SIGMATEK DIAS-Drive 335-23 User Manual

DIAS-Drive 335-23
Current version: 27.09.2017
Article No.: 10-501-351-23E
Publisher: SIGMATEK GmbH & Co KG
A-5112 Lamprechtshausen
Tel.: +43/6274/4321
Fax: +43/6274/4321-18
e-mail: office@sigmatek.at
WWW.SIGMATEK-AUTOMATION.COM
Copyright © 2013
SIGMATEK GmbH & Co KG
Translation from German
All rights reserved. No part of this work may be reproduced in any form whatever (printing, photocopying, microfilm or any other process), or processed, duplicated or distributed by means of electronic systems, without express permission.
We reserve the right to make changes to the content without notice. SIGMATEK GmbH & Co KG shall not be held responsible for technical or printing errors in this manual and shall accept no liability for damages caused as a result of using this manual.
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DIAS-Drive 335-23
The manual describes the servo amplifier of the DIAS-Drive series. Additional information on the safety functions and the existing inputs and outputs in the installed VAC 013 interface module can be found in the corresponding chapter.
Individual chapters:
Technical Data of the servo amplifier
Assembly and Installation
Interface description
Setup of the servo amplifier
Accessories
Transport, storage, maintenance, disposal
Abbreviations used in this manual
Abbreviation
Definition
AWG
American Wire Gauge (American cable coding)
BGND
Mass for the 24V auxiliary and braking supply
CE
Communité Europeenne
CLOCK
Clock signal
EMC
Electromagnetic Compatibility
EN
European Norm
IGBT
Insulated Gate Bipolar Transistor
LED
Light Emitting Diode
PELV
protected Extra Low Voltage
RES
Resolver
R
int.
Internal regen resistor connection
Rtr
Brake chopper connection
V AC
Alternating Current
V DC
Direct current
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Contents
1 General .................................................................................... 6
1.1 Symbols used in this manual ...................................................... 6
1.2 Safety Guidelines .......................................................................... 7
1.3 Servo Amplifier Components .................................................... 10
1.4 European Guidelines and Norms .............................................. 11
1.5 Designated Use ........................................................................... 12
1.6 Non-designated Use ................................................................... 13
1.7 Nameplate .................................................................................... 14
1.8 Block Diagram ............................................................................. 15
1.8.1 Hardware ........................................................................................... 16
1.8.2 DIAS-Drive Concept .......................................................................... 17
1.8.3 Software Functions ............................................................................ 18
1.9 Technical Data ............................................................................ 19
1.10 Environmental Conditions, Ventilation and Mounting ............ 21
1.11 Auxiliary Supply Voltage ............................................................ 21
2 Installation ..............................................................................22
2.1 Important Instructions ................................................................ 22
2.2 Construction of the Control Cabinet ........................................ 24
2.2.1 Wiring Diagram and Pin Assignment ................................................. 24
2.2.2 Mechanical Construction and Mounting ............................................. 26
2.2.3 Laying the Motor and Control Cables ................................................ 28
2.2.4 Connector Models ............................................................................. 29
2.2.5 Cable Types ...................................................................................... 29
2.2.6 External Fusing .................................................................................. 30
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2.2.7 Voltage Supply Options .................................................................... 31
2.2.8 Usage of Cooling Devices ................................................................. 32
2.2.9 Turn on/off Response of the Servo Amplifier .................................... 34
2.2.10 Holding Brake Control ....................................................................... 35
3 Connections........................................................................... 36
3.1 Main Power supply (X1B) ........................................................... 36
3.2 24 V Auxiliary supply – Holding Brake supply (X1A) .............. 37
3.3 DC-link (X1B) ............................................................................... 38
3.4 External Regen Resistor (X1B) .................................................. 38
3.5 Motor Connection (X3, X4, X5) .................................................. 39
3.5.1 Standard configuration ...................................................................... 39
3.5.2 Classic Emergency Stop Functions (Stop Category 0) ..................... 40
3.5.3 Personnel-Safe Holding Brake Control ............................................. 41
3.6 Feedback (X6, X7, X8) ................................................................. 42
3.6.1 Resolver Feedback ........................................................................... 43
3.6.2 EnDAT® Signal Encoder ................................................................... 44
3.6.3 Hiperface® Signal Encoder ................................................................ 45
3.6.4 Sine/Cosine & TTL Encoder Feedback ............................................. 46
4 Maintenance........................................................................... 47
4.1 Replace and Repair..................................................................... 47
5 Appendix ................................................................................ 49
5.1 Transport, Storage and Disposal .............................................. 49
5.2 Correcting Errors ........................................................................ 51
5.2.1 LED Display ...................................................................................... 51
5.2.2 Amplifier Malfunctions ....................................................................... 52
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5.2.3 Status Register .................................................................................. 53
6 DIAS Drive 300 Accessories .................................................57
6.1 Shielding Plate with Strain Relief .............................................. 57
6.1.1 Mounting Instructions ........................................................................ 57
6.2 Mounting Set ............................................................................... 58
6.2.1 Mounting Instructions ........................................................................ 59
6.2.2 Dimensions incl. Mounting Set .......................................................... 60
7 VARAN Interface for the DIAS Drive 3xx (VAC 013) ............61
7.1 Technical Data ............................................................................ 62
7.1.1 General .............................................................................................. 62
7.1.2 Electrical Requirements ..................................................................... 62
7.1.3 Input Specifications ........................................................................... 62
7.1.4 Relay Specifications .......................................................................... 63
7.1.5 Safety Conformity .............................................................................. 63
7.1.6 Miscellaneous .................................................................................... 63
7.1.7 Environmental Conditions .................................................................. 64
7.2 Mechanical Dimensions ............................................................. 65
7.3 Connector Layout ....................................................................... 66
7.4 Status Displays ........................................................................... 68
7.5 Additional Safety Information.................................................... 69
7.6 Additional Information ............................................................... 71
7.6.1 "Safe Restart Lock" STO (Safe Torque Off) ...................................... 71
7.7 Addressing .................................................................................. 81
7.8 Recommended Shielding for VARAN ....................................... 85
7.8.1 Wiring from the Control Cabinet to an External VARAN Component . 86
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7.8.2 Wiring Outside of the Control Cabinet ............................................... 87
7.8.3 Shielding for Wiring within the Control Cabinet ................................. 88
7.8.4 Connecting Noise-Generating Components...................................... 89
7.8.5 Shielding Between Two Control Cabinets ......................................... 90
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1 General
1.1 Symbols used in this manual
Danger! Electric shock Danger to personal from
electricity and its effects
Caution! General Danger to machines General warning
Caution! Hot surface Hot surface more than 80 °C (176 °F)
Important note See Manual
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1.2 Safety Guidelines
The safety instructions must be read before installation and initial start­up of the servo amplifier. Improper handling of the servo amplifier can lead to personal injury or material damage. Compliance with the technical data and connection specifications (nameplate and documentation) mandatory.
Only qualified personnel may perform tasks such as transportation, assembly, Initial startup and maintenance. Qualified personnel are those who are familiar with the transport, assembly, installation, setup and operation of the product, and have the appropriate qualifications for their task.
The machine manufacturer must perform a safety analysis for the entire machine. With the appropriate measures, the manufacturer ensures that no injuries or damage can be caused by unexpected movements.
Improper operation of the servo amplifier or failure to follow the following guidelines and improper handling of the safety equipment can result in damage to the machine, personnel injury, electrical shock or in extreme cases, death.
Annotations
Danger! Shock current
After disconnecting the servo amplifier from the voltage supply, a wait-time of at least 5 minutes is required before current conducting components of the amplifier (e.g. clamps) can be touched or connectors removed. After turning off the voltage supply, the internal capacitors can have dangerous voltage levels for up to 5 minutes. For safety purposes, measure the voltage in the intermediate circuit and wait until the voltage is below 40 V.
The electrical connectors of the servo amplifier can never be removed while voltage is applied. The danger of electrical arcing exists, which could cause personal injury as well as damage to the contacts.
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When using a ground fault interrupter in the circuit, a Type B FI-switch must be used. If an FI switch of Type A is used, a DC ground fault could cause it to malfunction.
Failure to follow these instructions can lead to death, serious injury or damage to the machine.
Warning General
The use of the servo amplifier is defined by EN61800-3. In living areas, this product can cause EMC interference problems. In such a case, the user must take additional filtering measures.
The servo amplifier contains electrostatic-sensitive components, which can be damaged by improper handling. Before touching the servo amplifier, the user must discharge their body by touching a grounded object with a conductive surface. Contact with highly insulated material (synthetic fiber, plastic foil etc.) must be avoided. The servo amplifier must be placed on a conductive surface.
Opening the device is not allowed. During operation, keep all covers and control cabinet doors closed. The danger of severe damage to health or material, as well as death exists.
During operation, servo amplifiers – according to their protection type – may have bare, voltage-carrying components. Control and power connections may be live, even if the motor is not turning.
The main voltage supply for the DIAS-Drive requires a fixed connection. If the servo amplifier is mounted on a moveable part of a machine with a connector plug, the ground connection must have a minimum cross-section of 10 mm² (8 AWG) because of the high leakage current of the servo amplifier (> 3.5 mA).
The +24 V auxiliary power supply and the power supply for the +24V-BR holding brake supply must be galvanically separated as protective extra-low voltage (PELV) according to EN 60950.
Failure to follow the above safety measures can lead to severe injuries and machine damage.
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Caution! Hot surface
During operation, the heat sink of the servo amplifier can reach temperatures of over 80° C (176° F). The heat sink temperature should be checked before handling and it may be necessary to wait until it has fallen below 40 °C (104 °F).
Failure to follow the above safety measures can lead to severe injuries.
Caution! Electromagnetic Fields (EMF) Risk of death!
Due to the electromagnetic fields generated during operation of the servo amplifier, people with pacemakers or implants are particularly at risk if they are in the immediate vicinity of the device.
Caution must therefore be taken to ensure that such persons maintain the necessary safety distance of at least 2 m.
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1.3 Servo Amplifier Components
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1.4 European Guidelines and Norms
Servo amplifiers are components designed for installation in electrical systems/machines for industrial use. During the installation into machines/systems, the servo amplifier should not be operated until it has been determined that the machine/system meets the requirements of the EG-machine guideline 2006/42/EG and the EG-EMC guideline 2004/108/EG.
Note: The machine manufacturer must perform a safety analysis for
the entire machine. With the appropriate measures, the manufacturer ensures that no injuries or damage can be caused by unexpected movements.
Conformity
With the delivery of servo amplifiers within the European community, compliance with the EG-EMC 2004/108/EG and low voltage 2006/95/EG guidelines is mandatory.
The harmonized standard EN 61800-5-1 (Electrical Power Amplifier Systems with Adjustable Speed - part 5-1: Requirements for the Safety of Electrical, Thermal and Energetic Demands) was included with the 2006/95/EG low voltage guideline for this servo amplifier.
The harmonized standard EN 61800-3 (Electrical Power Amplifier systems with Adjustable Speed - Part 3: EMI Product Norm including Special Test Processes) was included with the 2004/108/EG for this servo amplifier.
To meet the EMC conditions for the installation, the documentation contains detailed information on:
Shielding
Ground connection
Control cabinet wiring
Filters (as required)
The servo amplifier from the DIAS-Drive series was tested with the system components and the corresponding configuration defined in this document. Any change in the configuration and installation described in this document requires new measurements to ensure the standards are met.
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1.5 Designated Use
The servo amplifier from SIGMATEK GmbH & Co KG was designed and produced with state of the art technology. The product was tested for reliability before delivery, especially in terms of fail-safe conditions. It is an installed component for electrical systems and can only be operated as an integral part. Before installation, the following conditions for designated use must be met:
Each user of the product must read and understand the safety instructions for designated and non-designated use.
The machine manufacture must perform a safety analysis of the machine in order to ensure that no injuries or damage is caused to personnel and equipment by unexpected movements.
The servo amplifier must be operated under the assembly and installation conditions described in this document. The environmental conditions (temperature, protection class, humidity, voltage supply, EMC and mounting position) must be observed in particular.
The amplifier can only be operated in a control cabinet with minimum IP54.
The Servo amplifier must be operated in the original condition without any mechanical
or electrical changes.
Mechanically or electrically defective or faulty servo amplifiers may be not installed or operated.
The servo amplifier is provided for the control of synchronous servo, linear and torque motors, as well as frequency, torque, speed or position control of asynchronous motors.
The specified rated voltage of the motor must be at least as high as the power supply voltage of the servo amplifier (230 V, 400 V or 480 V).
Only motors with star circuit may be used.
This product can lead to EMC disruptions in living areas. In such a case, the user must
take additional filtering measures.
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1.6 Non-designated Use
If a servo amplifier is operated according to the environmental conditions described in this document, it is "designated use".
Single-phase operation is not authorized as standard use, but is allowed for initial startup and demonstration purposes.
Because of saline and therewith, conductive contamination, the servo amplifier cannot be used on ships (sea operation) or in offshore applications.
The servo amplifier cannot be operated under any environmental conditions other than those described in this documentation (meaning without a control cabinet, incorrect assembly etc.)
Particular caution is required in production facilities, in which conductive material such as carbon fiber, graphite, and cast iron or similar material is used. In such cases, the control cabinet must be hermetically sealed (no forced ventilation with fan filters) or placed outside of the contaminated area. Especially during the initial start-up, the danger posed by open control cabinet doors is extremely high. Contaminated servo amplifiers may no longer be used.
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1.7 Nameplate
The name plate is attached to the side of the amplifier heat sink. The information in the individual fields depends on the various amplifier types.
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1.8 Block Diagram
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1.8.1 Hardware
The main supply is connected to a rectifier, input filter and a charging circuit, which reduces the load current for the power-up moment.
IGBT – Power output stage with separate current measurement (short circuit protected).
Short circuit proof brake chopper with internal brake resistor. For insufficient power, the
internal resistor can be disconnected and replaced by an external one.
DC link for connection to additional amplifiers.
Auxiliary voltage for the internal supply.
Separate voltage supply for the holding brake.
Evaluation from the resolver, EnDAT and Hiperface sensors.
Micro controller system with communication to the interface
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1.8.2 DIAS-Drive Concept
1 and 3-axis amplifiers to reduce machine costs. 3-axis amplifiers have advantages reducing components
Auto-range function to optimize the resolution of the actual current value of 10 A axes, in various configurations.
Two different mounting options.
On a mounting place in the control cabinet Through-hole technology
Broad input voltage range from 3 x 230 VAC
-10%
… 3 x 480 VAC
+10%
supplied from TN­supply or TT-supply with grounded neutral point, with a maximum current of symmetrical 5000 A
RMS
.
TT supplies without grounded neutral lines require additional measures.
Charging circuit for limiting the maximum load current at the power-up moment.
Fuse installed by user (phase failure is monitored by the amplifier)
1-phase operation is possible, e.g. for initial start-up
24 V auxiliary supply, galvanically isolated for independent power.
Separate 24 Volt connection to power the holding brakes.
Noise filter for the main, 24 V auxiliary and holding brake supplies, class A (industrial
use)
Housing with connection for the cable shielding
Protective functions against:
Under or over voltage in the DC-link circuit. Several short circuit conditions Phase error in the main supply Brake resistance over heating Over temperature (heat sink, ambient and motor)
The overload protection is provided internally by the drive. The load current is limited to 100 % of peak output current. For the thermal protection of the motor the I2T regulation is used.
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Integral solid state short circuit protection does not provide branch circuit protection. Branch circuit protection must be provided in accordance with the Manufacturer Instructions, National Electrical Code and any additional local codes.
1.8.3 Software Functions
Modified space vector modulation (SVM) technique to reduce the power stage losses
Field oriented current controller (update time 62.5 µs)
Feedback evaluation and speed controller (update time 62.5 µs)
Spline interpolation and position controller (update time 62.5 µs)
Full synchronisation up to the output stage to the control frequency with cycle times of
250 µs, 500 µs and 1 ms to 8 ms
The servo amplifier has a volatile data storage medium. After power-up, the parameters are loaded into the servo amplifier via the host
Starting with FW version 1.82, the electrical rotary field frequency is limited to 599 Hz. The error bit 18 is set when the frequency is above 599 Hz for more than one second. The amplifier then changes to error status. The cause could be a high rotation speed with motors that have a high number of poles.
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1.9 Technical Data
DIM
DIAS-Drive
SDD335-23
Rated values
Rated input voltage (symmetrical opposite to earth) max. 5000 rms (L1, L2, L3)
VAC
3 x 230 V
-10%
– 480 V
10%
, 45 – 65 Hz
Max. peak current at power-up moment (limited by the charging circuit)
A
2.5
Rated power in S1 mode
kVA
14
Rated DC-link voltage
VDC
290 – 680
Over voltage protection – limit for the intermediate circuit
VDC
450 – 900
Additional supply voltage +24 V
VDC
22 – 30
Power from the additional +24 V
W
35
Holding brake supply +24 V-BR
VDC
25 – 27
Max. holding brake current per axis
ADC
2
Holding brake voltage drop with a load +24 V­BR
VDC
Max. 1 (at 3 x 2 A Holding brake current)
Max. switching energy of the holding brake
mJ
100
Rated current for axis 1 (rms +/- 3 %)
A
rms
10
Max. standstill current for axis 1 starting from 500 ms
A
rms
7
Rated current for axis 2 (rms +/- 3 %)
A
rms
10
Max. standstill current for axis 2 starting from 500 ms
A
rms
7
Rated current for axis 3 (rms +/- 3 %)
A
rms
15
Max. standstill current for axis 3 starting from 500 ms
A
rms
10.5
Max. continuous sum current of all axes (heat sink)
A
rms
20
Peak output current axis 1 for a max 5 s (rms +/- 3 %)
A
rms
20
Peak output current axis 2 for a max 5 s (rms +/- 3 %)
A
rms
30
Peak output current axis 3 for a max 5 s (rms +/- 3 %)
A
rms
35
The loss in the power output stage (add the average current of the 3 axis and multiply by the factor) without brake unit losses
W /
A
rms
10
Output frequency of the power output stage
kHz
8
Maximum output current for 8 V feedback systems at X6, X7, X8
mA
250
Minimum output current for 8 V feedback systems at X6, X7, X8
mA
0
Maximum output current for 5 V feedback systems at X6, X7, X8
mA
250
Minimum output current for 5 V feedback systems at X6, X7, X8
mA
50
Maximum residual current
mA
15
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Brake Unit
Capacitance of the intermediate circuit voltage
µF
700
External regen resistor Ω 25
Internal regen resistor Ω 25
Rated power of the internal regen resistor
W
200
G-VMAINS = 230 (rated supply voltage = 230 V)
Start-up limit
VDC
420
Switch-off level
VDC
400
Over voltage protection
VDC
450
Max. rated power of the external regen resistor
W
750
Peak internal regen resistor power (max. 1 s)
kW
6.5
G-VMAINS = 400 (rated supply voltage = 400 V)
Start-up limit
VDC
730
Switch-off level
VDC
690
Over voltage protection
VDC
800
Max. rated power of the external regen resistor
W
1200
Peak internal regen resistor power (max. 1 s)
kW
21
G-VMAINS = 480 (rated supply voltage = 480 V)
Start-up limit
VDC
850
Switch-off level
VDC
810
Over voltage protection
VDC
900
Max. rated power of the external regen resistor
W
1500
Peak internal regen resistor power (max. 1 s)
kW
27
Internal fuse
24 V auxiliary supply voltage (+24 V to BGND)
-
Electronic fuse
Holding brake supply 24 V-BR (+24 V-BR to BGND)
-
Electronic fuse
Regen resistor - Electronic protection
Resolver specification
Exciter frequency f
err
kHz
8
Exciter voltage U
Ref
U
eff
4
Number of poles m - 2, 4, 6 32
Resolver voltage U
sin/cos, max
U
eff
2.2
Connector types
Internal auxiliary power supply (X1A)
-
Combicon 5, 3-pole, 2.5 mm²
Power Supply (X1B)
-
Power Combicon 7.62, 8-pole, 4 mm²
Feedback (X6, X7, X8)
-
Sub-D 25-pole (female)
Motor (X3, X4, X5)
-
Power Combicon 7.62, 6-pole, 4 mm²
Dimensions
Height with/without connector plugs
mm
472 / 378
Width
mm
158
Depth
mm
240
Weight
kg
10
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General
Article number
09-501-351-23
Standard
UL 508C, E336350
1.10 Environmental Conditions, Ventilation and Mounting
Storage conditions
page 49
Transport conditions
page 49
Environmental temperatures in operation
0 … +45 °C (32 … 113 °F) at rated data +45 55 °C (113 131 °F) with power reduction by
2.5 % / K
Air humidity in operation
Relative humidity 85 %, no condensation
Operational altitude
Up to 1000 m above sea level at rated data 1000 to 2500 m above sea level with a
1.5 % / 100 m reduction
Pollution degree
2
Servo amplifier protection class
IP 20
Mounting position
page 26
Ventilation
Forced ventilation by controlled internal fan
1.11 Auxiliary Supply Voltage
The power supply mounted in the switchgear cabinet and used for the +24 V auxiliary supply voltage and holding brake supply (+24V-BR), must output a galvanically isolated protected extra-low voltage (PELV) according to EN60950. Due to the start current at the power-up moment, the rated current must be at least 5 A.
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2 Installation
2.1 Important Instructions
When using a ground fault interrupter in the circuit, a Type B FI-switch must be used. If an FI switch of Type A is used, a DC ground fault could cause it to malfunction. High-frequency leakage currents occur, which must be taken into consideration when selecting the FI (e.g. Schrack ID-B 4/XX/XX-B).
Trigger diagram:
The servo amplifier and motor must be grounded according to the guidelines. Uncoated mounting plates must be used in the control cabinet.
The DIAS-Drive must be connected to ground via the grounding terminal using a wire with a cross section of at least 10 mm² (8 AWG).
The main voltage supply for the DIAS-Drive requires a fixed connection. If the servo amplifier is mounted with a connector terminal to a moving machine part, the ground connection must have a cross section of at least 10 mm² (8 AWG) to avoid the high residual current (> 3.5 mA).
Before installation, the servo amplifier must be mechanically tested. If damage from transportation is determined, for example, the amplifier cannot be used. Electronic components cannot be handled.
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The rated voltage and current of the servo motor and servo amplifier must match. The electrical connection must correspond to the schematic on page 24.
The main supply can under no circumstances exceed the rated values for the servo amplifier. “Voltage Supply Options” on page 31 should be noted.
The external fuse for the main supply, the +24 V auxiliary and holding brake supply must meet the specifications for External fusing” on page 30.
The motor and control cable should be routed with a minimum clearance of 100 mm. This improves the effect of noise in the control cable, which is caused by the high noise generation of the motor cable. A shielded motor and feedback cable must be used, by which the shielding on both cable ends is applied.
As described on page 26, the correct mounting position is vertical.
The ventilation in the control cabinet must provide sufficient cool and filtered air.
Information on the “Environmental conditions, ventilation and mounting” can be found on page 21.
Any subsequent changes to a servo amplifier will render the warranty void, with exception of the parameter settings.
During the initial start-up of the servo amplifier, the peak current must be tested. small motors can be damaged quickly, especially if the servo amplifier settings are to high (e.g. a 1 A motor with a 10 A amplifier without being limited to 1 A).
Note: The mass symbol found in all schematic plans means that the electric connection between the indicated device and the mounting panel in your control cabinet must be made over the largest possible surface. This connection should enable
the dissipation of HF noise and should not be confused with the PE symbol . (Protective measure according to EN 60204)
Storage time: < 1 year: no limitations ≥ 1 year: The intermediate circuit capacitors of the servo amplifier must be reformed before the initial startup. In addition, all electrical connections must be removed and the servo amplifier supplied with 230 V AC, single phase at terminals L1 / L2 for 30 minutes.
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2.2 Construction of the Control Cabinet
2.2.1 Wiring Diagram and Pin Assignment
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2.2.1.1 SDD 335-23
Drive type
Axis 1
Axis 2
Axis 3
Cable
Motor
Feedback
Motor
Feedback
Motor
Feedback
SDD335-23
X3
X6
X4
X7
X5
X8
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2.2.2 Mechanical Construction and Mounting
378/ 472
without
/ with connectors
240
158
The drawing shows the servo amplifier dimensions.
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The cable channels below and above the servo amplifier must have the specified distances. This will ensure the sufficient air reaches the heat sink.
Material: 4 x M5 socket head screws to DIN 912 Tool required: 4 mm Allen key
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