Danfoss VLT Integrated Servo Drive ISD 510 System Operating Instructions Manual

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MAKING MODERN LIVING POSSIBLE

Operating Instructions

VLT® Integrated Servo Drive ISD® 510 System

vlt-drives.danfoss.com

Contents Operating Instructions

Contents

1 Introduction

1.1 Purpose of the Operating Instructions

1.2 Additional Resources

1.3 Copyright

1.4 Approvals and Certications

1.5 System Overview

1.5.1 Areas of Application 8

1.6 Software

1.7 Terminology

2 Safety

2.1 Symbols Used in this Manual

2.2 General

2.3 Safety Instructions and Precautions

2.4 Important Safety Warnings

2.5 Qualied Personnel

2.6 Due Diligence

2.7 Intended Use

2.8 Foreseeable Misuse

2.9 Service and Support

3 System Description

3.1 Overview

3.2 Servo Drive

3.2.1 Servo Drive Types 14

3.2.2 Motor Components 14

3.2.2.1 Shaft 14

3.2.2.2 Brake (Optional) 14

3.2.2.3 Cooling 15

3.2.2.4 Thermal Protection 15

3.2.2.5 Built-In Feedback Devices 15

3.2.3 Drive Components 15

3.2.3.1 Connectors on the Servo Drives 15

3.3 Servo Access Box (SAB)

3.3.1 Connections on the SAB 19

3.3.1.1 STO Connectors 20

3.3.1.2 Mains Connectors 20

3.3.1.3 Brake Connectors 21

3.3.1.4 Relay Connectors 21

3.3.1.5 Encoder Connectors 21

Contents

VLT® Integrated Servo Drive ISD® 510 System

3.3.1.6 Ethernet Connectors (not included) 22

3.3.1.7 AUX Connectors 22

3.3.1.8 24/48 V IN Connector 22

3.3.1.9 UDC Connectors 22

3.3.1.10 Hybrid Cable PE 22

3.4 Local Control Panel (LCP)

3.4.1 Overview 23

3.4.2 Local Control Panel (LCP) Layout 23

3.5 Cables

3.5.1 Hybrid Cable 25

3.5.2 I/O and/or Encoder Cable 25

3.5.3 Additional Cables 25

3.6 Connection Cables/Cabling

3.6.1 Layout and Routing 26

3.6.1.1 Standard Cabling Concept for 2 Lines 26

3.6.1.2 Standard Cabling Concept for 1 Line 26

3.7 Software

3.8 Fieldbus

3.8.1 EtherCAT

3.8.2 Ethernet POWERLINK

4 Mechanical Installation

4.1 Transport and Delivery

4.1.1 Items Supplied 29

4.1.2 Transport 29

4.1.3 Inspection on Receipt 29

4.2 Safety Measures during Installation

4.3 Installation Environment

4.4 Preparation for Installation

4.4.1 Servo Drive 30

4.4.2 Servo Access Box (SAB) 31

4.5 Installation Procedure

4.5.1 Installation and Space Requirements 32

4.5.2 Installation Aids and Tools Required 32

4.5.3 Fitting Instructions Servo Drive 32

4.5.4 Tightening Torques 33

4.5.5 Fitting Instructions Servo Access Box (SAB) 33

5 Electrical Installation

5.1 Warnings

5.2 Electrical Environmental Conditions

Contents Operating Instructions

5.3 EMC-Compliant Installation

5.4 Grounding

5.5 Mains Supply Requirements

5.6 Auxiliary Supply Requirements

5.7 Safety Supply Requirements

5.8 Connecting the Components

5.8.1 Servo Access Box 37

5.8.2 Servo Drive 39

5.8.2.1 Connecting/Disconnecting Hybrid Cables 39

5.8.2.2 Connecting/Disconnecting Cables from Ports X3, X4, and X5 41

6 Commissioning

6.1 Pre-Commissioning Checklist

6.2 ID Assignment

6.2.1 EtherCAT

6.2.2 Ethernet POWERLINK

6.2.2.1 Single Device ID Assignment 43

6.2.2.2 Multiple Device ID Assignment 43

6.3 Switching on the ISD 510 Servo System

6.4 Basic Programming

6.4.1 Programming with Automation Studio™

6.4.1.1 Requirements 44

6.4.1.2 Creating an Automation Studio™ Project

6.4.1.3 Connecting to the PLC 48

6.4.2 Programming with TwinCAT

6.4.2.1 ISD Deliverables 48

6.4.2.2 Creating a TwinCAT® Project 48

6.4.2.3 Conguration as a TwinCAT® NC Axis 54

6.4.2.4 Connecting to the PLC 55

6.4.3 Programming Guidelines 55

6.5 ISD Toolbox

6.5.1 Overview 56

6.5.2 System Requirements 56

6.5.3 Installation 56

6.5.4 ISD Toolbox Communication 56

6.5.4.1 Network Settings for Indirect Communication 57

6.5.4.2 Network Settings for Direct Communication with Ethernet POWERLINK

6.5.4.3 Network Settings for Direct Communication with EtherCAT

6.5.5 ISD Toolbox Commissioning 60

6.6 Motion Library

Contents

VLT® Integrated Servo Drive ISD® 510 System

6.6.1 Function Blocks 62

6.6.2 Simple Programming Template 62

7 Operation

7.1 Operating Modes

7.1.1 Motion Functions 63

7.2 Operating Status Indicators

7.2.1 Operating LEDs on the Servo Drive 64

7.2.2 Operating LEDs on the Servo Access Box 64

8 ISD Safety Concept

8.1 Applied Standards and Compliance

8.2 Abbreviations and Conventions

8.3 Qualied Personnel for Working with the STO Function

8.4 Safety Precautions

8.5 Functional Description

8.6 Installation

8.7 Operation of the ISD Safety Concept

8.7.1 Statusword 68

8.7.2 Error Codes 69

8.8 Fault Reset

8.9 Commissioning Test

8.10 Application Example

8.11 Safety Function Characteristic Data

8.12 Maintenance, Security, and User Accessibility

9 Diagnostics

9.1 Faults

9.2 Servo Drive

9.2.1 Troubleshooting 74

9.2.2 Error Codes 75

9.3 Servo Access Box (SAB)

9.3.1 Troubleshooting 77

9.3.2 Error Codes 78

10 Maintenance, Decommissioning, and Disposal

10.1 Maintenance Tasks

10.2 Inspection during Operation

10.3 Repair

10.3.1 Cable Replacement 82

10.3.1.1 Feed-In Cable Replacement 82

10.3.1.2 Loop Cable Replacement 83

Contents Operating Instructions

10.4 Servo Drive Replacement

10.4.1 Dismounting 83

10.4.2 Fitting and Commissioning 83

10.5 SAB Replacement

10.5.1 Dismounting 83

10.5.2 Fitting and Commissioning 83

10.6 Decommissioning of the ISD 510 Servo System

10.7 Product Returns

10.8 Recycling and Disposal

10.8.1 Recycling 84

10.8.2 Disposal 84

11 Specications

11.1 Servo Drive

11.1.1 Nameplate 85

11.1.2 Characteristic Data 85

11.1.3 Dimensions 86

11.1.4 Permitted Forces 88

11.1.5 General Specications and Environmental Conditions 88

11.2 Servo Access Box

11.2.1 Nameplate 89

11.2.2 Characteristic Data 89

11.2.3 Dimensions 90

11.2.4 General Specications and Environmental Conditions 92

11.3 Cables

11.4 Storage

11.4.1 Long-Term Storage 92

12 Appendix

12.1 Glossary

Index

Introduction

VLT® Integrated Servo Drive ISD® 510 System

1 Introduction

1.1 Purpose of the Operating Instructions

The purpose of these operating instructions is to describe

the VLT® Integrated Servo Drive ISD® 510 System.

These operating instructions contain information about:

Installation

•

Commissioning

•

Programming

•

Operation

•

Troubleshooting

•

Service and maintenance

•

These operating instructions are intended for use by qualied personnel. Read it in full to use the ISD 510 servo system safely and professionally, and pay particular attention to the safety instructions and general warnings. These operating instructions are an integral part of the ISD 510 servo system and also contains important service information. Therefore, keep it available with the ISD 510 servo system at all times.

Compliance with the information in these operating instructions is a prerequisite for:

Trouble-free operation.

•

Recognition of product liability claims.

•

Therefore, read these operating instructions before working with the ISD 510 servo system.

Additional Resources

1.2

Available manuals for the ISD 510 servo system:

Document 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 Documents for the ISD 510 Servo System

Technical literature for Danfoss drives is also available online at vlt-drives.danfoss.com/Support/Technical-Documen- tation/.

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.

1.3

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

1.4 Approvals and Certications

The ISD 510 servo 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

IEC/EN

61800-5-2

IEC/EN 61508 Functional safety of electrical/electronical/

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

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

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

IEC/EN 62061 Safety of machinery - Functional safety of

IEC/EN

61326-3-1

UL508C UL Standard for Safety for Power Conversion

2006/42/EC Machinery Directive

2014/30/EU EMC Directive

2014/35/EU Low Voltage Directive

RoHS

(2002/95/EC)

Adjustable speed electrical power drive

systems.

Part 5-1: Safety requirements - Electrical,

thermal and energy.

Adjustable speed electrical power drive

systems.

Part 5-2: Safety requirements - Functional.

programmable electronic safety-related

systems.

control systems.

Part 1: General principles for design.

control systems.

Part 2: Validation.

machines.

Part 1: General requirements.

safety-related electrical, electronic, and

programmable electronic control systems.

Electrical equipment for measurement, control,

and laboratory use – EMC requirements.

Part 3-1: Immunity requirements for safety-

related systems and for equipment intended

to perform safety-related functions (functional

safety) – General industrial applications.

Equipment.

Restriction of hazardous substances.

AUX 1

Status

Hand

O

Reset

Auto On

Back

Cancel

Info

Quick Menu

Main Menu

Alarm Log

AUX 2 SAFE 1 SAFE 2

Status

Hand On

O Reset

Auto On

Back

Cancel

Info

Quick Menu

Main Menu

Alarm Log

LCP

SAB

400-480 V AC

ISD 510

2 3 n

UDC + Real-Time Ethernet Bus + STO + U

AUX

. . .

130BE384.10

Real-Time Ethernet

Introduction Operating Instructions

EtherCAT

Ethernet for Control Automation Technology.

Ethernet-based eldbus system (see

chapter 12.1 Glossary for further information).

Ethernet

POWERLINK

PLCopen

Ethernet-based eldbus system:

Technical specication.

Function blocks for motion control (formerly

Part 1 and Part 2) Version 2.0 March 17, 2011.

Table 1.2 Approvals and Certications

1.5 System Overview

Illustration 1.1 Overview of the ISD 510 Servo System

The servo drives are self-contained distributed drives, whereby the drive electronics is housed together with the motor in the same casing. There are 2 versions of the ISD 510 servo drive:

1 1

Standard With 2 hybrid connectors (M23) that connect power

and communication signals from a hybrid cable.

Advanced As standard plus 3 additional interfaces for external

encoder or I/Os, eldbus devices, and for the local

control panel (LCP) to be connected directly.

Table 1.3 ISD 510 Servo Drive Versions

In this decentral system, the servo drives are operated in a DC group and controlled by a PLC. The motion control software runs independently in the servo drive, reducing the load on the PLC. The ISD 510 servo system requires hybrid cables that contain the DC supply voltage, the Real-Time Ethernet, U

, and STO signals.

AUX

The Servo Access Box (SAB®) is the central power supply for the ISD 510 servo system.

The ISD 510 servo system is designed to accommodate up to 64 ISD 510 servo drives and consists of:

ISD 510 servo drives

•

Servo Access Box (SAB)

•

1 PLC (not included)

•

Cabling

•

Blind caps

•

Software:

•

Introduction

VLT® Integrated Servo Drive ISD® 510 System

- Firmware for the servo drive

- Firmware for the SAB

- PC software tool: ISD Toolbox

- PLC libraries

Danfoss Motion library for VLT

•

Integrated Servo Drive ISD 510 system for AutomationStudio™

Danfoss Motion library for VLT

•

Integrated Servo Drive ISD 510

system for TwinCAT® 2

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.

1.5.1 Areas of Application

Potential areas of application are:

Food and beverage machines

•

Packaging machines

•

Pharmaceutical machines

•

Applications running with a group of decentral

•

servo drives.

Software

1.6

Updates to the rmware, ISD Toolbox software, and PLC libraries may be available. When updates are available, they can be downloaded from the danfoss.com website. The ISD Toolbox software or the PLC libraries can be used to install the rmware on the servo drives or on the SAB.

Terminology

1.7

ISD Integrated servo drive

ISD 510 Servo

Drive

VLT® Servo Access

Box (SAB)

PLC External device for controlling the ISD 510

Loop cable Hybrid cable for connecting drives in daisy-

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

Table 1.4 Terminology

Decentral servo drive

Unit that generates the DC-link voltage and

passes the U

signals to the ISD 510 servo drives via a

hybrid cable.

servo system.

chain format.

the 1st servo drive.

, Real-Time Ethernet, and STO

AUX

An explanation of all terminology and abbreviations can be found in chapter 12.1 Glossary.

Safety Operating Instructions

2 Safety

2.1 Symbols Used in this Manual

The following symbols are used in this manual:

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.

2.2 General

The following safety instructions and precautions relate to the ISD 510 servo 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.

2.3 Safety Instructions and Precautions

Compliance with the safety instructions and precautions is necessary at all times.

Orderly and proper transport, storage,

•

installation, as well as careful operation and maintenance, are essential for the trouble-free and safe operation of the ISD 510 servo system and its components.

Only suitably trained and qualied personnel may

•

work on the ISD 510 servo system and its components or in its vicinity. See chapter 2.5 Qualied Personnel.

tting, and

Only use accessories and spare parts approved by

•

Danfoss.

Comply with the specied ambient conditions.

•

For further information, see chapter 11.1.5 General

Specications and Environmental Conditions and chapter 11.2.4 General Specications and Environmental Conditions.

The information in this manual about the use of

•

available components is provided solely by way of examples of applications and suggestions.

The plant engineer or system engineer is

•

personally responsible for checking the suitability of the supplied components and the information provided in this manual for the specic application concerned:

- For compliance with the safety regulations and standards relevant to the specic application.

- For implementing the necessary measures, changes, and extensions.

Commissioning the ISD 510 servo system or its

•

components is not allowed until it has been ascertained that the machine, system, or plant in which they are installed conforms to the statutory provisions, safety regulations, and standards that apply to the application in the country of use.

Operation is only allowed in compliance with the

•

national EMC regulations for the application concerned.

Compliance with the limit values specied by

•

national regulations is the responsibility of the producer of the plant, system, or machine.

Compliance with the specications, connection

•

conditions, and installation conditions in this manual is mandatory.

The safety regulations and safety provisions of

•

the country in which the equipment is used must be observed.

To protect the user against electrical shock and to

•

protect the servo drive and the SAB against overload, protective grounding is obligatory and must be performed in accordance with local and national regulations.

2 2

Safety

VLT® Integrated Servo Drive ISD® 510 System

WARNING

the discharge safety warning in chapter 2.4 Important Safety Warnings).

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.

Operational safety

Safety-related applications are only allowed if

•

they are explicitly and unambiguously mentioned in this manual.

All applications that can cause hazards to people

•

or damage to property are safety-related applications.

The stop functions implemented in the software

•

of the PLC do not interrupt the mains supply to the SAB. Therefore, they must not be used as safety switches for the ISD 510 servo system.

The servo drive can be brought to a stop by a

•

software command or a zero speed setpoint, however DC voltage remains present on the servo drive and/or mains voltage in the SAB. Also when the servo drive is stopped, it may start up again on its own if the circuitry of the servo drive is defective or after the elimination of a temporary overload, a problem with the supply voltage, or a problem with the servo drive. If personal safety considerations (for example, risk of personal injury caused by contact with moving machine parts after an unintended start) make it necessary to ensure that an unintended start cannot occur, these stop functions are not case, ensure that the ISD 510 servo system is detached from the mains network, or that a suitable stop function is implemented.

The servo drive may start running unintentionally

•

during parameter conguration or programming. If this poses a risk to personal safety (for example, risk of personal injury due to contact with moving machine parts), prevent unintended motor starting, for example by using the Safe Torque O function, or by safe disconnection of the servo drives.

In addition to the L1, L2, and L3 supply voltage

•

inputs on the SAB, the ISD 510 servo system has other supply voltage inputs, including external auxiliary voltage. Before commencing repair work, check that all supply voltage inputs have been switched o and that the necessary discharge time for the DC-link capacitors has elapsed (see

sucient. In this

2.4 Important Safety Warnings

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

•

may only be performed by qualied personnel (see chapter 2.5 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

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 2.1 for the capacitors to fully discharge before carrying out any maintenance or repair work on the ISD 510 servo system or its components.

Safety Operating Instructions

Number Minimum waiting time (minutes)

0–64 servo drives 10

Table 2.1 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.

2.5 Qualied Personnel

Installation, commissioning, and maintenance of the ISD 510 servo system may only be carried out by qualied personnel. For the purposes of this manual and the safety instructions in this manual, qualied personnel are trained personnel who are authorized to t, install, commission, ground, and label equipment, systems, and circuits in accordance with the standards for safety technology and who are familiar with the safety concepts of automation engineering. Additionally, the personnel must be familiar with all the instructions and safety measures described in this manual. They must have suitable safety equipment and be trained in rst aid.

Due Diligence

2.6

The operator and/or fabricator must ensure that:

The ISD 510 servo system and its components are

•

used only as intended.

The components are operated only in a perfect

•

operational condition.

The operating instructions are always available

•

near the ISD 510 servo system in complete and readable form.

The ISD 510 servo system and its components are

•

tted, installed, commissioned, and maintained only by adequately qualied and authorized personnel.

These personnel are regularly instructed on all

•

relevant matters of occupational safety and environmental protection, as well as the contents of the operating instructions and the instructions it contains.

The product markings and identication markings

•

applied to the components, as well as safety and warning instructions, are not removed and are always kept in a legible condition.

The national and international regulations

•

regarding the control of machinery and equipment, that are applicable at the place of use of the ISD 510 servo system, are complied with.

The users always have all current information

•

relevant to their interests about the ISD 510 servo system and its use and operation.

2.7 Intended Use

The components of the ISD 510 servo system are intended to be installed in machines used in industrial environments in accordance with local laws and standards.

NOTICE

In a domestic environment, this product may cause radio interferences, in which case supplementary mitigation measures may be required.

To ensure that the product is used as intended, the following conditions must be fullled before use:

Everyone who uses Danfoss products in any

•

manner must read and understand the corresponding safety regulations and the description of the intended use.

Hardware must be left in its original state.

•

Software products must not be reverse-

•

engineered and their source code must not be altered.

Damaged or faulty products must not be installed

•

or put into operation.

It must be ensured that the products are installed

•

in conformance with the regulations mentioned in the documentation.

Any specied maintenance and service intervals

•

must be observed.

All protective measures must be complied with.

•

Only the components described in these

•

operating instructions may be tted or installed. Third-party devices and equipment may be used only in consultation with Danfoss.

The ISD 510 servo system may not be used in the following application areas:

Areas with potentially explosive atmospheres.

•

Mobile or portable systems.

•

Floating or airborne systems.

•

Inhabited facilities.

•

Sites where radioactive materials are present.

•

2 2

Safety

Areas with extreme temperature variations or in

•

which the maximum rated temperatures may be exceeded.

•

Under water.

VLT® Integrated Servo Drive ISD® 510 System

2.8 Foreseeable Misuse

Any use not expressly approved by Danfoss constitutes misuse. This also applies to failure to comply with the specied operating conditions and applications. Danfoss assumes no liability of any sort for damage attributable to improper use.

2.9 Service and Support

Contact the local service representative for service and support:

vlt-drives.danfoss.com/Support/Service/

130BE385.10

System Description Operating Instructions

3 System Description

3.1 Overview

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 drives in a servo drive system when using 2 hybrid lines. It generates a DClink 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 drives, making installation fast and simple. These hybrid cables contain the DC-link supply, the Real-Time Ethernet, U signals.

Servo Drive

3.2

oers benets in

and STO

AUX

encoder or I/Os, eldbus devices, and for the local control panel (LCP) to be connected directly.

3 3

LEDs on the top of the servo drive show the current status (see chapter 7.2 Operating Status Indicators for further information). Data transfer takes place via Real-Time Ethernet.

1 Operating LEDs (see chapter 7.2.1 Operating LEDs on the Servo

Drive for further information).

2 Connectors

Illustration 3.1 ISD 510 Servo Drive

The ISD 510 servo drive has the following ange sizes: 76 mm, 84 mm.

ISD is the abbreviation of integrated servo drive, which is a compact drive with an integrated permanent magnet synchronous motor (PMSM). This means 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 main 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

Further ange sizes of 108 mm and 138 mm are in planning.

