Danfoss VLT ISD Connection Box Operating Instructions Manual

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MAKING MODERN LIVING POSSIBLE

Operating Instructions

VLT® ISD Connection Box

Contents

VLT® ISD Connection Box Operating Instructions

1 General Information

1.1 Important Safety Warnings

1.2 Copyright

1.3 Product Names and Trademarks

1.4 Disclaimer

1.5 Approvals

1.6 Service and Support

2 Introduction

2.1 System Overview

2.2 Terminology

2.3 Purpose of the Operating Instructions

2.4 Additional Resources

3 Safety instructions

3.1 Symbols used in this Manual

3.2 General

3.3 Safety Instructions and Precautions for the ISD 410 Servo System

5 5 5 5 5 5 6

7 7 8 8 8

9 9 9 9

3.4 Qualified Personnel

3.5 Due Diligence

3.6 Intended Use

3.7 Foreseeable Misuse

4 Description

4.1 Controller

4.2 Display

4.3 Connection Cable/Cabling

4.3.1 ISD Servo System with 1 ISD Connection Box 15

4.3.2 ISD Servo System with 2 ISD Connection Boxes 17

4.4 Connections

4.4.1 Connections on the Front of the Connection Box 20

4.4.1.1 Safety Switch Connectors (Safety I & Safety II) 20

4.4.1.2 Fuse Holders 20

4.4.1.3 CAN Connectors (X11-X15/X22-X25) 21

4.4.2 Connections on the Underside of the Connection Box 21

4.4.2.1 DC Input Terminal (X1) 22

11 11 12 12

13 14 14 15

4.4.2.2 Brake Connector (X5) 22

4.4.2.3 24 V DC Power Supply (X4) 23

4.4.2.4 DC Output Terminals (X2 & X3) 23

4.5 Cooling

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Contents

VLT® ISD Connection Box Operating Instructions

5 Installation/Fitting

5.1 Transport and Delivery

5.1.1 Scope of Delivery 24

5.1.2 Transport 24

5.1.3 Inspection on Receipt 24

5.2 Safety Measures during Installation

5.3 Installation Environment

5.4 Preparation for Installation

5.5 Mechanical Installation

5.5.1 Mounting 26

5.5.2 Dismounting 26

5.6 Electrical Installation

5.6.1 Earthing (Grounding) the Connection Box 26

5.6.2 Electrical Environmental Conditions 26

5.6.3 24 V Power Supply Requirements 26

5.6.4 Connecting the CAN Cable 27

5.6.4.1 Overview of CAN Plugs 28

24 24

24 24 25 26

5.6.4.2 CAN Wiring Example 1 29

5.6.4.3 CAN Wiring Example 2 30

5.6.5 Connecting the Power Supply Cable 31

5.6.6 Connecting the Safety Cable 31

5.6.7 Connecting the Brake Cable 31

5.6.8 Connecting/Disconnecting Hybrid Cables (Feed Cable) 31

6 Commissioning

6.1 Connecting the Components

6.2 CAN-ID Setting

6.3 Functional Operation Test

6.4 Switching the Connection Box on

7 Operation

7.1 Operating Display

7.1.1 Operating LEDs 35

7.1.2 Display Mode 36

7.1.3 7-Segment Display 36

33 33 33 33 34

35 35

7.1.4 <SET> Push Button 37

7.1.5 <CAN-ID> BCD Switch 37

7.1.6 Service Interface 37

7.2 Display via Toolbox and CoDeSys

7.3 Machine States

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37 37

Contents

VLT® ISD Connection Box Operating Instructions

7.3.1 State "Init” (Initialisation) 38

7.3.2 State "Voltage Disabled" 38

7.3.3 State "Fault Discharged" 38

7.3.4 State "Power Up" 38

7.3.5 State "Power Down" 39

7.3.6 State "Fault Charged" 39

7.3.7 State "Operation Enabled" 39

7.3.8 State "Over Voltage" 39

7.3.9 State "Under Voltage" 39

8 Faults

8.1 Emergency

8.2 Error History

8.3 Debugging

8.4 Troubleshooting

9 Maintenance and Repair

9.1 Maintenance tasks

9.2 Inspection during Operation

9.3 Repair

9.3.1 Replacing the Fuses 43

10 Decommissioning and Disposal

10.1 Decommissioning

10.2 Dismounting

10.3 Recycling and Disposal

10.3.1 Recycling 44

10.3.2 Disposal 44

40 40 40 40 41

43 43 43 43

44 44 44 44

11 Specifications

11.1 Nameplate

11.2 Storage

11.3 Characteristic Data

11.4 Dimensions

11.4.1 Front View 46

11.4.2 Side View 47

12 Appendix

12.1 Glossary

12.2 Connection Box Parameters

12.2.1 Auto Power-Up (Index 0x2015, sub-index 01) 50

12.2.2 Discharge Resistor Check (Index 0x2015, sub-index 02) 50

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45 45 45 45 46

48 48 50

Contents

VLT® ISD Connection Box Operating Instructions

12.3 Emergency Codes

Index

4 MG75G102 - VLT® is a registered Danfoss trademark

General Information

VLT® ISD Connection Box Operating Instructions

1 General Information

1.1 Important Safety Warnings

WARNING

HIGH VOLTAGE

The ISD 410 servo system contains components which operate at a high voltage when connected to the electrical supply network. A hazardous voltage is present on the servomotors, the power supply module and the connection box whenever they are connected to the mains network. There are no indicators on the servomotor that indicate the presence of mains voltage. This indication is provided on the connection box. Installation, commissioning and maintenance may only be performed by qualified personnel. Incorrect installation, commissioning or maintenance can lead to death or serious injury.

WARNING

UNINTENDED START

The ISD 410 servo system contains servomotors which are connected to the electrical supply network and can start running at any time. This may be caused by an external switch, a CAN bus command, a reference signal, or clearing a fault condition. Servomotors and all connected devices must be in good operating condition. A deficient 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.

1.2

Disclosure, duplication and sale of this document, as well as communication of its content, are prohibited unless explicitly permitted. Infringement of this prohibition incurs liability for damages. All rights reserved with regard to patents, utility patents and registered designs. ISD is a registered trademark.

1.3 Product Names and Trademarks

VLT® and ISD® are registered trademarks of Danfoss. All other product names and trademarks used in this documentation are trademarks or registered trademarks of their respective titleholders.

1.4 Disclaimer

No liability is assumed for any damage or breakdown resulting from:

Failure to observe the information in the

•

instruction manuals Unauthorised modifications to the ISD servo

•

system or its components Operator error

•

Improper work on or with the ISD servo system

•

or its components.

1 1

WARNING

DISCHARGE TIME

The servomotors, the connection box and the power supply module contain DC link capacitors, that remain charged for some time after the mains supply is switched off at the power supply module. To avoid electrical shock, fully disconnect the power supply module from the mains before carrying out any maintenance on the ISD servo system or its components. Wait for at least the time listed below before carrying out maintenance work:

Number Minimum waiting time (discharge time) 0-60 servomotors 10 minutes

Note: High voltage may still be present even if the LED on the

ISD connection box is not lit!

Table 1.1 Discharge Time

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1.5

Approvals

1.5.1 ISD 410 Servomotor, ISD Encoder Box and ISD Connection Box

Table 1.2 Approvals for the ISD 410 Servomotor, ISD Encoder Box and ISD Connection Box

C US

General Information

VLT® ISD Connection Box Operating Instructions

1.5.2 ISD Power Supply Module

Table 1.3 Approvals for the ISD Power Supply Module

1.6 Service and Support

Contact your local service representative for service and support: www.danfoss.com/Contact/Worldwide/

6 MG75G102 - VLT® is a registered Danfoss trademark

130BC480.12

2 3

101112

ISD Connection Box

Failure Warning

Output (300V) OK

Stand-By

Output (90V) OK

Enable

Error

300V OK

90V OK

300V

Signal Outputs

10A

Signal Inputs

ISD Power Supply Module

AC/DC Power Supply 300VDC 8/10A

Run/Err U

24V

Safe

Warn Err

CAN-ID

CAN

RS232 Service

Set

2 8

Safety I Safety II

Fuse L I CAN 1.In CAN 2.In CAN 3.In CAN 4.In CAN 5.In

X11 X12 X13 X14 X15

Fuse L II CAN 1.Out CAN 2.Out CAN 3.Out CAN 4.Out CAN 5.Out

X21 X22 X23 X24 X25

Introduction

2 Introduction

2.1 System Overview

VLT® ISD Connection Box Operating Instructions

2 2

Illustration 2.1 ISD Servo System with 3 Servomotors

Number

Description Number Description 1 Ethernet 7 Master encoder 2 Power supply module 8 Terminating resistor 3 Connection box 9 ISD servomotor 4 Master 10 Hybrid cable (DC & CAN) 5 CAN line 11 DC line 6 Encoder box 12 AC line

Table 2.1 Legend to Illustration 2.1

The servomotors are self-contained distributed drives, which means that the drive electronics is housed together with the motor in the same casing. The motion control software also runs independently in the servomotor, which reduces the load on the higher-level control system.

A master system controls the servomotors. In this system servomotors operated in a DC group are controlled by a

Several motors can be operated in a group using a hybrid cable. This cable carries the DC supply voltage and the CAN bus signals.

The ISD 410 servo system complies with and is CE marked according to EN 61800-3, class C2 (industrial application).

master system.

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Introduction

VLT® ISD Connection Box Operating Instructions

The ISD 410 servo system is designed to accommodate up to 60 ISD 410 servomotors and consists of:

1 Power supply module

•

1 Connection box

•

1 Encoder Box

•

Servomotors

•

1 Master

•

Hybrid cables

•

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

Trouble-free operation

•

Recognition of product liability claims

•

Therefore, read these operating instructions before working with the connection box!

The operating instructions also contain important service information. The operating instructions should therefore be kept close to the connection box.

NOTE

The ISD 410 servomotors cannot be used in other servo systems from other manufacturers! Motors from other manufacturers cannot be used in the Danfoss ISD 410 servo system!

2.2 Terminology

ISD Integrated Servo Drives ISD servo system Complete system including all components. ISD master Control system hardware ISD master system Control system hardware and software ISD servo drive ISD servomotor with hybrid cable

Table 2.2 Terminology

2.3

Purpose of the Operating Instructions

The purpose of these operating instructions is to describe the Danfoss ISD connection box exclusively in the context of a Danfoss ISD 410 servo system.

