01C5 1.5 Nm F 02C1 2.1 Nm [27–30] Flange size C Customized 02C9 2.9 Nm F076 76 mm [38] Motor sealing 03C8 3.8 Nm F084 84 mm X Without sealing [13–14] DC voltage F108 D6 600 V DC-link voltage F138 [15–17] Drive enclosure [31–32] Flange type SX Standard E54 IP54 SX Standard CX Customized E67 IP67 (shaft IP65) C0 Customized version

[18–20] Drive feedback

FRX Resolver FS1 Single-turn feedback FM1 Multi-turn feedback

1) In preparation

VLT® Integrated Servo Drive

ISD® 510

Table 5.2 Legend to Typecode

Ethernet POWERLINK EtherCAT PROFINET EtherNet/IP™

Functional safety

108 mm 138 mm

®1)

N46 Rated speed 4600 RPM N40 Rated speed 4000 RPM

N29 Rated speed 2900 RPM N24 Rated speed 2400 RPM

S With sealing [39–40] Surface coating

Standard tted key

Typecode and Selection Design Guide

5.3 Servo Access Box

Description Ordering

number

175G0117

175G0118

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 eective 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/type Resolver Single-turn

encoder

Signal Sin/cos BiSS-B BiSS-B Accuracy Resolution 14 bit 17 bit 17 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.

Description Ordering

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.

5.5 Accessories

5.5.1 Flexible Hybrid Cable

5.5.1.1 Feed-In Cable

Description Length

[m]

Hybrid feed-in cable M23, 90° angled connector

Hybrid feed-in cable M23, straight connector

Table 5.6 Feed-In Cable Ordering Numbers

2 175G8920 4 175G8921 6 175G8922 8 175G8923 10 175G8924 15 175G8925 20 175G8926 25 175G8927 30 175G8928 40 175G8929 2 175G8930 4 175G8931 6 175G8932 8 175G8933 10 175G8934 15 175G8935 20 175G8936 25 175G8937 30 175G8938 40 175G8939

Ordering

number

5 5

Table 5.4 Characteristic Data of Available Feedback Devices

Typecode and Selection

VLT® Integrated Servo Drive ISD® 510 System

5.5.1.2 Loop Cable

Description Length

[m]

Hybrid loop cable M23, 90° angled connector

Hybrid loop cable M23, straight connector

Table 5.7 Loop Cable Ordering Numbers

0.5 175G8900 1 175G8901 2 175G8902 4 175G8903 6 175G8904 8 175G8905 10 175G8906 15 175G8907 20 175G8908 25 175G8909

0.5 175G8910 1 175G8911 2 175G8912 4 175G8913 6 175G8914 8 175G8915 10 175G8916 15 175G8917 20 175G8918 25 175G8919

Ordering

number

5.5.4 LCP Mounting Kit

Description Ordering

number

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

Description Ordering number

Blind cap for M23 connector, IP67 175G8805 Blind cap for M23 connector, IP40 175G8183 Blind cap for M12 connector 175G7162 Blind cap for M8 connector 175G8785

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

Description Length [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

2 175G8940

2 175G8941

The M8 Ethernet cable for the 3rd Ethernet port (X3) is not supplied by Danfoss.

5.5.3 LCP Cable

Description Length [m] Ordering number

LCP Cable (SUB-D to M8) 3 175G8942 SAB LCP cable 3 175Z0929

Table 5.9 LCP Cable Ordering Numbers

280

[11.02]

83.5

[3.29]

[3.35]

55.4

[2.18]

2.5

[0.09]

123

[4.84]

[3.07]

[0.55]

[2.99]

[2.76]

5.8 [0.23]

(X4)

44.5

[1.75]

[1.18]

130BE438.10

252

[9.92]

83.5

[3.29]

100

[3.94]

55.4

[2.18]

[0.12]

137

[5.39]

[3.62]

[0.75]

[3.31]

[3.15]

[0.236]

(X4)

[0.63]

[1.57]

130BE439.10

Specications Design Guide

6 Specications

6.1 Servo Drive

6.1.1 Dimensions

Flange

Servo drive Flange thickness

Size 1, 1.5 Nm 7 mm Size 2, 2.1 Nm – Size 2, 2.9 Nm 8 mm Size 2, 3.8 Nm 8 mm

Table 6.1 Flange Thickness

All dimensions are in mm (in).

Illustration 6.1 Dimensions of ISD 510 Size 1, 1.5 Nm

Illustration 6.2 Dimensions of ISD 510 Size 2, 2.1 Nm

281

[11.06]

83.5

[3.29]

100

[3.94]

55.4

[2.18]

[0.12]

137

[5.39]

[3.62]

[0.75]

[3.31]

[3.15]

[0.28]

(X4)

[1.77]

[1.57]

130BE440.10

310

[12.20]

83.5

[3.29]

100

[3.94]

55.4

[2.18]

[0.12]

137

[5.39]

[3.62]

[0.75]

[3.31]

[3.15]

[0.28]

(X4)

[1.57]

[2.91]

130BE441.10

Specications

VLT® Integrated Servo Drive ISD® 510 System

Illustration 6.3 Dimensions of ISD 510 Size 2, 2.9 Nm

Illustration 6.4 Dimensions of ISD 510 Size 2, 3.8 Nm

130BE386.10

130BE381.10

130BE382.10

Specications Design Guide

6.1.2 Terminal Locations

6.1.2.1 Connectors on the Servo Drives

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)

Connector Description

X1 M23 Feed-in or loop hybrid cable input X2 M23 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

M8 LCP cable (shielded) only)

Illustration 6.5 Connectors on the Servo Drive

Illustration 6.7 X2: Female Connector (M23)

130BE435.10

130BE433.10

Specications

VLT® Integrated Servo Drive ISD® 510 System

Pin Description Notes Rating/parameter

A UDC– Negative DC mains

supply

B UDC+ Positive DC mains

supply

C AUX+ Auxiliary supply 24–48 V DC, 15 A

D AUX– Auxiliary supply

ground PE PE PE connector 15 A 2 STO+ Safety supply 24 V DC ±10%, 1 A 3 STO– Safety supply

ground 5 TD+ Positive Ethernet

transmit 6 RD+ Positive Ethernet

receive 7 TD– Negative Ethernet

transmit 8 RD– Negative Ethernet

receive

Table 6.2 Pin Assignment of X1 and X2 Hybrid Connectors (M23)

Operating voltage: Negative DC supply (maximum –15 A) Operating voltage: Positive DC supply (maximum 15 A)

Absolute maximum 55 V DC 15 A

1 A

According to standard 100BASE-T

X3: 3rd Ethernet connector (M8, 4 pole)

The advanced servo drive has an additional eldbus port (M8) for connecting a device that communicates via the selected eldbus.

Pin Description Notes Rating/parameter

1 TD+ Positive Ethernet

transmit 2 RD+ Positive Ethernet

receive 3 TD– Negative Ethernet

transmit 4 RD– Negative Ethernet

receive

Illustration 6.8 Pin Assignment of X3 3rd Ethernet Connector

(M8, 4 pole)

According to standard 100BASE-T

X4: M12 I/O and/or encoder connector (M12, 8-pole)

The M12 I/O and/or encoder connector is available on the advanced servo drive and can be used or congured as:

Digital output

•

Digital input

•

Analog input

•

24 V supply

•

External encoder interface (SSI or BiSS).

•

Pin Description Notes Rating/parameter

1 Digital

output

2 Ground Ground isolated – 3 Input 1 Analog/Digital input Digital input:

4 /SSI CLK Negative SSI/BiSS

5 SSI DAT Positive SSI/BiSS data

6 SSI CLK Positive SSI/BiSS clock

7 Input 2 Analog/Digital input Digital input:

Switched 24 V as digital output or supply (24 V/150 mA)

clock out

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:

Fullls the RS485 specication.

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

Specications Design Guide

Pin Description Notes Rating/parameter

8 /SSI DAT Negative SSI/BiSS datainSSI:

Bus Speed: 0.5 Mbit with 25 m cable BiSS:

Fullls the RS485 specication.

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.

Pin Description Notes Rating/

parameter

1 Not connected – – 2 /LCP RST Reset Active at

<0.5 V

3 LCP RS485 Positive RS485

signal

4 /LCP RS485 Negative RS485

signal

5 GND GND – 6 VCC 5 V Supply for

LCP

Speed:

38.4 kBd The levels fulll the RS485 speci-

cation.

5 V ±10% at 120 mA maximum load

Illustration 6.10 Pin Assignment of X5 LCP Connector

(M8, 6-pole)

6.1.3 Characteristic Data

Table 6.3 and Table 6.4 provide a summary of typical servo drive characteristics.

Specications Unit Size 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 Voltage V DC 560/680 Inductance L 2 ph mH 18.5 26.8 32.6 33.9 Resistance R 2 ph Voltage constant EMK

max

RPM 4600 4000 2900 2400

Nm 1.5 2.1 2.9 3.8

A DC 1.4 1.7 1.8

kW 0.72 0.88 0.94

Nm 2.3 2.8 3.6 4.6

A DC 2.1 2.3 2.1 2.2

Nm 6.1 7.8 10.7 12.7

max

A DC 5.7 6.4

V/krms 70.6 80.9 111.0 132.0

9.01 7.78 8.61 8.64

Size 2

2.1 Nm

Size 2

2.9 Nm

Size 2

3.8 Nm

Specications

VLT® Integrated Servo Drive ISD® 510 System

Specications Unit Size 1

1.5 Nm

Torque constant KtNm/A 1.10 1.26 1.72 2.04 Inertia

Shaft diameter mm 14 19 Pole pairs – 4 5 Flange size mm 76 84 Weight kg 3.5 4.0 5.0 6.0

Table 6.3 Characteristic Data for Servo Drive without Brake

Specications Unit Size 1

Brake inertia

Brake weight kg 0.34 0.63

Table 6.4 Characteristic Data for Servo Drive with Brake

Kgm

0.000085 0.00015 0.00021 0.00027

1.5 Nm

0.0000012 0.0000068 0.0000068 0.0000068

6.1.4 General Specications and

Size 2

2.1 Nm

Size 2

2.1 Nm

Size 2

2.9 Nm

Size 2

2.9 Nm

6.1.5 Motor Output and Data

Size 2

3.8 Nm

Size 2

3.8 Nm

Environmental Conditions

Table 6.6 shows the nominal load points for the 4 dierent

Vibration test Random vibration: 7.54 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 EMC standard for emission and immunity

Table 6.5 General Specications and Environmental Conditions

for VLT® Integrated Servo Drive ISD 510

Storage/transport: 5–93% (non-condensing)

Stationary use: 15–85% (non-condensing)

5–40 °C above derating, maximum 55 °C

(24-hour average maximum 35 °C)

Transport: -25 to +70 °C

Storage: -25 to +55 °C

Maximum 1000 m above sea level

EN 61800-3

motor sizes. The DC-link voltage is 560 V and the ambient temperature is 40 °C.