Size 1,

1.5 Nm

Flange size 76 mm 84 mm

Table 3.1 Motor and Flange Sizes

All dimensions of the servo drive are listed in chapter 11.1.3 Dimensions.

Size 2,

2.1 Nm

Size 2,

2.9 Nm

Size 2,

3.8 Nm

System Description

VLT® Integrated Servo Drive ISD® 510 System

3.2.1 Servo Drive Types

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 3.2 Type Code

[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

VLT® Integrated Servo Drive

ISD® 510

Ethernet POWERLINK

EtherCAT

PROFINET

Ethernet/IP

Functional safety

108 mm

138 mm

®1)

™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

Table 3.3 Legend to Type code

1) In preparation

3.2.2 Motor Components

3.2.2.1 Shaft

3.2.2.2 Brake (Optional)

The optional mechanical holding brake is designed as a single-disc brake. The emergency stop function can be

The shaft transfers the motor force (torque) to the machine coupled to the shaft. The shaft material is C45+C or equivalent according to EN 10277-2. The ISD 510 servo drives can be sealed by a shaft seal (optional) to achieve IP65 on the A-side of the motor (see

chapter 11.1.5 General Specications and Environmental Conditions for further information).

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.

Electrical data: Power consumption:

Size 1: 1.5 W

•

Size 2: 1.8 W

•

130BE386.10

System Description Operating Instructions

NOTICE

Do not misuse the holding brake as a working brake because this causes increased wear, resulting in premature failure.

NOTICE

Using servo drives with brakes can reduce the number of drives allowed, depending on the total length of each

hybrid line. See the shell diagram in the VLT® Integrated

Servo Drive ISD® 510 System Design Guide for further information.

3.2.2.3 Cooling

The servo drives are self-cooling.

Cooling (heat dispersal) is primarily via the ange, with a small amount dispersed by the housing.

3.2.2.4 Thermal Protection

Thermal sensors monitor the maximum allowable temperature of the motor winding and switch the motor o if the limit of 140 °C is exceeded. Thermal sensors are also present in the drive to protect the electronics against overtemperature. An error message is sent via Real-Time Ethernet to the higher-level PLC and is also shown on the LCP.

3.2.2.5 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 3.4 summarizes the characteristic data of each variant.

3.2.3 Drive Components

3.2.3.1 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.

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

only)

X5 (advanced version

only)

Illustration 3.2 Connectors on the ISD 510 Servo Drive

M8 Ethernet cable (minimum CAT5,

shielded)

M12 I/O and/or encoder cable (shielded)

M8 LCP cable (shielded)

3 3

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

Table 3.4 Characteristic Data of Available Feedback Devices

±10 arc min ±1.6 arc min ±1.6 arc min

– – 4096 (12 bit)

Multi-turn

encoder

130BE381.10

130BE382.10

130BE435.10

System Description

VLT® Integrated Servo Drive ISD® 510 System

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 3.3 X1: Male Hybrid Connector (M23)

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

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

Table 3.5 Pin Assignment of X1 and X2 Hybrid Connectors (M23)

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

The ISD 510 advanced servo drive has an additional eldbus port (M8) for connecting a device that communicates via the selected eldbus.

Illustration 3.4 X2: Female Connector (M23)

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 3.5 Pin Assignment of X3 3rd Ethernet Connector

(M8, 4 pole)

According to standard

100BASE-T

130BE433.10

130BE434.10

System Description Operating Instructions

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

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 3.6 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

Illustration 3.7 Pin Assignment of X5 LCP Connector

(M8, 6-pole)

Speed:

38.4 kBd

The levels

fulll the

RS485 speci-

cation.

5 V ±10% at

120 mA

maximum load

3 3

3 4

192021

2224 2325

130BE387.10

System Description

VLT® Integrated Servo Drive ISD® 510 System

3.3 Servo Access Box (SAB)

The SAB is the power supply and central interface/gateway to the ISD 510 servo system. It guarantees the connection of the servo drives to the eldbus, generates the DC-link voltage for the ISD 510 servo system, and delivers a high-density output. It can be controlled using the local control panel (LCP) or via Ethernet-based eldbus. The LEDs on the front of the unit show the operating status and warnings (see chapter 7.2.2 Operating LEDs on the Servo

Access Box for further information).

NOTICE

The SAB has an IP-rating of IP20. It is only designed for use within a control cabinet. The SAB may be damaged if exposed to uids.

All power and signal cables are wired into the SAB and 2 independent lines of servo drives can be connected.

Service functions, such as voltage measuring, are performed by the SAB.

Illustration 3.8 Explosion Drawing of the Servo Access Box

System Description Operating Instructions

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 3.3.1.1 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 Decoupling xture for Ethernet

+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)

inputs

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 3.3.1.1 STO

Connectors)

L1 (91), L2 (92), L3

(93)

–

RJ45 connector

(not included)

RJ45 connector

(not included)

Not labeled

+STO–

+24V–

3 3

17 Hybrid cable line 1 – – – –

Table 3.6 Legend to Illustration 3.8

3.3.1 Connections on the SAB

All required connectors are included with the SAB.

All cabling must comply with national and local regulations on cable cross-sections and ambient temperature. Use shielded/armored cables to comply with EMC emission

specications.

130BE393.10

+ STO –

130BE396.10

+ 24V –

130BE394.10

+ STO –

130BE388.10

L1 L2 L3

130BE706.10

System Description

VLT® Integrated Servo Drive ISD® 510 System

3.3.1.1 STO Connectors

Item Position

on SAB

STO

Front Used for STO

1 IN:

STO

Front Used for STO

2 IN:

STO

Front These

1 IN:

24 V

STO

Front

2 IN:

24 V

Description Drawing/

pins

input voltage

Pins (left

to right):

STO+

STO-

connectors can

only be used

to make a

bridge to STO

1 IN: STO and

STO 2 IN: STO

if the STO

Pins (left

to right):

24+

24-

Ratings

Nominal voltage:

24 V DC ±10%

Nominal current:

Depends on the

number of servo

drives in the

application.

Maximum current:

1 A

Maximum cross-

section:

1.5 mm

Nominal voltage:

24 V DC ±10%

Nominal current:

1 A

Maximum cross-

section:

1.5 mm

3.3.1.2 Mains Connectors

Item Description Drawing/

pins

mains

supply

MainsPEThe PE screw is

Used to connect

L1/L2/L3

Pins (left

to right):

– Cross-section:

used to connect

the protective

earth, see

Illustration 3.9.

Table 3.8 Mains Connectors

Ratings

Nominal voltage:

400–480 V AC

Nominal current:

12.5 A

Maximum cross-section:

4 mm

10 mm

See

chapter 5.4 Grounding for

further information.

function is not

required in the

application.

This connector

cannot be

used for any

other function.

ISD

Underside Used for STO

Line

STO

ISD

Underside Used for STO

Line

STO

output voltage

Pins (left

to right):

STO+

STO-

Nominal voltage:

24 V DC ±10%

Nominal current:

Depends on the

number of servo

drives in the

application.

Maximum current:

1 A

Maximum cross-

1 PE screw

section:

0.5 mm

Illustration 3.9 PE Screw

Table 3.7 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

System Description Operating Instructions

3.3.1.3 Brake Connectors

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 cross-

section:

4 mm

Table 3.9 Brake Connectors

NOTICE

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

3.3.1.4 Relay Connectors

Item Description Drawing/pins Ratings

3.3.1.5 Encoder Connectors

Item Description Drawing/pins Ratings

Encoder

connector

Used to

connect SSI or

BiSS encoders.

Maximum

cross-

section:

3 3

0.5 mm2.

Pins (left to right

on SAB label):

See

Table 3.12.

RS422 RXD

/RS422 RXD

RS422 TXD

/RS422 TXD

24 V

GND

Table 3.11 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

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 cross-

section: 2.5 mm

Pin 4: Common

Pin 5: 400 V AC

Pin 6: 240 V AC

Nominal current:

2 A

Maximum cross-

section: 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 3.12 Pin Assignment for SSI and BiSS Encoders

Table 3.10 Relay Connectors

130BE395.10

130BE398.10

+ AUX –

130BE397.10

+ AUX –

130BE399.10

+ UDC –

System Description

VLT® Integrated Servo Drive ISD® 510 System

3.3.1.6 Ethernet Connectors (not included)

Connector

name

Ethernet X1 Connection to

Ethernet X2 Connection to

Ethernet X3 Connection to

Ethernet X4 Connection to

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–

3.3.1.8 24/48 V IN Connector

Connector

name

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 cross-

Table 3.13 Ethernet Connectors

NOTICE

The maximum length of the X1 and X2 shielded Ethernet cables is 30 m.

3.3.1.7 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 cross-

section: 2.5 mm

Table 3.15 24/48 V IN Connector

3.3.1.9 UDC Connectors

Connector

name

ISD Line 1:

UDC 1

ISD Line 2:

UDC 2

Description Drawing/

Used to connect

the DC-link

voltage from the

SAB to the

hybrid cable.

pins

Pins (left to

right):

UDC+

UDC–

section:

4 mm

Maximum cable

length: 3 m

Ratings

Nominal voltage:

565–778 V DC

Nominal current:

Depends on the

number of servo

drives in the

application

Maximum current:

15 A

Maximum cross-

section:

Table 3.14 AUX Connectors

2.5 mm

Table 3.16 UDC Connectors

3.3.1.10 Hybrid Cable PE

Item Description Drawing/pins Ratings

Hybrid

cable PE

Table 3.17 Hybrid Cable PE

Used to connect the

PE wire from the

hybrid cable to the

decoupling plate.

See callout 15 in

Illustration 3.8.

Maximum

cross-

section:

2.5 mm

130BE692.11

Auto

Reset

Hand

O

Status

Quick Menu

Main

Alarm

Log

Back

Cancel

Info

Status

271°

2850 RPM

Alarm

Warn.

38 °C

3.1 Nm

1.8 A

18 19 20 21

System Description Operating Instructions

3.4 Local Control Panel (LCP)

3.4.1 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 D-SUB 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. 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).

3.4.2 Local Control Panel (LCP) Layout

The local control panel is divided into 4 functional groups (see Illustration 3.10).

A. Display area.

B. Display menu keys.

C. Navigation keys and indicator lights (LEDs).

D. Operation keys and reset.

A. Display area

The values in the display area dier depending on whether the LCP is connected to an ISD 510 servo drive or the SAB as shown in Illustration 3.10 and Illustration 3.11.

The display area is activated when the ISD 510 servo drive or SAB it is connected to receives power from the mains supply, a DC bus terminal, or U

AUX

3 3

1 Actual torque

2 Temperature drive module

3 Position

4 Speed

5 Current

Display Description

Illustration 3.10 Display Area when Connected to an ISD 510

Servo Drive

130BE693.11

Auto

Reset

Hand

O

Status

Quick Menu

Main

Alarm

Log

Back

Cancel

Info

Status

11.5 A

2.1 kW

Alarm

Warn.

38 °C

24 V

565 V

18 19 20 21

System Description

VLT® Integrated Servo Drive ISD® 510 System

C. Navigation keys and indicator lights (LEDs)

Navigation keys are used for moving the display cursor and provide operation control in local operation. There are also 3 status LEDs in this area.

Key Function

Display Description

1 U

2 Temperature

3 Actual UDC (current)

4 ISD power consumption

5 Actual UDC (voltage)

Illustration 3.11 Display Area when Connected to the SAB

line voltage

AUX

10 Back Reverts to the previous step or list in the

menu structure.

11 Cancel Cancels the last change or command as long

as the display mode is not changed.

12 Info Press for a denition of the function being

shown.

13 Navigation

keys

Use the 4 navigation keys to move between

items in the menu.

14 OK Use to access parameter groups or to enable

a selection.

Table 3.19 Navigation Keys

LED Color Function

15 On Green The On LED activates when the

ISD 510 servo drive or SAB it is

connected to receives power from

the mains or auxiliary supply, or a

DC bus terminal.

16 Warn Yellow When warning conditions are met,

the yellow Warn LED activates and

text appears in the display area

identifying the problem.

17 Alarm Red A fault condition causes the red

Alarm LED to ash and an alarm

text is shown.

Table 3.20 Indicator Lights (LEDs)

B. Display menu keys

Menu keys are used for menu access for parameter set-up, toggling through status display modes during normal operation, and viewing fault log data.

Key Function

6 Status Shows operational information.

7 Quick Menu Allows access to parameters.

8 Main Menu Allows access to parameters.

9 Alarm Log Shows the last 10 alarms.

Table 3.18 Display Menu Keys

130BE383.10

System Description Operating Instructions

D. Operation keys and reset

Operation keys are located at the bottom of the LCP.

Key Function

18 Hand On Enables the connected ISD 510 servo drive

or SAB to be controlled via the LCP.

Switching between Hand On and Auto On

modes is only possible in certain states (see

the VLT® Integrated Servo Drive ISD® 510

System Programming Guide for further

information).

19 O Puts the SAB into state Standby and the

drive to state Switch on Disabled.

This only works in Hand On mode.

O mode enables transition from Hand On

mode to Auto On mode.

20 Auto On Puts the system in remote operational mode.

In Auto On mode, the device is controlled

•

by eldbus (PLC).

Note that switching between Auto On

and Hand On modes is only possible

when the drive is in state Switch on

disabled and/or the SAB is in state

Standby.

21 Reset Resets the ISD 510 servo drive or SAB after a

fault has been cleared.

The reset is only possible when in Hand On

mode

Table 3.21 Operation Keys and Reset

Both ends of the loop cable are tted with M23 connectors.

The feed-in cable is tted with an M23 connector at the output end for connection to the 1st servo drive. At the input end it is pigtailed with individual connectors for connection to the corresponding terminals on the SAB.

Minimum bending radius

The maximum number of bending cycles is 5 million at

7.5 x cable diameter (15.6 mm).

Permanently exible: 12 x cable diameter

•

Permanently installed: 5 x cable diameter

•

Description Shielded/

unshielded

Feed-in

cable

Loop cable Shielded

Shielded

Maximum

cable

length

40 m

25 m

Port Notes

Signal/

control

Signal/

control

Hybrid cable

(overall shield

with additional

eldbus and

safety section

shield).

Hybrid cable

(overall shield

with additional

eldbus and

safety section

shield).

3 3

NOTICE

To adjust the display contrast, press [Status] and the [▲]/[▼] keys.

3.5 Cables

3.5.1 Hybrid Cable

Illustration 3.12 Hybrid Loop Cable

There are 2 types of hybrid cables that are available with both angled and straight M23 connectors:

Feed-in cable for connecting the 1st servo drive of

•

a group to the connection point on the SAB.

Loop cable for connecting the ISD 510 servo

•

drives in daisy-chain format in an application.

Both these cables are provided by Danfoss and are

available in various lengths. See the VLT® Integrated Servo

Drive ISD® 510 System Design Guide for further information.

Table 3.22 Hybrid Cables

1) Maximum 100 m total length for each line.

3.5.2 I/O and/or Encoder Cable

This cable connects the I/O and/or encoder to the servo drive (see X4 in chapter 3.2.3.1 Connectors on the Servo Drives). The cable is not included with the servo drives. I/O and/or encoder cables with M12 connectors can be used for the ISD 510 servo system if they comply with the form factor dened in IEC 61076-2-101.

3.5.3 Additional Cables

Fieldbus extension cable

If this cable is not used, t the M23 blind cap to the X2 female connector on the last servo drive in the application.

LCP cables

There are 2 kinds of cable for the LCP module that can be

purchased from Danfoss (see the VLT® Integrated Servo

Drive ISD® 510 System Design Guide):

To connect the LCP to the servo drive.

•

To connect the LCP to the SAB.

•

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

. . .

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

. . .

System Description

VLT® Integrated Servo Drive ISD® 510 System

3.6 Connection Cables/Cabling

3.6.1.1 Standard Cabling Concept for 2 Lines

3.6.1 Layout and Routing

The servo drives are interconnected by hybrid loop cables. A hybrid feed-in cable with quick-release connectors

provides the supply voltage from the SAB to the 1st servo drive.

Routing in drag chains

The hybrid cable is compatible with drag chains and therefore suitable for use in moving systems. The number of bending cycles is dependent on individual conditions and must therefore be determined in advance for each application, see chapter 3.5.1 Hybrid Cable for further information.

Maximum cable lengths

M23 Feed-in cable 40 m

M23 Loop cable 25 m

Fieldbus extension cable Length: 2 m

Maximum length to next port:

100 m

Maximum cable length per line 100 m

Table 3.23 Maximum Cable Lengths

1 M23 Feed-in cable

2 M23 Loop cable

Chapter 3.6.1.1 Standard Cabling Concept for 2 Lines and chapter 3.6.1.2 Standard Cabling Concept for 1 Line show the

standard cabling concept without redundancy that can be used to connect 1 or 2 lines, each with up to 32 servo drives in an application.

NOTICE

For cabling with redundancy, see the VLT® Integrated

Servo Drive ISD® 510 System Design Guide.

Illustration 3.13 Standard Cabling Concept for 2 Lines

3.6.1.2 Standard Cabling Concept for 1 Line

1 M23 Feed-in cable

2 M23 Loop cable

Illustration 3.14 Standard Cabling Concept for 1 Line

EtherCAT

Slave Controller

(ESC)

OUT

Port 1 (B)

OUT

Port 2 (C)

Port 0 (A)

X2X1

130BE695.10

System Description Operating Instructions

3.7 Software

The software for the ISD 510 servo system comprises:

The rmware of the VLT® Integrated Servo Drive

•

ISD® 510 that is already installed on the device and provides the functionality described in chapter 7 Operation.

rmware of the VLT® Servo Access Box that is

The

•

already installed on the device.

A package of PLC libraries for Automation

•

Studio™ for operating the ISD 510 devices (see

chapter 6.4.1 Programming with Automation Studio™ for further information).

A PLC library for TwinCAT® 2 for operating the

•

ISD 510 devices (see chapter 6.4.2 Programming

with TwinCAT

ISD Toolbox: A Danfoss PC-based software tool for

•

commissioning and debugging the devices (see chapter 6.5 ISD Toolbox for further information).

for further information).

3.8 Fieldbus

The ISD 510 servo system has an open system architecture realized by fast Ethernet (100BASE-T) based communi-

cation. The system supports both EtherCAT® and Ethernet

POWERLINK®

ISD® 510 System Programming Guide for further information.

eldbuses. See the VLT® Integrated Servo Drive

3.8.1

EtherCAT

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

eldbuses. See the VLT® Integrated Servo Drive

both

ISD® 510 System Design Guide for further information.

The EtherCAT® port assignment for the servo drive and SAB are shown in Illustration 3.15 and Illustration 3.16.

3 3

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 ISD library (available for TwinCAT® and

•

Automation Studio™).

Using the NC axis functionality of TwinCAT®.

•

Using the CANopen® CiA DS 402 standard by

•

reading and writing to objects.

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.

certied for both

The servo drive and the SAB are eldbuses according to the corresponding rules and

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

X1 M23 hybrid cable connector to SAB or previous servo drive.

X2 M23 hybrid cable connector to the next servo drive.

M8 Ethernet cable connector to other EtherCAT® slaves, for

example EtherCAT® encoder.

The connector is only available on the advanced servo drive.

Illustration 3.15 EtherCAT® Port Assignment for the 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 Description

VLT® Integrated Servo Drive ISD® 510 System

X1 RJ45 cable connector to the PLC or previous slave.

X2 RJ45 cable connector to the PLC or next slave.

RJ45 to M23 hybrid adapter cable to the 1st servo drive on

line 1.

RJ45 to M23 hybrid adapter cable to the 1st servo drive on

line 2.

1 Ports always connected internally in the SAB.

Illustration 3.16 EtherCAT® Port Assignment for the SAB in

Line Topology Mode (default)

3.8.2

Ethernet POWERLINK

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

Work as controlled node.

•

Can be operated as multiplexed stations.

•

Support of cross-communication.

•

Ring redundancy is supported for media

•

redundancy.

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

Mechanical Installation Operating Instructions

4 Mechanical Installation

4.1 Transport and Delivery

4.1.1 Items Supplied

The items supplied for the ISD 510 servo system are:

ISD 510 servo drives

•

Servo Access Box (SAB) including connectors

•

This manual

•

Feed-in (hybrid) cable

•

Loop (hybrid) cable

•

Blind caps for connectors M8, M12, and M23

•

The packaging unit depends on the number of servo drives delivered. Save the packaging for use in the event of product return.

4.1.2 Transport

Always use means of transport and lifting gear

•

with sucient load capacity to transport the servo drives and the SAB.

Avoid vibration during transport.

•

Avoid heavy impacts and blows.

