DIAS-Drive 335-23
Date of creation: 01.10.2013
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.
DIAS-DRIVE 335-23
27.09.2017 Page 1
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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2.2.3 Laying the Motor and Control Cables
Note: The motor and control cable must absolutely be kept separate.
The voltage connection to X1B should also be laid mainly in the
cable channels on the left side of the control cabinet.
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2.2.4 Connector Models
All connections to the servo amplifier are connector plugs (except: grounding bolt). With this
method, the cable connection is simplified and the amplifier can be more easily exchanged.
Additionally, it also provides the possibility to manufacture pre-assembled cable sets for
large machine quantities.
The following is the technical data for the applicable connectors:
Connector
Type
Wire size
Max. screw torque
X1A
Phoenix MSTB 2,5
HC/3-ST
1-2.5 mm² (14-18 AWG)
0.3 Nm (2.25 inch lb)
X1B
Phoenix PC4/8
1-4 mm² (12-18 AWG)
1.3 Nm (12 inch lb)
X3, X4, X5
Phoenix PC4/6
1-2.5 mm² (14-18 AWG)
1.3 Nm (12 inch lb)
X6, X7, X8
D-Sub 25 with
metal housing
0.25-0.5 mm²
(21-24 AWG)
solder or crimp
Ground bolt
M5
10 mm² (8 AWG)
3.5 Nm (31 inch lb)
2.2.5 Cable Types
According to EN 60204 (for AWG: table 310-16 of the NEC 60 °C or 75 °C column), is
recommended:
Signal Cable rating
Alternating current
Maximum 4 mm² (12 AWG)
600 V 105 °C (221 °F)
DC-link voltage
Maximum 4 mm² (12 AWG)
1000 V 105 °C (221 °F)
Regen resistor
2.5 mm² (14 AWG)
1000 V 105 °C (221 °F)
Motor cable
Maximum 2.5 mm² (14 AWG), shielded,
max. 25 m, cable capacitance <150 pF/m
600 V 105 °C (221 °F)
Holding brake
Min. 0.75 mm² (18 AWG), component of the motor
cable, shielded separately, note voltage loss
600 V 105 °C (221 °F)
Resolver with thermo
contact
4x2x0.25 mm² (24 AWG), twisted pairs, shielded, max. 25 m,
cable capacitance <120 pF/m
EnDAT® signal encoder
7x2x0.25 mm² (24 AWG), twisted pairs, shielded, max. 25 m,
cable capacitance <120 pF/m
+24 V and +24 V-BR
input
Maximum 2.5 mm² (14 AWG) (check voltage drop)
Note: Use 60/75 °C Copper conductors only!
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2.2.6 External Fusing
The AC-mains and 24 V fuses are designed according to the customer requirements for the
circuit.
Signal
Fuses, time delay
AC mains input (L1-L3)
Suitable for use on a circuit
capable of delivering not more than
5000 rms symmetrical amperes,
528 volts maximum when
protected by RK5 class fuses rated
20 A
The size of the fuse depends on the average power consumption
of the connected amplifier. Max. 20 A with 4 mm²
(12 AWG) (FRS-25) wires
24 V DC input (24 V, 24 V-BR to
BGnd)
16 A slow-blow at 2.5 mm² (14 AWG) for the control
External regen resistor
10 A time delayed, 1200 V (e.g. SIBA 10 022 01,
3-pin-D-Fuse-Link) or FRS-10
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2.2.7 Voltage Supply Options
The main voltage supply for the DIAS-Drive requires a fixed connection. If the
servo amplifier is mounted on a moveable machine part with connector plug,
the ground connection has to have a minimum wire size of greater than 10
mm² (8 AWG) because of the high leakage current of the servo amplifier
(> 3.5 mA).
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.
Main voltage supply
(grounded)
The servo amplifier can be connected directly to a voltage
supply with a grounded neutral point without galvanic isolation.
Main voltage supply
(non-grounded)
If the servo amplifier is operated in a non-grounded system (IT
grid), the danger of over voltage or damage exists. The
following measures can be taken to provide protection against
over voltage:
• Use of a galvanically insolating transformer with a
grounded neutral point on the secondary side. This offers
the highest protection.
• Installation of over voltage protection in the voltage supply
of the control cabinet.
The servo amplifier is tested according to EN 61800-3 as
follows:
• Periodic over voltage between phase conductors (L1, L2,
L3) and the amplifier housing cannot exceed 1000 V
(amplitude).
• According to EN61800, the peak voltages (< 50 µs)
between the phase conductors cannot exceed 1000 V.
Peak voltages (< 50 µs) between the phase conductors
and the housing cannot exceed 2000 V..
Note: Non-grounded mains supplies always require
additional surge protection in the mains input.
High voltage supply
If the input supply voltage exceeds the specified maximum
value, a suitable transformer is required to reduce it.
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2.2.8 Usage of Cooling Devices
The servo amplifier functions up to an ambient temperature of 45 °C (55 °C with reduced
power). Under some circumstances, a cooling device is required.
Note: A cooling device always produces condensation water. Important
points must therefore be observed:
• Cooling units must be mounted in such a way that no condensation
water can drip into the control cabinet.
• Cooling units must be mounted so that condensation water is not
distributed over electrical or electronic components.
Cooling device mounted in the
top of the control cabinet
Cooling device mounted in the
cabinet door
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Condensation water can also be avoided as follows
• The switch point of the temperature regulator should be just below the building
temperature.
• In damp environments, the proper seals should be used in the control cabinet.
If electronic components are colder than the air in the control cabinet, condensation
water can accumulate; especially when the cabinet door is opened during servicing.
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2.2.9 Turn on/off Response of the Servo Amplifier
The turn on/off response of the servo amplifier is shown below.
Five seconds after turning on the 24 V auxiliary supply (start time of the micro controller),
the "Drive ready" signal is set to high.
The above image shows when the 24 V auxiliary supply activates the system through
turning on the main switch and the main supply is engaged later. This, however, is not
absolutely necessary. The main supply can also be activated with the 24 V auxiliary supply
at the same time.
Since the servo amplifier has a volatile memory, received parameters must be stored in the
host controller. The advantage here is in the automatic download of program data when an
amplifier is changed.
If the main supply is turned on, the capacitors in the intermediate circuit are loaded.
Approximately 0.7 seconds are needed.
If the main supply is turned off, the current of intermediate circuit is maintained and can be
used for controlled braking of the motor. If the motor is slowed, the energy is returned to the
intermediate circuit.
If the motor is stopped, the "enable" signal can be removed. After 5 minutes, the
intermediate circuit is discharged.
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2.2.10 Holding Brake Control
The figure above shows the holding brake function.
A standard holding brake with 24 volts DC and a maximum of 2 Amps can be used on the
servo amplifier.
The circuit has a high level of functional safety, but no personnel safety.
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3 Connections
3.1 Main Power supply (X1B)
The connection to the main supply voltage is designed for voltages from 230 V AC to
480 V AC. When using a non-earthed supply, over voltage protection must be built into the
main power supply of the control cabinet.
Note: If within a group of amplifiers, the intermediate circuit is bridged, the
input voltage in this group must also be bridged.
3-phase connection:
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3.2 24 V Auxiliary supply – Holding Brake supply (X1A)
If a 24 V supply is used in the control cabinet to power the relays, coils or other devices, it
can also be used for the servo amplifier (the maximum current of the supply must be taken
into consideration).
To deactivate the stop brake independently from the 24 V auxiliary voltage, the amplifier
has an additional input +24 V-BR.
Note: The mass of the 24 V power supply must be connected to ground
near the supply.
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3.3 DC-link (X1B)
To bridge the DC-link voltage with other servo amplifiers, the X1B/2 (+DC) and 3 (-DC)
connectors can be used.
The intermediate circuit power can be distributed to different servo amplifiers with this
method.
Note: If the intermediate circuit is bridged within a group of amplifiers,
the main power supply in this group must also be bridged.
3.4 External Regen Resistor (X1B)
If the power of the internal brake resistor is insufficient, an external resistor can be added.
Here, the connection to R
int
(terminal 4 of X1B) and Rtr (terminal 5 of X1B) must be
removed. The external resistor is connected to terminal 2 and 5 of X1B. The fuse on both
connections of the external brake resistor is mandatory. 1000 VDC fuses with slow trigger
characteristics must be used.
Note: The brake resistor fuse does not protect the resistor, rather the
connected cable in the event of a short circuit. The amplifier has
electronic protection for the brake resistor.
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3.5 Motor Connection (X3, X4, X5)
3.5.1 Standard configuration
The cable length for the motor is limited to 25 m. If a longer cable is used, additional
suppression coils in the motor output are required.
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3.5.2 Classic Emergency Stop Functions (Stop Category 0)
The cable length for the motor is limited to 25 m. If a longer cable is used, additional
suppression coils in the motor output are required.
Note: The KEM coil must be turned on before the amplifier is enabled and
can be turned off after at least 1 ms after the amplifier is disabled.
The resistance value and the power of the REM resistor are calculated using the following
formulas:
maxSPEED maximum revolutions [rpm]
I
max
maximum motor current allowed [A]
K
Erms
voltage constant of the motor [V*min]
8.0
max
max
I
KSPEED
R
Erms
EM
10
)²8.0(
max EM
EM
RI
WP
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3.5.3 Personnel-Safe Holding Brake Control
The servo amplifier has a high reliability in the brake control.
If a personnel-safe holding brake control is required, an additional safety contact in the
+24V-BR voltage path in keeping with the safety standards is needed.
Despite this, the danger of injury and/or damage to the machine still exists
with a mechanical defect in the holding brake.
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3.6 Feedback (X6, X7, X8)
The servo amplifier has various feedback inputs for different feedback devices.
• Resolver Feedback with thermo contact
• EnDAT® encoder (single and multi-turn)
• Hiperface® encoder (single and multi-turn)
• Sin/Cos & TTL Encoder
For EnDAT, Hiperface, Sin/Cos and TTL encoder systems, the current maximum number of
feedback signals of 8192 per mechanical turn is supported (M-RPULSE).
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3.6.1 Resolver Feedback
A resolver is used as the standard feedback. The servo amplifier supports the analysis of
single-speed (2-pin) and multi-speed resolvers (up to 32 pins). The maximum cable length
is 50 m. If a thermo contact is used, the signal is also wired into the resolver cable.
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3.6.2 EnDAT® Signal Encoder
The EnDAT® encoder is a high-resolution feedback system for motors. The cable length is
limited to 25 m. If a thermo contact is used, the signal is transmitted through the feedback
cable.
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3.6.3 Hiperface® Signal Encoder
The signal encoder with a Hiperface® interface is a high-resolution feedback system for
motors. The cable length is limited to 25 m.
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3.6.4 Sine/Cosine & TTL Encoder Feedback
A sine encoder is a high-resolution feedback system, used with linear or torque
servomotors. The maximum cable length is 10 m. If a thermo contact is used, the signal is
wired into the resolver cable.
The upper frequency limit for TTL encoders is 100 kHz. The reference signal is not
evaluated in the amplifier.
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4 Maintenance
The servo amplifier is maintenance-free.
Note: Opening the housing invalidates the warranty.
Dirt on the housing can be removed with isopropyl alcohol or similar products.
• Contamination in the device must be removed by the manufacturer.
• Dirty fan grates can be cleaned with a dry brush.
• Spraying or submersion is not allowed.
4.1 Replace and Repair
Repair: Repair of the servo amplifier must be performed by the
manufacturer.
Replace: If a servo amplifier must be replaced, the following checklist must
be observed (no special mounting tools are required):
Turn off the control cabinet supply and remove the servo amplifier fuses.
After disconnecting the servo amplifier from the main voltage supply, a wait-
time of 5 minutes is required before current-conducting components in the
amplifier (e.g. contacts) can be touched or connectors removed. Capacitors
can contain dangerous voltages for up to 5 minutes after the supply voltage
is removed. It is necessary to wait until the DC-link voltage is below 40 V.
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 is below 40 °C (104 °F).
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Disconnect the contact plug.
The connectors should be labeled to avoid confusing them later.
The servo amplifier can be dismantled.
The replacement unit must be compared with the original amplifier;
only identical amplifiers can be used!
Reestablish the connection. The connectors must not be crossed.
Insert the fuses for the servo amplifier,
turn on the main switch in the control cabinet.
Check whether the correct parameters were loaded into the amplifier.
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5 Appendix
5.1 Transport, Storage and Disposal
Transport:
• For transport, the original recyclable packaging from the manufacturer must be used.
• During transport dropping should be avoided.
• The storage temperature must be between –25 and +70 °C (-13 ... 158 °F), max.
change 20 K/h.
• The maximum humidity is 95 %, non-condensing
• 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 fibre, plastic foil etc.) must be avoided. The servo amplifier
must be placed on a conductive surface.
• If the packaging is damaged, the amplifier must be visually inspected for damage. If
damaged, the transport company and the manufacturer must be informed. The
amplifier should not be installed and operated if damaged.
Packaging:
• Recyclable cardboard with liner
• Dimensions: 500 mm x 300 mm x 400 mm (width, height, depth)
• Labelling: nameplate on the outer side of the box
Storage:
• Only the original recyclable packaging from the manufacturer can be used
• 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 fibre, plastic foil etc.) must be avoided. The servo amplifier
must be placed on a conductive surface.
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• A maximum of 6 servo amplifiers can be stacked on top of one another.
• The storage temperature must be between –25 and +70 °C (-13 ... 158 °F),
max. change 20 K/h.
• The maximum humidity 95 %, non-condensing.
• Storage time:
< 1 year: without 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 min.
Disposal:
• The servo amplifier can be disassembled by removing the screws in its main
components (heat sink, steel housing, circuit boards).
• Disposal should be carried out by certified companies.
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5.2 Correcting Errors
Errors and warnings are displayed via LED and over the bus system. On page 53 under
“Status Register”, the various errors that can occur are described.
5.2.1 LED Display
The DIAS-Drive has two LED’s, which display the status of the amplifier.
LED
Description
Green
Red
On
On
Controller in boot mode (Firmware damaged or not available)
1 Hz flashing
Off
Ready to start
8 Hz flashing
Off
Output current is limited by the I2T value (one or more axes)
On
Off
Operation
On
1 Hz flashing
Warning
Off
On
Error
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5.2.2 Amplifier Malfunctions
Malfunction of the drive
Possible Causes
Solution
When the motor is turning in the
clockwise direction (observe the
motor shaft), I-FPOS decreases
Resolver not functioning
correctly
Resolver connected incorrectly
Check resolver
Connect the resolver according to the
wiring diagram (see page 42 et seq.)
Motor does not rotate
Motor current has reached limit,
however, without torque
Motor is not connected correctly
Check connections on motor terminal
board
U, V, W
The motor "spins through"
The motor torque is too low or
different in the directions
M-ROFF is not set to the right
value
Motor and/or feedback is
connected incorrectly
Check the M-ROFF parameter
Check the motor and feedback
connection
Motor stops at certain positions
The setting of M-POL and/or M-
RPOL is incorrect
The motor cable has a wire
break
The motor cable is not
connected to all wires
Check the M-POL and M-RPOL
parameters corresponding to the motor
data.
Replace motor cable (especially for drag
chains)
Check motor cable connections
The motor oscillates
Control gain too high
Shielding of the feedback cable
has a defect
Reduce V-KP and/or P-KV
Check the feedback cable and
exchange it if needed (especially with
drag chains)
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5.2.3 Status Register
With I-STATUS, the status of the DIAS-Drive can be read. All error and status information is
contained in a 32-bit variable. The amplifier function can be changed by setting the
appropriate bits via using the G-MASKE1, G-MASKE2, G-MASKW and G-MASKD
commands.
According to the mask settings the amplifier detects errors, warnings or does not respond.
The individual bits have different values and limitations in the mask assignment.
Bit
Error
Cause
Solution
0
Single-phase
operation
The main supply voltage is single
phase only
Check the amplifier fuse
Check electrical connection
1
Error in the main
voltage supply
Amplifier is "enabled" without the
applied main voltage supply
check fuses in the mains supply
check electrical supply
Amplifier is enabled before the DC-link
voltage is loaded
2
reserved
3
DC over voltage
Internal / External regen resistor
not connected
Internal regen resistor defective
External regen resistor defective
connect regen resistor
replace amplifier
replace external regen resistor
4
DC under voltage
The main voltage supply for the
enabled amplifier is too low
disable amplifier before the DC-link
voltage crosses the under-voltage
threshold set by G-VBUSM
5
reserved
6
Holding brake error
No holding brake connected with
parameter M-BRAKE = 1
Short circuit in holding brake
cables
Short circuit in the holding brake
Use motor with holding brake
Check holding brake cable
Change M-BRAKE parameter to 0 as
long as a motor without brakes is used.
Check connector and motor cable
Check holding brake
7
Brake switch error
Defective internal stop brake
switch
No holding brake connected in
parameters
M-BRAKE = 1
Replace amplifier
Use motor with holding brake
Change M-BRAKE parameter to 0 as
long as a motor without brakes is used.
Check connector and motor cable
Check holding brake
8
reserved
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9
Motor temperature
Motor temperature switch is
triggered
Break in feedback cable or
connectors
Check cause (Motor underdimensioned; poor environmental
conditions)
Check feedback cable and connector,
exchange if necessary
10
Environmental
temperature
Internal temperature too high
improve ventilation in the cabinet and
check mounting position according to
this manual
11
Heat sink temperature
Heat sink temperature too high
Improve ventilation in the cabinet and
check mounting position according to
this manual
12
Feedback error
Feedback cable broken
feedback device defective
Bad feedback connection
Check feedback cable and replace if
necessary
Replace feedback device
Check feedback connection
13
Commutation error
Incorrect motor phase position
Wrong wiring of motor or
feedback cable
Check M-ROFF
Check motor connection
14
Motor over speed
Incorrect motor phase position
Incorrect motor connection or
wrong feedback cable
Over shoot (greater than
1.2 * V-NMAX)
Check M-ROFF
Check motor connection
Check feedback cable
Optimize control loop
15
Drag error
P-PEMAX lag window too small
Increase P-PEMAX and/or optimize
control loops
16
Trajectory error
The speed setting, which was
calculated using the change in
the position setting by the host, is
higher than 10000 r/min-1
Check P-PSCALE and
P-SSCALE parameters and the
reference value of the controller
17
Host communication
No new preset values were
transmitted for two successive
cycles
Internal communication error with
the interface
Synchronization is not engaged;
check A-CTIME and the cycle time of
the control
Check A-STIME
Communication disrupted, check
see also I-DERROR
18
Amplifier error E2
(I-DERROR)
Various internal errors
see also I-DERROR
Contact manufacturer
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19
Amplifier Error E1
(I-DERROR)
Various internal errors
see also I-DERROR
Contact manufacturer
Power output error:
Motor cable has a ground fault
Motor has a ground fault
Output stage defective
Check motor cable, replace if
necessary
replace motor
Replace amplifier
Ballast circuit error
regen resistor cable has ground
fault
regen resistor has ground fault
regen output stage is defective
replace regen resistor cable
replace regen resistor
Replace amplifier
20
"Enable locked" error
The amplifier is "enabled" via the
software when one of safety
inputs still has a "low" signal.
Enable amplifier only if ENABLE and
EN-BRAKE are "high".
21
Driver voltage error
The amplifier is "enabled" via the
software when LOCK still has a
"low" signal.
Enable the amplifier only if the LOCK
signal is "high".
22
DC over voltage and
regen resistor limit
reached.
Regen resistor power is
insufficient. Brake resistance
power has been reached and the
resistor was deactivated.
An external regen resistor must be
used to adjust the value of G-MBAL.
23
Brake supply voltage
error
Holding brake supply 24 V-BR
missing.
Holding brake switch is defective
If the motor has a holding brake, the
amplifier can only be "enabled" when
24 V-BR is applied to the brake.
Replace amplifier
24
reserved
25
I2T Error
I-I2T exceeds the warning value
A-I2TERR
Increase A-I2TERR
26
Motor temperature
warning
I-TEMPM exceeds the warning
value A-TEMPMW
Increase A-TEMPMW
27
Motor parameter error
M parameters were not found in
the encoder when using motors
with an EnDAT® or HIPERFACE®
encoder
M parameters were not loaded into the
encoder
Encoder defective
Defective signal lines or connectors,
faulty wiring or broken cables
28
Multi-turn error
When using an EnDAT® or
HIPERFACE® multi-turn encoder,
an error has occurred at the
extension at > 4096 turns
Motor with multi-turn encoder was
replaced
Encoder defect
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29
Total power limit
reached
The power of all axes has
exceeded the maximum load.
Reduce the load
Drive is insufficiently dimensioned
30
reserved
31
reserved
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6 DIAS Drive 300 Accessories
6.1 Shielding Plate with Strain Relief
(Article number: 09-501-101-Z1)
The shielding plate with strain relief is used to secure the DIAS Drive cables.
Included in delivery are:
1 pcs. Strain relief
(mounting on the upper side of the DIAS
Drive)
2 pcs. Allen screws
Type M5
6.1.1 Mounting Instructions
Remove the appropriate
connector. Insert the strain
relief into the slots provided.
The reconnected plug holds
the strain relief in position.
Run the cable through the
clamps and secure it to the
strain relief using the two
screws.
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6.2 Mounting Set
(Article number: 09-501-101-Z2)
The fixing (mounting) set serves for mounting the DIAS-Drive in the switchgear cabinet. By
doing so, the amplifier’s fan block is located outside of the switchgear cabinet (better
ventilation). An appropriate recess in the switchgear cabinet must be provided.
Included in delivery are:
2 pcs. Mounting Bracket
(mounting on the upper or
lower side of the DIAS Drive)
4 pcs. Allen screws
Type M5
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6.2.1 Mounting Instructions
Mounting on the upper side of the
amplifier.
Place the mounting bracket in the
provided slots and secure it with
both screws.
Mounting on the lower side of the
amplifier.
Place the mounting bracket in the
provided slots and secure it with
both screws.
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6.2.2 Dimensions incl. Mounting Set
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7 VARAN Interface for the DIAS Drive 3xx (VAC 013)
This VARAN interface module is used for communication between a DIAS drive and control
over the VARAN bus. It is integrated into the DIAS Drive.
It contains the safety functions SS1 (Safe Stop 1) (stop category 1 according to EN60204)
for safely shutting down the amplifier and the "safe restart" STO (Safe Torque Off).
In addition, it contains the interface for digital inputs that can be used as a fast positionlatch input.
Through the VARAN-Out port, the VARAN bus can be configured in a linear structure.
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7.1 Technical Data
7.1.1 General
Interfaces
1 x VARAN-In (RJ45) (maximum length: 100 m)
1 x VARAN-Out (RJ45) (maximum length: 100 m)
1 x DIAS-Drive interface (26-pin blade terminal)
4 fast digital inputs
2 safety inputs for the SSI (SAFE Stop 1) and
STO (SAFE Torque Off) safety functions
1 relay output for indicating the safety function status
7.1.2 Electrical Requirements
Supply voltage
+5 V DC
(supplied by the DIAS-Drive)
Current consumption
Supply voltage
Typically 400 mA
Maximum 500 mA
7.1.3 Input Specifications
Number
Digital inputs
(D-IN1 to D-IN4)
Safety inputs
(ENABLE_L and ENABLE_H)
Input voltage
Typically +24 V, maximal +30 V
Differential voltage between
ENABLE_H (+) and ENABLE_L (-)
typically 24 V, maximum 30 V
Signal level
Low: ≤+5 V, High: ≥+15 V
-
Switching threshold
Typically +9 V
Differential voltage between
ENABLE_H (+) and ENABLE_L (-)
typically 24 V, maximum 30 V
Low < +6 V, High > +14 V
Input current
10 mA at +24 V
Input delay
Typically 0,1 ms
Turn-on circa 20 ms,
Turn-off 0.5 s to 1 s
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7.1.4 Relay Specifications
Number of relays
1 x Relay output (contacts S3, S4)
Relay types
1 x normally open
Power supply
+24 V DC
Switching time
<10 ms
Switching range
Max. 30 V DC/ min. 100 µA, max. 0.5 A
Switching power
Max. 42 V AC / min. 100 µA, max. 0.5 A
7.1.5 Safety Conformity
Safety integration level
according to IEC EN 62061
SIL 3
Performance Level according to
EN ISO 13849-1
PLe
Probability of failure per hour
PFHD [10-9]
0,3
Mean time until a dangerous
error occurs
MTTFD symmetrized [Years]
High
Confirmation Test Interval
[Years]
20
7.1.6 Miscellaneous
Article number
16-059-013
Hardware version
2.x
Standardization
UL (336350)
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7.1.7 Environmental Conditions
Storage temperature
-20 … +85 °C
Environmental temperature
0 … +60 °C
Humidity
0 - 95 %, uncondensed
EMC stability
Tested in the DIAS Drive according to EN61800-3
Shock resistance
EN 60068-2-27
150 m/s²
Protection Type
EN 60529
IP 20
Pollution degree
2
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7.2 Mechanical Dimensions
Integrated into the SDD3xx servo amplifier
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7.3 Connector Layout
X1: VARAN-In
X2: VARAN-Out
Further information about the VARAN bus can be found in the VARAN bus
specifications!
Pin
Function
1
TX/RX+
2
TX/RX-
3
RX/TX+
4 – 5 - 6
RX/TX-
7 – 8
-
Pin
Function
1
TX/RX+
2
TX/RX-
3
RX/TX+
4 - 5 - 6
RX/TX-
7 - 8
-
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X3: IO
Applicable connectors
X3: 2 x 8-pin Phoenix plug with spring terminal FMC1, 5/8-ST-3.5
For the cable strain relief, it is important to ensure that the minimum bend radius
(eight times the cable diameter) of the cable is not undercut!
Pin
Function
1
ENABLE_L
2
ENABLE_H
3
Reserved
4
Reserved
5
Not used
6
Not used
7
S3 8 S4
9
Reserved
10
Reserved
11
Reserved
12
Ext. GND
13
D-IN 1
14
D-IN 2
15
D-IN 3
16
D-IN 4
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7.4 Status Displays
LED
LED color
Definition
VARAN IN
Green
LINK
Lights when the connection between the two PHYs is established
Yellow
ACTIVE
Lights when data is received or sent over the VARAN bus.
VARAN OUT
Green
LINK
Lights when the connection between the two PHYs is established.
Yellow
ACTIVE
Lights when data is received or sent over the VARAN bus.
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7.5 Additional Safety Information
The safety module "Safe Restart Lock" is an integral component of the DIAS Drive 3xx and
is already installed with delivery; it meets the conditions required for safe operation
according to SIL 3 in compliance with IEC 62061 and according to PL e in compliance with
EN 13849-1.
Safety modules can only be powered by supplies that meet the requirements for
PELV in compliance with EN60294.
Installation, mounting, programming, initial start-up, operation, maintenance and
discarding of safety modules can only be performed by qualified personnel.
Qualified personnel in this context are people, who have completed training or
have trained under supervision of qualified personnel and have been authorized
to operate and maintain safety-related equipment, systems and facilities in
compliance with the strict guidelines and standards of safety technology.
For your own safety and the safety of others, use safety modules for their
designated purpose only.
Correct EMC installation is also included under designated use.
Non-designated use consists of
• Any changes made to the Safety modules or the use of damaged
modules
• The use of the Safety modules inconsistent with the technical margins
described in these operating instructions
• The use of the Safety modules inconsistent with the technical data
described in these operating instructions (see the "Technical data"
sections of the respective production).
In addition, observe the warnings in the other sections of these
instructions. These instructions are visibly emphasized by symbols.
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• Only qualified personnel are authorized to install the "safe restart" STO
(Safe Torque off) and set the parameters.
• All control devices (switches, relays, PLC, etc.) and the control cabinet
must meet the requirements for EN 13849. This consists of:
➢ Door switches, etc. with at least IP54 protection
➢ Control cabinet with at least IP54 protection
• The proper cables and end-sleeves must be used
• All cables that affect safety (e.g. control cables for the ENABLE_L and
ENABLE_H inputs) must be laid in a conduit outside of the control
cabinet.
Short or crossed circuits in the signal lines must be avoided! See EN
ISO 13849
• The terminal connections X3/Pin 2, Pin 4, Pin 10 and Pin 12 are labelled
as “reserved” and cannot be used externally!
• When using the SS1 (Safe Stop 1) safety function, the typical turn-off
delay is 0.5 seconds. Subsequent actions that require the STO (Safe
Torque Off) function (e.g. manual access to the machine), can only be
released after 1 second.
• If external forces influence axes that are used with the STO safety
function (e.g. hanging load), additional measures must be taken (such
as an electromagnetic double-surface spring brake, instead of a
permanent magnet brake).
Failure to follow the above safety measures can lead to severe injuries.
The main power supply for the servo amplifier must be disconnected using the main switch
for the following instances:
• Cleaning, maintenance or repairs
• Extended still-stand periods
Failure to follow the above safety measures can lead to severe injuries.
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7.6 Additional Information
7.6.1 "Safe Restart Lock" STO (Safe Torque Off)
The DIAS Drive, in combination with the optional VARAN interface, supports the safety
functions SS1 (Safe Stop 1) and STO (Safe Torque Off), and meets the requirements for
Category 4 Performance Level "e" according to EN ISO 13849-1 and SIL3 according to EN
62061.
For his purpose, the servo amplifier has two safe inputs ENABLE_L und ENABLE_H.
The relay output S1/S2 can be used to provide the status of the safety function. It is not
safety-relevant, but can be used to test the safety function.
The holding brake control is not a component of the safety function. If a safe shutdown of
the holding brake is required, the +24 V-BR brake supply must also be shut down
externally.
For the 24 V supply, only PELV/SELV supplies can be used.
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7.6.1.1 Implementation
The block diagram below shows an overview of the internal switching circuits.
Motor
Main Power
Supply
0.5s
µP
ENABLE_H
ENABLE_L
Mains potential
UU
VV
WW
Astable Multi-
vibrator
IN AMV
Digital I/O potential
OPTO 01
OPTO 03
Electronic potential
TR
AMP 01
U_Treiber
CONTR 01
CONTR 02
Super
visor
1
Super
visor
2
S1
S2
REL 01
G 01
Control
OPTO 02
AMP 02
U_Treiber
U_Treiber
U_Treiber
Block diagram for safe restart lock
The blocks in the diagram above have the following functions:
Block IN
The input block IN generates the supply voltage for the AMV block. This is formed from the
voltage difference between ENABLE_H and ENABLE_L. Power is therefore available
shortly after the appropriated signal is applied to ENABLE_H and ENABLE_L. The voltage
difference between ENABLE_H and ENABLE_L must exceed the minimum HIGH level.
The level LOW ranges from 0 V to +5 V.
The level HIGH ranges from +15 V to +30 V.
If the input voltage is disconnected, the block maintains the supply voltage for the AMV
block for approximately 400 ms. Because the differential voltage is supplied to the OPTO03
block without a delay, the motor can be actively slowed before the amplifier goes into the
safe status by disabling U_Treiber.
S3
S4
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Blocks AMV, OPTO 01 and OPTO 02
As long as the AMV block is powered by the IN input block, it generates a pulse with a
constant frequency that is transmitted to the sequential electronics through blocks OPTO 01
and OPTO 02.
Blocks CONTR 01, CONTR 02, AMP 01, AMP 02 and TR
These blocks form a safe switching power supply, which generates the driver voltage for
U_Treiber through the transformer TR. It is ensured that the switching supply cannot
transmit energy if no control signal is sent from the AMV block via OPTO 01 and OPTO 02.
Blocks G01 and REL01
The relay output S1/S2 is closed when the servo amplifier is supplied with 24 V and the
safety function is active. The two blocks are not safety-relevant.
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7.6.1.2 Function
The safety functions in the DIAS Drive are controlled over two digital inputs.
The following table shows the status that the ENABLE_L and ENABLE_H inputs must
assume to enable normal operation or trigger the safety function.
Input Status
Relay output S3/S4
Description
ENABLE_L
ENABLE_H
Open
Open
When the servo amplifier is
supplied with 24 V, the
inputs are closed after a
minimum delay 0.4 of
seconds and a maximum of
1 seconds
Safe status of the drive system
Low
Low
When the servo amplifier is
supplied with 24 V, the
inputs are closed after a
minimum delay 0.4 of
seconds and a maximum of
1 seconds
• Single channel safe status, only
when using classic I/O
technology
• Safe status of the drive
system, when a safe output is
used by a Safety PLC. Also
when ENABLE_L is connected
to „Ext. GND“
Low
Open
Low
High
Open
Drive system ready
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Timing Diagram
If the ENABLE_L and ENABLE_H are changed from any status to the "Drive Ready" status,
the servo amplifier is not immediately enabled. In addition, in the software (K-EN = 1) or the
corresponding bit in the "control word" must be set so that the software "enable" can be set
and the drive therefore switched to the operational mode
7.6.1.3 Function Test
The safety function test is required to ensure correct operation. The entire
safety circuit must be tested for full functionality.
Tests must be performed at the following times:
• After installation
• In regular intervals, or at least once a year
If the function test results in an invalid machine status, the error must be found and
corrected before the safety function is retested. If the error reoccurs during the
function test, the machine can no longer be operated.
Failure to follow the above safety measures can lead to severe injuries and damage.
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7.6.1.4 Test conditions
The entire safety circuit must be tested for functionality.
The function test is performed from the following start condition:
• An operation-ready servo drive system
• Safe input ENABLE_L is LOW and ENABLE_H is HIGH
• Software application is running
• Motor(s) running
Depending on the wiring:
1. both the ENABLE_L and ENABLE_H inputs are opened
or when ENABLE_L is connected to „Ext. GND“ and the safe output of a Safe PLC is
used for ENABLE_H,
2. ENABLE_H is open or LOW (depending on the wiring).
The motor speed is expected to slow to null and the relay output S1/S2 to close after a
minimum delay of 0.4 s and a maximum of 1 s when the servo drive is supplied with 24 V.
The servo drive system should go into safe mode.
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7.6.1.5 Example Connection with Switching Contacts
To meet the requirements of safety category 4, performance level "e" for EN 13849-1 and
SIL3 according to EN 62061, a two-channel control must be provided for the safety
functions.
The wiring for both connections must be provided with protective insulation (to avoid the
"external voltage supply" error).
For ENABLE_H this means, the other signals that can have a 24 V potential must be led
separately.
For ENABLE_L this means, the other signals that can have "Ext. GND" potential must be
wired separately. Because the 24 V auxiliary voltage in the control cabinet is normally
grounded, caution must be taken to avoid a short-circuit with PE. This can occur through,
for example, wiring in a cable duct.
The schematic shows the possible wiring for use of conventional switch contacts.
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7.6.1.6 Example: Safety PLC Application
To meet the requirements of safety category 4, performance level "e" for EN 13849-1 and
SIL 3 according to EN 62061, an error-proof output of a safety PLC must be used.
There are two types of error-safe outputs.
1. A simple error-safe output, which functions based on "Ext. GND" only. This is then
connected to the ENABLE_H input. The wiring for both connections must be
provided with protective insulation (to avoid the "external voltage supply" error).
In this case, ENABLE_L is connected to "Ext. GND"
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2. Two-channel error-proof relay output, with which the “+” output is connected to
ENABLE_H and the “–“ output to ENABLE_L.
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7.7 Addressing
Address
(hex)
Size (bytes) Access
Description
Reset value
Axis 1
0000
1
r/w
Transmit Execution Register
Bit 0: 1 = Start Object Transfer
Bit 1: 1 = Repeat Object Transfer
Bit 2: 1 = Enable Value 3-5
Bit 3…7: Reserved
00
0001
1
r/w
Reserved
00
0002
1
r/w
Drive Control Byte
00
0003
1
r/w
Object Address
00
0004
4
r/w
Object Value
00000000
0008
4
r/w
Value 1
00000000
000C
4
r/w
Value 2
00000000
0010
4
r/w
Value 3
00000000
0014
4
r/w
Value 4
00000000
0018
4
r/w
Value 5
00000000
001C
4
r/w
Reserved
00000000
0020
1
r/w
Receive Status Register
Bit 0: 1 = Executed Object Transfer
Bit 1: 1 = CRC Error
Bit 2…7: Reserved
00
0021
1
r/w
Reserved
00
0022
1
r/w
Digital In/Out Byte
00
0023
1
r/w
Transmit Control Byte
00
0024
4
r/w
Object Value
00000000
0028
4 r Value 6
00000000
002C
4 r Value 7
00000000
0030
4 r Value 8
00000000
0034
4 r Value 9
00000000
0038
4 r Value 10
00000000
003C
4
r/w
Reserved
-
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Axis 2
0040
1
r/w
Transmit Execution Register
Bit 0: 1 = Start Object Transfer
Bit 1: 1 = Repeat Object Transfer
Bit 2: 1 = Enable Value 3-5
Bit 3…7: Reserved
00
0041
1
r/w
Reserved
00
0042
1
r/w
Drive Control Byte
00
0043
1
r/w
Object Address
00
0044
4
r/w
Object Value
00000000
0048
4
r/w
Value 1
00000000
004C
4
r/w
Value 2
00000000
0050
4
r/w
Value 3
00000000
0054
4
r/w
Value 4
00000000
0058
4
r/w
Value 5
00000000
005C
4
r/w
Reserved
00000000
0060
1
r/w
Receive Status Register
Bit 0: 1 = Executed Object Transfer
Bit 1: 1 = CRC Error
Bit 2…7: Reserved
00
0061
1
r/w
Reserved
00
0062
1
r/w
Digital In/Out Byte
00
0063
1
r/w
Transmit Control Byte
00
0064
4
r/w
Object Value
00000000
0068
4
r/w
Value 6
00000000
006C
4
r/w
Value 7
00000000
0070
4
r/w
Value 8
00000000
0074
4
r/w
Value 9
00000000
0078
4
r/w
Value 10
00000000
007C
4
r/w
Reserved
-
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Axis 3
0080
1
r/w
Transmit Execution Register
Bit 0: 1 = Start Object Transfer
Bit 1: 1 = Repeat Object Transfer
Bit 2: 1 = Enable Value 3-5
Bit 3…7: Reserved
00
0081
1
r/w
Reserved
00
0082
1
r/w
Drive Control Byte
00
0083
1
r/w
Object Address
00
0084
4
r/w
Object Value
00000000
0088
4
r/w
Value 1
00000000
008C
4
r/w
Value 2
00000000
0090
4
r/w
Value 3
00000000
0094
4
r/w
Value 4
00000000
0098
4
r/w
Value 5
00000000
009C
4
r/w
Reserved
00000000
00A0
1
r/w
Receive Status Register
Bit 0: 1 = Executed Object Transfer
Bit 1: 1 = CRC Error
Bit 2…7: Reserved
00
00A1
1
r/w
Reserved
00
00A2
1
r/w
Digital In/Out Byte
00
00A3
1
r/w
Transmit Control Byte
00
00A4
4
r/w
Object Value
00000000
00A8
4
r/w
Value 6
00000000
00AC
4
r/w
Value 7
00000000
00B0
4
r/w
Value 8
00000000
00B4
4
r/w
Value 9
00000000
00B8
4
r/w
Value 10
00000000
00BC
4
r/w
Reserved
-
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Axis 3 – Telegram Type 2 (Fast Axis)
00C0
1
w*
Transmit Execution Register
Bit 4 : 1 = Enable Telegram Typ 2
Bit 5 : 1 = Direct Access
00
00C1
1
w*
reserved
00
00C2
1
w*
Drive Control Byte
00
00C3
1
w*
reserved
00
00C4
4
w*
Value 3
00000000
00C8
4
w*
Value 4
00000000
00CC
4
w*
Value 5
00000000
00D0
16
-
reserved
-
00E0
1
r/w
reserved
00
00E1
1
r/w
reserved
00
00E2
1
r/w
Digital In/Out Byte
00
00E3
1
r/w
Transmit Control Byte
00
00E4
4
r/w
Value 8
00000000
00E8
4
r/w
Value 9
00000000
00EC
4
r/w
Value 10
00000000
00F0
16
r/w
reserved
-
For additional addressing, see the VARAN bus specifications
More addressing applications can be found in the DIAS drive parameter
documentation.
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7.8 Recommended Shielding for VARAN
The real-time VARAN Ethernet bus system exhibits a very robust quality in harsh industrial
environments. Using IEEE 802.3 standard Ethernet physics, the potentials between an
Ethernet line and sending/receiving components are separated. In the event of an error, the
VARAN Manager resends messages to a bus participant immediately. The shielding
described below is principally recommended.
For applications in which the bus is run outside the control cabinet, the correct shielding is
required. Especially when for structural reasons, the bus line must be placed next to strong
electromagnetic interference sources.
SIGMATEK recommends the use of CAT5e industrial Ethernet bus cables.
For the shielding, an S-FTP cable should be used.
It is a symmetric, multi-wire cable with unshielded pairs. For the total shielding, a
combination of foil and braiding is used. A non-laminated variant is recommended.
The VARAN cable must be secured at a distance of 20 cm from the connector to
protect against vibration!
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7.8.1 Wiring from the Control Cabinet to an External VARAN Component
If the Ethernet lines are connected from a VARAN component to a VARAN node located
outside the control cabinet, the shielding should be placed at the entry point to the control
cabinet housing. All noise can then be dissipated before reaching the electronic
components.
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7.8.2 Wiring Outside of the Control Cabinet
If a VARAN bus cable must be placed outside of the control cabinet only, no additional
shield support is required. This requires that only IP67 modules and connectors be used.
These components have extremely robust and noise-resistant construction. The shielding
for all sockets in IP67 modules are internally connected to common bus or electrically
connected to the housing, whereas the dissipation of voltage spikes does not flow through
the electronics.
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7.8.3 Shielding for Wiring within the Control Cabinet
Sources of strong electromagnetic noise located within the control cabinet (drives,
Transformers, etc.) can induce interference in a VARAN bus line. Voltage spikes are
dissipated over the metallic housing of a RJ45 connector. Noise is conducted over the
control cabinet without additional measures needed on the circuit board of electronic
components. To avoid error sources with data exchange, it is recommended that shielding
be placed before any electronic components in the control cabinet.
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7.8.4 Connecting Noise-Generating Components
When connecting power components to the bus that generate strong electromagnetic
noise, it is also critical to ensure correct shielding. The shielding should be placed before a
power element (or a group thereof).
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7.8.5 Shielding Between Two Control Cabinets
If two control cabinets must be connected over a VARAN bus, it is recommended that the
shielding be located at the entry points of each cabinet. Noise is therefore prevented from
reaching the electronic components in both cabinets.
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Documentation Changes
Change date
Affected
page(s)
Chapter
Note
27.05.2014
19
20
Added leakage currents notice
Added shelf life notice
17.07.2014
16 Max. holding brake switching energy added
30.04.2015
45 Sine/Cosine & TTL Encoder feedback changed
08.05.2015
34 main input DC-link
25.11.2015
1 VAC 013 note
08.02.2016
Document
AWG corrected
Shielding Plate extended
VAC 013 documentation added
23.05.2016
16 Limitation 599 Hz
21.11.2016
67, 69,
75, 76
Removed EN / IEC 61508
31.05.2017
16 max. standstill current added
19.07.2017
9 Added note regarding the star-connection
27.09.2017
7 Added warning regarding EMF
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