Unit Size 1

1.5 Nm

N_mech_ max N_n [RPM]4600 4000 2900 2400

M_n [Nm] 1.5 2.1 2.9 3.8 I_n_rms [A] 1.4 1.7 1.7 1.8 P_n [kW] 0.72 0.88 0.88 0.95 M_0 [Nm] 2.3 2.8 3.6 4.6 I_0_rms [A] 2.1 2.3 2.1 2.2 M_0max [Nm] 6.1 7.8 10.7 12.7 I_0max_pk[A] 8.0 9.0 9.0 9.0

I_0max_rms[A] 5.7 6.4 6.4 6.4

[RPM]7000 6000 5000 4000

Size 2

2.1 Nm

Size 2

2.9 Nm

Size 2

3.8 Nm

Table 6.6 Drive Loadpoints with 560 V DC and 40 °C

Ambient Temperature

The following subchapters show:

Speed-torque characteristics

•

Maximum speed related to voltage.

•

M [Nm]

0.00

1.00

2.00

3.00

4.00

5.00

6.00

7.00

0 1000 2000 3000 4000 5000 6000

n [rpm]

130BF916.10

0.00

1.00

2.00

3.00

4.00

5.00

6.00

7.00

M [Nm]

0 1000 2000 3000 4000 5000 6000

n [rpm]

130BF917.10

0.00

1.00

2.00

3.00

4.00

5.00

6.00

7.00

8.00

9.00

M [Nm]

0 1000 2000 3000 4000 5000

n [rpm]

130BF918.10

0.00

1.00

2.00

3.00

4.00

5.00

6.00

7.00

8.00

9.00

M [Nm]

0 1000 2000 3000 4000 5000

n [rpm]

130BF919.10

Specications Design Guide

6.1.5.1 Speed-Torque Characteristics: Size 1,

1.5 Nm at 25 °C Ambient Temperature

1 SOA 680 V 2 S3 3 SOA 560 V 4 S1

Illustration 6.11 Performance at 25 °C Ambient Temperature:

Size 1, 1.5 Nm

6.1.5.3 Speed-Torque Characteristics: Size 2,

2.1 Nm at 25 °C Ambient Temperature

1 SOA 680 V 2 S3 3 SOA 560 V 4 S1

Illustration 6.13 Performance at 25 °C Ambient Temperature:

Size 2, 2.1 Nm

6.1.5.2 Speed-Torque Characteristics: Size 1,

1.5 Nm at 40 °C Ambient Temperature

1 SOA 680 V 2 S3 3 SOA 560 V 4 S1

Illustration 6.12 Performance at 40 °C Ambient Temperature:

Size 1, 1.5 Nm

6.1.5.4 Speed-Torque Characteristics: Size 2,

2.1 Nm at 40 °C Ambient Temperature

1 SOA 680 V 2 S3 3 SOA 560 V 4 S1

Illustration 6.14 Performance at 40 °C Ambient Temperature:

Size 2, 2.1 Nm

0.00

2.00

4.00

6.00

8.00

10.00

12.00

M [Nm]

0 500 1000 1500 2000 2500 3000 3500 4000

n [rpm]

130BF920.10

0.00

2.00

4.00

6.00

8.00

10.00

12.00

M [Nm]

0 500 1000 1500 2000 2500 3000 3500 4000

n [rpm]

130BF921.10

0.00

2.00

4.00

6.00

8.00

10.00

12.00

14.00

M [Nm]

0 500 1000 1500 2000 2500 3000 3500

n [rpm]

130BF922.10

0.00

2.00

4.00

6.00

8.00

10.00

12.00

14.00

M [Nm]

0 500 1000 1500 2000 2500 3000 3500

n [rpm]

130BF923.10

Specications

VLT® Integrated Servo Drive ISD® 510 System

6.1.5.5 Speed-Torque Characteristics: Size 2,

2.9 Nm at 25 °C Ambient Temperature

1 SOA 680 V 2 S3 3 SOA 560 V 4 S1

Illustration 6.15 Performance at 25 °C Ambient Temperature:

Size 2, 2.9 Nm

6.1.5.7 Speed-Torque Characteristics: Size 2,

3.8 Nm at 25 °C Ambient Temperature

1 SOA 680 V 2 S3 3 SOA 560 V 4 S1

Illustration 6.17 Performance at 25 °C Ambient Temperature:

Size 2, 3.8 Nm

6.1.5.6 Speed-Torque Characteristics: Size 2,

2.9 Nm at 40 °C Ambient Temperature

1 SOA 680 V 2 S3 3 SOA 560 V 4 S1

Illustration 6.16 Performance at 40 °C Ambient Temperature:

Size 2, 2.9 Nm

6.1.5.8 Speed-Torque Characteristics: Size 2,

3.8 Nm at 40 °C Ambient Temperature

1 SOA 680 V 2 S3 3 SOA 560 V 4 S1

Illustration 6.18 Performance at 40 °C Ambient Temperature:

Size 2, 3.8 Nm

i_ph_out / I_ph_out_cont [%]

Installation altitude [m]

0 500 1000 1500 2000 2500 3000 3500 4000

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

130BF924.10

130BE670.10

Specications Design 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.

Servo drive size Derating

Size 1, 1.5 Nm 15% Size 2, 2.1 Nm 11% Size 2, 2.9 Nm 8% Size 2, 3.8 Nm 4%

Table 6.8 Derating using Servo Drives with Shaft Seals

6.1.6.4 Derating using Servo Drives with Mechanical Holding Brake

Servo drive size Derating

Size 1, 1.5 Nm 6% Size 2, 2.1 Nm 5% Size 2, 2.9 Nm 5% Size 2, 3.8 Nm 5%

Table 6.9 Derating using Servo Drives with Mechanical Holding Brake

6.1.7 Connection Tightening Torques

Illustration 6.20 and Illustration 6.21 show the xing screws and mounting of the servo drives.

6.1.6.2 Derating at High Ambient Temperature

Servo drive size Temperature derating factor

Size 1, 1.5 Nm Size 2, 2.1 Nm Size 2, 2.9 Nm Size 2, 3.8 Nm

Table 6.7 Derating at High Ambient Temperature

0.032 Nm/°C

0.048 Nm/°C

0.056 Nm/°C

0.081 Nm/°C

Illustration 6.20 Mounting of Size 1, 1.9 Nm, Size 2, 2.9 Nm,

and Size 2, 3.8 Nm Servo Drives

130BE671.10

130BE662.10

Specications

VLT® Integrated Servo Drive ISD® 510 System

6.1.8 Installation

6.1.8.1 Allowed Forces

Illustration 6.22 Allowed Forces

Illustration 6.21 Mounting of Size 2, 2.1 Nm Servo Drive

NOTICE

Do not machine the shaft. Do not use the servo drive if the shaft does not match the coupling arrangement.

Table 6.10 lists the tightening torque values for the xing screws. Always tighten the xing screws uniformly and crosswise.

NOTICE

Failure to adhere to the specications in Table 6.10 may result in damage to the servo drive.

Servo drive size Thread type/

hole size

Size 1, 1.5 Nm Size 2, 2.1 Nm M6 pitch 1 mm 23 mm 6 Nm Size 2, 2.9 Nm Size 2, 3.8 Nm

Table 6.10 Tightening Torques

∅ 5.8 mm

∅ 7 mm ∅ 7 mm

Maximum

thread length

– –

– – – –

Tightening

torque

NOTICE

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 size Radial Force (Fr) in N Axial Force (Fa) in N

Size 1 450 1050 Size 2 900 1700

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.

Innite 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 dierent speeds. The estimated life-span of the bearing with this condition is 20000 h.

100

200

300

400

500

0 100 200 300 400 500 600

600

Fa [N]

Fr [N]

130BF946.10

100

200

300

400

500

600

700

800

900

1000

1100

1200

0 200 400 600 800 1000 1200

130BF947.10

Fa [N]

Fr [N]

100

200

300

400

500

600

700

800

900

1000

1100

1200

0 200 400 600 800 1000 1200 1400

Fa [N]

Fr [N]

130BF948.10

100

200

300

400

500

600

700

800

900

1000

1100

1200

0 200 400 600 800 1000 1200 1400

130BF949.10

Fa [N]

Fr [N]

Specications Design Guide

Size 1, 1.5 Nm

1 500 RPM 2 1000 RPM 3 2000 RPM 4 3000 RPM 5 4000 RPM 6 5000 RPM

Illustration 6.23 Size 1, 1.5 Nm

Size 2, 2.9 Nm

1 500 RPM 2 1000 RPM 3 2000 RPM 4 3000 RPM

Illustration 6.25 Size 2, 2.9 Nm

Size 2, 3.8 Nm

Size 2, 2.1 Nm

1 500 RPM 2 1000 RPM 3 2000 RPM 4 3000 RPM 5 4000 RPM

Illustration 6.24 Size 2, 2.1 Nm

1 500 RPM 2 1000 RPM 3 2000 RPM 4 3000 RPM

Illustration 6.26 Size 2, 3.8 Nm

Specications

VLT® Integrated Servo Drive ISD® 510 System

6.1.8.3 Installation Safety and Warnings

General

The machine surface that comes in contact with

•

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 specic application.

The maintenance task for the shaft seal is

•

explained in Table 6.12.

Maintenance task Maintenance interval Instruction

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.

If damaged, replace the shaft seal.

190.5 (7.50)

268

(10.55)

371.5

(14.63)

130BE312.10

Specications Design Guide

6.2 SAB

6.2.1 Dimensions

All dimensions are in mm (in).

Front view

Illustration 6.27 Dimensions: Front View

246.4

(9.70)

11.5

(0.45)

218.7 (8.61)

130BE313.10

Specications

Side view

VLT® Integrated Servo Drive ISD® 510 System

Illustration 6.28 Dimensions: Side View

130BE423.10

130

862

5.5

110

6.5

752

Specications Design Guide

Mounting plate

Illustration 6.29 Dimensions: Mounting Plate

3 4

192021

2224 2325

130BE387.10

Specications

6.2.2 Clearance

The SABs can be mounted next to each other but

•

require a minimum space of 100 mm at the top and bottom for cooling.

In addition to its own dimensions, the SAB needs

•

100 mm space between the SAB decoupling plate and the cable duct for connecting cables.

6.2.3 Terminal Locations

VLT® Integrated Servo Drive ISD® 510 System

Illustration 6.30 Explosion Drawing of the Servo Access Box

Specications Design Guide

Number Description/connector name Name on

corresponding

connector

1 Local control panel (LCP) – 18 Hybrid cable line 2 – 2 Front cover – 19 Decoupling plate – 3 STO 1 IN: STO

(Used for STO input voltage 1)

4 STO 1 IN: 24 V

(Used for bridging when the STO function is not required, see chapter 6.2.3.1 STO Connectors)

5 LEDs for status of auxiliary output and

STO 6 Decoupling clamp for STO cable – 23 Relay 2 Relay 2 7 ISD Line 2: STO 2

(STO output to hybrid cable line 2) 8 ISD Line 2: NET 2 X4

(Ethernet output to hybrid cable line 2) 9 ISD Line 2: AUX 2

(Auxiliary output to hybrid cable line 2) 10 ISD Line 2: UDC 2

(UDC output to hybrid cable line 2) 11 ISD Line 1: STO 1

(STO output to hybrid cable line 1) 12 ISD Line 1: NET 1 X3

(Ethernet output to hybrid cable line 1) 13 ISD Line 1: AUX 1

(Auxiliary output to hybrid cable line 1)

14 ISD Line 1: UDC 1

(UDC output to hybrid cable line 1) 15 Grounding PE clamp for hybrid cable line2– 32 STO 2 IN: 24 V

16 Grounding PE clamp for hybrid cable line1– 33 Cover –

+STO– 20 Shielded cable grounding

+24V– 21 24/48 V IN

– 22 Relay 1 Relay 1

+STO– 24 Brake R– (81), R+ (82)

RJ45 connector (without label) +AUX– 26 Fixture for Ethernet inputs –

+UDC– 27 Decoupling clamp for encoder

+STO– 28 X1

RJ45 connector (without label) +AUX– 30 GND, 24 V, GX, /RS422 TXD,

+UDC– 31 STO 2 IN: STO

Number Description/connector name Name on

corresponding

connector

–

clamp and strain relief

+AUX–

(Auxiliary input terminal)

25 Mains

(Input terminal)

cable

(Ethernet input line 1)

29 X2

(Ethernet input line 2)

RS422 TXD, /RS422 RXD, RS422 RXD (Encoder terminal)

(Used for STO input voltage 2)

(Used for bridging when the STO function is not required, see chapter 6.2.3.1 STO Connectors)

L1 (91), L2 (92), L3 (93)

–

RJ45 connector (not included) RJ45 connector (not included) Not labeled

+STO–

+24V–

17 Hybrid cable line 1 – – – –

Table 6.13 Legend to Illustration 6.30

130BE393.10

+ STO –

130BE396.10

+ 24V –

130BE394.10

+ STO –

130BE388.10

L1 L2 L3

130BE706.10

Specications

VLT® Integrated Servo Drive ISD® 510 System

6.2.3.1 STO Connectors

Item Position

on SAB

STO

Front Used for STO 1 IN: STO STO

Front Used for STO 2 IN: STO

STO

Front These 1 IN: 24 V STO

Front 2 IN: 24 V

ISD

Underside Used for STO Line 1: STO 1 ISD

Underside Used for STO Line 2: STO 2

Description Drawing/

input voltage

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

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:

1.5 mm Nominal voltage: 24 V DC ±10% Nominal current: 1 A Maximum crosssection:

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:

0.5 mm

6.2.3.2 Mains Connectors

Item Description Drawing/

pins

AC mains supply

Mains PE (terminal

95)

Table 6.15 Mains Connectors

1 PE 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.

Pins (left to right): L1 L2 L3 – Minimum

Ratings

Nominal voltage: 400–480 V AC Nominal current:

12.5 A Maximum cross-section:

4 mm

cross-section:

10 mm

Table 6.14 STO Connectors

88 89 81 82

-DC +DC R- R+

130BE389.10

130BE390.10

RELAY 1

RELAY 2

130BE391.10

130BE392.10

GND

24 V

RS422 TXD

RS422 RXD

Specications Design Guide

6.2.3.3 Brake Connector

Item Description Drawing/pins Ratings

Brake Used for

connecting a

brake resistor

Nominal voltage: 565–778 V DC Maximum brake current:

–DC (88) = Do not use +DC (89) = Do not use R– (81) = Brake – R+ (82)= Brake +

14.25 A Maximum crosssection: 4 mm

Table 6.16 Brake Connector

NOTICE

The maximum length of the brake cable is 20 m (shielded).

6.2.3.4 Relay Connectors

Item Description Drawing/pins Ratings

6.2.3.5 Encoder Connectors

Item Description Drawing/pins Ratings

Encoder connector

Used to connect SSI or BiSS encoders.

Maximum crosssection:

0.5 mm2.

Pins (left to right on SAB label):

See Table 6.19.

RS422 RXD /RS422 RXD

RS422 TXD /RS422 TXD GX

24 V

GND

Table 6.18 Encoder Connectors

NOTICE

The maximum length of the encoder cable is 25 m (shielded).

Relay1Used for a customer-

dened reaction. For

example, the relay can be triggered if the SAB issues a warning.

Relay 2

Pins (left to right): 1: Common 2: Normally open 3: Normally closed

Pins (left to right): 4: Common 5: Normally open 6: Normally closed

Pin 1: Common Pin 2: 240 V AC Pin 3: 240 V AC Nominal current: 2 A Maximum crosssection: 2.5 mm

Pin 4: Common Pin 5: 400 V AC Pin 6: 240 V AC Nominal current: 2 A Maximum crosssection: 2.5 mm

Number Description Notes Rating/

parameter

SSI BiSS

1 RS422 RXD Positive data Bus speed: 2 /RS422 RXD Negative data 3 RS422 TXD Positive clock

4 /RS422 TXD Negative clock

SSI: 0.5 Mbit with 25 m cable BiSS: Fullls the RS485 speci-

cation

5 GX Isolated ground

–

If encoders are

powered externally, the

ground of the external

supply must be

connected to GX.

6 24 V

24 V DC ±10%

(used for powering the

encoder)

7 GND Ground for pin 6 –

Maximum current: 250 mA

Table 6.19 Pin Assignment for SSI and BiSS Encoders

Table 6.17 Relay Connectors

130BE395.10

130BE398.10

+ AUX –

130BE397.10

+ AUX –

130BE399.10

+ UDC –

Specications

VLT® Integrated Servo Drive ISD® 510 System

6.2.3.6 Ethernet Connectors

Connector

name

Ethernet X1 Connection to

Ethernet X2 Connection to

Ethernet X3 Connection to

Ethernet X4 Connection to

Table 6.20 Ethernet Connectors

Description Drawing/pins Ratings

Fulll the

eldbus

100BASE-T

specication

eldbus

Pins:

servo line 1

1: TD+ 2: TD–

servo line 2

3: RD+ 6: RD–

NOTICE

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

Description Drawing/

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

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

Item Description Drawing/pins Ratings

Hybrid cable PE

Table 6.24 Hybrid Cable PE

Description Drawing/

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:

2.5 mm

See callout 15 in Illustration 6.30.

Maximum crosssection:

2.5 mm

Table 6.21 AUX Connectors

6.2.3.8 24/48 V IN Connector

Connector

name

24/48 V IN Connector

Table 6.22 24/48 V IN Connector

Description Drawing/

pins

Used for 24– 48 V DC input to the SAB.

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: 34 A Maximum crosssection:

4 mm

Maximum

out

(%)

, M A X

Altitude (km)

t 100% I

out

100%

91%

82%

0 K

–5 K

–9 K

1 k m 2 k m 3 k

, M A X

)

Specications Design Guide

6.2.4 Characteristic Data

Denition Value and unit

Input

Input voltage Eciency 98.5% at 400 V Input current 12.5 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 power 8 kW at 400 V

Housing

Dimensions (W x H x D) 130 x 268 x 80 mm Weight 8.3 kg

400–480 V ±10%

20 A intermittent

565–679 V ±10%

24 V ±10%

24–48 V ±10%

15 A

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.

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 Specications and Environmental Considerations

Protection rating IP20 (UL rating: Open type) Vibration test Random 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 Specications 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.

130BE658.10

5 6 7 8

Danfoss ISD 510 Hybrid xxxx Cable

Length: xxxx

Ordering no. 175Gxxxx Rev. x.

1 7 5 G 8 9 X X

Specication no. 175Rxxxx Rev. xxx.

Signal rating Ethernet: 2 x 2 x AWG24 300V

yy.mm.dd

Power rating: 5 x 2.5mm 1000V 18A

Signal rating: 2 x 0.5mm 300V

120°

130BF953.10

Specications

VLT® Integrated Servo Drive ISD® 510 System

6.3 Cable

All cables supplied by Danfoss have a nameplate as per the example in Illustration 6.33.

1 Cable type 2 Ordering code 3 Revision of specication 4 Manufacturing date 5 Length 6 Power rating 7 Signal rating 8 Signal rating for Ethernet 9 Barcode 10 Manufacturer 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 qualied 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.

Connector Tightening torque [Nm]

M8 0.2 M12 0.4 M23 0.8

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

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 dier.

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

112

Rmin

130BF955.10

51.4

Rmin

65.5

140 min

130BF951.10

130BE383.10

Specications Design Guide

Each connector type requires specic 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

25 m

Description

Hybrid cable (overall shield with additional eldbus and safety section shield).

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

Bending Radius for M23 Straight Connector

•

M23 straight connector to M12 straight connector

•

See chapter 5.5.2 Fieldbus Cables for ordering numbers.

Specications

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 on the Servo Drives. Always use shielded cables.

Maximum length: 25 m (shielded)

•

Maximum cross-section: 0.5 mm

•

6.3.6 Ethernet Cable

See chapter 6.2.3.6 Ethernet Connectors for pin assignment.

Specication

Ethernet standard Standard Ethernet (in accordance with IEEE

802.3), 100Base-TX (Fast Ethernet)

Cable type S/FTP (shielded foiled twisted pair), ISO

(IEC 11801 or EN 50173), CAT 5e or 6 Damping 23.2 dB (at 100 Mhz and 100 m each) Crosstalk damping 24 dB (at 100 Mhz and 100 m each) Return loss 10 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.

Appendix Design Guide

7 Appendix

7.1 Glossary

A side

The A side is the shaft side of the servomotor.

Ambient temperature

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.

European test and certication mark.

CiA DS 402

Device prole 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 eciency and fast switching.

eldbus system.

Logo

7 7

Appendix

VLT® Integrated Servo Drive ISD® 510 System

Installation elevation

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

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.

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

denes a

standard for industrial control programming.

POU

Program organization unit. This can be a program, function block, or function.

PWM

Pulse width modulation.

Index Design Guide

Index

Aggressive atmospheres.................................................................... 35

Allowed forces....................................................................................... 62

Application examples......................................................................... 32

AUX connectors..................................................................................... 72

AUX power supply................................................................................ 48

Auxiliary power supply....................................................................... 44

Axial load................................................................................................. 62

Blind caps................................................................................................ 52

Block diagram

ISD 510 servo drive.......................................................................... 15

Servo Access Box.............................................................................. 15

Brake.......................................................................................................... 51

Brake connector.................................................................................... 71

Brake resistor.......................................................................................... 26

Cable specications

Encoder cable.................................................................................... 76

Ethernet cable................................................................................... 76

Feed-in cable (M23).................................................................. 51, 74

Fieldbus cable................................................................................... 52

Fieldbus extension cable............................................................... 75

LCP cable...................................................................................... 52, 76

Loop cable (M23)....................................................................... 52, 75

Nameplate.......................................................................................... 74

Sensor cable................................................................................ 52, 76

Cabling

EtherCAT® with redundancy........................................................ 14

Ethernet POWERLINK® with redundancy................................ 13

For 1 Ethernet POWERLINK® line................................................ 12

For 2 Ethernet POWERLINK® lines.............................................. 12

For more than 1 SAB....................................................................... 13

Maximum cable lengths................................................................ 47

Characteristic data

ISD 510 servo drive.......................................................................... 57

Servo Access Box.............................................................................. 73

Communication

DDS Toolbox...................................................................................... 22

EtherCAT®............................................................................................ 21

Ethernet POWERLINK®.................................................................... 22

Fieldbus............................................................................................... 21

Connectors on the ISD 510 servo drive........................................ 55

Connectors on the Servo Access Box

AUX....................................................................................................... 72

Brake..................................................................................................... 71

Encoder................................................................................................ 71

Ethernet X1–X4................................................................................. 72

Mains.................................................................................................... 70

PE........................................................................................................... 72

Relay.............................................................................................. 29, 71

STO........................................................................................................ 70

UDC....................................................................................................... 72

DDS Toolbox

Overview............................................................................................. 22

System requirements...................................................................... 22

User interface.................................................................................... 31

Derating

ISD 510 servo drive.......................................................................... 61

SAB........................................................................................................ 73

Dimensions

ISD 510 servo drive.......................................................................... 53

Servo Access Box.............................................................................. 65

Discharge time...................................................................................... 10

Drive congurator................................................................................ 50

Dust........................................................................................................... 36

ELCB........................................................................................................... 40

EMC

Earth leakage current..................................................................... 39

Emission requirements.................................................................. 36

Grounding for electrical safety.................................................... 38

Immunity requirements................................................................ 37

Interference........................................................................................ 39

Motor bearing currents.................................................................. 39

Overview............................................................................................. 36

Touch current.................................................................................... 40

Encoder............................................................................................. 28, 51

Encoder connector............................................................................... 71

Environmental conditions

ISD 510 servo drive.......................................................................... 58

SAB........................................................................................................ 73

EtherCAT®................................................................................................ 21

Ethernet connectors............................................................................ 72

Ethernet POWERLINK®........................................................................ 22

Fans in the SAB...................................................................................... 24

Faults......................................................................................................... 29

Feedback................................................................................................. 51

Feed-in cable (M23)............................................................................. 51

Fieldbus.................................................................................................... 21

Fieldbus cable........................................................................................ 52

Index

VLT® Integrated Servo Drive ISD® 510 System

Flange (customized)............................................................................ 51

Functional safety................................................................................... 16

Fuses.......................................................................................................... 43

Gases......................................................................................................... 35

Ground fault protection..................................................................... 24

Grounding

For electrical safety.......................................................................... 38

Harmonics............................................................................................... 43

High voltage warning..................................................................... 9, 74

Housing SAB........................................................................................... 73

Denition of ratings........................................................................ 41

ISD 510 servo drive.......................................................................... 41

Mounting positions......................................................................... 41

Servo Access Box.............................................................................. 41

IP rating

SAB........................................................................................................ 73

ISD 510 servo drive

Block diagram.................................................................................... 15

ISD 510 servo drive

Acoustic noise................................................................................... 34

Allowed forces................................................................................... 62

Ambient temperature.................................................................... 33

Bearing load curves......................................................................... 62

Characteristic data........................................................................... 57

Connectors......................................................................................... 55

Cooling................................................................................................ 33

Derating............................................................................................... 61

Dimensions........................................................................................ 53

Environmental conditions............................................................ 58

External interfaces........................................................................... 11

Flange sizes........................................................................................ 12

Humidity............................................................................................. 33

Installation safety and warnings................................................ 64

LEDs...................................................................................................... 29

Maintenance...................................................................................... 42

Motor and

Motor grounding............................................................................. 47

Motor output and data.................................................................. 58

Motor selection considerations.................................................. 47

Operating environment................................................................. 33

Options................................................................................................ 47

Overvoltage....................................................................................... 33

Speed-torque characteristics....................................................... 58

Terminal locations............................................................................ 55

Thermal protection......................................................................... 48

Tightening torques.......................................................................... 61

Types..................................................................................................... 50

Vibration and shock........................................................................ 34

X1 & X2 hybrid connectors........................................................... 55

X3 3rd Ethernet connector........................................................... 56

X4 I/O and/or encoder connector.............................................. 56

X5 LCP connector............................................................................. 57

ange sizes................................................................... 12

LCP

Cable..................................................................................................... 52

Mounting kit...................................................................................... 52

User interface.................................................................................... 31

LEDs on the ISD 510 servo drive

DRIVE STAT.......................................................................................... 29

Link/ACT X1........................................................................................ 30

Link/ACT X2........................................................................................ 30

Link/ACT X3........................................................................................ 30

NET STAT.............................................................................................. 29

LEDs on the Servo Access Box

Aux 1..................................................................................................... 30

Aux 2..................................................................................................... 30

Link/ACT X1........................................................................................ 30

Link/ACT X2........................................................................................ 31

Link/ACT X3........................................................................................ 31

Link/ACT X4........................................................................................ 31

NET STAT.............................................................................................. 30

SAB STAT.............................................................................................. 30

Safe 1.................................................................................................... 30

Safe 2.................................................................................................... 30

Libraries.................................................................................................... 31

Loop cable M23..................................................................................... 52

Index Design Guide

Mains conguration............................................................................ 43

Mains input............................................................................................. 43

Mains transients.................................................................................... 43

Maintenance.......................................................................................... 42

Motor bearing currents...................................................................... 39

Motor output and data....................................................................... 58

Motor selection considerations....................................................... 47

Operating environment

General................................................................................................. 35

ISD 510 servo drive.......................................................................... 33

SAB........................................................................................................ 34

Operation

Operating modes............................................................................. 23

Overview............................................................................................. 14

Sequence of operation.................................................................. 15

Switching on the ISD 510 servo system................................... 15

With SAB.............................................................................................. 14

Ordering information

Blind caps............................................................................................ 52

Brake..................................................................................................... 51

Customized ange........................................................................... 51

Feedback devices............................................................................. 51

Feed-in cable..................................................................................... 51

Fieldbus cable................................................................................... 52

ISD 510 servo drive.......................................................................... 50

LCP cable............................................................................................. 52

LCP mounting kit............................................................................. 52

Loop cable.......................................................................................... 52

SAB........................................................................................................ 51

Sensor cable....................................................................................... 52

Shaft seal............................................................................................. 51

PC-software............................................................................................ 22

PELV........................................................................................................... 41

Power supply.......................................................................................... 44

POWERLINK®........................................................................................... 22

Radial load............................................................................................... 62

Radio frequency interference.......................................................... 41

RCD............................................................................................................ 40

Relay connectors........................................................................... 29, 71

Resolver.................................................................................................... 51

Resources for ISD 510 servo system................................................. 7

Safety

Discharge time.................................................................................. 10

Grounding hazard.............................................................................. 9

High voltage.................................................................................. 9, 74

Instructions and precautions......................................................... 9

Unintended start................................................................................ 9

Sensor cable........................................................................................... 52

Sensors..................................................................................................... 49

Servo Access Box

Acoustic noise................................................................................... 35

Ambient temperature.................................................................... 34

AUX connectors................................................................................ 72

Block diagram.................................................................................... 15

Brake connector............................................................................... 71

Characteristic data........................................................................... 73

Clearance............................................................................................ 68

Cooling................................................................................................ 34

Derating............................................................................................... 73

Dimensions........................................................................................ 65

Eciency...................................................................................... 48, 73

Encoder connector.......................................................................... 71

Environmental conditions............................................................ 73

Ethernet connectors....................................................................... 72

Grounding.......................................................................................... 48

Humidity............................................................................................. 34

Input current...................................................................................... 73

Input voltage..................................................................................... 73

LEDs...................................................................................................... 30

Mains connectors............................................................................. 70

Maintenance...................................................................................... 42

Ordering numbers........................................................................... 51

Output voltage................................................................................. 73

Protection rating.............................................................................. 73

Relay connectors....................................................................... 29, 71

STO connectors................................................................................. 70

Terminal locations............................................................................ 68

Tightening torques.......................................................................... 73

UDC connectors................................................................................ 72

Vibration and shock........................................................................ 35

Weight.................................................................................................. 73

Shaft seal................................................................................................. 51

Short circuit protection...................................................................... 24

Specications

ISD 510 servo drive.......................................................................... 53

Servo Access Box.............................................................................. 65

STO (Safe Torque O)

Application example....................................................................... 20

Characteristic data........................................................................... 21

Connectors......................................................................................... 70

Installation.......................................................................................... 17

Overview............................................................................................. 16

Supply requirements...................................................................... 49

Storage..................................................................................................... 42

Switching on the ISD 510 servo system....................................... 15

System overview................................................................................... 11

SAB

Operating environment................................................................. 34

Thermal protection.............................................................................. 24

Index

Tightening torques

ISD 510 servo drive.......................................................................... 61

SAB........................................................................................................ 73

Touch current......................................................................................... 40

TwinCAT® NC Axis................................................................................. 31

VLT® Integrated Servo Drive ISD® 510 System

UDC connectors.................................................................................... 72

Unintended start..................................................................................... 9

User interfaces

DDS Toolbox...................................................................................... 31

LCP......................................................................................................... 31

Voltage warning............................................................................... 9, 74

Warnings

Discharge time.................................................................................. 10

High voltage.................................................................................. 9, 74

Unintended start................................................................................ 9

Weight

Brake..................................................................................................... 58

Servo Access Box.............................................................................. 73

Servo drive.......................................................................................... 58

Wiring........................................................................................................ 12

X1 & X2 hybrid connectors................................................................ 55

X3 3rd Ethernet connector................................................................ 56

X4 I/O and/or encoder connector.................................................. 56

X5 LCP connector................................................................................. 57

Index Design Guide

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 specications 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.

Danfoss A/S Ulsnaes 1 DK-6300 Graasten vlt-drives.danfoss.com

130R0694 MG36C102 08/2017

*MG36C102*

Danfoss ISD 510 Design guide

Specifications and Main Features

Frequently Asked Questions

User Manual