•

4.1.3 Inspection on Receipt

1. After receiving the delivery, immediately check whether the items supplied match the shipping documents. Danfoss does not honor claims for faults registered later.

2. Register a complaint immediately:

With the carrier if there is visible

•

transport damage.

With the responsible Danfoss represen-

•

tative if there are visible defects or the delivery is incomplete.

Safety Measures during Installation

4.2

Always observe the safety instructions in chapter 2 Safety during installation.

Pay particular attention to ensuring that the following points are always observed:

Installation may only be performed by

•

personnel - see chapter 2.5 Qualied Personnel.

Installation must be performed with due care and

•

attention.

All safety regulations and protective measures

•

must be complied with, and the environmental conditions must be observed.

The manual is read and understood.

•

qualied

4.3 Installation Environment

The installation must provide the following environmental conditions to allow the ISD 510 servo system to be operated safely and eciently.

Servo Drive

The allowable operating ambient temperature

•

range and vibration levels must not be exceeded (see chapter 11.1.5 General Specications and Environmental Conditions for further information).

The allowable relative humidity range is 3–93%,

•

non-condensing.

Unrestricted ventilation must be available.

•

The mounting structure must be suitable for the

•

application, adequately rigid, and so on.

SAB

The allowable operating ambient temperature

•

range and vibration levels must not be exceeded (see chapter 11.2.4 General Specications and Environmental Conditions for further information).

The allowable relative humidity range is 5–93%,

•

non-condensing.

Minimum 100 mm space is required above and

•

below the SAB (see chapter 4.5.1 Installation and Space Requirements for further information).

Contact Danfoss if it is not possible to comply with these environmental conditions.

4 4

Mechanical Installation

VLT® Integrated Servo Drive ISD® 510 System

4.4 Preparation for Installation

4.4.1 Servo Drive

Make the following preparations to ensure that the ISD 510 servo system can be installed reliably and

eectively.

1. Provide a suitable mounting arrangement for the application. This depends on the type, weight, and torque of the servo drives.

2. Seat the motor ange ush against the mounting surface before xing the servo drive. Misalignment shortens the life of the bearing and the coupling components and reduces heat transfer from the servo drive.

3. Provide contact protection according to local regulations if hot surfaces can be expected during operation.

4. Ground the servo drive as described in chapter 5.4 Grounding.

Always t couplings and other transfer components in accordance with local regulations.

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862

5.5

110

6.5

752

Mechanical Installation Operating Instructions

4.4.2 Servo Access Box (SAB)

Drill the holes for the mounting screws according to the template. All dimensions are in mm.

4 4

Illustration 4.1 SAB Mounting Template

min 100mm

130BE660.10

min 80mm

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Mechanical Installation

VLT® Integrated Servo Drive ISD® 510 System

4.5 Installation Procedure

4.5.1 Installation and Space Requirements

Servo Access Box

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 cable duct for connecting cables.

Servo Drive

In addition to its own dimensions, the servo drive

•

needs space for the hybrid cable. Illustration 4.2 shows the necessary space when using the angled connector. Illustration 4.3 shows the necessary space when using the straight connector.

The amount of space necessary for installation

•

depends on the tool used.

Illustration 4.2 Required Horizontal Space

4.5.3 Fitting Instructions Servo Drive

The servo drives are delivered with an M23 transport protection cap. The M23 blind cap used for IP protection must be ordered separately. The advanced servo drive is delivered additionally with M8 and M12 blind caps. These blind caps prevent contamination of the servo drive and are necessary to achieve the relevant IP protection rating. Always mount these caps if the connector is not used.

NOTICE

Ensure the machine surface that comes in contact with the servo ange is unpainted in order to guarantee good thermal behavior of the servo drive. The surface contact must also provide sucient grounding protection.

Clamping

Observe the following tting instructions to ensure reliable and eective tting of the servo drive:

1. Check the counterface of the motor mount and ensure that it has sucient heat dispersion capacity. An unpainted surface is mandatory.

2. Remove the protective end cap from the shaft.

3. Fix the servo drive with 4 screws using the 4 mounting holes provided for this purpose in the machine unit (see Illustration 4.4 and Illustration 4.5).

Always use the designated mounting

•

holes in the mounting ange to x the servo drive.

Do not modify the mounting holes.

•

Always use all 4 mounting holes. The

•

motor may run unevenly if fewer mounting holes are used.

See chapter 4.5.4 Tightening Torques for

•

tightening torques.

Illustration 4.3 Required Vertical Space

4.5.2 Installation Aids and Tools Required

For installation of the servo drives, the tools corresponding to the xing screws (not included) are required.

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Mechanical Installation Operating Instructions

Illustration 4.4 Mounting of Size 1, 1.9 Nm, Size 2, 2.9 Nm,

and Size 2, 3.8 Nm Servo Drives

General instructions

NOTICE

Do not use excessive force during the tting procedure:

Do not exceed the vibration limits as detailed in

•

chapter 11.1.5 General Specications and Environmental Conditions.

Do not exceed the permitted forces as detailed

•

in chapter 11.1.4 Permitted Forces.

1. Align the clamping set to the axis of the servo drive.

2. Insert the shaft in the clamping set.

3. Screw the clamping set together.

4.5.4 Tightening Torques

Table 4.1 lists the tightening torque values for the xing screws. Always tighten the xing screws uniformly and crosswise.

4 4

Illustration 4.5 Mounting of Size 2, 2.1 Nm Servo Drive

Coupling

NOTICE

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

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 4.1 Tightening Torques

∅ 5.8 mm

∅ 7 mm

Maximum

thread length

– –

Tightening

torque

NOTICE

The xing screws are not supplied and must be selected according to the machine xings.

4.5.5 Fitting Instructions Servo Access Box (SAB)

Step 1: Mount the decoupling plate

Mount the decoupling plate as shown in Illustration 4.6.

1. Slide the decoupling plate [3] into position, ensuring that the lips [2] are correctly inserted into the corresponding slots on the base plate.

2. Tighten the screw [1] at the top of the decoupling plate with 2 Nm.

3. Tighten the screws [4] at the bottom of the decoupling plate with 2 Nm.

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Mechanical Installation

VLT® Integrated Servo Drive ISD® 510 System

Illustration 4.6 Mounting the Decoupling Plate

Step 2: Mount the SAB in the control cabinet using the holes drilled as described in chapter 4.4.2 Servo Access Box (SAB) (preparation for installation).

Hook the SAB onto the holding screws on the

•

backplate of the control cabinet.

Tighten the holding screws.

•

Tighten the screws at the bottom of the SAB.

•

NOTICE

A remote mounting kit is available to mount the LCP in

the control cabinet door. See the VLT® Integrated Servo

Drive ISD® 510 System Design Guide for further information.

Electrical Installation Operating Instructions

5 Electrical Installation

5.1 Warnings

During electrical installation, observe the relevant local and national regulations in addition to the information in this manual.

WARNING

LEAKAGE/GROUNDING CURRENT HAZARD

Leakage/grounding currents are >3.5 mA. Failure to ground the SAB and the ISD 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 applicable national and local electrical standards and directives and the instructions contained in this manual.

WARNING

HIGH VOLTAGE

The SAB contains high voltage when connected to the supply that could result in death or serious injury.

Ensure that installation, start-up, and

•

maintenance are only performed by qualied personnel.

5.2 Electrical Environmental Conditions

Compliance with the following electrical environmental conditions is necessary to enable safe and eective operation of the ISD 510 servo system:

Grounded 3-phase mains network, 400–480 V AC

•

3-phase frequency 47–63 Hz

•

3-phase lines and PE line

•

External controller supply input, 24–48 V DC

•

(PELV)

Observe the national statutory provisions.

•

The leakage current is >3.5 mA. Therefore use a

•

type B residual current device (RCD).

The SAB must be mounted in a control cabinet.

•

EMC-Compliant Installation

5.3

To obtain an EMC-compliant installation, follow the instructions provided in chapter 5.4 Grounding and chapter 5.8 Connecting the Components.

Grounding

5.4

Grounding for electrical safety

Ground the ISD servo drive with the PE wire of

•

the feed-in cable (see chapter 5.8 Connecting the Components).

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. Refer to

the VLT® Integrated Servo Drive ISD® 510 System Design Guide for further information.

Use a dedicated ground wire for input power and

•

control wiring.

Do not ground 1 SAB to another in a 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

•

at least 10 mm2 or 2 separate ground wires both complying with the dimensioning rules. See EN/ IEC 61800-5-1 for further information.

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 (see chapter 5.8 Connecting the Components).

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 ISD 510 servo system and the machine is dierent. Install equalizing cables between the system components. The recommended cable crosssection is 16 mm2.

5 5

Electrical Installation

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.

5.5 Mains Supply Requirements

In addition to the electrical environmental conditions

stated in chapter 5.2 Electrical Environmental Conditions, ensure that the supply has these 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

•

VLT® Integrated Servo Drive ISD® 510 System

Safety Supply Requirements

5.7

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

•

NOTICE

Use fuses and/or circuit breakers on the supply side of the SAB to comply with CE or UL as detailed in Table 5.1.

CE Compliance (IEC 60364) UL Compliance

(NEC 2014)

Recommended

fuse size

gG-16 Eaton/Moller

Table 5.1 Fuses and Circuit Breakers

Auxiliary Supply Requirements

5.6

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.

Refer to the VLT® Integrated Servo Drive ISD® 510 System Design Guide for power ratings shell diagrams.

Recommended

circuit breaker

PKZM0-16

Maximum

trip level

in [A]

Recommended

maximum fuse

size

Littelfuse

•

KLSR015

Littelfuse

•

FLSR015

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 ISD 510 servo system, meaning that the supply is used exclusively for powering the SAB. The maximum cable length between the supply unit and the SAB is 3 m.

130BE659.10

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Electrical Installation Operating Instructions

5.8 Connecting the Components

5.8.1 Servo Access Box

WARNING

HIGH VOLTAGE

Potentially lethal voltage is present on the connectors.

Before working on the power connectors

•

(disconnecting or connecting the cable), disconnect the SAB from the mains and wait for the discharge time to elapse.

Step 1: Connect the feed-in cable

3. Secure the STO cable using the cable clamp [3], ensuring that the shield is positioned exactly under the clamp.

4. Ground the PE wire using the PE terminal [4].

NOTICE

If using 2 lines of servo drives, repeat the process for the 2nd line [7].

Step 2: Connect the AUX cable

5 5

1 Cable tie

2 Cable clamp for ISD Line 2: STO 2 (STO output to hybrid

1 24/48 V IN (auxiliary input terminal)

2 Cable tie

3 Cable clamp for ISD Line 1: STO 1 (STO output to hybrid

cable line 1)

4 PE grounding

5 Cable clamp for feed-in cable

6 Feed-in cable for line 1

7 Feed-in cable for line 2

Illustration 5.1 Connecting the Feed-In Cable

1. Insert the 4 connectors on the feed-in cable into

cable line 2)

Illustration 5.2 AUX Connector on the SAB

1. Insert the wires into the 24/48 V IN (auxiliary input) connector as described in chapter 3.3.1.7 AUX Connectors.

2. Insert the 24/48 V IN (auxiliary input) connector into the SAB and secure the cable using the cable tie [1].

their corresponding terminal block on the SAB.

2. Secure the feed-in cable [6] using the cable clamp [5], ensuring that the shield is positioned exactly under the clamp.

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Electrical Installation

VLT® Integrated Servo Drive ISD® 510 System

Step 3: Connect the mains cable

Step 4: Connect the encoder, Real-Time Ethernet, and STO cables

1. Open the terminal cover and the front cover with a screwdriver as shown in graphics Illustration 5.4 and Illustration 5.5.

Illustration 5.4 Opening the Terminal Cover

1 Mains connector

2 PE screw

3 Cable tie xing

4 Cable clamp for brake resistor cable (optional)

5 Cable clamp for mains cable

Illustration 5.3 Mains Connector on the SAB

1. Insert the wires into the mains connector as described in chapter 3.3.1.2 Mains Connectors.

2. Connect the PE wire to the PE screw [2].

3. Insert the mains connector [1].

4. Secure the mains cable using the cable clamp [5].

5. If using a brake resistor, decouple the cable using the brake cable clamp [4].

6. If using a relay, decouple the cable with a cable tie to the xing [3].

Illustration 5.5 Opening the Front Cover

130BE442.10

Electrical Installation Operating Instructions

1 Ethernet input X1 & X2

2 Encoder terminal

3 STO 1 IN: 24 V & STO 1 IN: STO

4 STO 2 IN: 24 V & STO 2 IN: STO

5 Cable clamps for STO cables

6 Cable ties for Ethernet cables

7 Cable clamp for encoder cable

Illustration 5.6 Encoder, Real-Time Ethernet, and STO Cables

5.8.2 Servo Drive

5.8.2.1 Connecting/Disconnecting Hybrid Cables

WARNING

HIGH VOLTAGE

Potentially lethal voltage is present on the connectors.

Before working on the power connectors

•

(disconnecting or connecting the cable), disconnect the SAB from the mains and wait for the discharge time to elapse.

WARNING

DISCHARGE TIME

To avoid electrical shock, fully disconnect the

•

SAB from the mains and wait for at least the time listed in Table 5.2 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 5.2 Discharge Time

5 5

1. Connect the Ethernet cables [1] and x them in position using cable ties [6] as shown in Illustration 5.6.

2. Connect the STO wires to the STO connectors STO 1 IN: 24 V [3] and STO 2 IN: 24 V [4] as described in chapter 3.3.1.1 STO Connectors and refer to the installation instructions in chapter 8.6 Installation.

3. Plug the connectors into the SAB and clamp the cables in position using the cable clamps [5].

4. If using an encoder:

4a Connect the encoder wires to the

relevant connector as described in chapter 3.3.1.5 Encoder Connectors.

4b Insert the encoder connector into the

encoder terminal [2] on the SAB and clamp the cable in position using the cable clamp [7]. Ensure that the shield is positioned exactly under the clamp.

General instructions for cable installation

Avoid mechanical tension for all cables, especially

•

regarding the range of motion of the installed servo drive.

Secure all cables in accordance with regulations

•

and depending on conditions on site. Ensure that cables cannot come loose, even after prolonged operation.

If the X3, X4, and X5 connectors are not used,

•

always mount the corresponding blind cap.

NOTICE

Never connect or disconnect the hybrid cables to or from the servo drive when the supply voltage is present. Doing so damages the electronic circuitry. Observe the discharge time for the DC-link capacitors. Do not forcefully connect or t the connectors. Incorrect connection causes permanent damage to the connector.

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Electrical Installation

VLT® Integrated Servo Drive ISD® 510 System

Connecting cables

1. Align the female connector of the M23 feed-in cable to the male input connector (X1) of the 1

9. Ensure that there is no mechanical tension on the cables.

servo drive.

2. Fully rotate the threaded ring of the cable connector counterclockwise. Use the marking OPEN as a reference for the cable connector.

3. Ensure the marking OPEN on the cable connector is facing the servo drive.

4. Press the connector towards the electronic housing on the servo drive until the sealing on

the servo connector is covered entirely by the cable connectors.

5. Tighten the M23 feed-in cable connector by rotating the threaded ring clockwise out of the at area around the OPEN marking.

1 X1 Male connector

2 X2 Female connector

3 M23 Metal blind cap

Illustration 5.8 Adding Servo Drives in Daisy-Chain Format

10. Screw the M23 metal blind cap onto the unused M23 female output connector (X2) on the last servo drive in the ISD 510 servo system.

11. Tighten the metal blind cap until the sealing on the servo connector is covered.

Illustration 5.7 Connecting the M23 Feed-In Cable

6. To add more servo drives in daisy-chain format, connect the male connector of the loop cable to the female connector (X2) of the 1st servo drive.

7. Connect the female connector of the loop cable to the male connector (X1) of the next servo drive, and so on.

Illustration 5.9 Mounting the M23 Blind Cap

8. Tighten the threaded rings by hand as described in step 5.

130BE667.10

Electrical Installation Operating Instructions

CAUTION

RISK OF INJURY AND/OR EQUIPMENT DAMAGE

Failure to use the M23 metal blind cap may result in injury to the operator and/or damage to the servo drive.

Always t the M23 metal blind cap as described

•

in steps 10 and 11.

NOTICE

An angled version of the M23 connector is also available. The procedure for connecting the angled M23 connector is the same as for the straight connector.

Disconnecting hybrid cables

1. Disconnect the SAB from its power source (mains network and U

2. Wait for the minimum discharge time to elapse.

3. Remove the connector of the feed-in cable from the SAB.

4. Rotate the threaded ring on the feed-in cable connector on the servo drive counterclockwise until the marking OPEN on the cable connector is facing the servo drive.

5. Pull the connector away from the electronic housing.

6. Protective blind caps are provided for the X1 and X2 connectors. Mount the blind caps after removing the corresponding connector.

5.8.2.2 Connecting/Disconnecting Cables from Ports X3, X4, and X5

AUX

5 5

Illustration 5.10 Connecting the I/O and/or Encoder Cable

Illustration 5.10 shows the connection of an I/O or encoder cable with straight connector to X4 on the servo drive.

NOTICE

The I/O and encoder cable is not supplied.

Cable routing

1. Avoid mechanical tension for all cables, especially regarding the range of motion of the installed servo drive.

2. Secure all cables in accordance with regulations and depending on conditions on site. Ensure that cables cannot come loose, even after prolonged operation.

Connecting I/O and/or encoder cables

1. Align the connector on the cable with the connector marked X4 on the servo drive.

2. Press the connector towards the electronic housing of the servo drive and tighten the threaded ring of the connector by turning it clockwise.

130BE669.10

130BE668.10

Electrical Installation

VLT® Integrated Servo Drive ISD® 510 System

Connecting the LCP cable

1. Align the connector on the cable with the LCP connector marked X5 on the servo drive.

2. Press the connector towards the electronic housing of the servo drive and tighten the threaded ring of the connector by turning it clockwise.

Connecting the 3rd Ethernet device cable

1. Align the connector on the cable with the Ethernet connector marked X3 on the servo drive.

2. Press the connector towards the electronic housing of the servo drive and tighten the threaded ring by turning it clockwise.

Illustration 5.11 Connecting the LCP Cable

NOTICE

The LCP cable is not supplied. It can be ordered as an accessory.

Illustration 5.12 Connecting the 3rd Ethernet Device Cable

Disconnecting cables from ports X3, X4, and X5

1. Loosen the threaded ring of the connector by turning it counterclockwise.

2. Disconnect the cable from the servo drive.

3. Protective blind caps are provided for the X3, X4, and X5 connectors. Mount the blind caps after removing the corresponding connector.

Commissioning Operating Instructions

6 Commissioning

WARNING

UNINTENDED START

The ISD 510 servo system contains servo drives 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 by 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 servo drive is connected to the electrical supply network.

Take suitable measures to prevent unintended

•

starts.

6.1 Pre-Commissioning Checklist

Always check the following before initial commissioning and before commencing operation after extended downtime or storage:

Are all threaded connectors of mechanical and

•

electrical components rmly tightened?

Is the free circulation of cooling air (inlet and

•

outlet) assured?

Are the electrical connections correct?

•

Is contact protection in place for rotating parts

•

and surfaces that can become hot?

ID Assignment

6.2

6.2.1

EtherCAT

EtherCAT® needs no special ID assignment (IP address). Special ID assignment is only required, when using indirect communication via the ISD Toolbox software (see chapter 6.5.4 ISD Toolbox Communication for further information).

6.2.2.1 Single Device ID Assignment

When assigning an ID to a single device, the Device Information window in the ISD Toolbox can be used (see

the VLT® Integrated Servo Drive ISD® 510 System Programming Guide for more information). Setting an ID to a device can also be done via the LCP.

Setting the node ID directly on a servo drive or on the SAB

All IP-related parameters are located in parameter group

12-0* IP Settings. According to the Ethernet POWERLINK standard, the IP address is xed to 192.168.100.xxx. The last number is the value in parameter 12-60 Node ID. For parameter 12-02 Subnet Mask, the IP address is xed to

255.255.255.0 and cannot be changed.

Attach the LCP to the servo drive or SAB for which the Node ID should be changed. Change the value in parameter 12-60 Node ID to select the desired IP address.

Setting the Node ID for a single servo drive via the SAB

It is also possible to change the Node ID of a servo drive when the LCP is connected to the SAB. This functionality is contained in parameter group 54-** ID Assignment on the SAB in sub-group 54-1* Manual.

1. Attach the LCP to the SAB that is connected to the servo drive for which the Node ID should be changed.

Congure the parameters:

2a 54-10 EPL ID assignment line

2b 54-11 Drive index (position of the servo

drive in the line)

2c 54-12 EPL ID assignment assign ID

3. Set parameter 54-13 EPL ID assignment start to [1] start.

6.2.2.2 Multiple Device ID Assignment

6.2.2

Ethernet POWERLINK

Ethernet POWERLINK® master communication cannot be active when using the ISD Toolbox to assign IDs to the devices. ID assignment via the ISD Toolbox is only possible

when acyclic Ethernet POWERLINK® communication is used. If cyclic communication is already started, send an NMT reset command to all devices manually or perform a

power cycle to stop the cyclic Ethernet POWERLINK communication.