These operating instructions contain information about:

Installation

•

Commissioning

•

Operation

•

Troubleshooting

•

Maintenance and repair

•

These operating instructions are intended for use by qualified personnel. Read these operating instructions in full in order to use the 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 connection box. Keep these operating instructions available with the servo system at all times.

2.4 Additional Resources

Available documents for the ISD 410 servo system:

Document Contents VLT® ISD 410

Servomotor Operating Instructions

VLT® ISD Encoder Box Operating Instructions

VLT® ISD Connection Box Operating Instructions

VLT® ISD Power Supply Module Operating Instructions

VLT® ISD 410 Design Guide

Table 2.3 Available Documents for the ISD 410 Servo System

Technical literature for Danfoss drives is also available online at http://www.danfoss.com/BusinessAreas/DrivesSolutions/Documentations/Technical+Documentation.htm.

Firmware updates may be available. When firmware updates are available, they can be downloaded from the www.danfoss.com website. For further information see the

VLT® ISD 410 Design Guide.

Information about the commissioning and operation of the servomotors

Information about the commissioning and operation of the encoder box

Information about the commissioning and operation of the connection box

Information about the commissioning and operation of the power supply module

Information about the construction and commissioning of the ISD 410 servo system

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Safety instructions

VLT® ISD Connection Box Operating Instructions

3 Safety instructions

3.1 Symbols used in this Manual

The following symbols are used in this document.

WARNING

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION

Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices.

CAUTION

Indicates a situation that may result in equipment or property-damage-only accidents.

NOTE

Indicates highlighted information that should be regarded with attention to avoid mistakes or operate equipment at less than optimal performance.

3.2 General

The following safety instructions and precautions relate to the ISD 410 servo system. The number of servomotors in the servo system is not significant. Read the safety instructions carefully before starting to work in any way with the servo system or its components. Pay particular attention to the safety instructions in the relevant sections of these operating instructions. Also observe the safety instructions and precautions in the operating instructions for the other system components.

WARNING

HIGH VOLTAGE

WARNING

HAZARDOUS SITUATION

If the servomotor or the bus lines is/are incorrectly connected, there is a risk of death, serious injury or damage to the unit. Always comply with the instructions within these operating instructions, as well as national and local safety regulations. Also read the operating instructions for the other servo system components.

3.3 Safety Instructions and Precautions for the ISD 410 Servo System

Read the safety instructions carefully before starting to work in any way with the servo system or its components. Compliance with the safety instructions and precautions is necessary at all times.

Orderly and proper transport, storage, fitting and

•

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

Only suitably trained and qualified personnel may

•

work on the servo system and its components or in its vicinity. See 3.4 Qualified Personnel.

Use only accessories and spare parts approved by

•

the manufacturer. Comply with the specified ambient conditions.

•

The information in these operating instructions

•

about the use of available components is

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Safety instructions

VLT® ISD Connection Box Operating Instructions

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 document for the specific application concerned:

- for compliance with the safety regulations and standards relevant to the specific application.

- for implementing the necessary measures, changes and extensions.

Commissioning the 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 in the country of use to that application.

Operation is allowed only in compliance with the

•

national EMC regulations for the application concerned.

See the VLT® ISD 410 Design Guide for information

•

regarding EMC-compliant installation of the servo system.

Compliance with the limit values specified by

•

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

Compliance with the specifications, connection

•

conditions and installation conditions in this instruction manual is mandatory.

The safety regulations and safety provisions of

•

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

Care must be taken to ensure that orderly

•

protective earthing (grounding) of the equipment, which protects the user against the supply voltage and protects the power supply module against overload, is performed in accordance with local and national regulations.

Overload protection for the servomotor can be

•

programmed using the master system. For more information, see Programming in the VLT® ISD 410

Design Guide. Do not remove or replace the SD card on the

•

encoder box during operation, otherwise the contents of the SD card could be destroyed. Switch the encoder box off and wait 10 seconds before removing the SD card.

WARNING

EARTHING HAZARD

For reasons of operator safety, the components of the servo system must be earthed correctly in accordance with national or local electrical regulations and the information in these operating instructions. The earth leakage current is greater than 3.5 mA. Improper earthing of the servomotor may result in death or serious injury.

Operational Safety

Safety-related applications are allowed only if

•

they are explicitly and unambiguously mentioned in the VLT® ISD 410 Design Guide. Otherwise they

are not allowed. 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 master system do not interrupt the mains voltage supply to the power supply module. Therefore they are not allowed to be used as safety switches for the servo system.

The motor can be brought to a stop by a

•

software command or a zero speed setpoint, but DC voltage remains present on the servomotor and/or mains voltage in the power supply module. If personal safety considerations (e.g. 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 sufficient. In this case the servo system must be detached from the mains network or a suitable stop function must be implemented.

When the servomotor is stopped, it may start up

•

again on its own if the circuitry of the servomotor is defective or after the elimination of a temporary overload, a problem with the supply voltage or a problem with the servomotor. If personal safety considerations (e.g. risk of personal injury caused by contact with moving machine parts after an unintentional start) make it necessary to ensure that an unintended start cannot occur, the normal stop functions of the servomotor are not sufficient. In this case the servo system must be disconnected from the mains network or a suitable stop function must be implemented.

The servomotor may start running unintentionally

•

during parameter configuration or programming. If this can pose a risk to personal safety (e.g. risk of personal injury due to contact with moving machine parts), unintended motor starting must

10 MG75G102 - VLT® is a registered Danfoss trademark

Safety instructions

be prevented, for example by using the Safe Stop function or by safe disconnection of the servomotors.

Do not disconnect the cables from the

•

servomotor while the servo system is connected to mains voltage. Ensure that the mains supply is disconnected and the required waiting time has elapsed before disconnecting or connecting the hybrid cable or disconnecting cables from the connection box and/or the power supply module.

In addition to the L1, L2 and L3 supply voltage

•

inputs on the power supply module, the servo system has other supply voltage inputs, including external 24 V DC. Before commencing repair work, check that all supply voltage inputs have been switched off and that the necessary discharge time for the intermediate circuit capacitors has elapsed.

The supply of power to the servo system must be

•

switched off for repair work. Before disconnecting or connecting the hybrid cable or disconnecting cables from the connection box and/or the power supply module, ensure that the mains supply is disconnected and the necessary discharge time has elapsed.

VLT® ISD Connection Box Operating Instructions

WARNING

DISCHARGE TIME

Number Minimum waiting time (discharge time) 0-60 servomotors 10 minutes

Note: High voltage may still be present even if the LED on the

ISD connection box is not lit!

Table 3.1 Discharge Time

CAUTION

Never connect or disconnect the hybrid cable to or from the servomotor when voltage is present. Doing so will damage the electronic circuitry. Observe the discharge time for the DC link capacitors.

3.4 Qualified Personnel

Installation, commissioning and maintenance of the ISD 410 servo system may only be carried out by qualified personnel. For the purposes of this document and the safety instructions in this document, qualified personnel are trained personnel who are authorised to fit, install, commission, earth 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 these operating instructions. They must have suitable safety equipment and be trained in first aid.

3.5 Due Diligence

The operator and/or fabricator must ensure that:

the 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 servo system in complete and readable form.

the servo system and its components are fitted,

•

installed, commissioned and maintained only by adequately qualified and authorised 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 in particular the instructions it contains.

the product markings and identification 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 servo system, are complied with.

the users always have all current information

•

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

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Safety instructions

VLT® ISD Connection Box Operating Instructions

3.6 Intended Use

The components of the ISD servo system are intended to be installed in machines used in commercial and industrial environments.

To ensure that the product is used as intended, the following conditions must be fulfilled 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, which

•

means that no structural changes may be made to the hardware.

software products may not be reverse-engineered

•

and their source code may not be altered. damaged or faulty products may not be installed

•

or put into service. it must be ensured that the products are installed

•

in conformance with the regulations mentioned in the documentation.

any specified maintenance and service intervals

•

must be observed. all protective measures must be complied with

•

only the components described in these

•

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

the documentation must be read completely and

•

correctly followed

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

3.7

Foreseeable Misuse

Any use not expressly approved by Danfoss constitutes misuse. This also applies to failure to comply with the specified operating conditions and applications.

Danfoss assumes no liability of any sort for damage attributable to improper use.

areas with potentially explosive atmospheres

•

mobile or portable systems

•

floating or airborne systems

•

inhabited facilities

•

sites where radioactive materials are present

•

areas with extreme temperature variations or in

•

which the maximum rated temperatures may be exceeded

under water

•

12 MG75G102 - VLT® is a registered Danfoss trademark

130BD101.10

Description

VLT® ISD Connection Box Operating Instructions

4 Description

The ISD connection box is the central interface/gateway for the ISD servo system. It provides the link between the power supply module and the servomotor and therefore ensures the 300 V DC power supply to the servomotors via a hybrid cable. Furthermore, the ISD connection box is the central unit, which provides the CAN communication throughout the ISD 410 servo system devices and external CAN slaves, if necessary. The LEDs on the front of the unit display the operating status and warnings.

CAUTION

The connection box has an IP-rating of IP20. It is only designed for use within a control cabinet. The unit may be damaged if exposed to fluids.

4 4

All power and signal cables are wired into the connection box and 2 independent groups of servomotors can be connected. It also enables the STO safety function to be realised via an external safety relay.

Furthermore, the connection box guarantees the DC power supply to all the servomotors and their connection to the fieldbus (CAN).

Illustration 4.1 ISD Connection Box

Service functions, such as voltage measuring and CAN diagnostics are also performed by the connection box.

Backplate for mounting

1 2 Vents 3 Display 4 Safety Connectors 5 CAN Connectors 6 Fuses

Table 4.1 Legend to Illustration 4.1

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130BD102.10

RUN/Err

24V

Safe

Warn

Err

CAN-ID

CAN

RS232 Service

Set

2 8

ISD Connection Box

Description

VLT® ISD Connection Box Operating Instructions

4.1 Controller

The connection box controller performs the following functions:

monitors voltage levels, currents, temperatures

•

and other variables. calculates power and derived values.

•

provides all values through its CAN object

•

dictionary. ensures the correct behaviour of the connection

•

box in terms of charging and discharging capacities through a state machine.

handles thermal budget, over-voltage, under-

•

voltage and fault cases.

The connection box controller is equipped with 1 CAN interface for communication with the system master and implements the CANopen DS301 standard.

4.2 Display

The display shows the operating status of the connection box.

Illustration 4.2 Connection Box Display

See 7.1 Operating Display for detailed information on the display.

14 MG75G102 - VLT® is a registered Danfoss trademark

130BD089.11

1 2

ISD Connection Box

Failure Warning

Output (300V) OK

Stand-By

Output (90V) OK

Enable

Error

300V OK

90V OK

300V

Signal Outputs

10A

Signal Inputs

ISD Power Supply Module

AC/DC Power Supply 300VDC 8/10A

Run/Err U

24V

Safe

Warn Err

CAN-ID

CAN

RS232 Service

Set

2 8

Safety I Safety II

Fuse L I CAN 1.In CAN 2.In CAN 3.In CAN 4.In CAN 5.In

X11 X12 X13 X14 X15

Fuse L II CAN 1.Out CAN 2.Out CAN 3.Out CAN 4.Out CAN 5.Out

X21 X22 X23 X24 X25

ERGHOF

AC DC 300 V

ISD 410

DC+CAN

CAN

Ethernet

Description

VLT® ISD Connection Box Operating Instructions

4.3 Connection Cable/Cabling

Depending on the application, it is possible to set up a servo system with either 1 or 2 connection boxes. These are detailed in the following 2 sections.

4.3.1 ISD Servo System with 1 ISD Connection Box

The ISD servo system is set up with 1 connection box if 1 connection box together with 1 power supply module can provide the power for the application.

4 4

Illustration 4.3 ISD Servo System with 1 ISD Connection Box

MG75G102 - VLT® is a registered Danfoss trademark 15

Description

VLT® ISD Connection Box Operating Instructions

No. Name Line Type Cross-section Flexible Cable 1 ISD Power Supply

– – –

Module 2 ISD Connection Box – – – 3 Feed cable Hybrid cable (DC & CAN)

1 mm

2 1)

/ 2.5 mm

X (only with 2.5

mm2) 4 Terminating resistor Connector with terminating resistor – – 5 ISD Encoder Box – – – 6 Master – – –

7 Control cabinet – – – – Ethernet Ethernet cable 4 x 2 x 0,27 mm², shielded twisted pairs

(CAT 5)

2 1)

/ 2.5 mm

–

X (only with 2.5

– CAN line CAN cable (screened) – Encoder line Encoder cable – Loop cable Hybrid cable (DC & CAN)

4 x 0.25 mm 4 x 0.25 mm 1 mm

mm2) – DC cable Single wire – AC feed Single wire

1.5 mm2 / 2.5 mm

1.5 mm

2 2)

–

Table 4.2 Legend to Illustration 4.3

1) Only without STO

2) Depending on the application

16 MG75G102 - VLT® is a registered Danfoss trademark

Description

VLT® ISD Connection Box Operating Instructions

4.3.2 ISD Servo System with 2 ISD Connection Boxes

The ISD servo system is set up with 2 connection boxes if the application requires more power than 1 connection box and 1 power supply module can deliver. The encoder box has 2 different CAN lines (CAN I and CAN II). Both of them use the same CAN-ID. If there is a machine with ISD 410 servomotors that are split up in 2 separate CAN lines and all of them have to listen to the same encoder value, then encoder box CAN I should be put on the first line and encoder box CAN II on the second line. Hereby, the drives can operate synchronously with the same guide value. CAN line II can be enabled or disabled via the SD card parameter (General.SecondCANLineEnable).

4 4

MG75G102 - VLT® is a registered Danfoss trademark 17

1 2

130BD088.11

ISD Connection Box

Failure Warning

Output (300V) OK

Stand-By

Output (90V) OK

Enable

Error

300V OK

90V OK

300V

Signal Outputs

10A

Signal Inputs

ISD Power Supply Module

AC/DC Power Supply 300VDC 8/10A

Run/Err U

24V

Safe

Warn Err

CAN-ID

CAN

RS232 Service

Set

2 8

Safety I Safety II

Fuse L I CAN 1.In CAN 2.In CAN 3.In CAN 4.In CAN 5.In

X11 X12 X13 X14 X15

Fuse L II CAN 1.Out CAN 2.Out CAN 3.Out CAN 4.Out CAN 5.Out

X21 X22 X23 X24 X25

ISD Connection Box

Failure Warning

Output (300V) OK

Stand-By

Output (90V) OK

Enable

Error

300V OK

90V OK

300V

Signal Outputs

10A

Signal Inputs

ISD Power Supply Module

AC/DC Power Supply 300VDC 8/10A

Run/Err U

24V

Safe

Warn Err

CAN-ID

CAN

RS232 Service

Set

2 8

Safety I Safety II

Fuse L I CAN 1.In CAN 2.In CAN 3.In CAN 4.In CAN 5.In

X11 X12 X13 X14 X15

Fuse L II CAN 1.Out CAN 2.Out CAN 3.Out CAN 4.Out CAN 5.Out

X21 X22 X23 X24 X25

ERGHOF

AC DC 300 V

ISD 410

CAN

CAN II CAN I

DC+CAN

Description

VLT® ISD Connection Box Operating Instructions

Illustration 4.4 ISD Servo System with 2 ISD Connection Boxes

18 MG75G102 - VLT® is a registered Danfoss trademark

Description

VLT® ISD Connection Box Operating Instructions

No. Name Line Type Cross-section Flexible Cable 1 ISD Power Supply Module – – – 2 ISD Connection Box – – – 3 Feed cable Hybrid cable (DC & CAN) 4 Terminating resistor Connector with terminating

2 1)

1 mm

/ 2.5 mm

– –

X (only with 2.5 mm2)

resistor 5 ISD Encoder Box – – – 6 Master – – – 7 Control Cabinet – – – – Ethernet Ethernet cable 4 x 2 x 0.27 mm², shielded twisted pairs

(CAT 5)

2 1)

/ 2.5 mm

2 2)

– – X (only with 2.5 mm2) – –

– CAN line CAN cable (screened) – Encoder line Encoder cable – Loop cable Hybrid cable (DC & CAN) – DC cable Single wire – AC feed Single wire

4 x 0.25 mm 4 x 0.25 mm 1 mm

1.5 mm2 / 2.5 mm

1.5 mm

Table 4.3 Legend to Illustration 4.4

1) Only without STO

2) Depending on the application

4 4

MG75G102 - VLT® is a registered Danfoss trademark 19

130BD104.10

130BD107.10

130BD106.10

Description

VLT® ISD Connection Box Operating Instructions

4.4 Connections

4.4.1.1

Safety Switch Connectors (Safety I & Safety II)

4.4.1 Connections on the Front of the Connection Box

The 24 V supply from the safety switch is connected via connector Safety I and/or Safety II. Use Safety I for line 1 and Safety II for line 2.

Illustration 4.6 Safety Housing and Plug

The input pin assignment is the same for Safety I and Safety II.

Signal Description Cross-Section

1 mm

Illustration 4.5 Connections on the Front of the Connection Box

Safety switch connectors

1 2 Fuse holders 3 CAN connectors

Table 4.4 Legend to Illustration 4.5

1 GND_24 V Safety Switch

Power Supply Input (Ground)

2 +24 V Safety Switch

Power Supply Input (24 V DC)

Table 4.5 Connector Pin Assignment

4.4.1.2

Fuse Holders

Fuses are used on the output side to protect the connection box and the ISD servo system if a short circuit occurs. The fuses sit in screw-in fuse holders Fuse I and Fuse II, which are accessible on the front of the connection box.

Fuse type: 16 A FF, size G (6.3 x 32 mm)

Illustration 4.7 Fuse Holders

20 MG75G102 - VLT® is a registered Danfoss trademark

130BD105.10

130BD108.10

Description

VLT® ISD Connection Box Operating Instructions

4.4.1.3 CAN Connectors (X11-X15/X22-X25)

Illustration 4.8 CAN Housing and Plug

The input and output pin assignment of the CAN plug connectors is the same.

Signal Description Cross-Section

Pin 1 CAN_GND CAN Power Supply

(Ground) 2 CAN_L CAN Low Signal 3 CAN_H CAN High Signal 4 CAN_V

CAN Power Supply

(+5 V)

0.5 mm

Connections on the Underside of the

4.4.2 Connection Box

Illustration 4.9 Connections on the Underside

4 4

Table 4.6 Connector Pin Assignment

DC Input terminal X1

1 2 Brake connector X5 3 24 V DC Power supply X4 4 DC Output terminal X3 5 DC Output terminal X2

Table 4.7 Legend to Illustration 4.9

MG75G102 - VLT® is a registered Danfoss trademark 21

130BD109.10

130BD163.10

Description

VLT® ISD Connection Box Operating Instructions

4.4.2.1 DC Input Terminal (X1)

4.4.2.2

Brake Connector (X5)

An external brake chopper is required for the servo system if the servomotors feed power back. The brake chopper is only required on 1 line.

Illustration 4.10 DC Housing and Plug

Pin Signal Description Cross-Section 1 FE Functional Earth

2 –U

3 +U

Power Supply Input (Ground)

Power Supply Input (300 V DC)

1.5 mm2 / 2.5

2 1)

1.5 mm2 / 2.5

2 1)

1.5 mm2 / 2.5

2 1)

Illustration 4.11 Brake Housing and Plug

Pin Signal Description 1 +BR Brake Chopper Output 2 FE Functional Earth 3 –BR Brake Chopper Input

Table 4.8 Connector Pin Assignment

1) Depending on the application

Table 4.9 Connector Pin Assignment

22 MG75G102 - VLT® is a registered Danfoss trademark

130BD164.10

130BD162.10

Description

VLT® ISD Connection Box Operating Instructions

4.4.2.3 24 V DC Power Supply (X4)

Illustration 4.12 DC Housing and Plug

Pin Signal Description Cross-Section 1 –UDC_24IN Power Supply

Input (Ground)

2 +UDC_24IN Power Supply

Input (24 V DC)

Table 4.10 Connector Pin Assignment

1 mm

4.4.2.4

DC Output Terminals (X2 & X3)

Use X2 for line 1 and X3 for line 2.

Illustration 4.13 DC Housing and Plug

The output pin assignment of the DC output terminals X2 and X3 is the same.

Signal Description Cross-Section

Pin 1 FE Functional Earth

2 –U

3 +U

4 24 V_S1/2 24 V DC Safety

Power Supply Output (Ground)

Power Supply Output (300 V DC)

Output

1.5 mm2 / 2.5 mm

2 2)

1 mm mm 1 mm mm 1 mm with PE

2 2)

/ 2.5

, shielded

4 4

Table 4.11 Connector Pin Assignment

1) Depending on the application

2) Only without STO

4.5

Cooling

Cooling takes place via the vents on the surface of the connection box.

MG75G102 - VLT® is a registered Danfoss trademark 23

Installation/Fitting

5 Installation/Fitting

VLT® ISD Connection Box Operating Instructions

5.1 Transport and Delivery

5.2

Safety Measures during Installation

5.1.1 Scope of Delivery

Always observe the safety instructions in 3 Safety instructions during installation.

The scope of delivery of the ISD connection box comprises:

Pay particular attention to ensuring that the following

5.1.2

The maximum weight of a packaged connection box is approximately 5.5 kg.

the connection box

•

1 set of plug connectors

•

these operating instructions

•

Transport

Avoid vibration during transportation.

•

Avoid heavy impacts and blows.

•

points are observed carefully:

installation may only be performed by qualified

•

personnel. installation must be performed with due care and

•

attention. all safety regulations and protective measures are

•

complied with, and the environmental conditions are observed.

the documentation is read and understood.

•

5.3 Installation Environment

Inspection on Receipt

5.1.3

After receiving the delivery, immediately check whether the scope of delivery matches the shipping documents. Danfoss will not honour claims for faults registered at a later time.

Environmental Conditions

The installation must provide the following environmental conditions to allow the connection box to be operated safely and efficiently.

with the carrier in case of visible transport

•

damage. with the responsible Danfoss representative in

•

case of visible defects or incomplete delivery.

The allowable operating ambient temperature

•

range is not exceeded. The relative humidity is 5-85%, non-condensing

•

(according to IEC 60721-3-3).

The vibration level is ≤1 g/9.81 m/s2 without

•

resonance excitation. Unrestricted ventilation is available.

•

The maximum operating temperature is 40 °C. A

•

control cabinet climate control should be used if necessary.

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

24 MG75G102 - VLT® is a registered Danfoss trademark

130BD041.10

130

268

5.5

110

257

Installation/Fitting

VLT® ISD Connection Box Operating Instructions

5.4 Preparation for Installation

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

5 5

Illustration 5.1 Drilling Template

NOTE

In addition to its own dimensions, the connection box needs space for connecting the cables.

MG75G102 - VLT® is a registered Danfoss trademark 25

Installation/Fitting

VLT® ISD Connection Box Operating Instructions

WARNING

5.5 Mechanical Installation

5.5.1 Mounting

Mount the connection box onto the backplate of the control cabinet using M5 screws (not included). Only use the designated keyways to mount the connection box. No alterations to the back panel are allowed.

1. Screw the holding screws in to the backplate so that there is enough space to hook the connection box onto them.

2. Remove the protective cover from the connection box.

3. Hook the connection box onto the 2 holding screws.

4. Tighten the holding screws.

5. Screw in the safety screws at the bottom of the connection box and tighten them.

The optional strain relief clamps can be mounted to the underside of the connection box by inserting them into the cooling vents and securing them with an M4 screw.

Dismounting

5.5.2

1. Unscrew and remove the safety screws at the bottom of the connection box.

2. Loosen the holding screws.

3. Lift the connection box off the holding screws.

5.6

Electrical Installation

HIGH VOLTAGE

The connection box contains high voltage when connected to the power supply module. Installation, start up, and maintenance should be performed by qualified personnel only. Failure to perform installation, start up, and maintenance by qualified personnel could result in death or serious injury.

5.6.1 Earthing (Grounding) the Connection Box

Connect the PE lines to the M6 earthing screw on the underside of the unit.

Electrical Environmental Conditions

5.6.2

Compliance with the following electrical environmental conditions is necessary to enable safe and effective operation of the connection box:

Mounting in a control cabinet.

•

Suitable 24 V DC power supply unit (see 5.6.3 24

•

V Power Supply Requirements). 300 V DC with 10 A from the power supply

•

module. PE line.

•

Pay attention to the leakage current. This is more

•

than 3.5 mA so a circuit breaker) is not effective. Therefore use an AC/DC sensitive RCCB (residual current circuit breaker).

Observe national statutory provisions.

•

24 V Power Supply Requirements

5.6.3

WARNING

GROUNDING HAZARD

For operator safety, it is important to ground the connection box properly in accordance with national and local electrical codes as well as instructions contained within these operating instructions. Ground currents are higher than 3.5 mA. Failure to ground the power supply module properly could result in death or serious injury.

26 MG75G102 - VLT® is a registered Danfoss trademark

The connection box must be supplied with 24 V DC power supply with the following properties:

Output range: 24 V DC ±20%

•

Power output: 5 A

•

NOTE

Use a 24 V power supply which is CE marked according to the standards EN 61000-6-2 and EN 61000-6-4 or similar for industrial use. The power supply can only be used for the ISD system.

Installation/Fitting

VLT® ISD Connection Box Operating Instructions

5.6.4 Connecting the CAN Cable

CAUTION

The 5 V CAN power supply is created by the connection box. No external 5 V power supply can be connected to the connection box CAN plugs. Failure to observe this warning may result in damage to the connection box. If an external 5 V power supply is needed, contact Danfoss Service.

The CAN cable connects the connection box to the ISD servo system.

1. Assemble the CAN cable according to the

connector pin assignment in 4.4.1.3 CAN Connectors (X11-X15/X22-X25).

2. Lay the CAN cable according to the local conditions.

3. Connect the CAN cable to the encoder box and the connection box. Use CAN line I if only 1 CAN line is being used. Pay attention to the correct CAN cable number when 2 CAN cables (for 2 connection boxes) are being used. Observe the connection diagrams in

4.3 Connection Cable/Cabling.

5 5

NOTE

Closed system All CAN bus connectors on the front of the connection box must be wired. Bridge plugs can be used.

MG75G102 - VLT® is a registered Danfoss trademark 27

130BD166.10

Safety I Safety II

Fuse L I

Fuse L II

CAN 1.In CAN 2.In CAN 3.In CAN 4.In CAN 5.In

X11 X12 X13 X14 X15

CAN 1.Out CAN 2.Out CAN 3.Out CAN 4.Out CAN 5.Out

X21 X22 X23 X24 X25

Installation/Fitting

VLT® ISD Connection Box Operating Instructions

5.6.4.1 Overview of CAN Plugs

Illustration 5.2 shows the CAN plugs on the front of the connection box. The lines represent the internal connections between the CAN plugs.

Illustration 5.2 Overview of CAN Plugs

Table 5.1 Legend to Illustration 5.2

Symbolises the connection box as a node in the CAN network.

28 MG75G102 - VLT® is a registered Danfoss trademark

130BD171.10

Failure Warning

Output (300V) OK

Stand-By

Output (90V) OK

Enable

Error

300V OK

90V OK

300V

Signal Outputs

10A

Signal Inputs

ISD Power Supply Module

AC/DC Power Supply 300VDC 8/10A

ERGHOF

CAN

DSP

CAN.In

X22

X12 X23

X13 X24

X14

X11

X21

X15

X25

Installation/Fitting

VLT® ISD Connection Box Operating Instructions

5.6.4.2 CAN Wiring Example 1

Illustration 5.3 shows an example of the CAN wiring for an ISD servo system with 1 output line, 1 connection box and 1 power supply module. In this example the CAN wiring starts at plug X11 and ends at plug X25. A CAN terminating resistor (120 Ω) is required at both ends. Use terminating resistor part number 175G7005 for the ISD servomotor.

5 5

Illustration 5.3 CAN Wiring Example 1

ISD Power Supply Module

2 ISD Connection Box 3 Servomotor 4 Hybrid Cable 1 (Output line 1) 5 Master 6 Encoder Box 7 Camera

Table 5.2 Legend to Illustration 5.3

MG75G102 - VLT® is a registered Danfoss trademark 29

130BD172.10

Failure Warning

Output (300V) OK

Stand-By

Output (90V) OK

Enable

Error

300V OK

90V OK

300V

Signal Outputs

10A

Signal Inputs

ISD Power Supply Module

AC/DC Power Supply 300VDC 8/10A

ERGHOF

CAN

DSP

CAN.In

X22

X12 X23

X13 X24

X14

X11

X21

X15

X25

Installation/Fitting

VLT® ISD Connection Box Operating Instructions

5.6.4.3 CAN Wiring Example 2

Illustration 5.4 shows an example of the CAN wiring for an ISD servo system with 2 output lines, 1 connection box and 1 power supply module. In this example the CAN wiring starts at plug X11 and ends at plug X21. A CAN terminating resistor (120 Ω) is required at both ends. Use terminating resistor part number 175G7005 for both servomotor lines.

Illustration 5.4 CAN Wiring Example 2

ISD Power Supply Module

2 ISD Connection Box 3 Servomotor 4 Hybrid Cable 1 (Output line 1) 5 Hybrid Cable 2 (Output line 2) 6 Camera 7 Encoder Box 8 Master

Table 5.3 Legend to Illustration 5.4

30 MG75G102 - VLT® is a registered Danfoss trademark

Installation/Fitting

VLT® ISD Connection Box Operating Instructions

5.6.5 Connecting the Power Supply Cable

1. Assemble the power supply cable according to the connector pin assignment in 4.4.2.3 24 V DC Power Supply (X4).

2. Connect the power supply cable from the power supply module to connector X1.

3. Secure the power supply cable using the strain relief clamps on the underside of the connection box.

Connecting the Safety Cable

5.6.6

The safety cable connects external safety relays to the connection box. Therefore the STO safety function can be realised via an external safety relay.

1. Assemble the safety cable according to the connector pin assignment in 4.4.1.1 Safety Switch Connectors (Safety I & Safety II).

2. Connect the safety cable to connector Safety I or Safety II. Use connector Safety I for line 1 and Safety II for line 2.

3. Connect the safety cable shield to PE.

Connecting/Disconnecting Hybrid

5.6.8 Cables (Feed Cable)

The hybrid (feed) cable connects the connection box to the first servomotor in the servo system, either directly or via a slip ring for turntable applications. All other servomotors are connected via a loop cable.

WARNING

HIGH VOLTAGE

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

WARNING

DISCHARGE TIME

5 5

Connecting the Brake Cable

5.6.7

The brake cable connects the brake chopper to an external brake resistor.

1. Assemble the brake cable according to the

connector pin assignment in 4.4.2.2 Brake Connector (X5).

2. Connect the brake cable to connector X5.

Number Minimum waiting time (discharge time) 0-60 servomotors 10 minutes

Note: High voltage may still be present even if the LED on the

ISD connection box is not lit!

Table 5.4 Discharge Time

MG75G102 - VLT® is a registered Danfoss trademark 31

130BC493.10

UDC+

UDC–

GND

CAN H

CAN L

71 mm

52 mm

+24 V

STO

Installation/Fitting

VLT® ISD Connection Box Operating Instructions

NOTE

Do not forcefully connect or fit the connectors. Incorrect connection will cause permanent damage to the connector.

1. Connect the wires to the DC output terminal (X2

& X3) as described in 4.4.2.4 DC Output Terminals (X2 & X3).

2. Secure the hybrid cable using the strain relief clamp on the underside of the connection box.

Illustration 5.5 Feed Cable Wires

Wire Colour Description

Pin Power 1 –U 2 PE Green/yellow Protective Earth 3 +U

1-Black Input (DC Ground)

2-Black Input (300 V DC) 4 +24 V STO 3-Black 24 V DC Safety Input CAN A GND Black CAN Power Input (Ground) B CAN_Low White CAN Low Signal Input C CAN_High Blue CAN High Signal Input D V

Red CAN Power Input (+5 V)

Table 5.5 Wire Assignment for Feed Cable

CAUTION

Never connect or disconnect the hybrid cables to or from the servomotors when the supply voltage is present. Doing so will damage the electronic circuitry. Observe the discharge time for the DC link capacitors.

32 MG75G102 - VLT® is a registered Danfoss trademark

Commissioning

6 Commissioning

6.1 Connecting the Components

VLT® ISD Connection Box Operating Instructions

following the acceptance of the new ID or after sending an NMT reset communication.

1. Connect the mains supply line to the power supply module and the control terminal strip of the power supply module in accordance with the

wiring diagram in the VLT

2. Connect the DC supply from the power supply module to the connection box and wire the safety circuit.

3. Connect the feed cable from the connection box to the first servomotor by connecting the cable leads on the connection box and the servomotor using the threaded connectors.

4. Using the loop cables intended for this purpose, connect the other servomotors in the group.

5. Fit a CAN terminating resistor on the last servomotor.

6. Connect the CAN bus to the connection box.

7. Connect the encoder box (if present) and the power supply module to the CAN network.

6.2

CAN-ID Setting

The default ID of the connection box is preset to 110. All the settings can be read from the object dictionary.

ISD 410 Design Guide.

Note that the other ISD servo system components will also be in ID setting mode after this message is sent, so an “NMT reset communication” message has to be sent to release all devices from this mode.

Note that whilst in ID setting mode, it is not possible to communicate with the device. An NMT reset communication leaves the ID setting mode for the connection box without changing any other state. This ensures that drive operation is not interrupted. The new ID is then valid when the connection box has been power cycled or the NMT reset node message has been sent to the connection box.

COB-ID Byte 0 Byte 1 Byte 2 Byte 3 Byte 4 Byte 5 0x7F2 0 0 New CAN-Node-ID

Table 6.1 ISD ID Setting Message

6.3 Functional Operation Test

Always check the following items before initial commissioning, before commencing operation after extended downtime, or before commencing operation after motor overhaul:

There are several ways to set/change the CAN-ID. The easiest way is setting via the BCD switch. The ID setting should be executed in an unpowered state.

BCD switch is set to 0

The ISD ID setting protocol can be used to give

•

another ID to the box.

BCD switch is set to between 1 and 9

The CAN-ID is calculated by the preset value of

•

110 + the value of BCD switch.

The message for the ID setting over CAN bus is shown in Table 6.1. Note that the first 4 bytes have to be 0, otherwise the connection box will ignore the ID setting message. This is also the case if the BCD switch is not set to 0. After this message is sent, the new CAN-ID will start blinking on the connection box display. Press the <SET> button on the connection box to accept the new ID. The connection box will only leave this ID setting mode

Are all threaded connectors of mechanical and

•

electrical components firmly tightened? Is the free circulation of cooling air (inlet and

•

outlet) assured? Are the devices for protection against

•

overheating (temperature sensor monitoring) operational?

Are the electrical connections OK?

•

Is contact protection in place for rotating parts

•

and surfaces that can become hot?

MG75G102 - VLT® is a registered Danfoss trademark 33

Commissioning

VLT® ISD Connection Box Operating Instructions

6.4 Switching the Connection Box on

The components of the ISD servo system must be wired and connected correctly before the connection box is switched on. Read the operating instructions of the other ISD components carefully. The cabling contains the power supply as well as the communication for the system. The servo system cannot be started until these basic requirements are fulfilled.

Switching on (booting up) The connection box can be switched on via the CAN communication from the PLC system if the Auto Power-up parameter is enabled.

CAUTION

Do not switch the connection box on and off repeatedly. Doing so will damage the internal components. Wait 5 minutes after switching the connection box off before switching it on again.

34 MG75G102 - VLT® is a registered Danfoss trademark

130BD167.10

Warn

Err

CAN-ID

RS232 Service

Set

2 8

ISD Connection Box

RUN/Err

24V

Safe

CAN

2 3

Operation

VLT® ISD Connection Box Operating Instructions

7 Operation

7.1 Operating Display

The display shows the operating status of the connection box.

Illustration 7.1 Connection Box Display

1 Operating LEDs 4 2 7-segment display 5 <SET> push button 3 BCD switch 6 Segment dots

Table 7.1 Legend to Illustration 7.1

1) Only for use by Danfoss Service.

Service interface RS232

Operating LEDs

7.1.1

The operating LEDs show the operating status.

LED Description RUN/Err (green/red)

UZK “Power” (green) 24V ”Power Supply” (green) 5V (green)

Safe (green)

CAN (green/red)

Table 7.2 Description of the Operating LEDs

Constant light (green): Normal operation.

•

LED is off: Connection box is being

•

initialised.

Constant light (red): Active connection box

•

error.

Constant light (green): Normal operation.

•

Flashing (slowly): Over voltage (UZK).

•

Constant light (green): 24 V DC available

•

LED is off: 24 V DC missing.

•

Constant light (green): CAN supply available.

•

LED is off: internal CAN supply missing.

•

Constant light (green): Safety power is

•

available.

Flashing LED (green): Only 1 of 2 safety

•

powers is available.

LED is off: No safety power detected.

•

Flashing LED (green): CAN communication.

•

Constant light (red): CAN error.

•

7 7

MG75G102 - VLT® is a registered Danfoss trademark 35

130BD087.10

CAN ID WARN ERROR

SET >3sec

SET SETSET

Idle

(max n=6)

WarningList[n] ErrorList[n]

Warn Error

Operation

VLT® ISD Connection Box Operating Instructions

7.1.2 Display Mode

The CAN-ID, warnings and error codes can be displayed on the 7-segment display.

A dot at the bottom right of the display segment shows the respective type of indicator. The sequence of the display occurs as demonstrated in the following graphic. Continually pressing the <SET> push button enables scrolling through the display.

7.1.3

7-Segment Display

During operation the 7-segment display shows the current connection box CAN-ID. The LED "RUN/Err" is constantly lit green.

The previous 6 warnings and error messages can be called up on the 7-segment display. Press the <SET> push button repeatedly to scroll through the individual lists. These are displayed as a continual loop (see Illustration 7.2):

CAN-ID

•

Warnings

•

Errors

•

CAN-ID

•

Warnings

•

Errors

•

...

•

If an error is active, the LED “RUN/Err” is lit red. All other entries are errors which have been eliminated.

Illustration 7.2 Display Sequence with <SET> Push Button

Display/ Segment Dot CAN-ID (no segment dot)

WARN (segment dot “Warn”)

ERROR (segment dot “Err”)

Table 7.3 Description of the Segment Dots

Description

Connection box CAN-ID

Display: decimal.

•

Factory setting: 110.

•

See 6.2 CAN-ID Setting for information on how to change the CAN-ID. Warning about a potential error, e.g. DC input voltage below minimum.

Display: 4-digit hexadecimal code

•

See 12.3 Emergency Codes for a description of the emergency codes. An error occurred, e.g. CAN emergency error.

Display: 4-digit hexadecimal code

•

See 12.3 Emergency Codes for a description of the emergency codes.

Press the <SET> push button for 3 seconds to jump to the start (CAN-ID).

When a new event occurs, it is displayed as follows:

the error code is shown on the 7-segment display

•

immediately. The type of event is shown via the "Warn" or "Err" segment dot.

the LED "RUN/Err" is constantly lit red.

•

the error message (CAN emergency message)

•

appears on the CAN bus. an entry is made in the error memory. This can

•

be read via SDO (Service Data Object).

Depending on the error, the connection box switches to a different state.

The full list of error codes are detailed in 12.3 Emergency Codes.

36 MG75G102 - VLT® is a registered Danfoss trademark

Init

Error Reset

Voltage

Disabled

Fault

Discharged

Power

Down

Fault

Charged

Operation

Enabled

Switch On

Switch O

Power

Under

Voltage

Over

Voltage

130BD168.10

Operation

VLT® ISD Connection Box Operating Instructions

NOTE

It is not possible to reset errors or warnings on the connection box itself. An active error can only be deleted by:

NMT-Reset

•

Restarting the connection box

•

Error reset via the ISD Toolbox software or

•

CoDeSys

See 12.3 Emergency Codes for further information.

7.1.4 <SET> Push Button

The <SET> push button can be used to scroll through the list of messages and to set IDs. The CAN-ID is shown when the push button is pressed for 3 seconds.

<CAN-ID> BCD Switch

7.1.5

7.3

Machine States

7 7

The <CAN-ID> BCD switch is used to assign the ID manually. See 6.2 CAN-ID Setting.

Service Interface

7.1.6

CAUTION

The service interface is only for use by Danfoss Service.

7.2 Display via Toolbox and CoDeSys

In addition to the display on the ISD connection box, it is possible to query the status of the connection box via ISD Toolbox. In order to do this, it is necessary to connect to the CAN bus network via a PC/laptop. A CAN dongle is required, which realises the physical connection between the CAN bus network and the connection box. The ISD Toolbox enables the individual ISD components to be displayed directly and thereby information about the ISD components to be attained. The parameters of the ISD components can also be read via CoDeSys on the master controller. The ISD Toolbox software, firmware updates, EDS files and CoDeSys libraries can be downloaded from the Danfoss website (www.danfoss.com).

Illustration 7.3 Machine States

Illustration 7.3 shows the main state machine transitions. The states 'Under Voltage' and 'Over Voltage' are substates of state 'Operation Enabled'. Therefore these states inherit all transitions of their base state.

State 'Init' performs checks related to state 'Voltage Disabled' and makes a direct transition into state 'Fault Charged' if the capacitors are found charged.

An emergency message is sent whenever the connection box enters into any fault state. Each commanded transition, that has been rejected because proper operation can't be guaranteed, results in a warning emergency message being sent. Emergency messages are added to the history and displayed on the connection box display. All measurements and derived values are accessible via the CAN object dictionary in all states. Servicing operations, such as firmware flash, connection box reset or CAN-ID setting are only allowed in unpowered states.

MG75G102 - VLT® is a registered Danfoss trademark 37

Operation

VLT® ISD Connection Box Operating Instructions

7.3.1 State "Init” (Initialisation)

Controller reboot and transition 'Error Reset' out of state 'Fault Discharged' places the state machine into state 'Init'. In this state, the process is initialized and the supply voltages are checked. The controller is reset if an NMT reset (reset node or reset communication) has been received in this state.

Into state 'Fault Charged' if hazardous voltage is

•

detected inside the connection box, determined by measuring UZK.

without safety supplies. Both safety supplies are checked and memorised for comparison. The loss of any safety supply in any charged state is irregular and leads to an emergency warning.

7.3.3 State "Fault Discharged"

Transitions:

Into state 'Fault Charged' if hazardous voltage is

•

detected inside the connection box, determined by measuring UZK.

Into state 'Fault Discharged' if the 24 V and 5 V

•

CAN power supplies can't be found by reading

7.3.2

the digital inputs. Into state 'Voltage Disabled' if the NMT state

•

machine has finished its initialization and the 24 V and 5 V CAN power supplies are good.

State "Voltage Disabled"

This is the unpowered fault state. This state can either be left through a 'Reset Error' transition, which restarts the state machine, or through an NMT reset (reset node or reset communication), which resets the controller.

Transitions:

Into state 'Init' following a 'Reset Error' transition

•

user request. Into state 'Fault Charged' if hazardous voltage is

•

detected inside the connection box, determined by measuring UZK.

This is the nominal unpowered state. UDC input supply is detached from the intermediate circuitry and the capacitor battery is not charged. Devices connected to the lines are not powered. The controller is reset if an NMT reset (reset node or reset communication) has been received in this state.

If auto power up is configured in the user configuration and all required conditions are met, the state machine carries out a transition 'Switch On' and proceeds to state 'Power Up.

Transitions:

Into state 'Power Up' following a 'Switch On'

•

transition request (either through user command or configuration of the auto power up flag). Required checks:

- Improper supply voltages (24 V and/or 5 V CAN supplies) lead to a warning and the state is not changed.

- Out of nominal range input voltage (UDC) leads to a warning and the state is not changed.

- Improper heat sink temperature leads to a warning and the state is not changed.

- Improper safety supplies lead to a warning but allow the transition into state 'Power Up' to allow operation

State "Power Up"

7.3.4

This state charges the internal capacitor battery. Connected devices are not placed into operating state while charging the capacitors. When the battery is charged, the charging resistor is bypassed. If the discharge resistor check flag is set in the user configuration, the resistor is checked for correct operation during this state. If the verification fails, an error is issued and the transition to state 'Fault Charged' is initiated.

Transitions:

Into state 'Power Down' following a 'Switch Off'

•

transition user request or following an NMT reset (reset node or reset communication) command.

Into state 'Operation Enabled' if the capacitor

•

battery is charged, determined by measuring the intermediate circuitry voltage UZK.

Into state 'Fault Charged':

•

- If the capacitors can't be charged within the typical time limit to protect the charge resistor.

- If the intermediate circuitry voltage (UZK) is greater than the input voltage (UDC).

- If the input voltage drops below or exceeds the absolute limits.

38 MG75G102 - VLT® is a registered Danfoss trademark

Operation

VLT® ISD Connection Box Operating Instructions

- If the discharge resistor check flag has been set and the resistor test was negative.

- If a fuse has blown. The fuses are checked by comparing the voltage level of the intermediate circuitry (UZK) against the voltage levels of the output lines (ULine1 and ULine2).

- If the 24 V and/or 5 V CAN supply voltages are lost.

7.3.5 State "Power Down"

This state discharges the internal capacitor battery. The intermediate circuitry is detached from the input power supply and the discharge resistor is used to discharge the capacitors.

Transitions:

Into state 'Voltage Disabled' if the capacitors are

•

discharged and the intermediate circuitry voltage (UZK) drops below the hazardous level.

Into state 'Fault Charged' if the capacitors can't

•

be discharged within the typical time limit.

State "Fault Charged"

7.3.6

Basic transitions:

Into state 'Power Down' following a 'Switch Off'

•

transition user request or in case of an NMT reset (reset node or reset communication) command.

Into state 'Fault Charged':

•

- If the intermediate circuitry voltage (UZK)

- If the input voltage drops below or

- In case of a blown fuse. The fuses are

- If the 24 V and/or 5 V CAN supply

Specific transitions:

Into state 'Over Voltage' if the intermediate

•

circuitry voltage (UZK) rises above the specified maximum.

Into state 'Under Voltage' if the intermediate

•

circuitry voltage (UZK) falls below the specified minimum.

drops more than 20 V below the defined minimum power up voltage.

exceeds the absolute limits.

checked by comparing the voltage level of the intermediate circuitry (UZK) against the voltage levels of the output lines (ULine1 and ULine2).

7 7

voltages are lost.

This is the powered fault state. The intermediate circuitry is detached from the input power supply. The capacitors must be discharged in order to leave this state. Use the discharge resistor to discharge the capacitors.

Transitions:

Into state 'Fault Discharged' if the capacitors are

•

discharged and the intermediate circuitry voltage (UZK) drops below the hazardous level.

State "Operation Enabled"

7.3.7

This is the nominal powered state. The intermediate circuitry is connected directly to the input power supply and no resistor is enabled. Fault transitions are initiated if the input voltage (UDC) is outside its maximum limits but no fault action is taken on the intermediate circuitry voltage (UZK). If UZK rises above or falls below the defined thresholds, the event is signalled through transitions into the sub-states 'Over Voltage' and 'Under Voltage'.

State "Over Voltage"

7.3.8

This is a sub-state of state 'Operation Enabled'. Apart from the transitions into states 'Over Voltage' and 'Under Voltage', all transitions of the base state are inherited. In this state the chopper resistor is enabled to reduce the energy in the connection box by heating externally. The state is signaled by the blinking of the UZK power LED.

Transitions:

Into state 'Operation Enabled' if the intermediate

•

circuitry voltage (UZK) is back in nominal U range.

7.3.9

State "Under Voltage"

This is a sub-state of state 'Operation Enabled'. Apart from the transitions into states 'Over Voltage' and 'Under Voltage', all transitions of the base state are inherited.

Transitions:

Into state 'Operation Enabled' if the intermediate

•

circuitry voltage (UZK) is back in nominal U range.

MG75G102 - VLT® is a registered Danfoss trademark 39

Faults

VLT® ISD Connection Box Operating Instructions

8 Faults

Connection box faults are displayed on the 7-segment display on the connection box (see 7.1 Operating Display).

The behaviour of the connection box is detailed in the following s. Information on troubleshooting can be found in 8.4 Troubleshooting.

NOTE

If a fault cannot be eliminated by one of the measures listed, notify Danfoss Service.

Have the following information available to enable Danfoss to help you quickly and effectively:

Type number

•

Error message number

•

Firmware version

•

8.1 Emergency

If an error occurs the connection box sends an emergency message. Possible emergencies are listed in 12.3 Emergency Codes.

8.2

Error History

The connection box keeps an error history with the emergency codes from 12.3 Emergency Codes along with a timestamp.

The connection box keeps a maximum of 32 emergency messages divided into 16 Errors and 16 Warnings. When the history is full the oldest is replaced. All emergency messages can be accessed via SDO.

8.3

Debugging

For debugging purposes the following information can be read from the ISD Toolbox software or via the CAN:

1. Power on Software version information

•

CAN settings: baud rate and CAN-ID

•

2. Emergencies

40 MG75G102 - VLT® is a registered Danfoss trademark

Faults

VLT® ISD Connection Box Operating Instructions

8.4 Troubleshooting

When problems occur in the servo system, they must first be located and properly identified. Table 8.1 lists potential faults on the connection box, their possible causes and actions for correcting the faults. Contact Danfoss Service if it is not possible to correct the fault.

Fault/Fault Code on 7segment Display

LED "CAN" is lit red constantly CAN error.

LED "CAN" is off No CAN messages on the bus.

LED "RUN/Err" is lit red constantly LED "UZK" is off although DC 300 V power supply is connected.

Error code 3100 (hex) Input voltage (UDC) above absolute

Error code 3101 (hex) Input voltage (UDC below absolute

Error code 3102 (hex) Input voltage (UDC) below intermediate

Error code 3110 (hex) 24 V power supply loss.

Error code 3111 (hex) 24 V power supply timeout during initiali-

Error code 3118 (hex) 5 V CAN power supply loss.

Error code 3119 (hex) 5 V CAN power supply timeout during

Warning code 3180 (hex) Switch on, nominal UDC range:

Warning code 3181 (hex) Switch on, nominal UDC range:

Warning code 3190 (hex) Switch on: 24 V power supply bad.

Warning code 3191 (hex) Switch on: 5 V CAN power supply bad.

Error code 3200 (hex) Hazardous intermediate circuitry voltage. Contact Danfoss Service

Possible Cause Possible Solution

Check cabling

•

Check terminating resistors

•

Check cabling

•

Check master

•

Active connection box error. See error and warning codes below.

Cable connected incorrectly.

•

300 V DC power supply voltage not

•

present.

Connection box not switched on.

•

maximum.

minimum.

voltage (UZK) during power up.

sation.

initialisation.

Input voltage above maximum.

Input voltage below minimum.

Check cabling

•

Check DC 300 V power supply

•

Switch connection box on via a command from the

•

master or by configuring parameter autoSwitchOn

Check stability of 300 V DC power supply

•

Ensure servomotors are not active during power up so

•

power feedback cannot occur

Ensure no power supply is connected on the output

•

side

Check cabling

•

Check 24 V power supply

•

Check cabling

•

Check 24 V power supply ramp-up time

•

Check cabling

•

Contact Danfoss Service to check the 5 V internal

•

power supply

Check cabling

•

Contact Danfoss Service to check the 5 V internal

•

power supply ramp-up time

Check power supply range

Check cabling

•

Check 24 V power supply

•

Check cabling

•

Contact Danfoss Service to check the 5 V internal

•

power supply

8 8

MG75G102 - VLT® is a registered Danfoss trademark 41

Faults

VLT® ISD Connection Box Operating Instructions

Fault/Fault Code on 7-

Possible Cause Possible Solution

segment Display

Error code 3201 (hex) Intermediate circuitry voltage (UZK) drops

below absolute minimum UDC during operation.

Warning code 3280 (hex) Intermediate circuitry voltage (UZK) over

voltage during operation.

Warning code 4280 (hex) Switch on: Heat sink temperature above

maximum.

Error code 5030 (hex) Fuse 1 blown. Replace fuse 1 Error code 5031 (hex) Fuse 2 blown. Replace fuse 2 Error code FF01 (hex) Power up timeout. Check output load Error code FF02 (hex) Power down timeout. Contact Danfoss Service Warning code FF90 (hex) Switch on: No safety power. Check cabling and power supply if safety power needed in

Warning code FF91 (hex) Safety power 1 loss. Check cabling and power supply stability if safety power

Warning code FF92 (hex) Safety power 2 loss. Check cabling and power supply stability if safety power

Table 8.1 Troubleshooting Overview

Contact Danfoss Service

Switch connection box off and allow it to cool for 30

•

minutes before switching it back on

Contact Danfoss Service if error recurs

•

application

needed in application

42 MG75G102 - VLT® is a registered Danfoss trademark

Maintenance and Repair

9 Maintenance and Repair

VLT® ISD Connection Box Operating Instructions

9.1 Maintenance tasks

The connection boxes are largely maintenance free.

The maintenance tasks listed in the following table may be performed by the customer. No other tasks are required.

Component Maintenance

Task

Vents Vacuum Regularly or as

Connection box

Table 9.1 Overview of Maintenance Tasks

Clean Regularly or as

Maintenance Interval

necessary

Instruction

Vacuum the vents with a vacuum cleaner Clean the surface with a dry cloth

9.2 Inspection during Operation

Carry out regular inspections during operation. Check the connection box at regular intervals for anything unusual.

Pay particular attention to:

9.3

Repair

9.3.1 Replacing the Fuses

WARNING

HIGH VOLTAGE

The connection box contains high voltage when connected to the power supply module. Disconnect the power supply and wait for the discharge time to elapse before changing the fuses.

Number Minimum waiting time (discharge time) 0-60 servomotors 10 minutes

Note: High voltage may still be present even if the LED on the

ISD connection box is not lit!

Table 9.2 Discharge Time

Fuse type: 16 A FF, size G (6.3 x 32 mm)

NOTE

No other repairs to the connection box are allowed. Always return defective connection boxes to Danfoss.

9 9

Loose fastenings

•

Condition of electrical wiring and cables

•

In the event of irregularities or problems, see 8.4 Trouble- shooting.

MG75G102 - VLT® is a registered Danfoss trademark 43

Decommissioning and Disposa...

VLT® ISD Connection Box Operating Instructions

10 Decommissioning and Disposal

10.1 Decommissioning

The procedure for decommissioning the connection box is the reverse of the installation procedure described in

5.5 Mechanical Installation.

Proceed as follows:

Disconnect the power supply and wait for the

•

discharge time to elapse.

10.2 Dismounting

The procedure for dismounting the connection box is the reverse of the fitting procedure described in 5.5 Mechanical Installation.

Proceed as follows:

1. Disconnect the power supply and wait for the

discharge time to elapse.

2. Disconnect the electrical cables.

3. Dismount the connection box.

10.3

Recycling and Disposal

10.3.1 Recycling

Take metals and plastics to recycling stations.

The entire connection box is classified as electronic waste, and the packaging is classified as packaging waste.

10.3.2

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

Disposal

Dispose of the connection box as hazardous waste, electrical waste, recyclable waste, etc. in accordance with applicable local regulations.

44 MG75G102 - VLT® is a registered Danfoss trademark

130BD169.10

ISD Connection Box

Made in Germany

Uin: 300VDC

Connection Box:

Iin/max: 10ADC

PART NO: 175G7760 SERIAL NO : 000402M352

175G776000000M000

Ambient: 5...40 C/41...104 F

o o

Enclosure: IP 20

Uout: 300VDC Iout/max: 10ADC

Pout/max: 3000W

Specifications

11 Specifications

VLT® ISD Connection Box Operating Instructions

11.1 Nameplate

Check the nameplate and compare it with the order data. Use the part number for reference.

The part number uniquely identifies the connection box.

Illustration 11.1 Nameplate

The following data is shown on the nameplate of the ISD connection box:

2 Max. input current 7 Protection rating 3 Output voltage 8 Part number 4 Max. output current 9 Serial number 5 Max. output power

Ensure that the nameplate is clearly legible.

11.2

Input voltage 6 Ambient temperature

range

Table 11.1 Legend to Illustration 11.1

Storage

11.3

Characteristic Data

Definition Value and Unit

Input

Input voltage 300 V DC Connections +300 V DC, –300 V DC, PE Input current DC 10 A Fuse protection External via line protection Power factor 94%

Output (with use of ISD Power Supply Module)

Output voltage line 1 300 V DC Output voltage line 2 300 V DC Tolerance ±1% Ripple 1 V Rated power 3.0 kW Rated current

Environmental Conditions

Climatic classification 3K3 Mounting In a control cabinet Ambient temperature 5–40 °C Humidity 5-85%, non-condensing

Cooling Via vents on housing Protection type IP20 Protection rating 1 with PE connection Over-voltage category III Vibration rating 3M4

Mechanical Conditions

Degree of pollution 2 Safety Standards EN 61508

Housing

Material Steel, aluminium for wall mounting Dimensions (W x H x D) 130 x 268 x 200 mm Weight 5 kg

Table 11.2 Characteristic Data

1) Only if 10 A is fed in

10 A

(according to IEC 60721-3-3)

Store the connection box in a dry, dust-free location with low vibration (V

The storage location must be free from corrosive gases.

Avoid sudden temperature changes.

≤0.2 mm/s).

eff

MG75G102 - VLT® is a registered Danfoss trademark 45

130BD170.10

130

254

Specifications

11.4 Dimensions

11.4.1 Front View

All dimensions are in mm.

VLT® ISD Connection Box Operating Instructions

Illustration 11.2 Front View

46 MG75G102 - VLT® is a registered Danfoss trademark

130BD057.10

202.5

205

862

5.21

452

Specifications

11.4.2 Side View

All dimensions are in mm.

VLT® ISD Connection Box Operating Instructions

Illustration 11.3 Side View

MG75G102 - VLT® is a registered Danfoss trademark 47

Appendix

12 Appendix

12.1 Glossary

VLT® ISD Connection Box Operating Instructions

A flange The A side is the shaft side of the motor.

Ambient temperature The temperature in the immediate vicinity of the servo system or component.

Axial force The force in newton-metres acting on the rotor axis in the axial direction.

BCD Binary-coded decimal

Bearings The ball bearings of the servo drive.

B flange The rear side of the servomotor with the plug-and-socket connectors.

BiSS Bi-directional Synchronous Serial

Clamping set A mechanical device, which, for example, can be used to secure gears to a motor shaft.

CoDeSys Controller Development System; a development environment for programming controller applications, based on IEC 61131-3 and developed by 3S-Smart Software Solutions GmbH.

Connection box The connection box provides the link between the power supply module and the servo drives.

Connector (M23) Servomotor connector.

Cooling ISD servo drives are cooled by convection, which means without fans.

CRC Cyclic Redundancy Check

Brake Power-off brake of the ISD servomotor, on the A side of the motor.

1212

CAN Controller Area Network

CANopen DS301 A standard that specifies the application layer and communication profile.

CANopen DS402 An object-based CAN standard that specifies the device profile for drives and motion control.

CANopen DS406

An object-based CAN standard that specifies the device profile for encoders.

CE European test and certification mark.

CSA Canadian test and certification mark.

DC link Each servomotor has its own DC link, consisting of capacitors.

DC link voltage A DC voltage shared by several ISD servomotors connected in parallel.

DC voltage A direct constant voltage.

DSP Digital signal processor; processor IC on an ISD control board.

Encoder box The encoder box allows external encoder signals to be sent to the servo drives over the CAN bus with high precision.

48 MG75G102 - VLT® is a registered Danfoss trademark

Appendix

VLT® ISD Connection Box Operating Instructions

Feed cable Hybrid connection cable between connection box and servomotor, with a connector.

Feedback system Feedback systems for servomotors in general.

Fieldbus Communication bus between controller and servo axis; in general between controller and field nodes.

Firmware Software in the unit; runs on the control board.

Flash Memory IC on the ISD control board; a form of EPROM.

Function block Device functionalities are accessible via CoDeSys.

Gear ratio The speed ratio of the input pinion and the output shaft of the gear unit.

Gear unit External gear unit used to change the output shaft speed and the torque on the motor shaft.

Hole circle The hole patterns of the ISD and IEC flanges.

IEC flange Industry-standard flange

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

ISD Integrated servo drive, integrated servomotor solution.

ISD flange The standard flange for ISD servo drives; larger than the IEC flange.

ISD servomotor Designates the ISD servomotor with hybrid cable.

M12 connector Input connector for connecting the sensor on the B side of the servomotor.

Motor shaft Rotating shaft on the A side of the servomotor, typically without a key groove.

Multi-turn encoder Describes a digital absolute encoder, in which the absolute position remains known after several revolutions.

NMT Network Management

PELV Low-voltage directive regarding voltage levels and distances between lines.

PDO Process Data Object (see CANopen DS301).

Planetary gear A specific type of gearing, typically used with servomotors.

Power-off principle The brake is normally engaged. It is released by applying a voltage (safety function).

Power supply module The power supply module provides a regulated 300 V DC from AC 400 V.

12 12

QEP Quadrature Encoder Pulse

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

Resolver A feedback device for servomotors, typically with two analog tracks (sine and cosine).

Safety (STO) A servomotor safety circuit that switches off the voltages of the driver components for the IGBTs.

Loop cable Hybrid connection cable between two servomotors, with two connectors.

MG75G102 - VLT® is a registered Danfoss trademark 49

Scope Used for diagnosis. Enables internal signals to be depicted.

SD Card Secure Digital Card for encoder box.

Appendix

SDO Service Data Object (see CANopen DS301).

Segment A segment refers to a movement within a curve.

SIL 2 Safety Integrated Level II.

Single-turn encoder Describes a digital absolute encoder, in which the absolute position for one revolution remains known.

SSI Synchronous Serial Interface

Toolbox A software tool used for parameter setting and diagnostics of ISD servomotors, the ISD connection box and the ISD encoder box.

VLT® ISD Connection Box Operating Instructions

12.2 Connection Box Parameters

The object dictionary is detailed in the VLT® ISD 410 Design Guide. The following functions can be enabled/disabled by writing to the object dictionary via SDO.

12.2.1

Auto Power-Up (Index 0x2015, subindex 01)

If auto power-up is configured in the user configuration and if all required conditions are met, the state machine

1212

makes a transition 'Switch On' and proceeds to state 'Power Up'. Auto power-up is defined to only initiate this transition once, after the connection box has been rebooted. Subsequent transitions into state 'Voltage disabled' require user interaction.

12.2.2

Discharge Resistor Check (Index 0x2015, sub-index 02)

If the discharge resistor check flag is set in the user configuration the resistor is checked for correct operation during power-up state. If the verification fails an error occurs and a transition to state 'Fault Charged' is initiated.

50 MG75G102 - VLT® is a registered Danfoss trademark

Appendix

VLT® ISD Connection Box Operating Instructions

12.3 Emergency Codes

Code Severity Description 0x3100 Error Input voltage (UDC) above absolute maximum. 0x3101 Error Input voltage (UDC) below absolute minimum. 0x3102 Error Input voltage (UDC) below intermediate voltage (UZK) during power-up. 0x3110 Error 24 V power supply loss. 0x3111 Error 24 V power supply timeout during initialisation. 0x3118 Error 5 V CAN power supply loss. 0x3119 Error 5 V CAN power supply timeout during initialisation. 0x3180 Warning Switch on, nominal UDC range: Input voltage above maximum. 0x3181 Warning Switch on, nominal UDC range: Input voltage below minimum. 0x3190 Warning Switch on: 24 V power supply bad. 0x3191 Warning Switch on: 5 V CAN power supply bad. 0x3200 Error Hazardous intermediate circuitry voltage. 0x3201 Error Intermediate circuitry voltage (UZK) drop during operation. 0x3280 Warning Intermediate circuitry voltage (UZK) over voltage during operation. 0x4280 Warning Switch on: Heat sink temperature above maximum. 0x5030 Error Fuse 1 blown. 0x5031 Error Fuse 2 blown. 0xFF01 Error Power-up timeout. 0xFF02 Error Power-down timeout. 0xFF90 Warning Switch on: No safety power. 0xFF91 Warning Safety power 1 loss. 0xFF92 Warning Safety power 2 loss.

Table 12.1 Emergency Codes

12 12

MG75G102 - VLT® is a registered Danfoss trademark 51

Index

VLT® ISD Connection Box Operating Instructions

Index

Ambient Temperature........................................................................ 45

Approvals................................................................................................... 5

BCD Switch.............................................................................................. 37

Booting Up.............................................................................................. 34

Brake

Cable..................................................................................................... 31

Connector........................................................................................... 22

Cabling..................................................................................................... 15

CAN

Cable..................................................................................................... 27

Connectors......................................................................................... 21

Plugs..................................................................................................... 28

Wiring Example 1............................................................................. 29

Wiring Example 2............................................................................. 30

CAN-ID

BCD Switch......................................................................................... 37

Setting.................................................................................................. 33

Climatic Classification......................................................................... 45

CoDeSys................................................................................................... 37

Connection............................................................................................. 15

Connections

Connections....................................................................................... 45

24 V DC Power Supply.................................................................... 23

Brake Connector............................................................................... 22

CAN....................................................................................................... 21

DC Input Terminal............................................................................ 22

DC Output Terminal........................................................................ 23

Safety Switch..................................................................................... 20

Cooling.............................................................................................. 23, 45

Input Terminal Connector............................................................ 22

Output Terminal Connector......................................................... 23

Debugging.............................................................................................. 40

Decommissioning................................................................................ 44

Delivery

Inspection On Receipt.................................................................... 24

Scope Of Delivery............................................................................. 24

Demounting........................................................................................... 44

Description Of ISD Connection Box............................................... 13

Dimensions

Front View........................................................................................... 46

Side View............................................................................................. 47

Discharge Time................................................................................. 5, 31

Disclaimer.................................................................................................. 5

Dismounting................................................................................... 26, 44

Display

Display.......................................................................................... 14, 35

Mode..................................................................................................... 36

Disposal.................................................................................................... 44

Documents................................................................................................ 8

Drilling Template.................................................................................. 25

Due Diligence........................................................................................ 11

Earthing The Connection Box.......................................................... 26

Electrical Environmental Conditions............................................. 26

Emergency

Codes.................................................................................................... 51

Message............................................................................................... 40

Environmental Conditions................................................................ 24

Error History............................................................................................ 40

Faults

Faults.................................................................................................... 40

Correcting Faults.............................................................................. 41

Foreseeable Misuse............................................................................. 12

Functional Operation Test................................................................. 33

Fuses................................................................................................... 20, 45

Glossary.................................................................................................... 48

Grounding............................................................................................... 26

High Voltage............................................................................................. 5

Housing.................................................................................................... 45

Humidity.................................................................................................. 45

Hybrid Cables Connecting/Disconnecting................................. 31

Initialisation............................................................................................ 38

Input

Current................................................................................................. 45

Voltage................................................................................................. 45

Inspection During Operation........................................................... 43

Installation

Electrical Installation....................................................................... 26

Mechanical Installation.................................................................. 26

Mounting............................................................................................ 26

Preparation For Installation.......................................................... 25

Intended Use.......................................................................................... 12

Introduction.............................................................................................. 7

52 MG75G102 - VLT® is a registered Danfoss trademark

Index

IP-Rating................................................................................................... 45

ISD Servo System.................................................................................... 7

VLT® ISD Connection Box Operating Instructions

LEDs

LEDs...................................................................................................... 35

5V........................................................................................................... 35

CAN....................................................................................................... 35

Power Supply.................................................................................... 35

RUN/Err................................................................................................ 35

Safe........................................................................................................ 35

UZK Power.......................................................................................... 35

Machine States...................................................................................... 37

Maintenance.......................................................................................... 43

Mass........................................................................................................... 45

Misuse Of The Product........................................................................ 12

Monitoring.............................................................................................. 43

Mounting.......................................................................................... 26, 45

Nameplate............................................................................................... 45

Operating Display................................................................................ 35

Operation Test....................................................................................... 33

Operational Safety............................................................................... 10

Output Voltage...................................................................................... 45

Safety

Cable..................................................................................................... 31

Discharge Time............................................................................. 5, 31

During Installation........................................................................... 24

High Voltage........................................................................................ 5

Instructions........................................................................................... 9

Standards............................................................................................ 45

Switch Connectors........................................................................... 20

Unintended Start................................................................................ 5

Warnings........................................................................................... 9, 5

Safety, Operational.............................................................................. 10

Service

Service.................................................................................................... 6

Interface On Display........................................................................ 37

SET Push Button.................................................................................... 37

Shutdown................................................................................................ 44

State

"Fault Charged"................................................................................. 39

"Fault Discharged"........................................................................... 38

"Operation Enabled"....................................................................... 39

"Over Voltage"................................................................................... 39

"Power Down"................................................................................... 39

"Power Up"......................................................................................... 38

"Under Voltage"................................................................................ 39

"Voltage Disabled"........................................................................... 38

“Init”...................................................................................................... 38

Storage..................................................................................................... 45

Support....................................................................................................... 6

Switching On.......................................................................................... 34

Symbols...................................................................................................... 9

System Overview..................................................................................... 7

Parameters.............................................................................................. 50

Power

Factor.................................................................................................... 45

Supply.................................................................................................. 31

Supply 24 V......................................................................................... 26

Protection Rating.................................................................................. 45

Qualified Personnel............................................................................. 11

Recycling................................................................................................. 44

Removal................................................................................................... 44

Repair........................................................................................................ 43

Resources, Additional Documents................................................... 8

Returns..................................................................................................... 43

Technical Data....................................................................................... 45

Terminology.............................................................................................. 8

Toolbox.................................................................................................... 37

Trademarks................................................................................................ 5

Transport................................................................................................. 24

Troubleshooting................................................................................... 41

Unintended Start..................................................................................... 5

Vibration Rating.................................................................................... 45

Voltage Warning..................................................................................... 5

MG75G102 - VLT® is a registered Danfoss trademark 53

Index

VLT® ISD Connection Box Operating Instructions

Warning

Codes.................................................................................................... 51

Discharge Time............................................................................. 5, 31

High Voltage........................................................................................ 5

Unintended Start................................................................................ 5

Weight...................................................................................................... 45

X1................................................................................................................ 22

X11-X15............................................................................................. 21, 23

X2/X3......................................................................................................... 23

X22-X25.................................................................................................... 21

X5................................................................................................................ 22

54 MG75G102 - VLT® is a registered Danfoss trademark

Index

VLT® ISD Connection Box Operating Instructions

MG75G102 - VLT® is a registered Danfoss trademark 55

www.danfoss.com/drives

175R1124 MG75G102 Rev. 2012-10-29

*MG75G102*

Danfoss VLT ISD Connection Box Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual