EPA digitax st User Manual

AC variable speed drive for servo motors

User Guide

Original Instructions

For the purposes of compliance with the EU Machinery Directive 2006/42/EC:

General Information

The manufacturer accepts no liability for any consequences resulting from inappropriate, negligent or incorrect installation or adjustment of the optional operating parameters of the equipment or from mismatching the variable speed drive with the motor.

The contents of this guide are believed to be correct at the time of printing. In the interests of a commitment to a policy of continuous development and improvement, the manufacturer reserves the right to change the specification of the product or its performance, or the contents of the guide, without notice.

All rights reserved. No parts of this guide may be reproduced or transmitted in any form or by any means, electrical or mechanical including photocopying, recording or by an information storage or retrieval system, without permission in writing from the publisher.

Drive software version

This product is supplied with the latest software version. If this drive is to be connected to an existing system or machine, all drive software versions should be verified to confirm the same functionality as drives of the same model already present. This may also apply to drives returned from an Emerson Industrial Automation Service Centre or Repair Centre. If there is any doubt please contact the supplier of the product.

The software version of the drive can be checked by looking at Pr 11.29 and Pr 11.34. This takes the form of xx.yy.zz where Pr 11.29 displays xx.yy and Pr 11.34 displays zz. (e.g. for software version 01.01.00, Pr 11.29 = 1.01 and Pr 11.34 displays 0).

Environmental statement

Emerson Industrial Automation is committed to minimising the environmental impacts of its manufacturing operations and of its products throughout their life cycle. To this end, we operate an Environmental Management System (EMS) which is certified to the International Standard ISO 14001. Further information on the EMS, our Environmental Policy and other relevant information is available on request, or can be found at:

http://www.emersonindustrial.com/en-EN/controltechniques/aboutus/environment/Pages/environment.aspx The electronic variable-speed drives manufactured by Emerson Industrial Automation have the potential to save energy and (through

increased machine/process efficiency) reduce raw material consumption and scrap throughout their long working lifetime. In typical applications, these positive environmental effects far outweigh the negative impacts of product manufacture and end-of-life disposal.

Nevertheless, when the products eventually reach the end of their useful life, they must not be discarded but should instead be recycled by a specialist recycler of electronic equipment. Recyclers will find the products easy to dismantle into their major component parts for efficient recycling. Many parts snap together and can be separated without the use of tools, while other parts are secured with conventional fasteners. Virtually all parts of the product are suitable for recycling.

Product packaging is of good quality and can be re-used. Large products are packed in wooden crates, while smaller products come in strong cardboard cartons which themselves have a high recycled fibre content. If not re-used, these containers can be recycled. Polythene, used on the protective film and bags for wrapping product, can be recycled in the same way. Emerson Industrial Automations' packaging strategy prefers easily-recyclable materials of low environmental impact, and regular reviews identify opportunities for improvement.

When preparing to recycle or dispose of any product or packaging, please observe local legislation and best practice.

REACH legislation

EC Regulation 1907/2006 on the Registration, Evaluation, Authorisation and restriction of Chemicals (REACH) requires the supplier of an article to inform the recipient if it contains more than a specified proportion of any substance which is considered by the European Chemicals Agency (ECHA) to be a Substance of Very High Concern (SVHC) and is therefore listed by them as a candidate for compulsory authorisation.

For current information on how this requirement applies in relation to specific Emerson Industrial Automations’ products, please approach your usual contact in the first instance. Emerson Industrial Automations’ position statement can be viewed at:

www.emersonindustrial.com/en-EN/controltechniques/aboutus/environment/reachregulation/Pages/reachregulation.aspx. Copyright © September 2015 Emerson Industrial Automation. The information contained in this guide is for guidance only and does not form part of any contract. The accuracy cannot be guaranteed

as Emerson have an ongoing process of development and reserve the right to change the specification of their products without notice. Control Techniques Limited. Registered Office: The Gro, Newtown, Powys SY16 3BE. Registered in England and Wales. Company

Reg. No. 01236886. Moteurs Leroy-Somer SAS. Headquarters: Bd Marcellin Leroy, CS 10015, 16915 Angoulême Cedex 9, France. Share Capital: 65 800

512 €, RCS Angoulême 338 567 258. Issue Number: 5 Software: 01.06.00 onwards For patent and intellectual property related information please go to: www.ctpatents.info.

How to use this guide

NOTE

1 Safety information

2 Product information

3 Mechanical installation

4 Electrical installation

5 Getting started

6 Basic parameters

7 Running the motor

8 Optimization

9 SMARTCARD operation

11 Advanced parameters

12 Technical data

13 Diagnostics

14 UL listing information

10 Onboard PLC

This User Guide provides information for operating the drive from start to finish. The information is in logical order, taking the reader from receiving the drive through to fine tuning the performance.

There are specific safety warnings throughout this guide, located in the relevant sections. In addition, Chapter 1 Safety Information on page 6 contains general safety information. It is essential that the warnings are observed and the information considered when working with or designing a system using the drive.

This map of the user guide helps to find the right sections for the task you wish to complete:

Contents

1 Safety Information .................................6

1.1 Warnings, Cautions and Notes .............................6

1.2 Electrical safety - general warning ........................6

1.3 System design and safety of personnel ................6

1.4 Environmental limits ..............................................6

1.5 Access ...................................................................6

1.6 Fire protection .......................................................6

1.7 Compliance with regulations .................................6

1.8 Motor .....................................................................6

1.9 Mechanical brake control ......................................6

1.10 Adjusting parameters ............................................6

1.11 Electrical installation ..............................................6

2 Product information ..............................8

2.1 Introduction ...........................................................8

2.2 Drive ratings ..........................................................8

2.3 Drive model numbers ............................................9

2.4 Drive nameplate description ..................................9

2.5 Features of the drive ...........................................10

2.6 Options ................................................................11

2.7 Items supplied with the drive ...............................14

3 Mechanical installation .......................15

3.1 Safety information ...............................................15

3.2 Planning the installation ......................................15

3.3 Solutions Module / keypad installation / removal 16

3.4 Drive dimensions .................................................17

3.5 External EMC filter rating ....................................18

3.6 Optional braking resistor .....................................19

3.7 Terminal torque settings ......................................20

3.8 Routine maintenance ..........................................20

4 Electrical installation ...........................21

4.1 Power terminal connections ................................22

4.2 Ground connections ............................................23

4.3 AC supply requirements ......................................23

4.4 DC bus design .....................................................24

4.5 DC drive voltage levels .......................................24

4.6 Ratings ................................................................25

4.7 Output circuit and motor protection .....................25

4.8 Braking ................................................................26

4.9 Ground leakage ...................................................27

4.10 EMC (Electromagnetic compatibility) ..................28

4.11 Internal and external conducted emissions

conformity ............................................................30

4.12 Serial communications connections ....................31

4.13 Control connections ............................................32

4.14 Control terminals .................................................34

4.15 Encoder connections ...........................................37

4.16 Encoder terminals ...............................................38

4.17 Safe Torque Off ...................................................42

5 Getting started .................................... 43

5.1 User interfaces ................................................... 43

5.2 CT Soft ............................................................... 43

5.3 SYPTPro (Indexer & Plus only) .......................... 43

5.4 EZMotion PowerTools Pro ................................. 43

5.5 Keypad operation ............................................... 44

5.6 Understanding the display .................................. 44

5.7 Displaying parameters with non-default

values only ......................................................... 47

5.8 Displaying destination parameters only ............. 47

5.9 Communications ................................................ 47

6 Basic parameters ................................ 49

6.1 Single line descriptions ...................................... 49

6.2 Full descriptions ................................................. 54

7 Running the motor .............................. 60

7.1 Quick start Connections ..................................... 60

7.2 Quick Start set-up .............................................. 64

7.3 Setting up a feedback device ............................. 65

7.4 Setting up a buffered encoder output ................. 68

8 Optimization ........................................ 69

8.1 Motor map parameters ....................................... 69

9 EtherCAT interface ............................. 72

9.1 Features ............................................................. 72

9.2 What is EtherCAT? ............................................ 72

9.3 EtherCAT interface information .......................... 72

9.4 EtherCAT interface terminal descriptions ........... 72

9.5 Module grounding .............................................. 72

9.6 Network topology ............................................... 72

9.7 Minimum node-to-node cable length .................. 72

9.8 Quick start guide ................................................ 72

9.9 Quick start flowchart ........................................... 74

9.10 Saving parameters to the drive .......................... 75

9.11 EtherCAT interface Node address ..................... 75

9.12 EtherCAT interface RUN .................................... 75

9.13 Re-initializing the EtherCAT interface ................ 75

9.14 Process Data Objects (PDOs) ........................... 75

9.15 Service Data Object (SDO) parameter access .. 75

9.16 CANopen over EtherCAT (CoE) ........................ 76

9.17 Ethernet over EtherCAT (EoE) ........................... 80

9.18 Drive profile (DSP-402) support ......................... 81

9.19 Interpolated position mode ................................. 87

9.20 vl velocity mode .................................................. 88

9.21 Profile torque mode ............................................ 90

9.22 Homing mode ..................................................... 91

9.23 Cyclic sync position mode .................................. 94

9.24 Advanced features ............................................. 94

9.25 Advanced cyclic data configuration .................... 96

9.26 Internal shortcuts ................................................ 97

9.27 Quick reference .................................................. 98

4 Digitax ST User Guide

Issue: 5

10 SMARTCARD Operation ...................101

10.1 Introduction .......................................................101

10.2 Transferring data ...............................................102

10.3 Data block header information ..........................104

10.4 SMARTCARD parameters ................................104

10.5 SMARTCARD trips ...........................................106

11 Onboard PLC .....................................108

11.1 Onboard PLC and SYPTLite .............................108

11.2 Benefits .............................................................108

11.3 Limitations .........................................................108

11.4 Getting started ..................................................108

11.5 Onboard PLC parameters .................................108

11.6 Onboard PLC trips ............................................109

11.7 Onboard PLC and the SMARTCARD ...............109

14 Diagnostics ........................................183

14.1 Trip indications ..................................................183

14.2 Alarm indications ...............................................198

14.3 Status indications ..............................................199

14.4 EtherCAT Diagnostics .......................................199

14.5 Network configuration objects ...........................200

14.6 Diagnostic parameters ......................................200

14.7 Drive trip display codes .....................................200

14.8 EtherCAT interface temperature .......................201

14.9 EtherCAT interface serial number .....................201

14.10 EtherCAT interface error codes ........................201

14.11 Error handling ...................................................201

14.12 Critical task % free ............................................203

14.13 SDO abort codes ..............................................203

14.14 FLASH file system % free .................................203

12 Advanced parameters .......................110

12.1 Menu 1: Speed reference .................................116

12.2 Menu 2: Ramps .................................................120

12.3 Menu 3: Speed feedback and control ...............124

12.4 Menu 4: Torque and current control ..................127

12.5 Menu 5: Motor control .......................................130

12.6 Menu 6: Sequencer and clock ..........................133

12.7 Menu 7: Analog I/O ...........................................135

12.8 Menu 8: Digital I/O ............................................138

12.9 Menu 9: Programmable logic, motorized

pot, binary sum and timers ................................141

12.10 Menu 10: Status and trips .................................144

12.11 Menu 11: General drive set-up .........................146

12.12 Menu 12: Threshold detectors, variable

selectors and brake control function .................147

12.13 Menu 13: Position control .................................152

12.14 Menu 14: User PID controller ............................156

12.15 Menus 15 and 16: Solutions Module set-up ......159

12.16 Menu 17: Motion processors .............................160

12.17 Menu 18: Application menu 1 ...........................163

12.18 Menu 19: Application menu 2 ...........................163

12.19 Menu 20: Application menu 3 ...........................163

12.20 Menu 21: Second motor parameters ................164

12.21 Menu 22: Additional Menu 0 set-up ..................165

12.22 Advanced features ............................................166

15 UL listing information .......................204

15.1 Common UL information ...................................204

15.2 AC supply specification .....................................204

15.3 Maximum continuous output current .................204

15.4 Common DC bus ..............................................204

15.5 DC Supplied drive .............................................205

15.6 UL listed accessories ........................................205

13 Technical Data ...................................173

13.1 Drive technical data ..........................................173

13.2 Optional external EMC filters ............................182

13.3 Overall EMC filter dimensions ...........................182

Digitax ST User Guide 5 Issue: 5

Safety

WARNING

CAUTION

NOTE

Information

Product

information

Mechanical

installation

Electrical

installation

Getting started

Basic

parameters

Running the

motor

Optimization

EtherCAT

interface

SMARTCARD

Operation

Onboard

PLC

Advanced

parameters

Technical

Data

Diagnostics

UL listing

information

1 Safety Information

1.1 Warnings, Cautions and Notes

A Warning contains information which is essential for avoiding a safety hazard.

A Caution contains information which is necessary for avoiding a risk of damage to the product or other equipment.

A Note contains information which helps to ensure correct operation of the product.

1.2 Electrical safety - general warning

The voltages used in the drive can cause severe electrical shock and/or burns, and could be lethal. Extreme care is necessary at all times when working with or adjacent to the drive.

Specific warnings are given at the relevant places in this guide.

1.3 System design and safety of personnel

The drive is intended as a component for professional incorporation into complete equipment or a system. If installed incorrectly, the drive may present a safety hazard.

The drive uses high voltages and currents, carries a high level of stored electrical energy, and is used to control equipment which can cause injury.

Close attention is required to the electrical installation and the system design to avoid hazards either in normal operation or in the event of equipment malfunction. System design, installation, set-up and maintenance must be carried out by personnel who have the necessary training and experience. They must read this safety information and this guide carefully.

The STOP and Safe Torque Off functions of the drive do not isolate dangerous voltages from the output of the drive or from any external option unit. The supply must be disconnected by an approved electrical isolation device before gaining access to the electrical connections.

With the sole exception of the Safe Torque Off function, none of the drive functions must be used to ensure safety of personnel, i.e. they must not be used for safety-related functions.

Careful consideration must be given to the functions of the drive which might result in a hazard, either through their intended behavior or through incorrect operation due to a fault. In any application where a malfunction of the drive or its control system could lead to or allow damage, loss or injury, a risk analysis must be carried out, and where necessary, further measures taken to reduce the risk - for example, an over-speed protection device in case of failure of the speed control, or a fail-safe mechanical brake in case of loss of motor braking.

The Safe Torque Off function has been approved by IFA as meeting the requirements of the following standards, for the prevention of unexpected starting of the drive:

EN 61800-5-2:2007 SIL 3 EN ISO 13849-1:2006 PL e EN 954-1:1997 Category 3 (This standard is withdrawn and

should not be used for new designs, information provided for legacy applications only).

The Safe Torque Off function may be used in a safety-related application. The system designer is responsible for ensuring that the complete system is safe and designed correctly according to the relevant safety standards.

1.4 Environmental limits

Instructions regarding transport, storage, installation and use of the drive must be complied with, including the specified environmental limits. Drives must not be subjected to excessive physical force.

1.5 Access

Access must be restricted to authorized personnel only. Safety regulations which apply at the place of use must be complied with.

1.6 Fire protection

The drive enclosure is not classified as a fire enclosure. A separate fire enclosure must be provided. For details regarding fire protection please refer to section 3.2.5 Fire protection on page 15.

1.7 Compliance with regulations

The installer is responsible for complying with all relevant regulations, such as national wiring regulations, accident prevention regulations and electromagnetic compatibility (EMC) regulations. Particular attention must be given to the cross-sectional areas of conductors, the selection of fuses or other protection, and protective ground (earth) connections.

Within the European Union, all machinery in which this product is used must comply with the following directives:

2006/42/EC: Safety of machinery. 2004/108/EC: Electromagnetic Compatibility.

1.8 Motor

Ensure the motor is installed in accordance with the manufacturer’s recommendations. Ensure the motor shaft is not exposed.

The values of the motor parameters set in the drive affect the protection of the motor. The default values in the drive should not be relied upon.

It is essential that the correct value is entered in Pr 0.46 motor rated current. This affects the thermal protection of the motor.

1.9 Mechanical brake control

The brake control functions are provided to allow well co-ordinated operation of an external brake with the drive. While both hardware and software are designed to high standards of quality and robustness, they are not intended for use as safety functions, i.e. where a fault or failure would result in a risk of injury. In any application where the incorrect operation of the brake release mechanism could result in injury, independent protection devices of proven integrity must also be incorporated.

1.10 Adjusting parameters

Some parameters have a profound effect on the operation of the drive. They must not be altered without careful consideration of the impact on the controlled system. Measures must be taken to prevent unwanted changes due to error or tampering.

1.11 Electrical installation

1.11.1 Electric shock risk

The voltages present in the following locations can cause severe electric shock and may be lethal:

• AC supply cables and connections

• DC bus, dynamic brake cables and connections

• Output cables and connections

• Many internal parts of the drive, and external option units Unless otherwise indicated, control terminals are single insulated and

must not be touched.

1.11.2 Isolation device

The AC supply must be disconnected from the drive using an approved isolation device before any cover is removed from the drive or before any servicing work is performed.

1.11.3 STOP function

The STOP function does not remove dangerous voltages from the drive, the motor or any external option units.

6 Digitax ST User Guide

Issue: 5

Safety

Information

Product

information

Mechanical

installation

Electrical

installation

Getting started

Basic

parameters

Running the

motor

Optimization

1.11.4 Stored charge

Normally, the capacitors are discharged by an internal resistor. Under certain, unusual fault conditions, it is possible that the capacitors may fail to discharge, or be prevented from being discharged by a voltage applied to the output terminals. If the drive has failed in a manner that causes the display to go blank immediately, it is possible the capacitors will not be discharged. In this case, consult Emerson Industrial Automation or their authorized distributor.

1.11.5 Equipment supplied by plug and socket

Special attention must be given if the drive is installed in equipment which is connected to the AC supply by a plug and socket. The AC supply terminals of the drive are connected to the internal capacitors through rectifier diodes which are not intended to give safety isolation. If the plug terminals can be touched when the plug is disconnected from the socket, a means of automatically isolating the plug from the drive must be used (e.g. a latching relay).

1.11.6 Permanent magnet motors

If the motor load is capable of rotating the motor when the supply is disconnected, then the motor must be isolated from the drive before gaining access to any live parts.

EtherCAT

interface

SMARTCARD

Operation

Onboard

PLC

Advanced

parameters

Technical

Data

Diagnostics

UL listing

information

Digitax ST User Guide 7 Issue: 5

Safety

Information

Product

information

Mechanical

installation

Electrical

installation

Getting started

Basic

parameters

Running the

motor

Optimization

EtherCAT

interface

SMARTCARD

Operation

Onboard

PLC

Advanced

parameters

Technical

Data

Diagnostics

UL listing

information

2 Product information

2.1 Introduction

The Digitax ST family of servo drives are available with five levels of intelligence:

• Digitax ST Base

• Digitax ST Indexer

• Digitax ST Plus

• Digitax ST EZMotion

• Digitax ST EtherCAT

The Digitax ST Base drive operates in velocity or torque modes and is designed to operate with a centralized motion controller or as a standalone drive.

The Digitax ST Indexer drive performs point-to-point motion profiling including relative, absolute, rotary plus, rotary minus, registration and homing motion. The Digitax ST Indexer will operate as a single standalone system controller. Alternatively, the Digitax ST Indexer can form part of a distributed system where commands are sent over a fieldbus or through digital input/output signals. The Digitax ST Indexer drive is commissioned using a simple and easy to use indexing tool that resides within CTSoft, a set-up tool for Emerson Industrial Automation products.

The Digitax ST plus drive offers all the features available o the Digitax ST Indexer drive with the addition of performing complex motion as a single axis or synchronized to a reference axis. This offers digital lock and electronic camming via a virtual master reference. The Digitax ST Plus drive is commissioned using a simple and easy to use indexing tool that resides within CT Soft, a set-up tool for Emerson Industrial Automation products.

For more complex systems using the Digitax ST Indexer and Digitax ST Plus drives, an export feature is available that allows the user to import applications into SYPTPro for further development.

The Digitax ST EZMotion drive is part of the Motion Made Easy family of servo drives and allows the user to create programs to sequence motion, I/O control, and other machine operations in one environment. Digitax ST EZMotion also supports advanced functions such as a Position Capture Object, Multiple Profile Summation, Queuing, and Program Multitasking.

The Digitax ST EtherCAT drive offers onboard EtherCAT allowing the product to be connected to an EtherCAT network as a slave device. It can be used in a variety of applications, including those requiring accurate synchronization and precise motion control.

All variants provide a Safe Torque Off function. Four documentation guides are available for Digitax ST, these cover all

variants: All guides are available for download at: http://www.emersonindustrial.com/en-EN/controltechniques/downloads/

userguidesandsoftware/Pages/downloads.aspx or www.emersonindustrial.com/en-EN/leroy-somer-motors-drives/

downloads/Pages/manuals.aspx

Installation Guide (packed with product)

• Designed to be used by an "Electrician/Wireman" installing the drive (FIGS Available).

Technical Data Guide

• Designed as a reference guide for experienced drive users (FIGS Available).

User Guide

• Designed as a step by step guide to help the user become familiar with the product, and as a reference guide for experienced drive users (FIGS Available).

Advanced User Guide

• In-depth parameter descriptions.

2.2 Drive ratings

The drive rating is limited by numerous systems which protect the power stage hardware. (Rectifier, DC bus, inverter)

These systems come into operation under various extremes of operating conditions. (I.e. ambient, supply imbalance, output power.)

2.2.1 Maximum ratings

Table 2-1 Maximum ratings

Nominal current

Model

No of input

phases

DST1201 1 1.1* 2.2 DST1202 1 2.4* 4.8 DST1203 1 2.9* 5.8 DST1204 1 4.7* 9.4 DST1201 3 1.7 5.1 DST1202 3 3.8 11.4 DST1203 3 5.4 16.2 DST1204 3 7.6 22.8 DST1401 3 1.5 4.5 DST1402 3 2.7 8.1 DST1403 3 4.0 12.0 DST1404 3 5.9 17.7 DST1405 3 8.0 24.0

*The maximum rating information, in Table 2-1 above, for the 200 V single phase supply, illustrates a 200 % overload capability. When the Digitax ST 120x is used with a single phase supply it is possible to achieve the three phase nominal current rating as long as the single phase peak current rating is observed.

The rating information shown in section 2.3 Drive model numbers on page 9 is based on the limitations of the drive output stage only.

The ratings are based on the following operating conditions:

• Ambient temperature = 40 °C

• Altitude = 1000 m

• Not exceeding power ratings

• DC bus voltage = 565 V for DST140X

• DC bus voltage = 325 V for DST120X The sizing tool should be used to select a drive for a profile or condition

that is not given as an example in section 13.1.2 Typical pulse duty on page 173.

Peak current

MAX

8 Digitax ST User Guide

Issue: 5

Safety

Model: Digitax ST

Frame size

Voltage rating

2:4:200V to 240V

380V to 480V

Current rating step

Variant

DST 1 2 01 B

B: I: P: Z: E:

Base Indexer Plus EZMotion EtherCAT

Model

3098-0010

2.2/5.1Apk 250ms

S/N: 3000005001

Serial number

Rating

Please read the manual before connecting

Electric Shock Risk: Wait 10 mins

between disconnecting supply

and accessing terminals

UL file: E171230

Approvals

Approvals label

Designed in the U.K. Made in China

IND. CONTROL EQUIPMENT

RoHS

Compliant

I/P 200-240V 50-60Hz 1/3ph 4.0/3.1A

O/P 0-240V 2.2/5.1Apk

Input

voltage

CT Model type

Serial

number

Single/three phase peak output current

Output voltage

ST 1.1A M/TL 3ph

Rating label

S/N: 3000005001

Single/three phase input

current

Frequency

LS Model

type

CUS

R10

Date code

N1652

Information

Product

information

Mechanical

installation

Electrical

installation

Getting started

Basic

parameters

Running the

motor

Optimization

EtherCAT

interface

SMARTCARD

Operation

2.3 Drive model numbers

Each drive variant and rating has a unique model number.

Figure 2-1 Model code explanation

2.4 Drive nameplate description

The drive rating label provides the user with various details relating to the drive variant and rating.

Figure 2-2 Typical drive label

Onboard

PLC

Advanced

parameters

Technical

Data

Diagnostics

UL listing

information

Digitax ST User Guide 9 Issue: 5

Safety

Solutions Module slot 2 cover

Solutions Module slot 1 cover

Buffered encoder output

Encoder In connection

Motor connections

Line to ground varistor screw

AC supply

48V connection (for low voltage DC operation)

Braking resistor connections

SMARTCARD slot

Serial port connector

Control terminals

Relay terminal

Keypad connection

EMC bracket

Ground

screw

EMC bracket

Ground screw

Status LED

Marker tag location

Internal EMC filter screw

Rating label

Approvals

label

Brake

resistor slot

Reset button

Fan

Control cable strain relief

Product identifier

NOTE

WARNING

CAUTION

Information

Product

information

Mechanical

installation

Electrical

installation

2.5 Features of the drive

Figure 2-3 Features of the drive

Getting started

Basic

parameters

Running the

motor

Optimization

EtherCAT

interface

SMARTCARD

Operation

Onboard

PLC

Advanced

parameters

Technical

Data

Diagnostics

UL listing

information

The Marker Tag (as shown in Figure 2-3 above), is where markers can be placed to identify a particular drive which can prove beneficial where several Digitax

ST drives are located in the same panel. ** A drive reset can be performed even when a keypad is not installed, by pressing the recessed reset button.

If the embedded interface is removed, the warranty for the drive will be void.

The drive is supplied with a SMARTCARD installed. Do not remove until after first power-up, as defaults are stored on the SMARTCARD.

Be aware of possible live terminals when inserting the SMARTCARD.

Static precautions must be taken when removing the Solutions Module slot covers.

10 Digitax ST User Guide

Issue: 5

Safety

SM-Keypad Plus

SMARTCARD*

DST Keypad

CT Comms cable

External footprint/ bookcase EMC filter

Internal braking resistor

Grounding

bracket

15-way D-type

converter

I/O Expansion

Applications

Automation

Fieldbus

Feedback

Inputs Outputs

• Incremental encoders • Quadrature

• SinCos encoders • Frequency and direction

• SSI encoders • SSI simulated outputs

• EnDat encoders

Information

Product

information

Mechanical

installation

Electrical

installation

Getting started

2.6 Options

Figure 2-4 Options available with Digitax ST

Basic

parameters

Running the

motor

Optimization

EtherCAT

interface

SMARTCARD

Operation

Onboard

PLC

Advanced

parameters

Technical

Data

Diagnostics

UL listing

information

* A SMARTCARD is provided as standard. For further information refer to Chapter 10 SMARTCARD Operation on page 101. All Solutions Modules are color-coded in order to make identification easy. The following table shows the color-code key and gives further details on

their function.

Table 2-2 Solutions Module identification

Type Solutions Module Color Name Further Details

Universal Feedback interface

Feedback interface for the following devices:

SM-Universal Encoder Plus

Resolver interface

Feedback interface for resolvers. Simulated quadrature encoder outputs

Feedback

Light Green

Light Blue SM-Resolver

Incremental encoder interface

Brown SM-Encoder Plus

Feedback interface for incremental encoders without commutation signals. No simulated encoder outputs available

Digitax ST User Guide 11 Issue: 5

Safety

• Digital inputs x 3

• Analog output (voltage) x 1

• Digital I/O x 3 • Relay x 2

• Analog inputs (voltage) x 2

Information

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Electrical

installation

Getting started

Basic

parameters

Running the

motor

Optimization

EtherCAT

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Operation

Onboard

PLC

Advanced

parameters

Type Solutions Module Color Name Further Details

Incremental encoder interface

Feedback interface for incremental encoders without commutation signals. Simulated encoder output for quadrature, frequency and

Dark Brown

SM-Encoder Output Plus

direction signals

Drive encoder input converter

Provides screw terminal interface for encoder wiring and spade terminal for shield

Single ended encoder interface

Provides an interface for single ended ABZ or UVW encoder signals, such as those from hall effect sensors. 15 V and 24 V versions are available.

Feedback

N/A

15-way D-type converter

Single ended encoder interface (15 V or 24 V)

ERN1387 Encoder Interface Board

Provides an interface for Heidenhain ERN1387 and ERN487 SinCos encoder which use a single SinCos cycle per revolution commutation track. A SM-Universal Encoder Plus module is

N/A

ERN1387 Encoder Interface Board

required to use this interface board.

Extended I/O interface

Increases the I/O capability by adding the following to the

Yellow SM-I/O Plus

existing I/O in the drive:

Extended I/O interface

Increase the I/O capability by adding the following to the

Yellow SM-I/O 32

existing I/O in the drive:

• High speed digital I/O x 32

• +24 V output

Additional I/O

1 x Analog input (±10 V bi-polar or current modes) 1 x Analog output (0-10 V or current modes) 3 x Digital input and 1 x Relay

Additional I/O with real time clock

As per SM-I/O Lite but with the addition of a Real Time Clock

Automation

(I/O

Expansion)

Dark Yellow SM-I/O Lite

Dark Red SM-I/O Timer

for scheduling drive running

Isolated I/O to NAMUR NE37 specifications

For chemical industry applications

Turquoise SM-I/O PELV

1 x Analog input (current modes) 2 x Analog outputs (current modes) 4 x Digital input / outputs, 1 x Digital input, 2 x Relay outputs

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Olive SM-I/O 120V

Cobalt Blue

Automation

(Applications)

12 Digitax ST User Guide

Golden

brown

SM-I/O 24V Protected

SM-Register

Additional I/O conforming to IEC 61131-2 120 Vac

6 digital inputs and 2 relay outputs rated for 120 Vac operation

Additional I/O with overvoltage protection up to 48 V

2 x Analog outputs (current modes) 4 x Digital input / outputs, 3 x Digital inputs, 2 x Relay outputs

Applications Processor

processor for running position capture functionality with

CTNet support.

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Fieldbus

Purple

SM-PROFIBUS-DP-V1Profibus option

Medium Grey SM-DeviceNet

Dark Grey SM-INTERBUS

Pink SM-CAN

Light Grey SM-CANopen

Red SM-SERCOS

Beige SM-Ethernet

PROFIBUS DP adapter for communications with the drive

DeviceNet option

Devicenet adapter for communications with the drive

Interbus option

Interbus adapter for communications with the drive

CAN option

CAN adapter for communications with the drive

CANopen option

CANopen adapter for communications with the drive

SERCOS option

Class B compliant. Torque velocity and position control modes supported with data rates (bit/sec): 2 MB, 4 MB, 8 MB and 16 MB. Minimum 250 μsec network cycle time. Two digital high speed probe inputs 1 μsec for position capture

Ethernet option

10 base-T / 100 base-T; Supports web pages, SMTP mail and multiple protocols: DHCP IP addressing; Standard RJ45 connection

Pale Green SM-LON

Brown Red SM-EtherCAT

LonWorks option

LonWorks adapter for communications with the drive

EtherCAT option

EtherCAT adapter for communications with the drive

SLM interface

The SM-SLM allows SLM feedback to be connected directly to

SLM Orange SM-SLM

the Digitax ST drive and allows operation in either of the following modes:

• Encoder only mode

• Host mode

Table 2-3 Keypad identification

Type Keypad Name Further Details

Digitax ST Keypad

LED keypad option

Keypad with a LED display

Keypad

SM-Keypad Plus

Remote keypad option

Keypad with an alpha-numeric LCD display with Help function

Digitax ST User Guide 13 Issue: 5

Safety

Control connectors

Relay connector

Ground screws

Cable guides

Grounding bracket

Ground screws

Digitax ST Plus additional connectors

123

Digitax ST EtherCAT additional connector

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Table 2-4 Other options

Type Option Name Further details

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EMC EMC Filters

CT Comms cable

Communications

CTSoft

SyPTLite

These additional filters are designed to operate together with the drive’s own integral EMC filter in areas of sensitive equipment

Cable with isolation RS232 to RS485 converter. For connecting PC/Laptop to the drive when using the various interface software (e.g. CTSoft)

Software for PC or Laptop which allows the user to commission and store parameter settings.

Software for PC or Laptop which allows the user to program PLC functions within the drive.

Both CTSoft and SyPTLite can be downloaded at: http://www.emersonindustrial.com/en-EN/

controltechniques/downloads/userguidesandsoftware/Pages/digitaxst.aspx

Internal braking

resistor

SMARTCARD SMARTCARD

Braking resistor Optional braking resistor 70R 50 W

Standard feature that enables simple configuration of parameters in a variety of ways

2.7 Items supplied with the drive

The drive is supplied with the following items:

• Installation Guide

•SMARTCARD

• Safety Information booklet

• Certificate of Quality

An accessory box containing the items illustrated in Figure 2-5 is also provided.

Figure 2-5 Accessory box contents

Issue: 5

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3 Mechanical installation

This chapter describes how to use all mechanical details to install the drive. The drive is intended to be installed in an enclosure. Key features of this chapter include:

• Through-hole mounting

• IP54 as standard or through-panel mounting

• Enclosure sizing and layout

• Solutions Module installing

• Terminal location and torque settings

3.1 Safety information

Follow the instructions

The mechanical and electrical installation instructions must be adhered to. Any questions or doubt should be referred to the supplier of the equipment. It is the responsibility of the owner or user to ensure that the installation of the drive and any external option unit, and the way in which they are operated and maintained, comply with the requirements of the Health and Safety at Work Act in the United Kingdom or applicable legislation and regulations and codes of practice in the country in which the equipment is used.

Stored charge

The drive contains capacitors that remain charged to a potentially lethal voltage after the AC supply has been disconnected. If the drive has been energized, the AC supply must be isolated at least ten minutes before work may continue. Normally, the capacitors are discharged by an internal resistor. Under certain, unusual fault conditions, it is possible that the capacitors may fail to discharge, or be prevented from being discharged by a voltage applied to the output terminals. If the drive has failed in a manner that causes the display to go blank immediately, it is possible the capacitors will not be discharged. In this case, consult Emerson Industrial Automation or their authorized distributor.

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• corrosive gasses

During installation it is recommended that the vents on the drive are covered to prevent debris (e.g. wire off-cuts) from entering the drive.

3.2.3 Cooling

The heat produced by the drive must be removed without its specified operating temperature being exceeded. Note that a sealed enclosure gives much reduced cooling compared with a ventilated one, and may need to be larger and/or use internal air circulating fans.

3.2.4 Electrical safety

The installation must be safe under normal and fault conditions. Electrical installation instructions are given in Chapter 4 Electrical installation on page 21.

3.2.5 Fire protection

The drive enclosure is not classified as a fire enclosure. A separate fire enclosure must be provided.

For installation in the USA, a NEMA 12 enclosure is suitable. For installation outside the USA, the following (based on IEC 62109-1,

standard for PV inverters) is recommended. Enclosure can be metal and/or polymeric, polymer must meet

requirements which can be summarized for larger enclosures as using materials meeting at least UL 94 class 5VB at the point of minimum thickness.

Air filter assemblies to be at least class V-2. The location and size of the bottom shall cover the area shown in Figure

3-1. Any part of the side which is within the area traced out by the 5° angle is also considered to be part of the bottom of the fire enclosure.

Figure 3-1 Fire enclosure bottom layout

Competence of the installer

The drive must be installed by professional assemblers who are familiar with the requirements for safety and EMC. The assembler is responsible for ensuring that the end product or system complies with all the relevant laws in the country where it is to be used.

Enclosure

The drive is intended to be mounted in an enclosure which prevents access except by trained and authorized personnel, and which prevents the ingress of contamination. It is designed for use in an environment classified as pollution degree 2 in accordance with IEC 60664-1. This means that only dry, non-conducting contamination is acceptable.

3.2 Planning the installation

The following considerations must be made when planning the installation:

3.2.1 Access

Access must be restricted to authorized personnel only. Safety regulations which apply at the place of use must be complied with.

3.2.2 Environmental protection

The drive must be protected from:

• moisture, including dripping water or spraying water and

condensation. An anti-condensation heater may be required, which must be switched off when the drive is running.

• contamination with electrically conductive material

• contamination with any form of dust which may restrict the fan, or

impair airflow over various components

• temperature beyond the specified operating and storage ranges

The bottom, including the part of the side considered to be part of the bottom, must be designed to prevent escape of burning material - either by having no openings or by having a baffle construction. This means that openings for cables etc. must be sealed with materials meeting the 5VB requirement, or else have a baffle above. See Figure 3-2 for acceptable baffle construction. This does not apply for mounting in an enclosed electrical operating area (restricted access) with concrete floor.

Digitax ST User Guide 15 Issue: 5

Safety

Notless than 2X

Ba ffle plates (m ay be above orbelow bottom ofenclosure)

Bo ttom of fire

enclosure

Not less than 2 times ‘X’

Baffle plates (may be above or

below bottom of enclosure)

Bottom of fire enclosure

CAUTION

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Figure 3-2 Fire enclosure baffle construction

3.2.6 Electromagnetic compatibility

Variable speed drives are powerful electronic circuits which can cause electromagnetic interference if not installed correctly with careful attention to the layout of the wiring.

Some simple routine precautions can prevent disturbance to typical industrial control equipment.

If it is necessary to meet strict emission limits, or if it is known that electromagnetically sensitive equipment is located nearby, then full precautions must be observed. In-built into the drive, is an internal EMC filter, which reduces emissions under certain conditions. If these conditions are exceeded, then the use of an external EMC filter may be required at the drive inputs, which must be located very close to the drives. Space must be made available for the filters and allowance made for carefully segregated wiring. Both levels of precautions are covered in section 4.10 EMC (Electromagnetic compatibility) on page 28.

3.2.7 Hazardous areas

The drive must not be located in a classified hazardous area unless it is installed in an approved enclosure and the installation is certified.

3.3 Solutions Module / keypad installation

/ removal

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Figure 3-4 Installation of a keypad

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Power down the drive before installing / removing the Solutions Module. Failure to do so may result in damage to the product.

Figure 3-3 Installation of a Solutions Module

The protective tab from the Solutions Module slot must be removed before attempting to install a Solutions Module.

Be aware of possible live terminals when installing the keypad.

16 Digitax ST User Guide

Issue: 5

Safety

WARNING

62mm

(2.44in)

249.7mm (9.83in)

220mm (8.66in)

47mm

(1.85in)

7.5mm

(0.3in)

304mm

(11.96in)

292mm

(11.49in)

6mm

(0.24in)

∅

5.4mm (0.21in)

322mm

(12.68in)

226mm (8.9in)

229mm (9.02in)

Ingress protective labels

NOTE

100mm (4in)

*2mm (0.08in)

NOTE

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3.4 Drive dimensions

Enclosure

The drive complies with the requirements of IP20 as standard.

Figure 3-5 Dimensions

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Figure 3-6 Ingress protective label

The ingress protective labels (shown on Figure 3-6 above) should remain in place while the drive is mounted, and until all the electrical wires have been connected. The labels should be removed before first power up.

Figure 3-7 Minimum mounting clearances

*2 mm clearance between drives to allow for mechanical tolerance. If Solutions Modules are installed, a larger clearance between drives will be required if access to the modules is needed without removing the drive.

Digitax ST User Guide 17 Issue: 5

Safety

47mm (1.85in)

312.7mm (12.31in)

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Digitax ST can be mounted using a DIN rail, either fixed at the top or the bottom of the drive (as illustrated in Figure ). Two screws are required to fix the drive to the backplate at the opposite end to the DIN rail.

Figure 3-8 DIN rail mounting

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3.5 External EMC filter rating

Filter details for each drive rating are provided in the tables below.

Table 3-1 External EMC filter ratings

Worst

case

leakage

current

Used with

Number

phases

Filter part number

CT Schaffner

Maximum

continuous

current

@40°C (104°F)

@50°C

Power

losses at rated current

Weight

rating

Operational

leakage

current

(122°F)AWKglbmAmANmlb ft

DST120X 1 4200-6000 FS23072-19-07 19 17.3 11 DST120X 3 4200-6001 FS23073-17-07 17 15.5 13 1.2 2.64 8 50 0.8 0.6

1.2 2.64 29.5 56.9 0.8 0.6

DST140X 3 4200-6002 FS23074-11-07 11 10 10 1.2 2.64 16 90 0.8 0.6

The external EMC filters can be footprint or bookcase mounted, see Figure 3-9 and Figure 3-10.

Figure 3-9 Bookcase mounting Figure 3-10 Footprint mounting

Filter

terminal

tightening

torque

18 Digitax ST User Guide

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Safety

29mm (1.14in)

359mm (14.13in)

339mm (13.35in)

304mm (11.97in)

38mm (1.50in)

61mm (2.40in)

M5 M5

Torque settings of connector = 0.8 N m

∅

5.3mm (M5) (0.21in)

∅

5.3mm (M5) (0.21in)

Brake connections

Thermistor connection

WARNING

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Figure 3-11 External EMC filter dimensions

Figure 3-11 shows a 3 phase filter. For a single phase filter, there are only 3 input terminals (L1, N, ground) and 3 output cables (L1, N, ground).

3.6 Optional braking resistor

3.6.1 Optional internal braking resistor

Figure 3-12 Installing an optional internal braking resistor (top view of drive)

1. Remove screws.

2. Remove grill.

3. Install the braking resistor shield.

4. Install the optional internal braking resistor in the slot provided (note the angle).

5. Electrically connect the braking resistor and thermistor (connections shown in Figure 4-1 Power terminal connections on page 22).

6. Re-install the grill and mounting screws by reversing the procedure in points 1 and 2.

3.6.2 Optional external braking resistor

If using an external braking resistor, the following Warning must be adhered to:

Digitax ST User Guide 19 Issue: 5

Braking resistor: High temperatures and overload protection

Braking resistors can reach high temperatures. Locate braking resistors so that damage cannot result. Use cable having insulation capable of withstanding the high temperatures.

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3.7 Terminal torque settings

Table 3-2 Torque settings

Terminals Torque setting*

Power terminals 1.0 N m (12.1 lb in)

Control terminals 0.2 N m (1.7 lb in)

Status relay terminals 0.5 N m (4.5 lb in)

Ground terminals 4 N m (35 lb in)

Small ground terminal screws 2 N m (17.7 lb in)

*Torque tolerance = 10 %

Table 3-3 Plug-in terminal block maximum cable sizes

Model size Terminal block description Max cable size

All 11 way control connectors

All 2 way relay connector

1.5 mm

2.5 mm

(16 AWG)

(12 AWG)

3.8 Routine maintenance

The drive should be installed in a cool, clean, well ventilated location. Contact of moisture and dust with the drive should be prevented.

Regular checks of the following should be carried out to ensure drive / installation reliability are maximized:

Environment

Ambient temperature

Dust

Moisture

Enclosure

Enclosure door filters

Electrical

Screw connections

Crimp terminals

Cables Check all cables for signs of damage

Ensure the enclosure temperature remains at or below maximum specified

Ensure the drive remains dust free – check that the heatsink and drive fan are not gathering dust. The lifetime of the fan is reduced in dusty environments.

Ensure the drive enclosure shows no signs of condensation

Ensure filters are not blocked and that air is free to flow

Ensure all screw terminals remain tight

Ensure all crimp terminals remains tight – check for any discoloration which could indicate overheating

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20 Digitax ST User Guide

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4 Electrical installation

Many cable management features have been incorporated into the product and accessories, this chapter shows how to optimize them. Key features include:

• Safe Torque Off function

• Internal EMC filter

• EMC compliance with shielding / grounding accessories

• Product rating, fusing and cabling information

• Brake resistor details (selection / ratings)

Electric shock risk

The voltages present in the following locations can cause severe electric shock and may be lethal:

• AC supply cables and connections

• DC and brake cables, and connections

• Output cables and connections

• Many internal parts of the drive, and external option units Unless otherwise indicated, control terminals are single insulated and must not be touched.

Isolation device

The AC supply must be disconnected from the drive using an approved isolation device before any cover is removed from the drive or before any servicing work is performed.

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STOP function

The STOP function does not remove dangerous voltages from the drive, the motor or any external option units.

Safe Torque Off function

The Safe Torque Off function does not remove dangerous voltages from the drive, the motor or any external option units.

Stored charge

Equipment supplied by plug and socket

Permanent magnet motors

Permanent magnet motors generate electrical power if they are rotated, even when the supply to the drive is disconnected. If that happens then the drive will become energized through its motor terminals. If the motor load is capable of rotating the motor when the supply is disconnected, then the motor must be isolated from the drive before gaining access to any live parts.

Digitax ST User Guide 21 Issue: 5

Safety

L1*L2

L2L1L3/N

UVW

Optional EMC

filter

Optional

line reactor

Fuses

Mains

supply

Supply

ground

connections

High current

-DC connections

Low voltage

DC (48V)

DST12XX = 200 to 240V 10%

DST14XX = 380 to 480V 10%

± ±

Connectors specification:

Maximum size of power cable = 4.0mm (10AWG) Torque setting = 1 N m

It is essential that the braking resistor be protected against overload caused by a failure of the brake control. Unless the resistor has in-built protection, a circuit like those shown in Figure 4-1 should be used, where the thermal protection device disconnects the AC supply to the drive. Do not use AC relay contacts directly in series with the braking resistor circuit, because it carries DC.

WARNING

Terminals Torque setting

Power terminals

1.0 N m

(12.1 lb in)

Control terminals

0.2 N m

(1.7 lb in)

Status relay

terminals

0.5 N m

(4.5 lb in)

Ground terminal

screws

4 N m

(35 lb in)

Small ground

terminal screws

2 Nm

(17.7 Ib in)

* *Torque tolerance = 10%

NOTE

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Figure 4-1 Power terminal connections

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* When using a 200 V drive on a single phase supply, the live and neutral conductors can be connected to any of the AC connections on the drive. ** This is not required if the optional internal braking resistor is used.

22 Digitax ST User Guide

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Supply ground

Motor ground

WARNING

100

----------

-------

2π f I

------------

×=

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4.2 Ground connections

Electrochemical corrosion of grounding terminals

Ensure that grounding terminals are protected against corrosion i.e. as could be caused by condensation.

The drive must be connected to the system ground of the AC supply. The ground wiring must conform to local regulations and codes of practice. The supply and motor ground connections are made using the M6 threaded hole in the metal back plate of the drive located at the top and bottom of the drive. See Figure 4-2 for details.

The ground loop impedance must conform to the requirements of local safety regulations. The drive must be grounded by a connection capable of carrying the prospective fault current until the protective device (fuse, etc.) disconnects the AC supply. The ground connections must be inspected and tested at appropriate intervals.

Figure 4-2 Ground connection

4.3 AC supply requirements

Table 4-1 Supply requirements

Model Voltage

DST120X 200 V to 240 V ±10 % single phase 48 Hz to 65 Hz DST120X 200 V to 240 V ±10 % three phase* 48 Hz to 65 Hz DST140X 380 V to 480 V ±10 % three phase* 48 Hz to 65 Hz

*Maximum supply in-balance: 2 % negative phase sequence (equivalent to 3 % voltage in-balance between phases).

For UL compliance only, the maximum supply symmetrical fault current must be limited to 100 kA.

4.3.1 Supply types

All drives are suitable for use on any supply type i.e TN-S, TN-C-S, TT and IT.

• Supplies with voltage up to 600 V may have grounding at any potential, i.e. neutral, centre or corner (“grounded delta”)

• Supplies with voltage above 600 V may not have corner grounding

Drives are suitable for use on supplies of installation category III and lower, according to IEC60664-1. This means they may be connected permanently to the supply at its origin in a building, but for outdoor installation additional over-voltage suppression (transient voltage surge suppression) must be provided to reduce category IV to category III.

Frequency

range

Operation with IT (ungrounded) supplies:

Special attention is required when using internal or external EMC filters with ungrounded supplies, because in the event of a ground (earth) fault in the motor circuit the drive may not trip and the filter could be over-stressed. In this case, either the filter must not be used (removed) or additional independent motor ground fault protection must be provided. Refer to Table 4-2.

For instructions on removal, refer to Figure 4-4 Removing the internal EMC filter and line to ground varistors on

page 28. For details of ground fault protection contact the supplier of the drive.

A ground fault in the supply has no effect in any case. If the motor must continue to run with a ground fault in its own circuit then an input isolating transformer must be provided and if an EMC filter is required it must be located in the primary circuit.

Unusual hazards can occur on ungrounded supplies with more than one source, for example on ships. Contact the supplier of the drive for more information.

Table 4-2 Behavior of the drive in the event of a motor circuit

ground (earth) fault with an IT supply

Drive size Internal filter only External filter (with internal)

0 (200 V)

May not trip – precautions

required

Drive trips on fault

0 (400 V) Drive trips on fault Drive trips on fault

4.3.2 Line reactors

Input line reactors reduce the risk of damage to the drive resulting from poor phase balance or severe disturbances on the supply network.

Where line reactors are to be used, reactance values of approximately 2 % are recommended. Higher values may be used if necessary, but may result in a loss of drive output (reduced torque at high speed) because of the voltage drop.

For all drive ratings, 2 % line reactors permit drives to be used with a supply imbalance of up to 3.5 % negative phase sequence (equivalent to 5 % voltage imbalance between phases).

Severe disturbances may be caused by the following factors, for example:

• Power factor correction equipment connected close to the drive

• Large DC drives having no or inadequate line reactors connected to the supply

• Direct-on-line started motor(s) connected to the supply such that when any of these motors are started, the voltage dip exceeds 20 %

Such disturbances may cause excessive peak currents to flow in the input power circuit of the drive. This may cause nuisance tripping, or in extreme cases, failure of the drive.

Drives of low power rating may also be susceptible to disturbance when connected to supplies with a high rated capacity.

When required, each drive must have its own reactor(s). Three individual reactors or a single three-phase reactor should be used.

Reactor current ratings

Continuous current:

Not less than the continuous input current rating of the drive.

Repetitive peak current:

Not less than three times the continuous input current rating of the drive.

4.3.3 Input inductor calculation

To calculate the inductance required (at Y%), use the following equation:

Where:

I = drive rated input current (A)

L = inductance (H) f = supply frequency (Hz) V = voltage between lines

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4.4 DC bus design

4.4.1 DC bus design

Parallel connections

The power limit of the rectifier must be adhered to for all combinations of drives in parallel. In addition to this If the total rated bus power required exceeds the capability of 1 x Digitax ST rectifier then two or more Digitax ST's can be connected with the AC & DC in parallel. If the AC supply is connected to more than one drive in a parallel DC bus application, balancing of the current in the input stage of each drive must be considered.

Using DC bus chokes makes the current in the rectifier diodes of each drive the same, so providing a solution to sharing.

There are many possible combinations for paralleling drives through the DC bus connections. Table 4-3 gives details of the internal capacitance for each drive and the additional capacitance which can be powered from the drive. The capacitance must incorporate its own soft-start circuit. All Digitax ST drives incorporate this feature.

Table 4-3 DC bus data

Internal DC bus

Drive

capacitance

(μF)

DST1201 440 1760 DST1202 880 1320 DST1203 880 1320 DST1204 1320 880 DST1401 220 660 DST1402 220 660 DST1403 220 660 DST1404 220 660 DST1405 220 660

For additional details regarding DC bus paralleling please contact the supplier of the drive.

Maximum additional DC

bus capacitance which can

be connected

(μF)

4.5 DC drive voltage levels

4.5.1 Low voltage DC operation

The drive can be operated from low voltage DC supplies, nominally 24 Vdc (control) and 48 Vdc (power). The low voltage DC power operating mode is designed either, to allow for motor operation in an emergency back-up situation following failure of the AC supply, for example in robotic arm applications; or to limit the speed of a servo motor during set-up of equipment, for example a robot cell.

With low voltage DC operation there is a reduction in the level of safety of the Safe Torque Off function. There exist certain unlikely faults which might permit the drive to produce some limited motor torque, if the DC supply has its negative terminal connected to ground. See section 4.17 Safe Torque Off on page 42 for methods on preventing a loss of the safety function under these

conditions. The working voltage range of the low voltage DC power supply is shown in Table 4-4.

Table 4-4 Low voltage DC levels

Condition Value

Minimum continuous operating voltage 36 V Minimum start up voltage 40 V Nominal continuous operating voltage 48 V to 72 V Maximum braking IGBT turn on voltage 63 V to 95 V Maximum over voltage trip threshold 69 V to 104 V

4.5.2 High voltage DC levels

Table 4-5 High voltage DC levels

Condition

DST120X DST140X

Undervoltage trip level 175 330

Undervoltage reset level* 215 425

Overvoltage trip level 415 830

Braking level 390 780

Maximum continuous voltage level for 15 s 400 800

* These are the absolute minimum DC voltages that the drive is capable of operating from. If the drive is not supplied with the minimum voltage, it will not reset following a UV trip at power-up.

4.5.3 Control 24 Vdc supply

The 24 Vdc input has three main functions:

• It can be used as a back-up power supply to keep the control circuits of the drive powered up when the line power supply is removed. This allows any fieldbus modules or serial communications to continue to operate.

• It can be used to supplement the drive’s own internal 24 V when multiple SM-I/O Plus modules are being used and the current drawn by these modules is greater than the drive can supply. (If too much current is drawn from the drive, the drive will initiate a 'PS.24V' trip)

• It can be used to commission the drive when line power supply voltages are not available, as the display operates correctly. However, the drive will be in the UV trip state unless either line power supply is reapplied or low voltage DC operation is enabled, therefore diagnostics may not be possible. (Power down save parameters are not saved when using the 24 V back-up power supply input.)

The working voltage range of the 24 V power supply is shown in Table 4-6.

Table 4-6 Control supply voltage levels

Condition Value

Maximum continuous operating voltage 30.0 V Minimum continuous operating voltage 19.2 V Nominal operating voltage 24.0 V Minimum start up voltage 21.6 V Maximum power supply requirement at 24 V 60 W Recommended fuse 3 A, 50 Vdc

Minimum and maximum voltage values include ripple and noise. Ripple and noise values must not exceed 5 %.

24 Digitax ST User Guide

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4.6 Ratings

Fuses The AC supply to the drive must be installed with suitable protection against overload and short-circuits. The following section shows recommended fuse ratings. Failure to observe this requirement will cause risk of fire.

Table 4-7 Fuse ratings and cable sizes

No of

Model

input

phases

DST1201 1 DST1202 1 DST1203 1 DST1204 1

Typical input

current

Maximum

continuous input

current

4.0 6 10 0.75 16 0.75 24

7.6 10 10 1 16 0.75 22

9.0 16 15 2.5 14 0.75 20

13.4 16 20 2.5 12 0.75 18 DST1201 3 3.1 3.5 6 10 0.75 16 0.75 24 DST1202 3 6.4 7.3 10 10 1 16 0.75 22 DST1203 3 8.6 9.4 16 15 2.5 14 0.75 20 DST1204 3 11.8 13.4 16 20 2.5 12 0.75 18 DST1401 3 2.6 2.8 4 10 0.75 16 0.75 24 DST1402 3 4.2 4.3 6 10 0.75 16 0.75 24 DST1403 3 5.9 6.0 8 10 0.75 16 0.75 22 DST1404 3 7.9 8.0 10 10 1 16 0.75 20 DST1405 3 9.9 9.9 12 15 1.5 14 0.75 18

Control cable

Fuse rating Cable size

IEC class

Class CC

Input Output

AWG

≥0.5 20

UL listing

information

AWG

PVC insulated cable should be used.

Installation class (ref: IEC60364-5-52:2001)

B1 - Separate cables in conduit. B2 - Multicore cable in conduit C - Multicore cable in free air.

Cable sizes are from IEC60364-5-52:2001 table A.52.C with correction factor for 40°C ambient of 0.87 (from table A52.14) for cable installation method B2 (multicore cable in conduit).

Cable size may be reduced if a different installation method is used, or if the ambient temperature is lower.

The recommended cable sizes above are only a guide. The mounting and grouping of cables affects their current-carrying capacity, in some cases smaller cables may be acceptable but in other cases a larger cable is required to avoid excessive temperature or voltage drop. Refer to local wiring regulations for the correct size of cables.

The recommended output cable sizes assume that the motor maximum current matches that of the drive. Where a motor of reduced rating is used the cable rating may be chosen to match that of the motor. To ensure that the motor and cable are protected against overload, the drive must be programmed with the correct motor rated current.

UL listing is dependent on the use of the correct type of UL-listed fuse, and applies when symmetrical short-circuit current does not exceed 100kA. See Chapter 15 UL listing information on page 204 for sizing information.

An MCB (miniature circuit breaker) may be used in place of fuses under the following conditions:

• The fault-clearing capacity must be sufficient for the installation

• The I2T rating of the MCB must be less than or equal to that of the fuse rating listed above.

A fuse or other protection must be included in all live connections to the AC supply.

For a parallel DC bus system the maximum AC input fusing is shown in Table 4-8 below.

Table 4-8 Maximum AC input fusing

Fuse rating

IEC class gG

Fuse rating

class CC

Input cable size

Model

AWG

All 20 20 4.0 12

Refer to the supplier of your drive for further information regarding DC bus paralleling.

4.7 Output circuit and motor protection

The output circuit has fast-acting electronic short-circuit protection which limits the fault current to typically no more than five times the rated output current, and interrupts the current in approximately 20 µs. No additional short-circuit protection devices are required.

The drive provides overload protection for the motor and its cable. For this to be effective, Pr 0.46 Motor rated current must be set to suit the motor.

Pr 0.46 Motor rated current must be set correctly to avoid a risk of fire in the event of motor overload.

There is also provision for the use of a motor thermistor to prevent overheating of the motor, e.g. due to loss of cooling.

4.7.1 Motor cable size and maximum lengths

Since capacitance in the motor cable causes loading on the output of the drive, ensure the cable length does not exceed the values given in Table 4-9.

Use 105 °C (221 °F) (UL 60/75 °C temp rise) PVC-insulated cable with copper conductors having a suitable voltage rating, for the following power connections:

Digitax ST User Guide 25 Issue: 5

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Normal capacitance

Shield or armour separated from the cores

High capacitance

Shield or armour close to the cores

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• AC supply to external EMC filter (when used)

• AC supply (or external EMC filter) to drive

• Drive to motor

• Drive to braking resistor

•

When operating in ambient >45 °C UL 75 °C cable should be used.

Cable sizes are given for guidance only and may be changed depending on the application and the method of installation of the cables.

The mounting and grouping of cables affect their current capacity, in some cases a larger cable is required to avoid excessive temperature or voltage drop.

Input cable sizes should generally be regarded as a minimum, since they have been selected for co-ordination with the recommended fuses.

Output cable sizes assume that the maximum motor current matches that of the drive.

Where a motor of reduced rating is used the cable rating may be chosen to match that of the motor.

To ensure that the motor and cable are protected against overload, the drive must be programmed with the correct motor rated current.

• Cable lengths in excess of the specified values may be used only when special techniques are adopted; refer to the supplier of the drive.

• The default switching frequency is 6 kHz.

The drive power terminals are designed for a maximum cable size of 4.0

(minimum 0.2 mm / 24 AWG).

Where more than one cable per terminal is used the combined diameters should not exceed the maximum.

The terminals are suitable for both solid and stranded wires.

Table 4-9 Motor cable size and maximum lengths

Output cable 6kHz 8kHz 12kHz

Model

DST1201

AWG m m m

24 DST1202 22 DST1203 20 DST1204 18 DST1401 DST1402

0.75 24

DST1403 22 DST1404 20 DST1405 18

High-capacitance cables

The maximum cable length is reduced from that shown in Table 4-9 if high capacitance motor cables are used.

Most cables have an insulating jacket between the cores and the armor or shield; these cables have a low capacitance and are recommended. Cables that do not have an insulating jacket tend to have high capacitance; if a cable of this type is used, the maximum cable length is half that quoted in the tables. (Figure 4-3 shows how to identify the two types).

Figure 4-3 Cable construction influencing the capacitance

4.7.2 Motor winding voltage

The PWM output voltage can adversely affect the inter-turn insulation in the motor. This is because of the high rate of change of voltage, in conjunction with the impedance of the motor cable and the distributed nature of the motor winding.

For normal operation with AC supplies up to 500 Vac and a standard motor with a good quality insulation system, there is no need for any special precautions. In case of doubt the motor supplier should be consulted.

Special precautions are recommended under the following conditions, but only if the motor cable length exceeds 10 m:

• AC supply voltage exceeds 500 V

• DC supply voltage exceeds 670 V

• Operation of 400 V drive with continuous or very frequent sustained braking

For the other cases listed, it is recommended that an inverter-rated motor be used. This has a reinforced insulation system intended by the manufacturer for repetitive fast-rising pulsed voltage operation.

If it is not practical to use an inverter-rated motor, an output choke (inductor) should be used. The recommended type is a simple iron-cored component with a reactance of about 2 %. The exact value is not critical. This operates in conjunction with the capacitance of the motor cable to increase the rise-time of the motor terminal voltage and prevent excessive electrical stress.

4.7.3 Output contactor

If the cable between the drive and the motor is to be interrupted by a contactor or circuit breaker, ensure that the drive is disabled before the contactor or circuit breaker is opened or closed. Severe arcing may occur if this circuit is interrupted with the motor running at high current and low speed.

A contactor is sometimes required to be installed between the drive and motor for safety purposes.

The recommended motor contactor is the AC3 type. Switching of an output contactor should only occur when the output of

the drive is disabled. Opening or closing of the contactor with the drive enabled will lead to:

1. OI.AC trips (which cannot be reset for 10 seconds)

2. High levels of radio frequency noise emission

3. Increased contactor wear and tear

The Drive Enable terminal (T31) when opened provides a Safe Torque Off function. This can in many cases replace output contactors.

For further information see section 4.17 Safe Torque Off on page 42.

4.8 Braking

The internal braking resistor can be used with the drive even though its resistance is lower than the minimum resistance values given in Table 4-11, because of the following reasons.

• The braking resistor overload protection function in the drive is set up to limit the power dissipated in the resistor.

• The braking resistor is installed with a thermistor which will trip the drive if the resistor is too hot.

• The power rating of the resistor is only 50 W

The internal braking resistor for Digitax ST is installed with a thermistor which must be connected to the drive whenever the internal braking resistor in installed.

If an external resistor is used with the drive, its resistance must be equal to or greater than the value given in Table 4-11.

The cable used for Table 4-9 is shielded and contains four cores. Typical capacitance for this type of cable is 130 pF/m (i.e. from one core to all others and the shield connected together).

26 Digitax ST User Guide

Issue: 5

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Parameter

200 V drive

400 V

drive

Full power braking time

Pr 10.30 0.06 0.01

Full power braking period

Pr 10.31 2.6 1.7

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Table 4-10 Internal braking resistor data

Parameter

Part number 1299-0001 DC resistance at 25 °C 70 Ω

Peak instantaneous power over 1ms at nominal resistance

200 V 400 V

2.2 kW 8.7 kW

Average power over 60 s 50 W

Braking resistor overload protection parameter settings Failure to observe the following information may

damage the resistor.

The drive’s software contains an overload protection function for a braking resistor. On Digitax ST this function is enabled at default to protect the internally mounted resistor. Below are the parameter settings.

For more information on the braking resistor software overload protection, see Pr 10.30 and Pr 10.31 full descriptions in the Advanced User Guide.

If the internally mounted braking resistor is to be used at more than half of its average power rating then the drive's cooling fan must be at full speed, controlled by setting Pr 6.45 to On (1).

4.8.1 External braking resistor

Overload protection When an external braking resistor is used, it is essential that an overload protection device is incorporated in the braking resistor circuit.

When a braking resistor is to be mounted outside the enclosure, ensure that it is mounted in a ventilated metal housing that will perform the following functions:

• Prevent inadvertent contact with the resistor

• Allow adequate ventilation for the resistor When compliance with EMC emission standards is required, external

connection requires the cable to be armored or shielded, since it is not fully contained in a metal enclosure. See section 4.10 EMC (Electromagnetic compatibility) on page 28 for further details.

Internal connection does not require the cable to be armored or shielded.

Table 4-11 Minimum resistance and power ratings

Average

power for

0.25s

Model

Minimum

resistance*

Peak

power

rating

Continuous

power rating

Ω kW kW kW

DST1201 DST1202 1.2 3.5

23 6.6

0.5 1.6

DST1203 1.6 4.9 DST1204 16 9.3 2.3 7.0 DST1401 DST1402 1.4 4.1

111 5.5

0.8 2.3

DST1403 75 8.1 2.0 6.1 DST1404 DST1405 4.1 12.2

28 21.7

3.0 9.0

* Resistor tolerance: ±10 %

4.9 Ground leakage

The ground leakage current depends upon whether the internal EMC filter is installed. The drive is supplied with the filter installed. Instructions for removing the internal filter are given in Figure 4-4.

With the internal EMC filter installed the ground leakage current is as follows:

Table 4-12 Ground leakage current with internal EMC filter installed

3 phase Star

Model

ground

DST120X at 220 V 4 10 3 DST140X at 400 V 12 40

The above leakage current is just the leakage current of the drive with the internal EMC filter connected and does not take into account any leakage currents of the motor or motor cable.

With internal EMC filter removed the ground leakage current = <1 mA.

In both cases, there is an internal voltage surge suppression device connected to ground. Under normal circumstances, this carries negligible current.

When the internal EMC filter is installed, the leakage current is high. In this case, a permanent fixed ground connection must be provided with a cross sectional area equal to 10mm

4.9.1 Use of residual current device (RCD)

There are three common types of ELCB / RCD:

1. AC - detects AC fault currents

2. A - detects AC and pulsating DC fault currents (provided the DC

current reaches zero at least once every half cycle)

3. B - detects AC, pulsating DC and smooth DC fault currents

• Type AC should never be used with drives

• Type A can only be used with single phase drives

• Type B must be used with three phase drives

3 phase Delta

ground

1 phase

Digitax ST User Guide 27 Issue: 5

Only type B ELCB / RCD are suitable for use with 3 phase inverter drives.

If an external EMC filter is used, a delay of at least 50ms should be incorporated to ensure spurious trips are not seen. The leakage current is likely to exceed the trip level if all of the phases are not energized simultaneously.

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4.10 EMC (Electromagnetic compatibility)

4.10.1 Internal EMC filter

It is recommended that the internal EMC filter is kept in place unless there is a specific reason for removing it.

Special attention is required when using a DST120X model on an ungrounded supply (IT supply). In the event of a ground fault in the motor circuit the drive may not trip and the filter could be overstressed. In this case, either the filter must be removed or additional independent motor ground fault protection must be provided.

The internal EMC filter reduces radio-frequency emissions into the line power supply. Where the motor cable is short, it permits the requirements of EN 61800-3:2004 to be met for the second environment.

For longer motor cables, the filter continues to provide a useful reduction in emission level, and when used with any length of shielded cable up to the limit for the drive, it is unlikely that nearby industrial equipment will be disturbed. It is recommended that the filter be used in all applications unless the ground leakage current is unacceptable or the above conditions are true.

The supply must be disconnected before removing the internal EMC filter or line to ground varistor screws.

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Figure 4-4 Removing the internal EMC filter and line to ground

varistors

1. Internal EMC filter. Remove the bottom screw as shown.

2. Line to ground varistors. Remove the top screw as shown.

The line to ground varistors should only be removed in special circumstances.

4.10.2 Further EMC precautions

Further EMC precautions are required if more stringent EMC emission requirements apply:

• Operation in the first environment of EN 61800-3:2004

• Conformity to the generic emission standards

• Equipment which is sensitive to electrical interference operating nearby

In this case it is necessary to use:

• The optional external EMC filter

• A shielded motor cable, with shield clamped to the grounded metal panel

• A shielded control cable, with shield clamped to the grounded metal panel via the grounding bracket.

It is not necessary to remove the external EMC filter when using an IT supply.

28 Digitax ST User Guide

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Metal back plate

External controller

Signal cables Plan for all signal cables to be routed at least 300mm (12in) from the drive and any power cable

Optional braking resistor

Locate optional braking resistor and overload external to cubicle (preferably near to or on top of the cubicle).

Note For EMC compliance:

1) When using an external EMC

filter, one filter is required for

each drive

2) Ensure direct metal contact at drive and filter mounting points (any paint must be removed)

The external EMC filter can be bookcase mounted (next to the drive) or footprint mounted (with the drive mounted onto the filter).

Thermal overload

protection

device

AC supply

contactor and

fuses or MCB

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Figure 4-5 Drive cable clearances

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Figure 4-6 Grounding bracket at the top of the drive

Figure 4-7 Grounding bracket at the bottom of the drive

Grounding bracket and drive to be directly connected to a grounded backplate.

1. The distance for EMC (shown in Figure 4-7 above) from the drive is as

follows:

200 V drive - Allowance up to 65 mm (2.56 in) 400 V drive - Allowance up to 100 mm (3.94 in)

The grounding bracket can remain mounted when the drive is removed. as follows.

Figure 4-8 Multiple drives with single grounding bracket

If installing multiple drives, one grounding bracket can be used for two drives.

4.11 Internal and external conducted emissions conformity

Table 4-13 Immunity compliance

Standard

IEC61000-4-2 EN61000-4-2

IEC61000-4-3 EN61000-4-3

IEC61000-4-4 EN61000-4-4

IEC61000-4-5 EN61000-4-5

IEC61000-4-6 EN61000-4-6

IEC61000-4-11 EN61000-4-11

IEC61000-6-1 EN61000-61:2007

IEC61000-6-2 EN61000-62:2005

EN 618003:2004 IEC61800-3

Type of

immunity

Electrostatic discharge

Radio frequency radiated field

Test specification Application Level

6 kV contact discharge 8 kV air discharge

10V/m prior to modulation 80 - 1000 MHz 80 % AM (1 kHz) modulation

5/50 ns 2 kV transient at 5 kHz repetition frequency

Fast transient burst

via coupling clamp 5/50 ns 2 kV

transient at 5 kHz repetition frequency by direct injection

Common mode 4 kV

1.2/50 μs waveshape

Surges

Differential mode 2 kV

1.2/50 μs waveshape

Lines to ground

Conducted radio frequency

Voltage dips and interruptions

10V prior to modulation

0.15 - 80 MHz 80 % AM (1 kHz) modulation

-30 % 10 ms +60 % 100 ms

-60 % 1 s <-95 % 5 s

Generic immunity standard for the residential, commercial and light industrial environment

Generic immunity standard for the industrial environment

Product standard for adjustable speed power drive systems (immunity requirements)

Module enclosure

Control lines

Level 3 (industrial)

Level 4 (industrial harsh)

Power lines

AC supply lines:

Level 3 (industrial)

Level 4

line to ground

AC supply lines: line to line

Signal ports to ground

Control and power lines

AC power ports

Level 3

Level 2

Level 3 (industrial)

Complies

Meets immunity requirements for first and second environments

30 Digitax ST User Guide

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+ 179 hidden pages

EPA digitax st User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1 Safety Information

1.1 Warnings, Cautions and Notes

1.2 Electrical safety - general warning

1.3 System design and safety of personnel

1.4 Environmental limits

1.5 Access

1.6 Fire protection

1.7 Compliance with regulations

1.8 Motor

1.9 Mechanical brake control

1.10 Adjusting parameters

1.11 Electrical installation

1.11.1 Electric shock risk

1.11.2 Isolation device

1.11.3 STOP function

1.11.4 Stored charge

1.11.5 Equipment supplied by plug and socket

1.11.6 Permanent magnet motors

2 Product information

2.1 Introduction

2.2 Drive ratings

2.2.1 Maximum ratings

2.3 Drive model numbers

2.4 Drive nameplate description

2.5 Features of the drive

2.6 Options

2.7 Items supplied with the drive

3 Mechanical installation

3.1 Safety information

3.2.3 Cooling

3.2.4 Electrical safety

3.2.5 Fire protection

3.2 Planning the installation

3.2.1 Access

3.2.2 Environmental protection

3.2.6 Electromagnetic compatibility

3.2.7 Hazardous areas

3.4 Drive dimensions

3.5 External EMC filter rating

3.6 Optional braking resistor

3.6.1 Optional internal braking resistor

3.6.2 Optional external braking resistor

3.7 Terminal torque settings

3.8 Routine maintenance

4 Electrical installation

4.1 Power terminal connections

4.2 Ground connections

4.3 AC supply requirements

4.3.1 Supply types

4.3.2 Line reactors

4.3.3 Input inductor calculation

4.4 DC bus design

4.4.1 DC bus design

4.5 DC drive voltage levels

4.5.1 Low voltage DC operation

4.5.2 High voltage DC levels

4.5.3 Control 24 Vdc supply

4.6 Ratings

4.7 Output circuit and motor protection

4.7.1 Motor cable size and maximum lengths

4.7.2 Motor winding voltage

4.7.3 Output contactor

4.8 Braking

4.8.1 External braking resistor

4.9 Ground leakage

4.9.1 Use of residual current device (RCD)

4.10 EMC (Electromagnetic compatibility)

4.10.1 Internal EMC filter

4.10.2 Further EMC precautions

4.10.3 Recommended cable management

4.11 Internal and external conducted emissions conformity