When assigning IDs to several devices (for example, when setting up a new machine), the ISD Toolbox sub-tool SAB

ID assignment can be used (see the VLT® Integrated Servo

Drive ISD® 510 System Programming Guide for more

information). Setting the IDs of all the servo drives connected to an SAB at the same time can also be done via the LCP when it is connected to the SAB.

Setting the Node IDs of all servo drives on an SAB line

The automatic SAB ID assignment is used for automatically setting the Node IDs on all servo drives for a specied SAB line. This functionality is contained in parameter group 54- ** ID Assignment on the SAB in sub-group 54-0* Automatic.

Commissioning

VLT® Integrated Servo Drive ISD® 510 System

1. Attach the LCP to the SAB that is connected to the servo drives for which the Node IDs should be changed.

2. Congure the parameters:

2a 54-02 EPL ID assignment line

2b 54-03 EPL ID assignment start ID

3. Set parameter 54-04 EPL ID assignment start to [1] start.

6.3 Switching on the ISD 510 Servo System

Complete the cabling of the ISD 510 servo system before applying power to the servo drives. This cabling provides the supply voltage and the communication signals for the ISD 510 servo system. 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, STO, and U

•

communication to the SAB internal controller is established and U to the connected servo drives.

If the SAB is only powered by U

•

and servo drive control units are running.

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 on U to the SAB and servo drives to be established.

2. Switch on the mains.

3. Set the SAB to state Normal operation (see

chapter 6.5.5 ISD Toolbox Commissioning and chapter 6.6.2 Simple Programming Template).

Now the SAB and servo drives are ready for operation.

Basic Programming

6.4

The libraries provided for the ISD 510 servo 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 runtime on the controller. The

provided function blocks conform to the PLCopen standard. Knowledge of the underlying eldbus communi-

cation 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.

AUX

is automatically passed on

AUX

, then the SAB

AUX

power to enable communication

AUX

Function blocks and structures for creating Basic

•

CAM proles.

Function blocks and structures for creating

•

Labeling CAM proles.

6.4.1 Programming with Automation

Studio™

6.4.1.1 Requirements

The following les are needed to integrate the VLT

Integrated Servo Drive ISD® 510 and the VLT® Servo Access Box into an Automation Studio™ project:

Package of libraries for the ISD 510 servo system:

•

Danfoss_VLT_ISD_510.zip

XDD le (XML Device Description) for the servo

•

drive: 0x0300008D_ISD510.xdd

XDD le (XML Device Description) for the SAB:

•

6.4.1.2

0x0300008D_SAB.xdd

Creating an Automation Studio™

Project

The following instructions are for Automation Studio™

3.0.90.

Information on how to install Automation Studio™ can be found in detail in the Automation Studio™ help. Open the B&R Help Explorer and go to [Automation software → Software Installation → Automation Studio].

Information on how to create a new project in Automation Studio™ can be found in detail in the Automation Studio™ help. Open the B&R Help Explorer and go to [Automation Software → Getting Started → Creating programs with Automation Studio → First project with X20 CPU].

How to include the ISD 510 libraries into an Automation Studio™ project:

In the Logical View, open the menu entry [File → Import…].

2. In the next window, select the Danfoss_VLT_ISD_510.zip location on the hard drive).

3. Click on Open.

4. Assign the libraries to the CPU in the next window.

5. Click on Finish. Now the libraries are integrated into the Automation Studio™ project.

A new folder containing the ISD libraries is created during integration:

ISD_51x

•

le (according to the

Commissioning Operating Instructions

- Contains program organization units

(POUs) that are dened by PLCopen (name starting with MC_) and POUs that are dened by Danfoss (name starting with DD_). The Danfoss POUs provide additional functionality for the servo drive.

- It is possible to combine POUs dened

by PLCopen® with POUs dened by Danfoss.

- The names of the POUs that target the servo drive all end with _ISD51x.

SAB_51x

•

- Contains POUs that are dened by

Danfoss (name starting with DD_) and provide the functionality for the SAB.

- The names of the POUs that target the SAB all end with _SAB.

BasCam_51x

•

- Contains POUs for the creation of basic

CAMs.

LabCam_51x

•

- Contains POUs for the creation of

labeling CAMs.

Intern_51x

•

- Contains POUs that are needed

internally for the libraries.

- Do not use these POUs in an application.

When integrating the ISD_51x package, some standard libraries are integrated automatically, unless they are already part of the project.

Illustration 6.1 Standard Libraries

NOTICE

Do not remove these libraries otherwise the ISD libraries will not work.

Inside the library, the following lists of constants are

dened:

AxisErrorCodes

•

- Constants for error codes of the axis.

- Error codes can be read using the

function block MC_ReadAxisError_ISD51x and/or DD_ReadAxisWarning_ISD51x.

AxisTraceSignals

•

- Constants for the trace signals of the

axis.

- Intended to be used with the function block DD_Trace_ISD51x.

BasCam_51x

•

- Constants for the creation of basic

CAMs.

CamParsingErrors

•

- Constants for parsing problems of a

CAM.

- Error reason is returned by function block MC_CamTableSelect_ISD51x.

Danfoss_VLT_ISD510

•

- Contains the version information of the

library

FB_ErrorConstants

•

- Constants for errors inside POUs.

- The reason is given in an output

ErrorInfo.ErrorID that is available in all POUs.

Intern_ISD51x

•

- Constants which are needed internally

for the library.

- They are not intended to be used in an application.

LabCam_51x

•

- Constants for the creation of labeling

CAMs.

SabErrorCodes

•

- Constants for error codes of the SAB.

- Error codes can be read using the

function block DD_ReadSabError_SAB and/or DD_ReadSabWarning_SAB.

SabTraceSignals

•

Commissioning

VLT® Integrated Servo Drive ISD® 510 System

- Constants for the trace signals of the

SAB.

- Intended to be used with the function block DD_Trace_SAB.

SdoAbortCodes

•

- Constants for errors concerning reading

and writing of parameters.

- The reason is given in an output AbortCode that is available in several POUs.

Instantiating AXIS_REF_ISD51x

Inside the library ISD_51x there is a function block called AXIS_REF_ISD51x. Create 1 instance of this function block

for every servo drive that has to be controlled or monitored. To create a link to the physical servo drive, link each instance to 1 physical servo drive. This is done (in the Logical View) by initializing each instance with its node number and the slot name (for example, ‘IF3’) it is connected to. Each instance of AXIS_REF_ISD51x is the logical representation of 1 physical servo drive.

Import eldbus device and add to Physical View

The next step is to import the ISD 510 servo drive into Automation Studio™:

Select the menu entry [Tools → Import Fieldbus Device…].

2. Select the XDD le 0x0300008D_ISD510.xdd from its location on the hard drive. This import only has to be done once per project. The device is then known to Automation Studio™.

3. The ISD 510 servo drive can now be added to the

Ethernet POWERLINK® interface of the controller in the Physical View:

3a Right-click on the controller in the

Physical View and select [Open → POWERLINK].

3b Right-click on the interface and select

Insert….

3c In the Select controller module window,

select the ISD 510 in the group POWERLINK Devices.

3d Click on Next.

3e In the next window, enter the node

number of the servo drive.

Illustration 6.2 Instantiation of AXIS_REF and Setting of Initial

Values

Instantiating SAB_REF

Inside the library SAB_51x there is a function block called SAB_REF. Create 1 instance of this function block for every

SAB that has to be controlled or monitored. To create a link to the physical SAB, link each instance to 1 physical SAB. This is done (in the Logical View) by initializing each instance with its node number and the slot name (for example, IF3) it is connected to. Each instance of SAB_REF is the logical representation of 1 physical SAB.

Illustration 6.3 Add an ISD 510 Servo Drive to the Project

NOTICE

The procedure described here applies to Automation Studio™ Version 3.0.90. Refer to the Automation Studio™ Help for the corresponding steps with V4.x.

For each physical servo drive, add 1 entry to the Physical View of Automation Studio™.

Commissioning Operating Instructions

The next step is to import the Servo Access Box into Automation Studio™:

Select the menu entry [Tools → Import Fieldbus Device…].

2. Select the XDD le 0x0300008D_SAB.xdd from its location on the hard drive. This import only has to be done once per project. The device is then known to Automation Studio™.

3. The SAB can now be added to the Ethernet

POWERLINK® interface of the controller in the Physical View:

3a Right-click on the controller in the

Physical View and select [Open → POWERLINK].

3b Right-click on the interface and select

Insert….

3c In the Select controller module window,

select the SAB in the group POWERLINK Devices.

3d Click on Next.

3e In the next window, enter the node

number of the SAB.

For each physical SAB, add 1 entry to the Physical View of Automation Studio™.

The I/O Conguration of the SAB has to be parameterized in a way that the library has access to all necessary objects:

1. Right-click on the entry of the SAB and select Open I/O Conguration.

2. In the Channels section, change the Cyclic transmission of the following objects:

2a All subindexes of object 0x5050 (Lib pdo

rx_I5050 ARRAY[]) to Write.

2b All subindexes of object 0x5051 (Lib pdo

tx_I5051 ARRAY[]) to Read.

These settings congure the cyclic communication with the device. These parameters are needed to make the library work.

NOTICE

It is possible to use copy & paste to apply the same I/O

Conguration to multiple devices of the same type.

NOTICE

Set Module supervised to o for the servo drives and the SAB. The parameter is found in the I/O Conguration of the device.

Illustration 6.4 1 SAB and 2 ISD 510 Servo Drives Added to the

Ethernet POWERLINK® Interface

I/O conguration and I/O mapping

The I/O Conguration of the servo drive has to be parameterized in a way that the library has access to all necessary objects:

1. Right-click on the entry of the ISD 510 and select Open I/O Conguration.

2. In the Channels section, change the Cyclic transmission of the following objects:

2a All subindexes of object 0x5050 (Lib pdo

rx_I5050 ARRAY[]) to Write.

2b All subindexes of object 0x5051 (Lib pdo

tx_I5051 ARRAY[]) to Read.

Illustration 6.5 I/O Conguration of an ISD 510 Device

Commissioning

VLT® Integrated Servo Drive ISD® 510 System

Illustration 6.6 I/O Mapping after Successful Conguration

Map the inputs and outputs of the instance of the AXIS_REF_ISD51x function block and the physical data points of the servo drive according to Illustration 6.7 (here myAxis is an instance of AXIS_REF_ISD51x):

Illustration 6.7 I/O Mapping of an ISD 510 Servo Drive

Map the inputs and outputs of the instance of the SAB_REF function block and the physical data points of the SAB accordingly.

Cycle time settings

The minimum cycle time is 400 µs. The ISD 510 devices

can run Ethernet POWERLINK® cycle times in multiples of 400 µs and multiples of 500 µs. The devices are automatically parameterized by the PLC on start-up, depending on

the Ethernet POWERLINK® conguration of the physical

interface. The Ethernet POWERLINK® conguration can be accessed by right-clicking [CPU → Open IF3 POWERLINK Conguration] in the Physical View.

NOTICE

The task cycle time of the PLC program should be the

same as the Ethernet POWERLINK® cycle time. Otherwise, data could be lost and performance may be reduced.

Illustration 6.8 Ethernet POWERLINK®

to Parameterize Ethernet POWERLINK® Cycle Time

Set the PLC cycle time in Automation Studio™:

Right-click [CPU → Open Software Conguration] in the Physical View.

2. Ensure that the PLC cycle time is the same as the

Ethernet POWERLINK® cycle time.

Conguration Window

6.4.1.3 Connecting to the PLC

Information on how to connect to the PLC can be found in detail in the Automation Studio™ Help. Open the B&R Help

Explorer and go to [Automation Software → Getting Started → Creating programs with Automation Studio → First

project with X20 CPU → Congure online connection].

6.4.2

Programming with TwinCAT

6.4.2.1 ISD Deliverables

To integrate the servo drive and the SAB into a TwinCAT project, the following les are needed:

Library for the ISD 510 servo system:

•

Danfoss_VLT_ISD_510.lib

ESI le (EtherCAT® Slave Information) for the

•

servo drive and the SAB: Danfoss ISD 500.xml

6.4.2.2

Information on how to install TwinCAT® can be found in detail in the Beckho Information System (infosys.beckho.com). Open the information system and select [TwinCAT 2 → TwinCAT Quick Start → Installation].

Information on how to create a new project in TwinCAT can be found in detail in the Beckho Information System (http://infosys.beckho.com). Open the information system and select [TwinCAT 2 → TwinCAT Quick Start or TwinCAT 2 → TX1200 TwinCAT PLC → TwinCAT PLC Control].

Creating a TwinCAT® Project

Commissioning Operating Instructions

How to include the ISD 510 library into a TwinCAT project:

In the Resources tab of TwinCAT® PLC Control, open the Library Manager.

2. In the upper left area of the Library Manager window, right-click and select Additional Library ….

3. Select the Danfoss_VLT_ISD_510.lib le (according to the location on the hard drive).

4. Click on Open. Now the libraries are integrated

into the TwinCAT® PLC control project.

Inside the library, the POUs are organized into folders:

BasCam_51x

•

- Contains POUs for the creation of basic

CAMs.

ISD_51x

•

Contains POUs (Name starting with MC_) and POUs dened by Danfoss (name starting with DD_). The POUs dened by Danfoss provide additional functionality for the axis.

- It is possible to combine POUs dened

by PLCopen® with POUs dened by Danfoss.

- The names of the POUs that target the servo drive all end with _ISD51x.

Intern_51x

•

- Contains POUs that are needed

internally for the libraries.

- Do not use these POUs in an application.

LabCam_51x

•

- Contains POUs for the creation of

labeling CAMs.

SAB_51x

•

- Contains POUs that are dened by

Danfoss (Name starting with DD_) and provide the functionality for the SAB.

- The names of the POUs that target the SAB all end with _SAB.

When integrating the ISD 510 library, some standard libraries are integrated automatically, unless they are already part of the project.

dened by PLCopen

NOTICE

Do not remove these libraries otherwise the ISD libraries will not work.

Illustration 6.9 Library Manager after Including the ISD 51x

Library

Inside the library, the following lists of constants are

dened:

AxisErrorCodes

•

- Constants for error codes of the axis.

- Error codes can be read using the

function block MC_ReadAxisError_ISD51x and/or DD_ReadAxisWarning_ISD51x.

AxisTraceSignals

•

- Constants for the trace signals of the

axis.

- Intended to be used with the function block DD_Trace_ISD51x.

BasCam_51x

•

- Constants for the creation of basic

CAMs.

CamParsingErrors

•

- Constants for parsing problems of a

CAM.

- Error reason is returned by function block MC_CamTableSelect_ISD51x.

Danfoss_VLT_ISD510

•

- Contains the version information of the

library.

FB_ErrorConstants

•

- Constants for errors inside POUs.

- The reason is given in an output

ErrorInfo.ErrorID that is available in all POUs.

Intern_51x

•

- Constants that are needed internally for

the library.

- They are not intended to be used in an application.

LabCam_51x

•

Commissioning

- Constants for the creation of labeling

CAMs.

SabErrorCodes

•

- Constants for error codes of the SAB.

- Error codes can be read using the

function block DD_ReadSabError_SAB and/or DD_ReadSabWarning_SAB.

SabTraceSignals

•

- Constants for the trace signals of the

SAB.

- Intended to be used with the function block DD_Trace_SAB.

SdoAbortCodes

•

- Constants for errors concerning reading

and writing of parameters.

- The reason is given in an output AbortCode that is available in several POUs.

Instantiating AXIS_REF_ISD51x

Inside the folder ISD_51x in library Danfoss_VLT_ISD_510 there is a function block called AXIS_REF_ISD51x. Create 1 instance of this function block for every servo drive that has to be controlled or monitored. Each instance of AXIS_REF_ISD51x is the logical representation of 1 physical servo drive.

Instantiating SAB_REF

Inside the folder SAB_51x in library Danfoss_VLT_ISD_510 there is a function block called SAB_REF. Create 1 instance of this function block for every SAB that has to be controlled or monitored.

Each instance of SAB_REF is the logical representation of 1 physical SAB.

VLT® Integrated Servo Drive ISD® 510 System

NOTICE

When compiling the library, check that the option Replace constants under [Project → Options... → Build] is activated.

Afterwards, save and compile the project to update the automatically generated variable information for the

TwinCAT® System Manager.

Illustration 6.10 Instantiation of AXIS_REF_ISD51x

Append a PLC Project into TwinCAT® System Manager

To create a link between the TwinCAT® PLC Control project

and the TwinCAT® System Manager, connect the saved

project, especially the inputs and outputs, to the TwinCAT System Manager:

To add the project information to the TwinCAT System Manager, right-click on PLC-Conguration and select Append PLC project….

2. In the Insert IEC1131 Project window, select the project information le according to the location on the hard drive. The le has the same name as the PLC project, but with the le extension .tpy.

3. Click on Open.

Import

eldbus device and add to TwinCAT

The next step is to import the servo drive and the SAB into

the TwinCAT® System Manager software:

1. Copy the ESI le Danfoss ISD 500.xml into the folder TwinCAT Installation Folder\Io\EtherCAT on the hard drive. This only has to be done once per

project. The TwinCAT® System Manager automatically searches for ESI les at this location on the hard drive during startup.

To add an EtherCAT® master, right-click on [I/O-

Conguration → I/O Devices] and select Append Device….

In the following window, select [EtherCAT → EtherCAT] (see Illustration 6.11).

4. Click on OK.

Select Device 1 (EtherCAT®) and select the correct Network Adapter on the right side of the window in the Adapter tab.

Commissioning Operating Instructions

To add an SAB, right-click on Device1 (EtherCAT®) and select Append Box….

7. In the Insert EtherCAT Device window, select

[Danfoss GmbH → VLT® ISD Series → VLT® Servo

Access Box L1] for Line 1 of the SAB (and/or VLT Servo Access Box L2 for Line 2 of the SAB).

8. Click on OK.

9. To add a servo drive to line 1 of the SAB, right-

click on Box 1 (VLT select Append Box...

10. In the Insert EtherCAT Device window, select

[Danfoss GmbH → VLT® ISD Series → VLT® ISD 510 Integrated Servo Drive].

11. Click on OK.

12. Answer the question if the drive is used as an NC axis with No. If the drive should be used as an NC axis, see chapter 6.4.2.3 Conguration as a

TwinCAT® NC Axis.

Servo Access Box L1) and

Illustration 6.12 Add an ISD 510 Servo Drive to the Project

NOTICE

Add 1 entry to the EtherCAT® master of the TwinCAT System Manager for each physical servo drive and SAB.

Add the servo drive to the correct SAB line.

Illustration 6.11 Add an EtherCAT® Master to the Project

Commissioning

VLT® Integrated Servo Drive ISD® 510 System

1. Click on the ISD servo drive entry.

2. Select the Slots tab on the right side of the window.

3. Remove the current PDO conguration by selecting the entry Module 1 (CSV PDO) in the Slot box.

4. Click on X.

5. Select Library PDO in the Module box.

6. Click on <.

Illustration 6.13 TwinCAT® System Manager after Appending

the PLC Project and Adding an SAB and 2 Servo Drives

I/O conguration and I/O mapping

When connecting >1 servo drive, connect port C (X2) of the previous drive to port A (X1) of the next servo drive. The SAB port assignment must also be followed, see

chapter 3.8.1 EtherCAT®. If the hardware set-up is already

present, the TwinCAT® System Manager Scan devices function can be used to automatically add the connected devices to the conguration in the correct order.

The servo drive has to be congured so that the PDO mapping matches the requirements of the library. This is

done inside the TwinCAT® System Manager.

Illustration 6.14 ISD 510 Servo Drive with Correct I/O Congu-

ration

Attach the input and output variables of the PLC program to the physical inputs and outputs of the device. This is

done inside the TwinCAT® System Manager so that the library has access to all necessary objects.

1. Select Library TxPDO via menu [I/O-Conguration → I/O Devices → Device1 (EtherCAT®) → Box 1

(VLT® Servo Access Box L1) → Drive 2 (VLT® ISD 510 Integrated Servo Drive) → Module 1 (Library PDO) → Library TxPDO].

2. Select all entries Lib pdo tx1 to Lib pdo tx9 on the right side of the window (see Illustration 6.15).

3. Right-click and select Change Multi Link….

4. In the Attach Variable 36.0 Byte(s) (Input) window, select [PLC-Conguration → MyFirstIsd510Project → Standard → .myAxis.TPDO]. Ensure that the Matching Size option is selected in the Attach Variable window.

5. Click OK.

6. Click on Library RxPDO via menu [I/O-Congu- ration → I/O Devices → Device1 (EtherCAT®) →

Box1 (VLT® Servo Access Box L1) → Drive2 (VLT ISD 510 Integrated Servo Drive) → Module1 (Library PDO) → Library RxPDO].

7. Select all entries Lib pdo rx1 to Lib pdo rx9 on the right side of the window.

Commissioning Operating Instructions

8. Right-click and select Change Multi Link….

9. In the Attach Variable 36.0 Byte(s) (Output) window

select [PLC-Conguration → MyFirstIsd510Project → Standard → .myAxis.RPDO].

10. Click on OK.

11.

Right-click on WcState via [I/O-Conguration → I/O Devices → Device1 (EtherCAT®) → Box1 (VLT Servo Access Box L1) → Drive2 (VLT® ISD 510 Integrated Servo Drive) → WcState] and select

Change Link….

12. In the Attach Variable State (Input) window select

[PLC-Conguration → MyFirstIsd510Project → Standard → .myAxis.WcState.

13. Click on OK.

14.

Right-click on State via Devices → Device1 (EtherCAT®) → Box1 (VLT Servo Access Box L1) → Drive2 (VLT® ISD 510 Integrated Servo Drive) → InfoData] and select

Change Link….

15. In the Attach Variable State (Input) window select

[PLC-Conguration → MyFirstIsd510Project → Standard → .myAxis.State.

16. Click on OK.

17.

Right-click on netId via [I/O-Conguration → I/O Devices → Device1 (EtherCAT®) → Box1 (VLT Servo Access Box L1) → Drive2 (VLT® ISD 510 Integrated Servo Drive) → InfoData → AdsAddr]

and select Change Link….

18. In the Attach Variable netId (Input) window select

[PLC-Conguration → MyFirstIsd510Project → Standard → .myAxis.AmsNetId.].

19. Click on OK.

20.

Right-click on port via [I/O-Conguration → I/O Devices → Device1 (EtherCAT®) → Box1 (VLT Servo Access Box L1) → Drive2 (VLT® ISD 510 Integrated Servo Drive) → InfoData → AdsAddr]

and select Change Link….

21. In the Attach Variable port (Input) window select

[PLC-Conguration → MyFirstIsd510Project → Standard → .myAxis.NodeNumber.].

22. Click on OK.

[I/O-Conguration → I/O

Illustration 6.15 Attaching Inputs and Outputs to the Physical

Data Points

NOTICE

Repeat the steps 2–22 for Box 1 (VLT® Servo Access Box L1) and the instance mySAB.

To transfer the mappings back to the PLC program, select Activate Conguration… in menu item Actions.

After a rebuild in TwinCAT conguration is according to Illustration 6.16 (here myAxis and mySecondAxis are instances of AXIS_REF_ISD51x and mySAB is an instance of SAB_REF). The concrete addresses can be dierent.

Illustration 6.16 TwinCAT® Conguration: I/O Mapping of 2

Servo Drives and an SAB

PLC Control, the TwinCAT

Commissioning

VLT® Integrated Servo Drive ISD® 510 System

NOTICE

It is recommended to put the SAB to a separate SYNC unit so that the communication to the SAB is not interrupted if the U switched o due to an error.

Cycle time settings

The minimum cycle time is 400 µs. The ISD 510 devices

can run EtherCAT® cycle times in multiples of 400 µs or 500 µs. The devices are automatically parameterized by the

PLC on start-up, depending on the EtherCAT® conguration of the physical interface. The system base time can be accessed by selecting

Settings] in the TwinCAT® System Manager. Multiples of this

base time can then be used as EtherCAT® cycle times.

supply to the servo drives is

AUX

[SYSTEM-Conguration → Real-Time

NOTICE

Set the task cycle time of the PLC program to be the

same as the EtherCAT® cycle time. Otherwise data can get lost and performance is reduced.

Set the PLC cycle time in TwinCAT® PLC Control:

1. Double-click Task conguration in the Resources tab.

2. Ensure that the PLC cycle time is the same as the

EtherCAT® cycle time.

Illustration 6.17 Task Conguration to Parameterize PLC Cycle

Time

NOTICE

After changing the task cycle time in TwinCAT® PLC Control, carry out a ReScan of the PLC conguration

inside the TwinCAT® System Manager to update the settings. Afterwards, activate the conguration in the PLC.

6.4.2.3

Conguration as a TwinCAT® NC Axis

It is possible to use the servo drives with the built-in NC

functionality of TwinCAT®. Everything that is related to the SAB needs to be done as described in

chapter 6.4.2.2 Creating a TwinCAT

1. In addition to the Danfoss_VLT_ISD_510.lib le, include the TcMC2.lib le (the Danfoss_VLT_ISD_510.lib le is still needed for the SAB to be operated).

2. Create 1 instance of AXIS_REF (instead of AXIS_REF_ISD51x) for each servo drive that is used as an NC axis.

Append the PLC project into the TwinCAT System Manager, import the devices and add

them to TwinCAT® as described in

chapter 6.4.2.2 Creating a TwinCAT

however in the last step, answer the question if the servo drive is used as an NC axis with Yes. Then an NC task is created automatically.

In the TwinCAT® System Manager a ration needs to be selected for the drives that are used as NC axes.

1. Depending on the mode of operation to be used, select either the slot CSP PDO or CSV PDO. Per default, CSV PDO is mapped and pre-selected. If the drive should work with CSP PDO, the variables need to be mapped:

1a In the Settings Tab of the NC Axis select

[NC-Conguration → NC-Task 1 SAF → Axes → Axis 1]. Click on the Link To (all Types)… button and select the desired servo drive.

2. In the same tab, select the preferred Unit.

3. Depending on the selected Unit, adjust the

Scaling Factor for the axis encoder via menu [NC- Conguration → NC-Task 1 SAF → Axes → Axis 1 →

Axis 1_Enc] in the Parameter tab. Example: When the unit Degrees is selected, the scaling factor is 360°/220 = 0.00034332275390625.

4. Set the Reference Velocity in the Parameter tab via

[NC-Conguration → NC-Task 1 SAF → Axes

menu → Axis 1 → Axis 1_Enc.

5. Set the Output Scaling Factor ( Velocity) to 125.

6. Test the functionality and the conguration in the

Online tab of the axis.

Project.

Project,

dierent I/O Congu-

Commissioning Operating Instructions

6.4.2.4 Connecting to the PLC

Information on how to connect to the PLC can be found in detail in the Beckho Information System (http:// infosys.beckho.com). Open the information system and go to [TwinCAT 2 → TwinCAT System Manager → Operation → Controls → Choose Target System].

6.4.3 Programming Guidelines

Recommendations for implementation:

Initialize parameters that usually do not change

•

only once at the beginning of the program. In Automation Studio™, use the _INIT section.

Call up function blocks that provide status or

•

error information with Enable input at the beginning of the program.

It is recommended to have 1 instance of the

•

function block MC_Power_ISD51x for every axis in order to control its power stage. Call up this function block in every PLC cycle.

It is recommended to have 1 instance of the

•

function block DD_Power_SAB for every SAB to control the DC-link voltage on the output lines. Call up this function block in every PLC cycle.

Call up function blocks that execute (motion)

•

commands at the end of the program.

Do not use any POUs of the library (folder)

•

Intern_51x.

Do not change the reference to the axis on a

•

function block while it is busy.

Illustration 6.18 shows sample code for TwinCAT®.

Illustration 6.18 Sample Code for TwinCAT

NOTICE

The full parameter list can be found in the VLT

Integrated Servo Drive ISD® 510 System Programming Guide.

Commissioning

VLT® Integrated Servo Drive ISD® 510 System

6.5 ISD Toolbox

6.5.1 Overview

The ISD Toolbox is a standalone PC software designed by Danfoss. It is used for parameterization and diagnostics of the servo drives and the SAB. It is also possible to operate the devices in a non-productive environment. The ISD Toolbox contains several functionalities, called sub-tools, 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

•

Drive control/SAB control to operate the servo

•

drives and/or SAB for testing purposes.

CAM editor for designing CAM proles for the

•

servo drives.

The detailed description of the ISD Toolbox functionality

and the full list of parameters can be found in the VLT

Integrated Servo Drive ISD® 510 System Programming Guide.

6.5.2 System Requirements

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

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

•

Supported operating systems: 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, 20 MB hard disk space.

Recommended hardware requirements: Minimum

•

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

6.5.3 Installation

Administrator rights are required for installing the software with the Windows operating system. Contact your administrator if necessary.

4. Follow the on-screen instructions to complete the installation process.

6.5.4 ISD Toolbox Communication

This chapter describes the Ethernet specic network interface settings needed by the ISD Toolbox. There are 2 basic communication methods: direct communication and indirect communication. Their particular network settings are described in the respective sections.

Read and perform the steps with care - incorrect network congurations can lead to loss of connectivity of a network interface.

Firewall

Depending on the rewall settings and the eldbus used, the messages sent and received by the ISD Toolbox may be blocked by the rewall on the ISD Toolbox host system. This may lead to a loss of communication and the inability to communicate with the devices on the eldbus. Therefore, ensure that the ISD Toolbox is allowed to communicate through the rewall on the ISD Toolbox host system. Read and perform the steps with care - inappropriate changes to rewall settings may lead to security issues.

NOTICE

When using a dedicated network interface, the ISD Toolbox should be allowed to communicate specically through this network interface.

Indirect communication

Communication between ISD 510 devices and the ISD Toolbox through a PLC is called indirect communication. Between the PLC and the ISD 510 devices there is Ethernet-based eldbus communication (marked A in Illustration 6.19), whereas there is non-eldbus communi- cation between the PLC and the ISD Toolbox host system (marked B in Illustration 6.19).

In the scenario in Illustration 6.19, the PLC has the master function and uses cyclic communication with the devices. Therefore, not all functionalities of the ISD Toolbox, for example the drive control, can be used. The restrictions when using indirect communication are detailed in the

VLT® Integrated Servo Drives ISD® 510 Programming Guide.

1. Check that your system meets the system requirements as described in chapter 6.5.2 System Requirements.

2. Download the ISD Toolbox installation le (http:// vlt-drives.danfoss.com/products/engineeringsoftware/software-download/).

3. Right-click on the .exe le and select Run as administrator.

130BE309.10

Aux 1

Aux 2

Safe

2 n

SAB

PLC

. . .

Aux 1

Aux 2

Safe 1

Safe

2 n

SAB

. . .

130BE310.10

Commissioning Operating Instructions

A Fieldbus

B General purpose network

Illustration 6.19 Logical View of Indirect Ethernet-based

Fieldbus Communication (Communication via PLC)

NOTICE

The logical view only shows the connectivity from a high-level software perspective and does not reect the actual physical topology of the network.

Direct communication

For Ethernet-based eldbus communication (direct communication), the ISD Toolbox must use a dedicated network interface on the ISD Toolbox host system. This network interface should not simultaneously be used for any other communication.

NOTICE

The logical view only shows the connectivity from a high-level software perspective and does not reect the actual physical topology of the network.

6.5.4.1 Network Settings for Indirect Communication

Any network interface can be used to communicate through a PLC and a dedicated network interface is not needed.

When establishing the communication through a PLC, the ISD Toolbox congures a routing table using the selected Network Address Translation (NAT). Adding a route to the Windows routing table requires administrator privileges. Therefore, administrator credentials may be requested when initializing the connection.

Carry out the following steps to enable indirect communication.

Disable IPv6 on the network interfaces used for communication on the PC:

1. Open the Network and Sharing Center.

2. Select Change adapter settings.

3. Right-click on the network interface used for eldbus communication and select Properties.

4. If the TCP/IPv6 is available for the network interface, disable it.

A Fieldbus

B General purpose network

Illustration 6.20 Logical View of Direct Ethernet-based Fieldbus

Communication

Illustration 6.21 Local Area Connection Properties

Commissioning

VLT® Integrated Servo Drive ISD® 510 System

NOTICE

When observing the network packets via Wireshark®, checksum ooading often causes confusion as the network packets to be transmitted are handed over to

Wireshark® before the checksums have been calculated.

Wireshark® shows these empty checksums as invalid, even though the packets contain valid checksums when they leave the network hardware later.

Use 1 of these 2 methods to avoid this checksum ooading problem:

Turn o the checksum ooading in the network

•

driver if possible.

Turn o the checksum validation of the specic

•

protocol in the Wireshark® preferences.

Additional settings for indirect communication over

EtherCAT

Set the IP address of the EtherCAT® Master:

Activate IP routing on the EtherCAT® Master:

Open the TwinCAT

Select [I/O-Conguration → I/O Devices → Device1

(EtherCAT®)] and check the IP-address in the Adapter tab. The IP-address of the PLCs network adapter may not be a link-local address (so not in the range of

169.254.0.1 to 169.254.255.254).

3. If necessary, change the IP-address inside the IPv4 Protocol properties according to the given operating system. This can be done on the controller locally or via Remote Desktop.

System Manager.

NOTICE

The procedure described here may vary depending on the type of PLC and operating system installed.

Open the TwinCAT® System Manager.

2. Click on Advanced Settings… under [I/O-Congu- ration → I/O Devices → Device1 (EtherCAT®)] in

the EtherCAT tab.

3. Select EoE Support in the Advanced Settings window.

4. Enable Connect to TCP/IP Stack in the Windows Network section.

5. Enable IP Enable Router in the Windows IP Routing section.

6. Reboot the PLC for the changes to take eect.

Set the IP address of the EtherCAT SAB):

Open the TwinCAT® System Manager.

2. Click on Advanced Settings… under [I/O-Congu-

ration → I/O Devices → Device1 (EtherCAT®) → Box

1 (VLT® Servo Access Box L1 → Drive 2 (VLT Integrated Servo Drive ISD 510)] in the EtherCAT tab.

Select [Mailbox → EoE] in the Advanced Settings window.

4. Enable Virtual Ethernet Port and enter a valid IP Address.

5. Each slave in the conguration requires an IPaddress. This address is reassigned with every transition from INIT to Pre-Operational state of the slave state machine. The IP communication of the slaves is deactivated per default.

slave (servo drive or

NOTICE

The last number of the IP address is the ID that is used in the ISD Toolbox to identify the device.

6.5.4.2 Network Settings for Direct Communication with Ethernet

POWERLINK

Disable all network protocols except TCP/IPv4 on the

network interface used for direct Ethernet POWERLINK communication. This prevents other PC software or the operating system using this network interface for other tasks, such as le and printer sharing and network discovery. Disabling these protocols reduces the number of non-relevant packets sent over the network interface and thus reduces the overall network load.

How to disable all unused protocols on the network interface on the PC:

1. Open the Network and Sharing Center.

2. On the left, click on Change adapter settings.

3. Right-click on the network interface used for eldbus communication and select Properties.

4. Uncheck all checkboxes except the one for Internet Protocol Version 4 (TCP/IPv4).

Commissioning Operating Instructions

Illustration 6.22 Local Area Connection 2 Properties

Disable the IPv4 Checksum ooad on the network interfaces as described in chapter 6.5.4.1 Network Settings for Indirect Communication.

How to set the correct Ethernet POWERLINK® master IP address:

1. Open the Network and Sharing Center.

2. On the left, click on Change adapter settings.

3. Right-click on the network interface used for eldbus communication and select Properties.

4. Click on Internet Protocol Version 4 (TCP/IPv4) (the checkbox must be checked) and then click on Properties.

5. Select Use the following IP address and use

192.168.100.240 as the IP address and

255.255.255.0 as the subnet mask. Leave all other elds empty.

Illustration 6.23 Internet Protocol Version 4 (TCP/IPv4)

Properties

6.5.4.3 Network Settings for Direct Communication with EtherCAT

No EtherCAT®-specic network interface conguration needs to be performed on the ISD Toolbox host PC.

130BE311.10

1 2

Commissioning

VLT® Integrated Servo Drive ISD® 510 System

6.5.5 ISD Toolbox Commissioning

STEP 1: Open the main window

The Main Window is the basis for all ISD Toolbox functionalities. It consists of the following components:

Illustration 6.24 Main Window

Commissioning Operating Instructions

1 Menu bar Contains the general functionalities for saving and loading projects, managing connections,

showing and changing settings, managing open sub-tools, and showing help contents.

2 Tool bar Contains shortcuts for saving and loading projects, connecting to and disconnecting from

networks, automatic searching for online devices, or manually adding devices.

3 Online/Oine status and state

information

4 Available sub-tools A sub-tool is opened by double-clicking the left mouse button on its name in the Device

5 Device environment The Device Environment section of the Main Window lists all logical devices managed by the

6 Workspace This is the space for hosting the sub-tools and its size depends on the Main Window size. The

7 Watchlist window Evaluates the parameter values of 1 or more devices by cyclically reading them from the

8 Output window Shows operating information, warnings, and errors. Depending on the user settings, shows

9 Status strip Shows the communication state of the ISD Toolbox. If connected to a network, it shows the

Online devices are indicated by a glowing light bulb next to the device ID.

•

- An online device is a logical device for which a physical device exists, which the

ISD Toolbox is currently connected to.

- The color indicates the state of the device and is device–specic.

Oine devices are indicated by a gray light bulb next to the device ID.

•

- An oine device is a logical device without a corresponding physical device. An

oine device can represent a saved device conguration or state, for example for

oine analysis or troubleshooting. It also contains pre-congured parameter

values to be written to a physical device.

Environment, or by selecting the entry and pressing the Enter key on the keyboard.

ISD Toolbox, visualizes their states, and serves as the user interface for accessing the device

functionalities.

The Device Environment window lists all available sub-tools for each added device. See the

VLT® Integrated Servo Drive ISD® 510 System Programming Guide for further information on the

sub-tools.

sub-tools can be maximized, minimized, horizontally or vertically aligned, or cascaded.

devices. Allows parameter values to be logged and saved to a text le. It is also possible to

modify/write values in the watchlist.

messages of up to 3 dierent logging levels (high, medium, and low). Used for showing

advanced error and warning information.

used hardware interface (for example, network adapter) and the network name.

Table 6.1 Legend to Illustration 6.24

STEP 2: Connect to network

NOTICE

Pre-congure the appropriate communication settings to connect to a network. See chapter 6.5.4 ISD Toolbox Communication for further information.

1. In the Main Window toolbar, click on the Connect to bus icon to open the Connect to Network

window.

2. Select the eldbus type and the network interface to connect to.

3. Click on OK to connect.

4. Verify that the connection is successful by checking the status strip in the Main Window.

Illustration 6.25 Connect To Network Window (Ethernet

POWERLINK®)

Commissioning

VLT® Integrated Servo Drive ISD® 510 System

STEP 3: Scan for devices

1. After verifying that the ISD Toolbox is connected to the selected network, click on the Scan for Devices icon in the toolbar to trigger the device scan procedure.

NOTICE

If connected to an Ethernet POWERLINK® network in cyclic mode, select the scan range (minimum and maximum IDs) in the next window to reduce the time needed for scanning. In all other cases, the complete ID range is scanned.

2. When the scan is complete, a list of available devices is showed in the Select Devices window. Select which devices to add to the Device Environment and click on OK.

3. All selected devices appear in the Device Environment window and automatically go online (indicated by a glowing light bulb next to each device name).

NOTICE

See the VLT® Integrated Servo Drive ISD® 510 System Programming Guide for further information on the ISD

Toolbox software.

6.6.2 Simple Programming Template

Automation Studio™

Detailed information on how to open the sample project within the ISD package in Automation Studio™ can be found in the Automation Studio™ Help. Open the B&R Help Explorer and go to [Programming → Examples → Adding sample programs] and follow the instructions for library samples.

TwinCAT

A basic sample PLC application for starting up the ISD 510 servo system with 1 SAB and 2 axes is provided. The project ISD_System_SampleProject can be downloaded from the Danfoss website.

6.6 Motion Library

6.6.1 Function Blocks

The PLC library provides function blocks that support the functionality of the ISD devices and comply with this standard:

PLCopen® Technical Specication Function blocks for motion control (Formerly Part 1 and Part 2) Version 2.0 March 17, 2011.

Additionally,

functionality that is not described by PLCopen®.

The following PLCopen® characteristics apply to all function blocks:

•

specic ISD function blocks provide the

Commanding (using the inputs)

Signaling (behaviour of the outputs)

General calling conventions

NOTICE

See the VLT® Integrated Servo Drive ISD® 510 System Programming Guide for further information on the

available function blocks and their behavior.

Operation Operating Instructions

7 Operation

7.1 Operating Modes

The servo drive 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

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 parame-

terized.

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 is done by means of a CAM prole that contains slave positions corresponding to master positions.

CAMs can be designed graphically with the ISD 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. The

dierent CAM prole types are described in the VLT® Integrated Servo Drive ISD® 510 System Programming

Guide.

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.

7 7

Table 7.1 Operating Modes

7.1.1 Motion Functions

Function Description

Digital CAM

switch

ISD touch

probe

Table 7.2 Motion Functions

This functionality controls whether the digital

output is enabled or disabled, depending on the

axis position. It performs a function comparable

to switches on a motor shaft. Forward and

backward movements of the axis position are

allowed. On and o compensation and hysteresis

can be parameterized.

This functionality stores the position actual value

after a rising or falling edge at the congured

digital input.

7.2 Operating Status Indicators

The operating status of the servo drive and SAB is indicated via the LEDs on each device.

DRIVE STAT X1

NET STAT

LINK/ACT

DRIVE STAT X1

X2NET STAT

LINK/ACT

Advanced Standard

130BE677.10

Aux 1 Aux 2

Safe 1 Safe 2

130BE733.10

Operation

VLT® Integrated Servo Drive ISD® 510 System

7.2.1 Operating LEDs on the Servo Drive

Illustration 7.1 shows the operating LEDs on the servo drive.

Illustration 7.1 Operating LEDs on the Servo Drive

LED Color Flash status Description

DRIVE

Green On Servo drive is in state

STAT

Flashing Auxiliary voltage is

Red On Servo drive is in Fault

Flashing DC-link voltage is not

NET

Green/

Fieldbus dependent Network status of the

STAT

red

Link/A

Green – Link/activity status of

CT X1

On Ethernet link

Flashing Ethernet link

O No link.

Link/A

Green – Link/activity status of

CT X2

On Ethernet link

Flashing Ethernet link

O No link.

Operation enabled.

applied.

or Fault reaction active

state.

applied.

device (see

corresponding eldbus

standard).

Hybrid In (X1)

established.

established and active.

Hybrid Out (X2)

established.

established and active.

LED Color Flash status Description

Link/A

Green – Link/activity status of

Table 7.3 Legend to Illustration 7.1

1) Advanced version only

On Ethernet link

Flashing Ethernet link

O No link.

the Ethernet port (X3).

established.

established and active.

7.2.2 Operating LEDs on the Servo Access Box

Illustration 7.2 Operating LEDs on the SAB

LED Color Flash status Description

Aux 1 Green – State of the auxiliary

voltage on line 1.

On Statemachine is in

state Standby, Power

up, or Operation

enabled. Auxiliary

voltage is applied to

the output connectors

on line 1.

O Statemachine is in

state U

Fault. Auxiliary voltage

is not applied to line 1.

disabled or

AUX

Operation Operating Instructions

LED Color Flash status Description

Aux 2 Green – State of the auxiliary

voltage on line 2.

On Statemachine is in

state Standby, Power

up, or Operation

enabled. Auxiliary

voltage is applied to

the output connectors

on line 2.

O Statemachine is in

state U

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

Flashing Auxiliary voltage is

O No auxiliary voltage is

Red On The SAB is in state

Flashing Mains is not applied at

NET

Green/

Fieldbus dependent. Network status of the

STAT

red

Link/A

Green – Link/activity status of

CT X1

On Ethernet link

Flashing Ethernet link

O No link.

Link/A

Green – Link/activity status of

CT X2

On Ethernet link

Flashing Ethernet link

O No link.

Operation enabled.

applied at the input.

Fault.

the input.

device (see

corresponding eldbus

standard).

In.

established.

established and active.

Out.

established.

established and active.

disabled or

AUX

LED Color Flash status Description

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 7.4 Legend to Illustration 7.2

line 1.

established.

established and active.

line 2.

established.

established and active.

7 7

ISD Safety Concept

8 ISD Safety Concept

VLT® Integrated Servo Drive ISD® 510 System

8.1 Applied Standards and Compliance

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: 2008 Category 3 PL d

•

The ISD 510 servo system has been tested for higher EMC immunity as described in IEC/EN 61326-3-1.

8.2 Abbreviations and Conventions

Abbreviation Reference Description

Cat. EN ISO

13849-1

DC – Diagnostic coverage

FIT – Failure in time

H EN IEC 61508 Hardware fault tolerance

MTTFd EN ISO

13849-1

PFH EN IEC 61508 Probability of dangerous failures

PFD EN IEC 61508 Average probability of failure on

PL 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

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.

demand.

This value is used for low demand

operation.

Performance level

A discrete level used to specify the

capability of safety-related parts of

a system to perform safety-

oriented functions under

foreseeable conditions. Levels: a–e.

Abbreviation Reference Description

SFF EN IEC 61508 Safe Failure Fraction [%]

Proportion of safe failures and

detected dangerous failures of a

safety function or a subsystem as a

percentage of all possible failures.

SIL EN IEC 61508

EN IEC 62061

STO EN IEC

61800-5-2

SS1 EN IEC

61800-5-2

SRECS EN IEC 62061 Safety-related electrical control

SRP/CS EN ISO

13849-1

PDS/SR EN IEC

61800-5-2

Table 8.1 Abbreviations and Conventions

Safety Integrity Level

Safe Torque O

Safe stop 1

system

Safety-related parts of control

systems

Power drive system (safety-related)

8.3 Qualied Personnel for Working with

the STO Function

The STO function may only be installed, programmed, commissioned, maintained, and decommissioned by qualied personnel. Qualied personnel for the STO function are qualied electrical engineers, or persons who have received training from qualied electrical engineers and are suitably experienced to operate devices, systems, plant, and machinery in accordance with the general standards and guidelines for safety technology.

Furthermore they must:

Be familiar with the basic regulations concerning

•

health and safety/accident prevention.

Have read and understood the safety guidelines

•

given in this manual.

Have a good knowledge of the generic and

•

specialist standards applicable to the specic application.

Users of power drive systems (safety-related) (PDS(SR)) are responsible for:

Hazard and risk analysis of the application.

•

Identifying safety functions required and

•

allocating SIL or PLr to each of the functions, other subsystems, and the validity of signals and commands from them.

Designing appropriate safety-related control

•

systems (hardware, software, parameterization, and so on).

ISD Safety Concept Operating Instructions

Protective measures

Install the ISD 510 servo system components with

•

a protective rating of less than IP54 in an IP54 cabinet as per IEC 60529 or in an equivalent environment. In special applications, higher IP protection may be necessary.

If external inuences can inuence the motor

•

axis, for example suspended loads, use additional measures, such as a safety holding brake, to eliminate hazards.

8.4 Safety Precautions

NOTICE

After installing the STO function, perform a commissioning test as described in chapter 8.9 Commissioning Test. A passed commissioning test is mandatory after initial installation and after each change to the safety installation.

WARNING

UNCONTROLLED MOVEMENT

External forces on the motor could cause an uncontrolled and hazardous movement that could result in death or serious injury.

Equip the motor with additional measures for

•

preventing uncontrolled and hazardous movement, for example mechanical brakes.

WARNING

RISK OF ELECTRICAL SHOCK

The STO function does not isolate mains voltage to the ISD 510 servo system or auxiliary circuits. Only perform work on electrical parts of the ISD510 system or the servo drive after isolating the mains voltage supply and waiting the length of time specied in chapter 2 Safety. Failure to isolate the mains voltage supply and waiting the time specied could result in death or serious injury.

Do not use the STO function to stop a running

•

ISD 510 servo system in normal operation. When using the STO function the servo drive coasts to stop. Depending on the application, a mechanical brake may be required.

Use the STO function when performing

•

mechanical work on the ISD 510 servo system or aected area of a machine. The STO function does not provide electrical safety and must not be used as a control to start and/or stop the ISD 510 servo system.

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.

8 8

WARNING

RISK OF ELECTRICAL SHOCK

The STO function itself does not supply electrical safety and is not sucient to implement the Emergency-O function as dened by EN 60204-1, resulting in risk of death or serious injury.

Ensure electrical isolation for Emergency-O, for

•

example by switching o the mains via an additional contactor.

WARNING

RISK OF RESIDUAL ROTATION

Due to failures in the power semiconductor of the drive, a residual rotation can result from a fault that could result in death or serious injury. The rotation can be calculated to angle = 360°/(number of poles).

Take this residual rotation into consideration

•

and ensure that it does not pose a safety risk.

NOTICE

Take measures to ensure that common mode voltage disturbances, as described in EN/IEC 61000-4-16, do not occur in the installation. This can be done, for example, by installing according to the requirements of EN/ IEC 60204-1.

NOTICE

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

130BE690.10

SAB

STO 1 IN: + STO

STO 1 IN: – STO

STO 2 IN: + STO

STO 2 IN: – STO

ISD Safety Concept

VLT® Integrated Servo Drive ISD® 510 System

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.

8.5 Functional Description

The STO function in the ISD 510 servo system features a separate STO function for each line of servo drives in daisychain 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.

8.6 Installation

Install the ISD 510 servo system as described in

chapter 4 Mechanical Installation and chapter 5 Electrical 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 ISD 510 servo system to activate STO (see Illustration 8.1). Route the wires for STO 1 and STO 2 separately and not in a single multicore cable.

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

The external supply must be a SELV/PELV supply.

8.7 Operation of the ISD Safety Concept

This chapter details the basic STO signals. Some of the signals can be reached in several ways, however only

access via eldbus is described here. See the VLT

Integrated Servo Drive ISD® 510 System Programming Guide

for further information.

The STO function does not require any parameterization and is always enabled. To disable the function permanently, connect the STO inputs directly to the 24 V outputs STO 1 IN: 24 V or STO 2 IN: 24 V on the SAB.

The ISD 510 servo drive provides STO status signals via the

eldbus.

For general information on how to access and map data

objects, see the VLT® Integrated Servo Drive ISD® 510 System Programming Guide.

Danfoss provides a library for ISD 510 to simplify the use

of the eldbus functions. See the VLT® Integrated Servo

Drive ISD® 510 System Programming Guide for further information.

8.7.1 Statusword

The statusword in 0x6041 provides the STO status in bit 14. The bit is set to 1 if STO is active and 0 if STO is deactivated. All servo drives on each STO line must display the same information in this bit. Carry out a check via the PLC to compare the STO status of all servo drives on each line.

If STO is activated when the servo drive is disabled, and no attempt is made to enable the servo drive while STO is active, it is not necessary to reset the STO function after reapplying supply to the STO terminals.

If STO is activated when the servo drive is enabled, an error code is issued (see chapter 8.7.2 Error Codes).

Illustration 8.1 Safety Relay with Plus and Minus Switching

Output

ISD Safety Concept Operating Instructions

8.7.2 Error Codes

If bit 3 of the statusword is set, this indicates any faults that occur on the servo drive. If the fault occurred because of the STO circuit, the cause of the fault can be found in object 0x603F.

Error

code

0xFF80 Fault STO activated while the servo

0xFF81 Safety

0xFF85 Safety

Table 8.2 Error Codes

Classi-

cation

fault

Description Reset

Reset via the

drive was enabled, or an

attempt to enable the servo

drive was made while STO

was active.

Servo drive internal diagnostic

fault.

Internal STO supply on the

power card is not within

limits.

PLC.

Carry out a

power cycle.

Carry out a

power cycle.

8.9 Commissioning Test

Error code 0xFF80 can be a normal status of the application. In this case, the servo drive requires a reset signal from the PLC. To use the STO function in an application that requires a control guard (see ISO 12100 for details), this reset information can be given automatically by the PLC.

Error code 0xFF81 means that there is a fault on the servo drive that can only be reset by carrying out a power cycle. Complete the commissioning test as described in chapter 8.9 Commissioning Test after the power cycle. Operation of the ISD 510 servo system can only be resumed if the test is completed successfully. If error code 0xFF81 or 0xFF85 is issued again, contact Danfoss Service.

8.8 Fault Reset

Change bit 7 of the controlword from 0 to 1 to reset faults.

See the VLT® Integrated Servo Drive ISD® 510 System Programming Guide for further information.

8 8

NOTICE

Perform a commissioning test after installation of the STO function, after every change to the installed function, or after a safety fault (described in chapter 8.7.2 Error Codes). 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

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.

Check that the application can

run.

Application runs as expected. Application runs as expected.

RPM.

Expected result for TwinCAT

library

All servo drives are at speed 0

RPM.

ISD Safety Concept

VLT® Integrated Servo Drive ISD® 510 System

Test steps Reason for the test step Expected result for Danfoss

library

4 Enable STO. Check that STO can be

activated without error.

5 Disable STO. Check that STO can be

deactivated without error. No

reset is required.

6 Run the application (all the

servo drives are enabled).

7 Enable STO. Check that errors are

– Application runs as expected. Application runs as expected.

generated correctly when STO

is activated while the servo

drives are running.

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).

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.

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

–

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 8.3 Commissioning Test using Libraries

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

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.

servo drives.

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

servo drives.

ISD Safety Concept Operating Instructions

Test steps Reason for the test step Expected result

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).

Table 8.4 Commissioning Test using Bit-Wise Readout

– Application runs as expected.

Motors are torque free. Motors coast and

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.

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.

8 8

+24 V DC

–24 V DC

130BE689.10

ISD Safety Concept

VLT® Integrated Servo Drive ISD® 510 System

8.10 Application Example

Illustration 8.2 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 ISD 510 servo system.

The 2 lines in the example are controlled separately. If the Safe Torque O function is triggered on line 1, line 2 remains in 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.

1a/1b ISD 510 servo drive on line 1 7 Safety device on line 2

2a/2b ISD 510 servo drive on line 2 8 Line 2 emergency stop button

3 Servo Access Box (SAB) 9 Line 2 safety device contacts

4 Safety device on line 1 10 Line 1 hybrid cable

5 Line 1 emergency stop button 11 Line 2 hybrid cable

6 Line 1 safety device contacts 12 24 V DC supply

Illustration 8.2 Application Example: Safe Torque O Function with 2 Lines

ISD Safety Concept Operating Instructions

8.11 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

<100 ms

233 years (limited to

100 years if the ISD

510 servo system

forms an entire safety

channel)

<5 x 10-8/h

8 8

Table 8.5 Safety Function Characteristic Data

Maintenance, Security, and User

8.12 Accessibility

Maintenance

Operate the STO function at least once per year.

Security

If security risks exist, take suitable measures to prevent them.

User accessibility

Restrict access to the servo drives, SAB, and other ISD 510 servo system components if access to them could result in safety risks.

Diagnostics

9 Diagnostics

VLT® Integrated Servo Drive ISD® 510 System

9.1 Faults

If faults occur during servo system operation, check:

The LEDs on the servo drive for general problems

•

relating to communication or device status.

The LEDs on the SAB for general problems with

•

communication, auxiliary supply, or STO voltage.

The error codes can be read using the ISD Toolbox software, the LCP, or the PLC. The LCP only shows faults relating to the device it is connected to.

NOTICE

If the fault cannot be eliminated by 1 of the measures listed in Table 9.1 or Table 9.3, notify Danfoss Service.

Have the following information available to enable Danfoss to provide help quickly and eectively:

Type number

•

Error code

•

9.2

9.2.1 Troubleshooting

First use Table 9.1 to check the possible causes of the fault and possible solutions. The error codes are listed in chapter 9.2.2 Error Codes.

Fault Possible cause Possible solution

LCP display dark

or has no

function.

Firmware version

•

System set-up (for example, number of servo

•

drives and lines).

Servo Drive

Missing input power. Check the input

power source.

Missing or open fuses

or circuit breaker

tripped.

No power to the LCP.

Check the fuses and

circuit breaker.

•

Incorrect contrast

setting.

Display is defective. Replace the faulty

Press [Status] +

[▲]/[▼] to adjust the

contrast.

LCP or connection

cable.

Check the LCP

cable for proper

connection or

damage.

Replace any faulty

LCP or connection

cables.

Fault Possible cause Possible solution

Servo drive

overheats (high

surface

temperature).

Servo drive not

running.

Servo drive does

not run or only

starts up slowly or

with diculty.

Drive hums and

draws high

current.

Drive stops

suddenly and

does not restart.

Wrong motor

rotation direction.

Drive runs

normally, but

does not generate

the expected

torque.

Drive screaming.

Uneven running. Defective bearing. Check the shaft.

Vibration.

Excessive load. Check the torques.

No drive communi-

cation or drive in

error mode.

Bearing wear.

•

Incorrect

•

parameter

settings.

Incorrect control

•

loop parameters.

Incorrect torque

•

settings.

Drive defective. Contact Danfoss.

No drive

•

communication.

Servo drive in

•

error mode.

Parameter error.

Drive defective.

•

Parameter error.

•

Incorrect

•

calibration.

Faulty current

•

measurement.

Incorrect control

•

loop parameters.

Defective bearing.

•

Incorrect control

•

loop parameters.

Check the eldbus

connection and the

status LEDs on the

servo drive.

Check the

•

bearings and

shaft.

Check the

•

parameter

settings.

Check the eldbus

connection and the

status LEDs on the

servo drive.

Check the

•

parameter

settings.

Change the

•

rotation direction

if appropriate.

Check the

•

parameter

settings.

Contact Danfoss.

•

Check the

•

parameter

settings.

Contact Danfoss.

•

Check the shaft.

•

Check the

•

parameter

settings.

Diagnostics Operating Instructions

Fault Possible cause Possible solution

(Unusual) running

noises

System fuse

blows, circuit

breaker trips, or

drive protection

trips immediately.

Drive speed drops

sharply under

load.

Brake does not

release.

Holding brake

does not hold the

servo drive.

Brake

engagement

delayed.

Noises when

power-o brake

engaged.

LEDs do not light

up.

Error 0xFF91

occurs.

Table 9.1 Troubleshooting Servo Drive

Defective bearing.

•

Defects on

•

connected

mechanics.

Incorrect control

•

loop parameters.

Short circuit.

•

Incorrect control

•

loop parameters.

Drive is running at

•

current limit.

Drive is running

•

with incorrect

parameters.

Brake control

defective.

Mechanical brake

•

defective.

Shaft load exceeds

•

the holding torque

of the brake.

Software error. Contact Danfoss.

Mechanical brake

damaged.

No power supply. Check the power

Increments between

succeeding values too

big.

Check the shaft.

•

Check for loose

•

mechanical

components on

the attached

mechanics.

Check the

•

parameter

settings.

Check the wiring.

•

Contact Danfoss.

•

Check the

•

application.

Check the

•

parameter

settings.

Contact Danfoss.

supply.

Check for velocity or

guide value plausi-

bility distance.

9.2.2 Error Codes

Code Name Severity

(Warning/

Error/Trip

lock)

0x0000 No error Error No error. –

0x1000 Generic

application

error

0x2310 Overcurrent

on output

Error Generic

Error Overcurrent

Description LCP name

generic err

application

error.

overcurr out

on output.

Code Name Severity

(Warning/

Error/Trip

lock)

0x239B Overload on

output (I2T)

0x3210 DC link

overvoltage

0x3220 DC link

undervoltag

0x4290 Overtem-

perature:

Power

module

0x4291 Overtem-

perature:

Control card

0x4295 Overtem-

perature:

Power card

0x4310 Overtem-

perature:

Motor

0x5112 UAUX

undervoltag

0x5530 EE

Checksum

Error

(parameter

missing)

0x6320 Parameter

error

0x7320 Internal

position

sensor error

0x7380 External

position

sensor error

0x8693 Homing

error on

entering

homing

mode

Warning,

error

Error Overvoltage

Error Undervoltag

Error Overtem-

Error, trip

lock

Trip lock Missing

Trip lock An internal

Trip lock Absolute

Error External

Warning Could not

Description LCP name

I2t thermal

state.

on DC-link

voltage

e on DC-link

voltage.

perature on

power

module.

perature on

control PCB.

perature on

power PCB.

perature on

motor.

Undervoltag

e on

auxiliary

voltage.

parameter in

internal

drive cong-

uration.

parameter

has an

invalid value.

position

sensor error.

encoder

data could

not be read.

enter

homing

mode (for

example

velocity not

0).

overload

UDC

overvolt

UDC

undervolt

overtemp

overtemp CC

overtemp PC

overtemp

motor

undervolt

UAUX

cong err

param err

int sensor

err

ext sensor

err

Homing

mode fail

9 9

Diagnostics

VLT® Integrated Servo Drive ISD® 510 System

Code Name Severity

(Warning/

Error/Trip

lock)

0x8694 Homing

error on

start homing

method

0x8695 Homing

error

distance

0xFF01 Mechanical

brake failure

0xFF02 Short circuit

mechanical

brake

control

0xFF0A External

interface

power

failure

Warning Could not

Warning Homing

Trip lock No brake or

Trip lock Short circuit

Error External

0xFF60 Timing

violation 1

0xFF61 Timing

violation 2

0xFF62 Timing

violation 3

0xFF63 Timing

violation 4

0xFF64 Timing

violation 5

0xFF65 Timing

violation 6

0xFF70 Firmware:

Package

description

mismatch

0xFF71 Firmware:

Power cycle

needed

Trip lock Contact

Trip lock Firmware

Warning,

error

Description LCP name

Homing

start homing

method (for

example

drive not in

standstill).

distance

reached.

wire failure.

in brake

control.

interface

power

supply

failure.

Danfoss.

found does

not match

the package

description.

Firmware

update

transfer is

completed

but a power

cycle is

required

before the

new

rmware is

active.

method fail

Homing

distance

brake mech

fail

brake mech

short

ext IF pwr

fail

timing err 1

timing err 2

timing err 3

timing err 4

timing err 5

timing err 6

FW pack err

need

powercycle

Code Name Severity

(Warning/

Error/Trip

lock)

0xFF72 Firmware:

Update

started

0xFF80 STO active

while drive

enabled

0xFF81 STO

mismatch

0xFF85 P_STO error Trip lock P_STO

0xFF90 Guide value

reversed

0xFF91 Guide value

implausible

Table 9.2 Error Codes for Servo Drive

Warning,

error

Error STO

Trip lock Dual

Error Position

Error Increments

Description LCP name

Firmware

update in

progress.

The warning

becomes an

error when

an attempt

is made to

enable the

drive in this

state.

activated

while servo

drive was

enabled or

tried to

enable while

STO active.

diagnosis of

STO voltage

not

plausible.

voltage on

power card

not within

limits.

guide value

went

backwards

while servo

drive in CAM

mode.

between

succeeding

values too

big.

FW update

STO active

STO

mismatch

P_STO error

guide val rev

guide val

impl

Diagnostics Operating Instructions

9.3 Servo Access Box (SAB)

9.3.1 Troubleshooting

Table 9.3 lists potential faults on the SAB, their possible causes, and actions for correcting the faults.

Fault Possible cause Possible solution

LCP display

dark or has no

function.

Open power

fuses or circuit

breaker trip.

DC-link voltage

too high.

DC-link voltage

too low.

DC overcurrent. The sum of the

Missing input

power.

Missing or

open fuses or

circuit breaker

tripped.

No power to

the LCP.

Incorrect

contrast

setting.

Display is

defective.

Phase-to-phase

short.

Brake resistor

not connected.

Brake resistor

too high

resistance.

Several servo

drives are

decelerating

with

insucient

ramp time.

Brake resistor

functionality

not activated.

Incorrect mains

supply.

servo drive

current exceeds

the maximum

rating of the

SAB.

Check the input power source.

Check the fuses and circuit

breaker.

Check the LCP cable for

•

proper connection or

damage.

Replace any faulty LCP or

•

connection cables.

Press [Status] + [▲]/[▼] to

adjust the contrast.

Replace the faulty LCP or

connection cable.

Check the cabling.

•

Check for loose

•

connections.

Check the brake resistor

cabling.

Check if the lowest resistance

value has been entered.

Avoid simultaneous

•

deceleration of several

servo drives.

Change the deceleration

•

speed of the servo drives.

Activate the brake function.

Check supply voltage matches

the allowed specication

detailed in chapter 8 ISD

Safety Concept.

Check the servo drive

•

current consumption.

Avoid simultaneous

•

acceleration of all servo

drives.

Fault Possible cause Possible solution

AUX

overcurrent.

AUX

overvoltage.

AUX

undervoltage.

Mains phase

loss.

Grounding fault. Grounding

Brake resistor

error.

Brake chopper

error.

Table 9.3 Troubleshooting SAB

The servo

drives are

consuming

more power on

the U

line

AUX

than allowed.

Incorrect U

supply.

Incorrect U

supply.

A phase is

missing on the

supply side, or

the voltage

imbalance is

too high.

fault.

Faulty brake

resistor.

Faulty brake

chopper.

AUX

Check the number of

•

attached servo drives with

the shell diagrams in the

VLT® Integrated Servo Drive

ISD® 510 System Design

Guide.

Avoid simultaneous lifting

•

of the servo drive brakes.

Check that the supply

matches the allowed speci-

cation detailed in

chapter 5.6 Auxiliary Supply

Requirements.

Check that the supply

•

voltage matches the

allowed specication

detailed in

chapter 5.6 Auxiliary Supply

Requirements.

Check that the output

•

power of the supply is

sucient.

Check the supply voltages and

supply currents to the SAB.

Check for proper

•

grounding and loose

connections.

Check the hybrid cables

•

for short circuits or

leakage currents.

Remove the power to the

SAB, wait for the discharge

time to elapse then replace

the brake resistor.

Check the setting in

parameter 2-15 Brake Check.

9 9

Diagnostics

9.3.2 Error Codes

VLT® Integrated Servo Drive ISD® 510 System

Code Name Severity

(Warning/

error/trip

lock)

0x0000 No error Error No error. –

0x1000 Generic application error Error Generic application error. generic err

0x2120 Ground fault Error There is current from the output

0x2340 Short circuit Error There is a short circuit in UDC output

0x2391 AUX 1 overcurrent Error Current on AUX Line 1 reached

0x2392 AUX 2 overcurrent Error Current on AUX Line 2 reached

0x2393 AUX 1 user limit current Warning,

error

0x2394 AUX 2 user limit current Warning,

error

0x2395 AUX 1 fuse failure Error HW fuse failure.

0x2396 AUX 2 fuse failure Error HW fuse failure.

0x2397 DC 1 overcurrent Error Overcurrent on DC Line 1. The SAB

0x2398 DC 2 overcurrent Error Overcurrent on DC Line 2. The SAB

0x2399 DC overcurrent Error Overcurrent. The SAB has reached the

0x239B Overload on output (I2T) Warning,

error

0x239D DC overcurrent Warning,

error

0x3130 Mains phase loss Warning,

error

0x3210 DC link overvoltage Error The DC-link voltage exceeds the limit

0x3220 DC link undervoltage Error The DC-link voltage is below the limit

0x3291 U

0x3292 U

high voltage Warning U

AUX

overvoltage Error U

AUX

Description LCP name

ground fault

phases to ground.

short circuit

from SAB (DC Line1 and/or DC Line2).

Remove power to the SAB and repair

the short circuit.

AUX1 overcurr

overcurrent limit.

AUX2 overcurr

overcurrent limit.

Current on AUX Line 1 reached user-

dened limit.

Current on AUX Line 2 reached user-

dened limit.

Current or voltage above limit on AUX

Line 1.

Current or voltage above limit on AUX

Line 2.

peak current limit (approximately 200%

of the rated current) is exceeded.

peak current limit (approximately 200%

of the rated current) is exceeded.

current limit and shuts down to

prevent any damage to the hardware.

The SAB is about to cut out due to an

overload (more than 100% for too

long). The counter for electronic,

thermal SAB protection triggers a

warning at 90% and trips with an error

at 100%.

Overcurrent. The SAB has reached the

current limit and shuts down to

prevent any damage to the hardware.

Mains phase loss detected. This occurs

when a phase on mains is missing, or

when the mains is imbalanced.

and the SAB trips.

above warning limit. UAUX high volt

AUX

above overvoltage limit. UAUX overvolt

AUX

AUX1 curr limit

AUX2 curr limit

AUX1 fuse fail

AUX2 fuse fail

DC1 overcurr

DC2 overcurr

DC overcurr

overload

DC overcurr

phase loss

UDC overvolt

UDC undervolt

Diagnostics Operating Instructions

Code Name Severity

(Warning/

error/trip

lock)

0x3293 U

0x3294 U

0x3295 UDC high voltage Warning The DC-link voltage (DC) is higher than

0x3296 UDC low voltage Warning The DC-link voltage (DC) is lower than

0x4220 Too low temperature: Heat

0x4290 Overtemperature: Heat sink Warning,

0x4291 Overtemperature: Control

0x4292 Overtemperature: SAB card Warning,

0x4293 Inrush overtemperature: SAB

0x4294 Inrush overtemperature:

0x4410 Overtemperature: SAB Error Logic OR of control card temperature

0x6320 Parameter error Trip lock A parameter has an invalid value. param err

0x6380 Conguration error

0x6381 Reinitialization of parameters

0x7111 Brake chopper short circuit Error The brake chopper is monitored during

0x7181 Brake resistor failure Error The brake resistor is monitored during

low voltage Warning U

AUX

undervoltage Error U

AUX

Warning Heat sink temperature low. The SAB is

sink

Error

Warning,

card

power module

(parameter missing)

from powercard

Error

Error Inrush fault. Too many transitions into

Error Inrush fault. Too many power-ups have

Trip lock A parameter is missing. cong err

Trip lock Conguration reinitialization.

Description LCP name

below warning limit. UAUX low volt

AUX

below undervoltage limit. UAUX undervolt

AUX

UDC high volt

the high-voltage warning limit.

UDC low volt

the low-voltage warning limit.

low temp PM

too cold to operate. This warning is

based on the temperature sensor in

the IGBT module. This warning only

occurs when DC-link voltage is >250 V.

The maximum temperature of the heat

sink has been exceeded. The

temperature fault does not reset until

the temperature drops below a dened

heat sink temperature (115 °C).

Control card overtemperature.

The cutout temperature of the control

card is 80 °C.

SAB card overtemperature.

The cutout temperature of the SAB

card is 80 °C.

state Normal operation have occurred

within a short time period.

occurred within a short time period.

(see 0x4291) and/or heat sink

temperature (see 0x4290) and/or SAB

card temperature (see 0x4292).

Conguration parameter for power unit

has been reinitialized.

operation. This error appears if a short

circuit occurs.

operation. This error appears if a short

circuit occurs.

overtemp PM

overtemp CC

overtemp SC

inrush SC

inrush PM

overtemp SAB

cong reinit

brake ch short

brake r short

9 9

Diagnostics

VLT® Integrated Servo Drive ISD® 510 System

Code Name Severity

(Warning/

error/trip

lock)

0x7182 Brake resistor power limit Error Brake resistor power limit exceeded.

0x7183 Brake chopper check failed Error Brake check failed. The brake resistor is

0x7380 External position sensor error Error External encoder data could not be

0xFF21 Internal fan fault Warning Internal fan fault. The fan warning

0xFF31 AUX Line 1 min o time Warning The minimum o time required to

0xFF32 AUX Line 2 min o time Warning The minimum o time required to

0xFF51 Internal error 1 Trip lock Internal error 1, contact Danfoss. PM int err 1

0xFF52 Internal error 2 Trip lock Internal error 2, contact Danfoss. PM int err 2

0xFF53 Internal error 3 Trip lock Internal error 3, contact Danfoss. PM int err 3

0xFF54 Internal error 4 Trip lock Internal error 4, contact Danfoss. PM int err 4

0xFF55 Internal error 5 Trip lock Internal error 5, contact Danfoss. PM int err 5

0xFF56 Internal error 6 Trip lock Internal error 6, contact Danfoss. PM int err 6

0xFF70 Firmware: Package description

mismatch

0xFF71 Firmware: Power cycle

needed

0xFF72 Firmware: Update started Warning,

Trip lock Firmware found does not match

Warning,

error

Description LCP name

brake r pwr lim

The power transmitted to the brake

resistor is calculated as an average

value over the last 120 s of run time.

The calculation is based on the DC-link

voltage and the brake resistor value set

in parameter 2-16 (Brake resistor power

120 s). The error is reported when the

value is exceeded within 120 s.

brake ch check

not connected or not working.

ext sensor err

read.

fan fault

function checks if the fan is running/

mounted.

AUX1 min o

protect the internal hardware has not

been met.

AUX2 min o

protect the internal hardware has not

been met.

FW pack err

package description.

Firmware update transfer is completed

but a power cycle is required before

the new rmware is active.

Firmware update in progress. The

warning becomes an error when an

attempt is made to enable the drive in

this state.

need powercycle

FW update

Table 9.4 Error Codes for SAB

Maintenance, Decommissionin... Operating Instructions

10 Maintenance, Decommissioning, and Disposal

Maintenance Tasks

WARNING

HIGH VOLTAGE

Potentially lethal voltage is present on the connectors. Before working on the power connectors (disconnecting or connecting the cable), disconnect the SAB from the mains and wait for the discharge time to elapse.

10.1

The servo drives are largely maintenance free. Only the shaft seal (if used) is subject to wear.

The maintenance tasks listed in Table 10.2 can be performed by Personnel). No other tasks are required.

qualied personnel (see chapter 2.5 Qualied

WARNING

DISCHARGE TIME

To avoid electrical shock, fully disconnect the

•

SAB from the mains and wait for at least the time listed in Table 10.1 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 10.1 Discharge Time

Component Maintenance

task

Servo drive Carry out a

visual

inspection.

Shaft seal Check the

condition and

check for

leakage.

Hybrid

cable

Mechanical

holding

brake

(optional)

Functional

safety

SAB Check the

Check for

damage and

wear.

Check the

brake.

Perform a

system power

cycle and

check the

STO function.

fan.

Maintenance

interval

Every 6

months

Every 6

months

Every 6

months

Every 6

months

Every 12

months

Every 12

months

Instruction

Check for any

abnormalities on the

surface of the servo

drive.

If damaged, replace

the shaft seal.

If damaged or worn:

Replace the hybrid

cable (see

chapter 10.3.1 Cable

Replacement).

Ensure that the brake

can achieve the

holding torque as

detailed in

chapter 3.2.2.2 Brake

(Optional).

Activate STO and

check the status with

the PLC. See

chapter 8 ISD Safety

Concept for further

information.

Check that the fan

can turn and remove

any dust or dirt.

10 10

Table 10.2 Overview of Maintenance Tasks

1) A shorter interval may be necessary depending on the application.

Contact Danfoss for more information.

Maintenance, Decommissionin...

VLT® Integrated Servo Drive ISD® 510 System

10.2 Inspection during Operation

Servo drives

Carry out regular inspections during operation. Check the servo drives at regular intervals for anything unusual.

Pay particular attention to:

Unusual noises.

•

Overheated surfaces (temperatures up to 100 °C

•

can occur in normal operation).

Uneven running.

•

Strong vibrations.

•

Loose fastenings.

•

Condition of electrical wiring and cables.

•

Poor heat dispersion.

•

If irregularities or problems occur, see chapter 9.2 Servo Drive.

SAB

Carry out regular inspections during operation.

Ensure that:

The cooling vents are not blocked.

•

The fan is not making any unusual noises.

•

If irregularities or problems occur, see chapter 9.3 Servo

1010

Access Box (SAB).

Repair

10.3

NOTICE

Always return defective equipment to the local Danfoss sales company.

The repair tasks listed in this chapter can be performed by qualied personnel (see chapter 2.5 Qualied Personnel).

10.3.1 Cable Replacement

Replace the cables when the rated number of bending cycles has been reached or the cable is damaged.

NOTICE

Never disconnect or connect the cable from the servo drive with the supply voltage connected. Doing so damages the electronic circuitry. Observe the discharge time for the DC-link capacitors.

10.3.1.1 Feed-In Cable Replacement

Proceed as follows:

Disconnecting cables

1. Disconnect the SAB from its power source (mains network and all auxiliary supplies).

2. Wait for the necessary discharge time to elapse.

3. Disconnect any cables connected to the X3, X4, or X5 ports on the servo drive for easier access to the feed-in cable.

4. Disconnect the PE wire from the decouping plate on the SAB.

5. Open the cable clamp holding the STO cable.

6. Open the cable clamp holding the feed-in cable on the SAB.

7. Loosen the feed-in cable connectors on the SAB.

8. Dismount the feed-in cable on the SAB.

9. Loosen the threaded ring of the connector on the servo drive.

10. Disconnect the feed-in cable from the servo drive.

Cable replacement

Replace the feed-in cable with a cable of identical type

and length. See the VLT System Design Guide for ordering numbers.

Connecting cables

1. Connect the female connector of the feed-in cable to the male connector of the 1st servo drive.

2. Turn the threaded rings of the connectors hand tight.

3. Ensure that there is no mechanical tension on the cables.

4. Insert the feed-in cable connectors into the correct position on the SAB (see chapter 5.8.1 Servo Access Box).

5. Secure the feed-in cable ensuring that the shield is positioned exactly under the clamp.

6. Secure the STO cable in the cable clamp ensuring that the shield is positioned exactly under the clamp.

7. Connect the PE wire to the decoupling plate.

8. Reconnect any cables that were connected to the X3, X4, or X5 ports.

Integrated Servo Drive ISD® 510

NOTICE

Do not forcefully connect or t the connectors. Incorrect connection causes permanent damage to the connectors.

Maintenance, Decommissionin... Operating Instructions

10.3.1.2 Loop Cable Replacement

Proceed as follows:

Disconnecting cables

1. Disconnect the SAB from its power source (mains network).

2. Wait for the necessary discharge time to elapse.

3. Disconnect any cables connected to the X3, X4, or X5 ports on both servo drives for easier access to the loop cable.

4. Loosen the threaded rings of the loop cable connectors on both servo drives.

5. Disconnect the loop cable from the servo drives.

Cable replacement

Replace the loop cable with a cable of identical type and

length. See the VLT® Integrated Servo Drive ISD® 510 System Design Guide for part numbers.

Connecting cables

1. Connect the male connector of the loop cable to the female connector on the servo drive (see

chapter 5.8.2.1 Connecting/Disconnecting Hybrid Cables).

2. Connect the female connector of the loop cable to the male connector on the adjacent servo drive (see chapter 5.8.2.1 Connecting/Disconnecting Hybrid Cables).

3. Turn the threaded rings hand tight on both servo drives.

4. Ensure that there is no mechanical tension on the cables.

5. Tighten the threaded rings of the connectors on both servo drives.

6. Reconnect any cables that were connected to the X3, X4, or X5 ports on both servo drives.

Servo Drive Replacement

10.4

10.4.1 Dismounting

The procedure for dismounting the servo drive is the reverse of the tting procedure described in chapter chapter 5 Electrical Installation.

Proceed as follows:

1. Disconnect the supply and wait for the discharge time to elapse.

2. Disconnect the electrical cables.

3. Dismount the servo drive.

4. Replace the ISD 510 servo drive with an ISD 510

servo drive of the same type. See the VLT

Integrated Servo Drive ISD® 510 System Design Guide for part numbers.

10.4.2 Fitting and Commissioning

The procedure for tting and commissioning the servo drive is described in chapter 4.5.3 Fitting Instructions Servo Drive and chapter 6 Commissioning.

Proceed as follows:

1. Check if preparation is required (see chapter 4.4.1 Servo Drive).

2. Fit the servo drive (see chapter 4.5.3 Fitting Instructions Servo Drive).

3. Connect the hybrid cables (see

chapter 5.8.2.1 Connecting/Disconnecting Hybrid Cables).

4. Connect the I/O and/or encoder cables (see

chapter 5.8.2.2 Connecting/Disconnecting Cables from Ports X3, X4, and X5).

5. Congure the servo drive parameters according to the eldbus used (see chapter 6.2 ID Assignment).

6. Conduct a test run.

SAB Replacement

10.5

10.5.1 Dismounting

The procedure for dismounting the SAB is as follows:

1. Disconnect the supply and wait for the discharge time to elapse.

2. Disconnect the electrical cables.

3. Remove the decoupling plate.

4. Dismount the SAB.

10.5.2 Fitting and Commissioning

The procedure for tting and commissioning the SAB is described in chapter 4.5.5 Fitting Instructions Servo Access Box (SAB) and chapter 6 Commissioning.

Proceed as follows:

1. Check if preparation is required (see chapter 4.4.2 Servo Access Box (SAB)).

2. Fit the SAB as described in chapter 4.5.5 Fitting Instructions Servo Access Box (SAB).

3. Connect the electrical cables as described in chapter 5.8.1 Servo Access Box.

4. Switch on the system as described in chapter 6.3 Switching on the ISD 510 Servo System.

5. Congure the SAB parameters according to the eldbus used (see chapter 6.2 ID Assignment).

6. Conduct a test run.

10 10

Maintenance, Decommissionin...

VLT® Integrated Servo Drive ISD® 510 System

10.6 Decommissioning of the ISD 510 Servo System

The procedure for decommissioning the servo system is the reverse of the installation procedure described in chapter 4 Mechanical Installation.

Proceed as follows:

1. Disconnect all supplies to the servo system and wait for the discharge time to elapse.

2. Disconnect the electrical cables.

3. Dismount the servo drive.

4. Dismount the SAB.

10.7 Product Returns

Danfoss products can be returned for disposal at no charge. A prerequisite for this is that they are free of deposits, such as oil, grease, or other types of contamination that hamper disposal. Furthermore, foreign materials or third-party components cannot be included with the returned product. Ship the products free on board to the local Danfoss sales company.

Recycling and Disposal

10.8

1010

10.8.1 Recycling

Take metals and plastics to recycling stations.

The entire servo drive and the SAB are classied as electronic waste, and the packaging is classied as packaging waste.

10.8.2 Disposal

Devices containing electronic components cannot be disposed of as normal domestic waste.

Dispose of the servo drives and the SAB as hazardous waste, electrical waste, recyclable waste, and so on, in accordance with applicable local regulations.

130BE613.10

V LT ISD 510

Input1: 560-680VDC 1.4A Input2: 24-48VDC 0.3A

Ambient: 5˚ ... 40˚C/41˚ ... 104˚F Enclosure: IP54

PART NO: 000G0000 SERIAL NO: 000000M000

000G0000000000M000

Made in Germany

UL xxxxx

M : 2.6Nm n : 3000rpm P : 800W

N NN

M : 10.5Nm n : 3800rpm M : 3.5Nm

max 0max

ISD510AT01C9D6E54FRXECSXXTF084SXN40XSXSX

Specications Operating Instructions

11 Specications

11.1 Servo Drive

11.1.1 Nameplate

Check the nameplate and compare it with the order data. Use the part number for reference. The part number uniquely chapter 3.2.1.1 Types). Ensure that the nameplate is clearly legible. The servo drives can be identied externally only by the original Danfoss nameplate. The following data is shown on the servo drive nameplate:

identies the drive type (see

11.1.2 Characteristic Data

Table 11.1 and Table 11.2 provide a summary of typical servo drive characteristics.

Specications Unit Size 1

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

max

Rated Voltage V DC 560/680

Inductance L 2ph mH 18.5 26.8 32.6 33.9

Resistance R 2ph

Voltage constant

EMK

Torque constant KtNm/A 1.10 1.26 1.72 2.04

Inertia

Shaft diameter mm 14 19

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

kgm

1 Typecode 7 U

2 Supply voltage 8 Rated power

3 Rated torque 9 Standstill torque

4 Maximum torque 10 Rated speed

5 Ambient temperature range 11 Maximum speed

6 Protection rating – –

Illustration 11.1 Servo Drive Nameplate

Size 2

1.5 Nm

9.01 7.78 8.61 8.64

2.1 Nm

Size 2

2.9 Nm

0.000085 0.00015 0.00021 0.00027

supply

AUX

Size 2

3.8 Nm

11 11

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

Specications

VLT® Integrated Servo Drive ISD® 510 System

Specications Unit Size 1

1.5 Nm

Size 2

2.1 Nm

Size 2

2.9 Nm

Size 2

3.8 Nm

Pole pairs – 4 5

Flange size mm 76 84

Weight kg 3.5 4.0 5.0 6.0

Table 11.1 Characteristic Data for Servo Drive without Brake

Specications Unit Size 1

1.5 Nm

Brake inertia

kgm

0.0000012 0.0000068 0.0000068 0.0000068

Size 2

2.1 Nm

Size 2

2.9 Nm

Size 2

3.8 Nm

Brake weight kg 0.34 0.63

Rated torque

% 8 6 7

derating

Table 11.2 Characteristic Data for Servo Drive with Brake

11.1.3 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

1111

Table 11.3 Flange Thickness

All dimensions are in mm (in).

Illustration 11.2 Dimensions of ISD 510 Size 1, 1.5 Nm

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

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 Operating Instructions

Illustration 11.3 Dimensions of ISD 510 Size 2, 2.1 Nm

11 11

Illustration 11.4 Dimensions of ISD 510 Size 2, 2.9 Nm

Illustration 11.5 Dimensions of ISD 510 Size 2, 3.8 Nm

130BE662.10

130BE724.10

IM B5 IM V1 IM V3

Specications

VLT® Integrated Servo Drive ISD® 510 System

11.1.4 Permitted Forces

Illustration 11.6 Permitted Forces

Illustration 11.6 shows the maximum permitted 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 11.4. The shaft must be loaded slowly and in a constant manner: Avoid pulsating loads.

See the VLT Guide for bearing load curves.

Integrated Servo Drive ISD® 510 System Design

11.1.5 General Specications and Environmental Conditions

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 11.5 General Specications and Environmental Conditions

for Servo Drive

Protection ratings

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

NOTICE

The bearing could be permanently damaged if the maximum permitted forces are exceeded.

1111

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

Size 1 450 1050

Size 2 900 1700

Table 11.4 Permitted Forces

Illustration 11.7 Mounting Positions

Mounting position of

servo drive

(according to DIN 42 950)

Housing All positions IP67

Shaft without shaft

seal

Shaft with shaft

seal

Table 11.6 Protection Ratings

IM B5 & IM V1 IP54

IM V3 IP50

IM B5 & IM V1 IP65

IM V3 IP60

IP rating

(according to

EN 60529)

130BE612.10

V LT Servo Access Box

P : 8.47KW(400V) / 10.18KW(480V ) Input: 3x400-480V 50/60Hz 12.5A

Output: 565VDC - 679VDC / 15A Ambient: 50˚C/122˚F Enclosure: IP20

PART NO: 000X0000 SERIAL NO: 000000M000

000X00000000000M000

Made in Germany

UL xxxxx

CAUTION:

WARNING:

See manual for special condition/mains fuse Voir manuel de conditions spéciales/fusibles

Stored charge, wait 10 min. Charge residuélle, attendez 10 min.

1 2 3 4

Specications Operating Instructions

11.2 Servo Access Box

11.2.1 Nameplate

The following data is shown on the SAB nameplate:

1 Rated power 4 Ambient temperature

2 Supply voltage 5 Protection rating

3 Output voltage – –

Illustration 11.8 SAB Nameplate

11.2.2 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 15 A

Output current

ISD Line 1: STO 1 & ISD Line 2: STO 2

Output power

Housing

Dimensions (W x H x D) 130 x 268 x 80 mm

Weight 8.3 kg

Table 11.7 Servo Access Box Characteristic Data

1) Depends on the number of servo drives connected in the

application. The current per drive is 6.7 mA

2) Depends on the input voltage.

400–480 V ±10%

20 A intermittent

565–679 V ±10%

24 V ±10%

24–48 V ±10%

15 A

1 A

8.47–10.18 kW

11 11

Ensure that the nameplate is clearly legible.

190.5 (7.50)

268

(10.55)

371.5

(14.63)

130BE312.10

Specications

11.2.3 Dimensions

All dimensions are in mm (in).

Front view

VLT® Integrated Servo Drive ISD® 510 System

1111

Illustration 11.9 Dimensions: Front View

246.4

(9.70)

11.5

(0.45)

218.7 (8.61)

130BE313.10

Specications Operating Instructions

Side view

Illustration 11.10 Dimensions: Side View

11 11

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

Specications

VLT® Integrated Servo Drive ISD® 510 System

11.2.4 General Specications and

11.3 Cables

Environmental Conditions

NOTICE

Protection rating IP20

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 11.8 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

1111

See the VLT® Integrated Servo Drive ISD® 510 System Design Guide for cable dimensions and drawings.

All cables supplied by Danfoss have a nameplate as per the example in Illustration 11.11.

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 11.11 Example of a Cable Nameplate

Storage

11.4

Store the servo drives and the SAB 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 temperature changes.

11.4.1 Long-Term Storage

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.

Appendix Operating Instructions

12 Appendix

12.1 Glossary

A ange

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-metres 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, specialising 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

ISD servo drives are cooled by 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.

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 a registered trademark and patented technology, licensed by Beckho Automation GmbH, Germany.

Illustration 12.1 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

Feedback systems for servo drives in general.

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.

Installation elevation

Installation elevation above normal sea level, typically associated with a derating factor.

ISD

Integrated servo drive.

eldbus system.

Logo

12 12

Appendix

VLT® Integrated Servo Drive ISD® 510 System

ISD devices

Refers to both the ISD 510 servo drives and the SAB.

ISD servomotor

Designates the ISD servomotor (without the drive electronics).

ISD Toolbox

A Danfoss PC software tool used for parameter setting and diagnostics of ISD servo drives and the SAB.

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

1212

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

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 ISD 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 ISD 510 servo 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.

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 drives and SAB.

Wireshark

Wireshark® is a network protocol analyzer released under the GNU General Public License version 2.

Protected extra low voltage. Low voltage directive regarding voltage levels and distances between lines.

PLCopen

The name PLCopen® is a registered trademark and,

together with the PLCopen® logos, is owned by the

association PLCopen®. PLCopen® is a vendor- and productindependent worldwide association, which

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.

Radial force

The force in newton-metres acting at 90° to the longitudinal direction of the rotor axis.

Index Operating Instructions

Index

Alarm log (on LCP)................................................................................ 24

Application areas.................................................................................... 8

Auto on (on LCP)................................................................................... 25

AUX connectors..................................................................................... 22

Auxiliary supply requirements......................................................... 36

Axial load................................................................................................. 88

Brake.......................................................................................................... 14

Brake connector.................................................................................... 21

Cable

Encoder................................................................................................ 25

Fieldbus extension cable............................................................... 25

Hybrid................................................................................................... 25

I/O.......................................................................................................... 25

Layout.................................................................................................. 26

Maximum lengths............................................................................ 26

Nameplate.......................................................................................... 92

Routing................................................................................................ 26

Cabling

Connecting the 3rd Ethernet device cable............................. 42

Connecting the AUX cable........................................................... 37

Connecting the encoder cable................................................... 38

Connecting the feed-in cable...................................................... 37

Connecting the LCP cable............................................................. 42

Connecting the mains cable........................................................ 38

Connecting the Real-Time Ethernet cable.............................. 38

Connecting the STO cable............................................................ 38

For 1 lines............................................................................................ 26

For 2 lines............................................................................................ 26

Replacing the feed-in cable......................................................... 82

Replacing the loop cable.............................................................. 83

CAM mode.............................................................................................. 63

Characteristic data

Servo Access Box.............................................................................. 89

Servo drive.......................................................................................... 85

Checklist for commissioning............................................................ 43

Command................................................................................................ 66

Commissioning..................................................................................... 43

Connectors on the Servo Access Box

AUX....................................................................................................... 22

Brake..................................................................................................... 21

Encoder................................................................................................ 21

Ethernet............................................................................................... 22

Mains.................................................................................................... 20

PE........................................................................................................... 22

Relay..................................................................................................... 21

UDC....................................................................................................... 22

Connectors on the servo drive........................................................ 15

Control system....................................................................................... 66

Cooling..................................................................................................... 15

Creating a TwinCAT®............................................................................ 48

Creating an Automation Studio™ Project.................................... 44

Cyclic synchronous position mode................................................ 63

Cyclic synchronous velocity mode................................................. 63

Decommissioning of the ISD 510 servo system........................ 84

Delivery.................................................................................................... 29

Description of the ISD 510 servo system..................................... 13

Diagnostics............................................................................................. 74

Digital CAM switch............................................................................... 63

Dimensions

Servo Access Box.............................................................................. 90

Servo drive.......................................................................................... 86

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

Disposal.................................................................................................... 84

Due diligence......................................................................................... 11

Electrical environmental conditions.............................................. 35

Electrical installation........................................................................... 35

EMC-compliant installation.............................................................. 35

Encoder.................................................................................................... 15

Encoder cables

Connecting/disconnecting.......................................................... 41

Encoder connector............................................................................... 21

EtherCAT®................................................................................................ 27

Ethernet connectors............................................................................ 22

Ethernet POWERLINK®........................................................................ 28

Fault log (on LCP).................................................................................. 24

Faults......................................................................................................... 74

Feedback................................................................................................. 15

Feed-in cable replacement............................................................... 82

Fieldbus.................................................................................................... 27

Foreseeable misuse............................................................................. 12

Function blocks..................................................................................... 62

Gear mode.............................................................................................. 63

Glossary.................................................................................................... 93

Grounding............................................................................................... 35

Hand on (on LCP).................................................................................. 25

Index

VLT® Integrated Servo Drive ISD® 510 System

High voltage........................................................................................... 10

Homing mode........................................................................................ 63

Housing.................................................................................................... 89

Hybrid cable

Connecting/Disconnecting.......................................................... 39

Overview............................................................................................. 25

PE........................................................................................................... 22

I/O cables

Connecting/disconnecting.......................................................... 41

Encoder................................................................................................ 25

ID assignment

EtherCAT®............................................................................................ 43

Ethernet POWERLINK®.................................................................... 43

Inertia measurement mode.............................................................. 63

Inspection during operation............................................................ 82

Installation

Aids and tools required.................................................................. 32

Auxiliary supply requirements.................................................... 36

Clamping............................................................................................. 32

Connecting the components...................................................... 37

Coupling.............................................................................................. 33

Electrical.............................................................................................. 35

Environment...................................................................................... 29

Grounding.......................................................................................... 35

ISD Toolbox........................................................................................ 56

Mains supply requirements.......................................................... 36

Mechanical......................................................................................... 32

Preparation......................................................................................... 30

Safety measures during installation.......................................... 29

Safety power supply requirements........................................... 36

Space requirements........................................................................ 32

Tightening torques.......................................................................... 33

Intended use.......................................................................................... 11

IP rating

SAB........................................................................................................ 92

Servo drive.......................................................................................... 88

ISD servo system overview.................................................................. 7

ISD Toolbox

Commissioning................................................................................. 60

Communication................................................................................ 56

Installation.......................................................................................... 56

Overview............................................................................................. 56

System requirements...................................................................... 56

ISD touch probe.................................................................................... 63

LCP

Cable..................................................................................................... 25

Display area........................................................................................ 23

Menu key............................................................................................. 23

Navigation key.................................................................................. 23

Operation key.................................................................................... 23

Overview............................................................................................. 23

Reset..................................................................................................... 23

LEDs (on LCP)......................................................................................... 24

LEDs on the SAB

Aux 1..................................................................................................... 64

Aux 2..................................................................................................... 65

Link/ACT X1........................................................................................ 65

Link/ACT X2........................................................................................ 65

Link/ACT X3........................................................................................ 65

Link/ACT X4........................................................................................ 65

NET STAT.............................................................................................. 65

SAB STAT.............................................................................................. 65

Safe 1.................................................................................................... 65

Safe 2.................................................................................................... 65

LEDs on the servo drive

DRIVE STAT.......................................................................................... 64

Link/ACT X1........................................................................................ 64

Link/ACT X2........................................................................................ 64

Link/ACT X3........................................................................................ 64

NET STAT.............................................................................................. 64

Libraries.................................................................................................... 44

Local control panel (LCP)................................................................... 23

Long-term storage............................................................................... 92

Loop cable replacement.................................................................... 83

Main menu (on LCP)............................................................................ 24

Mains supply requirements.............................................................. 36

Maintenance.......................................................................................... 81

Mechanical installation............................................................... 29, 32

Menu keys (on LCP).............................................................................. 24

Misuse of the product......................................................................... 12

Modes of operation............................................................................. 63

Monitoring.............................................................................................. 82

Motion functions

Digital CAM switch.......................................................................... 63

ISD touch probe................................................................................ 63

Motion library........................................................................................ 62

Motor components.............................................................................. 14

Nameplate

Cable..................................................................................................... 92

SAB........................................................................................................ 89

Servo drive.......................................................................................... 85

Navigation keys (on LCP)................................................................... 24

NC axis...................................................................................................... 54

Operating modes.................................................................................. 63

Operation................................................................................................ 63

Operational safety................................................................................ 10

Permitted forces.................................................................................... 88

Index Operating Instructions

POWERLINK®........................................................................................... 28

Pre-commissioning checklist........................................................... 43

Product returns..................................................................................... 84

Prole position mode......................................................................... 63

Prole torque mode............................................................................ 63

Prole velocity mode.......................................................................... 63

Programming

Automation Studio™....................................................................... 44

Connecting to the PLC................................................................... 55

Creating an Automation Studio™ Project............................... 44

Creating an TwinCAT® Project..................................................... 48

Guidelines........................................................................................... 55

Requirements.................................................................................... 44

Template............................................................................................. 62

TwinCAT®............................................................................................. 48

TwinCAT® NC Axis............................................................................. 54

Qualied personnel............................................................................. 11

Quick menu (on LCP)........................................................................... 24

Radial load............................................................................................... 88

Recycling................................................................................................. 84

Relay connectors.................................................................................. 21

Repair........................................................................................................ 82

Replacing cables................................................................................... 82

Replacing the Servo Access Box...................................................... 83

Replacing the servo drive.................................................................. 83

Reset (on LCP)........................................................................................ 25

Resolver.................................................................................................... 15

Returning the product........................................................................ 84

Safe Torque O (STO).......................................................................... 66

Safety

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

During installation........................................................................... 29

Grounding hazard............................................................................ 10

High voltage...................................................................................... 10

Instructions........................................................................................... 9

Operational........................................................................................ 10

Power supply requirements......................................................... 36

Precautions........................................................................................... 9

Symbols.................................................................................................. 9

Unintended start.............................................................................. 10

Warnings............................................................................................. 10

Safety concept

Abbreviations and conventions.................................................. 66

Application example....................................................................... 72

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

Commissioning test........................................................................ 69

Error codes.......................................................................................... 69

Fault reset........................................................................................... 69

Functional description................................................................... 68

Installation.......................................................................................... 68

Maintenance...................................................................................... 73

Operation............................................................................................ 68

Precautions......................................................................................... 67

Qualied personnel......................................................................... 66

Security................................................................................................ 73

Standards............................................................................................ 66

User accessibility.............................................................................. 73

Service...................................................................................................... 12

Servo Access Box

AUX connectors................................................................................ 22

Brake connectors............................................................................. 21

Characteristic data........................................................................... 89

Connections....................................................................................... 19

Dimensions........................................................................................ 90

Dismounting...................................................................................... 83

Eciency............................................................................................. 89

Encoder connector.......................................................................... 21

Environmental conditions............................................................ 92

Error codes.......................................................................................... 78

Ethernet connectors....................................................................... 22

Faults.................................................................................................... 77

General specications.................................................................... 92

Input current...................................................................................... 89

Input voltage..................................................................................... 89

Inspection during operation........................................................ 82

Mains connectors............................................................................. 20

Nameplate.......................................................................................... 89

Output voltage................................................................................. 89

Overview............................................................................................. 18

Protection rating.............................................................................. 92

Relay connectors.............................................................................. 21

Replacement...................................................................................... 83

Storage................................................................................................. 92

Troubleshooting............................................................................... 77

UDC connectors................................................................................ 22

Weight.................................................................................................. 89

Index

Servo drive

Characteristic data........................................................................... 85

Connectors......................................................................................... 15

Dimensions........................................................................................ 86

Dismounting...................................................................................... 83

Environmental conditions............................................................ 88

Error codes.......................................................................................... 75

Flange sizes........................................................................................ 13

General

Inspection during operation........................................................ 82

Maintenance...................................................................................... 81

Motor sizes......................................................................................... 13

Nameplate.......................................................................................... 85

Overview............................................................................................. 13

Permitted forces............................................................................... 88

Protection rating.............................................................................. 88

Replacement...................................................................................... 83

Shaft...................................................................................................... 14

Storage................................................................................................. 92

Troubleshooting............................................................................... 74

Types..................................................................................................... 14

X1 & X2 hybrid connectors........................................................... 16

X3 3rd Ethernet connector........................................................... 16

X4 I/O and/or encoder connector.............................................. 17

X5 LCP connector............................................................................. 17

Shaft.......................................................................................................... 14

Signal........................................................................................................ 66

Software.............................................................................................. 8, 27

Specications......................................................................................... 85

Startup...................................................................................................... 43

STO

Connectors......................................................................................... 20

Installation.......................................................................................... 68

Statusword......................................................................................... 68

Storage..................................................................................................... 92

Supply requirements

Auxiliary............................................................................................... 36

Mains.................................................................................................... 36

Safety power...................................................................................... 36

Support.................................................................................................... 12

Switching on the ISD 510 servo system....................................... 44

System overview..................................................................................... 7

specications.................................................................... 88

VLT® Integrated Servo Drive ISD® 510 System

UDC connectors.................................................................................... 22

Unintended start.................................................................................. 10

Voltage warning.................................................................................... 10

Warnings

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

Grounding.......................................................................................... 35

High voltage............................................................................... 10, 35

Leakage current................................................................................ 35

Unintended start.............................................................................. 10

Weight

Brake..................................................................................................... 86

Servo Access Box.............................................................................. 89

Servo drive.......................................................................................... 86

X1 & X2 hybrid connectors................................................................ 16

X3 3rd Ethernet connector................................................................ 16

X4 I/O and/or encoder connector.................................................. 17

X5 LCP connector................................................................................. 17

Template for programming.............................................................. 62

Terminology.............................................................................................. 8

Thermal protection.............................................................................. 15

Tightening torques.............................................................................. 33

Toolbox..................................................................................................... 56

Transport................................................................................................. 29

Troubleshooting

Error codes for SAB.......................................................................... 78

Error codes for servo drive............................................................ 75

Servo Access Box.............................................................................. 77

Servo drive.......................................................................................... 74

TwinCAT® NC Axis................................................................................. 54

Danfoss VLT Integrated Servo Drive ISD 510 System Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual