Unitek DS-405.2, DS-412.2, DS-400.2 Series, DS-420.2 User Manual
Hans-Paul-Kaysser-Straße 1
Ausgabe / Version
71397 Leutenbach-Nellmersbach
04/2019 - V01
Tel.: 07195 / 92 83 - 0
Fax: 07195 / 92 83 - 129
contact@unitek.eu
www.unitek.eu
M A N U A L
Digitale three-phase Servo Amplifier
DS-400.2
for EC/AC-Servo Motors
Basic information
1
04/2019 - V01
DS 400.2
1 Contents
2 Basic information ....................................................................................................................... 3
2.1 History ................................................................................................................................ 3
2.2 Further UNITEK products ................................................................................................... 3
2.3 Engineering instructions (MANUAL) .................................................................................. 3
2.4 Validity ................................................................................................................................ 4
2.5 Designations and symbols .................................................................................................. 4
2.6 Scope of delivery ................................................................................................................ 4
2.7 General product information ............................................................................................. 5
2.8 Application/build/features ................................................................................................. 6
2.9 Safety regulations ............................................................................................................... 8
2.10 Commissioning ................................................................................................................. 10
2.11 Safety advices ................................................................................................................... 11
2.12 Intended applications ....................................................................................................... 12
2.13 Regulations and guidelines .............................................................................................. 13
2.14 Risks .................................................................................................................................. 14
2.15 Technical data .................................................................................................................. 15
3 Mechanical Installation ............................................................................................................ 18
3.1 Important advices ............................................................................................................ 18
3.2 Dimensions DS 405 – DS 420 ............................................................................................ 19
3.3 Dimensions - accessories.................................................................................................. 20
3.4 Installation ........................................................................................................................ 21
4 Electrical installation ................................................................................................................ 22
4.1 Important advice .............................................................................................................. 22
4.2 Circuit diagram ................................................................................................................. 23
4.3 Connection diagram ......................................................................................................... 25
4.4 Connections DS405.2, DS412.2, DS420.2 ......................................................................... 26
4.5 Connectors DS405.2/DS412.2/DS420.2 ......................................................................... 27
4.6 EMC .................................................................................................................................. 28
4.7 Mains connection ............................................................................................................. 29
4.8 Pre-charging ..................................................................................................................... 31
4.9 Auxiliary voltage connection ............................................................................................ 32
4.10 Motor connection ............................................................................................................ 33
4.11 Ballast circuit DS405 / DS412 / DS420 ............................................................................. 34
4.12 Ballast – dimensioning ..................................................................................................... 35
5 Control connection ................................................................................................................... 36
5.1 Digital input ...................................................................................................................... 36
Basic information
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2
5.2 Safety input RFE (rotating field enable) Stopp-Class 0 ..................................................... 37
5.3 Digital outputs (open emitter) ......................................................................................... 38
5.4 Serial interface RS 232 ...................................................................................................... 40
5.5 CAN-BUS ........................................................................................................................... 41
5.6 Resolver connection ......................................................................................................... 42
5.7 Encoder TTL connection ................................................................................................... 43
5.8 SIN COS 1Vss CONNECTION .............................................................................................. 45
5.9 Rotor position encoder – connection via a bl-tacho ....................................................... 46
5.10 X8 TTL-Encoder output or input (2) .................................................................................. 47
5.11 X8 as TTL Encoder output ................................................................................................. 48
5.12 Display .............................................................................................................................. 49
5.13 Error display on the servo ................................................................................................ 50
5.14 Warning signals ................................................................................................................ 51
6 Warranty .................................................................................................................................. 52
6.1 Warranty .......................................................................................................................... 52
Basic information
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DS 400.2
History
Version
Modification
Date
04/2013 - V04
new English version
13.06.2013
04/2013 - V05
drawing news, fault list
Nov 2013
04/2019 - V01
CAN BUS data / Inrush Limiter updated
April 2019
Digital servo-amplifiers for small power values
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DPCxx
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Analog dc servo-amplifiers
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Series Classic
200W to 800kW
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Series BAMOBIL
Series BAMOCAR
1.
MANUAL
DS xxx
Hardware
2.
MANUAL
NDrive2
Software
3.
MANUAL
DS, DPC
Commissioning Troubleshooting
2 Basic information
2.1 History
2.2 Further UNITEK products
2.3 Engineering instructions (MANUAL)
Use all three MANUALs for the engineering, the installation, and the commissioning!
CD (UNITEK-DOKU-SOFT) supplied with the delivery of the units.
Online: www.unitek-online.eu
The hardware MANUAL comprises warning and safety advices, explanations of standards,
mechanical and electrical installation advices.
The MANUAL must be available for all persons who are concerned with the unit.
Basic information
DS 400-2
04/2019 - V01
4
Validity
Hardware state:
Firmware state:
Manufacturers or operators of machines or installations in the industrial
2.4 Validity
2.5 Designations and symbols
Unit DS xxx (BDM)
User:
Manufacturer: UNITEK Industrie Elektronik GmbH
sector (B2B, secondary environment)
Dealer:
2.6 Scope of delivery
Caution - Danger to life!
High voltage
Warning!
Important
Dangerous electric fields
Divece DS405-x, DS412-x or DS420-x
documentation DS400, NDrive, CD Unitek-Docu-Soft
Connector plug Phönix 10pin. and 11pin.
D-connector X7 15pin., X8 9pin
In the shipping container
Not in the delivery
D-connectorr X9, X10 9pin.
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DS 400.2
General product information
2.7 General product information
The digital 3-phase current servo amplifiers DS/DPC xxx as component (BDM) in combination with
the synchronous servo motor (EC motor) or the asynchronous servo motor (ac motor) provide a
drive solution (PDS) free of maintenance and with a wide dynamic control range.
The drive displays the well-known good control characteristics of dc drives without the
disadvantages of the carbon brushes' wear and the commutation limits.
For synchronous motors the generated heat in the motor only occurs in the stator, the rotor
remains cold. The motors can easily be cooled via the surface (efficiency up to 96%).
The physical characteristics correspond to those of dc motors, i.e., the current is proportional to
the torque and the voltage is proportional to the speed. The speed is steadily controlled up to the
current limit (max. torque. In case of an overload the speed drops and the current remains
constant.
The speed/torque characteristic is rectangular.
Current, speed, and position are precisely measured. The field frequency is not controllable, it is
automatically adjusted.
The rotor moment of inertia is notably smaller and the limiting performance is higher which
results in up to 5 times higher acceleration values.
Asynchronous servo motors are less expensive and do not require solenoids in the rotor.
The control characteristics are very good due to the space-vector control, the performance and
the efficiency are lower. Due to the heated rotor it is necessary to use a motor fan for large
control ranges.
The EC and ac motors have the protection rating IP65.
The motor voltages and the motor currents are sinusoidal. A maximum motor efficiency is
achieved by means of a compensating current control.
DS/DPCxx drives can be used as single-axis position amplifiers or torque or speed amplifiers.
The position and speed actual value is generated in the encoder unit (resolver, incremental, or
SIN/COS encoder). The encoder pulses are emitted from the amplifier for a superordinate
PLC/CNC control.
The control circuits of current, speed, and position are PID controllers which are easy to program.
They can be programmed by means of the PC Software NDrive2.
The communication with superordinate controls is effected by means of BUS systems (standard
CAN-BUS, RS232) or by analogue interfaces.
Note:
For dc, ac, or EC servo amplifiers which are supplied by a bus circuit, it must be checked that the
energy is fed back into the bus during brake operation (lift drives, winding machines, great
centrifugal masses).
An internal or possibly external ballast resistor is necessary.
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Application/build/features
2.8 Application/build/features
Application in machines and installations for all types of industrial use with a drive power of
13.5 kW under hard application conditions especially as 4Q-servo-drive
- highly dynamic acceleration and braking cycles
- a wide control range
- a high efficiency
- small motor dimensions
- a uniform, accurate and smooth running
For speed or torque control or combined speed/torque control incorporated within or
independent of position control loops.
Suitable for:
Machines and installations
as well as component inserting machines, testing machines, sheet-metal working machines,
machine tools, plastic working machines, assembly machines,
knitting and sewing machines, textile working machines, grinding machines,
wood and stone working machines, metal working machines, food processing machines, robots
and handling systems, conveyors, extruders, calenders, and many other machines and
installations for industrial applications.
Build:
- Robust units for switch cabinet mounting, steel housing,
according to the VDE, DIN and EC regulations,
protection rating IP20, VGB4
- Standard digital control electronics
- Power electronics of 5 and 20 A (S1 operation)
- Power input voltage 30V~ to 480 V~ (40 V= to 500 V=)
- Independent 24 V chopper power supply unit for the internal auxiliary voltages
Galvanic isolation
- between the housing and all electric parts
- between the auxiliary voltage connection and the power section and the control electronics
- between the power section and the control electronics
- between the control electronics and the logic inputs/logic outputs
The distance of air gaps and leakage paths adhere to the EU standards.
Components used:
- completely isolated IGBT power semi-conductors, comfortably over-dimensioned
- only components customary in trade and industrially standardised are used
- SMD equipment
- LED displays , 7-segment displays
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Application/build/features
Features:
EMC protected steel housing
Shock and vibration-proof build
Direct mains connection 230 V~ to 480 V~
Independent auxiliary voltage connection 24 V=
Digital interfaces RS232, CAN-BUS (further option)
Analog inputs, programmable differential inputs
Digital inputs/outputs, programmable, optically de-coupled
Output for brake 24 V/3 A with load watchdog
logic for enable and the output stage switch, emergency stop function, safety
BTB ready for operation, solid state relay
Position, speed and torque control
Encoder systems: resolver, TTL incremental encoder, SINCOS 1Vss, rotor position
Encoder output
Static and dynamic current limiting
Uniform, completely digital control unit
Intrinsically safe and short-circuit proof power section (EN50178)
Anti-interference choke in the bus circuit
Integrated ballast circuitry
DC power bus
Processor-independent hardware switch-off in case of short-circuits, circuits to earth, over-
voltage, under-voltage, and over-temperature of the amplifier or the motor
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Safety regulations
Caution - High voltage
Discharge time of the bus circuit > 4 min!
2.9 Safety regulations
Electronic equipment is not fault proof!
> 900V AC/DC ~/=
Shock hazard! / Danger to life!
Before installation or commissioning begins, this manual must be thoroughly read and
understood by the skilled technical staff involved. It must be ensured that the documentation
(manuals) and thus, the knowledge of the unit and especially the safety advices must be available
for all persons who are concerned with the unit
If any uncertainty arises or if any function is not or not sufficiently described in the
documentation, the manufacturer or dealer should be contacted.
Any incorrect installation/connection may damage the device!
Any incorrect programming may cause dangerous movements!
Intended applications:
The devices of the DSxx series are power electric parts used for regulating energy flow.
They are designed as components (BDM) to control EC synchronous motors and ac asynchronous
motors in stationary machines or installations for industrial applications.
For applications in residential areas additional EMC measures are necessary.
Any other type of application must be approved by the manufacturer.
The user must draw up a hazard analysis for his end product.
Protection rating IP20 for stationary switch cabinet mounting.
Power supply connection only to an earthed three-phase current system!
Protective conductor PE must be firmly connected!
Operation only allowed when the switch cabinet is closed or
locked!
The control and power connections may be voltage-carrying
without the axis operating!
The discharge time of the bus circuit is superior to 4 min!
Measure the voltage before any disassembly!
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DS 400.2
Safety regulations
The user must ensure that in the event of:
It must also be ensured that the machines, equipment, or
movements at any time!
During operation the switch cabinet must be closed and the
The user must draw up a hazard analysis for his machine, vehicle, or installation.
- device failure
- incorrect operation,
- loss of regulation or control
the axis will be safely de-activated.
vehicles are fitted with device independent monitoring and
safety features.
The user must take appropriate measures so that man as well as
property are not exposed to danger due to incorrect or improper
safety systems must be enabled.
When the switch cabinet is open and/or the safety systems are
de-activated, it must be ensured by the operator that only skilled
and suitably trained personnel has access to the units.
Assembly
- should only be carried out when all voltages have been removed and the units are secured
- should only be carried out by suitably trained personnel
Installation
- should only be carried out when all voltages have been removed and the units are secured
- should only be carried out by suitably trained personnel for electrics
- should only be carried out in accordance with health and safety guidelines
Adjustments and programming
- should only be carried out by suitably trained personnel with knowledge in electronic drives and
their software
- should only be carried out in accordance with the programming advice
- should only be carried out in accordance with health and safety guidelines
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Commissioning
2.10 Commissioning
The servo amplifiers DS4xx (BDM) are components of the electronic drive technology. They are
functional only in connection with an electrical consumer (e.g. a motor). Their use is limited for
industrial, commercial applications.
When mounting the units into machines and installations the proper operation of the units may
not be started until it is ensured that the machine, the installation, or the vehicle comply with the
regulations of the EC machinery directive 2006/42/EG and the EMC guideline 2004/108/EG.
On the installation and test conditions described in the chapter 'EMV advices' it is adhered to the
EC guideline 2004/108/EG including the EMC standards EN61000-2 and EN61000-4.
For applications in residential areas additional EMC measures are necessary.
A manufacturer's declaration can be requested.
The manufacturer of the machine or installation is responsible for observing the threshold values
demanded by the EMC laws.
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Safety advices
2.11 Safety advices
Machinery directive
The manufacturer of the machine or installation must draw up a hazard analysis for his product.
He must make sure that any unpredictable movements do not cause damage neither to persons
nor to property.
Skilled personnel
Hardware
The skilled qualified personnel must feature a training and instruction for an assignment in the
field of electronic drive engineering. They must have knowledge of the standards and accident
prevention regulations for drive engineering applications and they must be familiar with this field
of activity. Eventually occuring dangerous situations are realized.
The local regulations (IEC, VDE, VGB) are known to the qualified personnel and they are observed
during the works.
Software
The skilled qualified personnel for handling the software must be trained to safely program the
units in the machines and installations. Incorrect parameter settings may cause improper and
impermissible movements. Any parameter settings have to be checked for faulty operation.
Acceptance tests must be thoroughly carried out according the four-eyes principle
Working environment
Incorrect handling of the units may cause damage to persons or property.
When operating the units the switch cabinet must be closed and the safety systems must be
enabled! Exceptions to this are the first commissioning or if switch cabinet repair works have to
be carried out by the skilled qualified personnel.
Any unit covers must not be removed!
Disconnect the power supply prior to any works on electric connections and safeguard the switch
cabinet against switching-on.
Any voltages and residual voltages (buffer circuit) must be measured prior to any works on the
unit. Max. permissible voltage <42 V.
High temperatures > 70°C may arise.
The working environment may be dangerous for persons having electronic medical aids or
appliances (e.g. cardiac pacemakers). Sufficient distance to these electrical parts must be
observed.
Exposure
During transport and storage the prescribed and specified climatic conditions must be adhered to.
The units must not be mechanically damaged. Warped and bent housing parts may influence or
damage the isolation distances. Damaged units must never be installed!
The units comprise parts which may be damaged by electrostatic discharge. The general
recommendations for handling electrostatic devices must be observed. Special attention should
be paid to strongly isolating plastic films and synthetic fiber.
For the operation it must be ensured that the environmental conditions in the switch cabinet are
adhered to. This applies in particular to the impermissible condensation on the units.
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Intended applications
2.12 Intended applications
The devices are designed as components (BDM) to control EC synchronous motors and ac
asynchronous motors in stationary machines or installations.
Any other type of application must be approved by the manufacturer.
Protection rating IP20.
It is only allowed to install the units in stationary switch cabinets or machine frames which are
similar to switch cabinets. Industrial site of operation only.
For applications in residential areas additional EMC measures are necessary.
The user must draw up a hazard analysis for his end product.
Power supply connection only to the earthed TN three-phase current system with a maximum
three-pase voltage of 480V~ (max. 280 V~, phase - N (PE)). For any other types of power supply
(IT, TT power supply) matching transformers have to be installed.
Voltage peaks must not exceed 1000 V between the phase conductors and they must not exceed
2000 V between the phase conductors and the housing.
The capacities between the clocked power modules (converter, motor, filter) result in high
leakage currents. It is necessary to provide a safe and screwed earthing on the switch cabinet and
the motor. Protective earth conductors must comply with the standards EN 50178, EN61800-5-1,
and IEC 364.
Bad protective earth conductors are highly hazardous for health and life.
Protective parts for earth leakage (earth leakage circuit breakers) must be ac/dc sensitive and
designed and rated according to the standards EN 50178.
For emergency battery connection it must be borne in mind that the battery voltages are at
power supply voltage. All safety regulations regarding direct power supply connections must be
observed (protection against accidental contact with exposed parts, short-circuit protection, etc.).
The control connections of the unit (terminals X1, pins X7, X8, X9, X10) adhere to the 'safe
electrical isolation SELV' according to the standard EN 61800-5-1. The user must ensure that the
complete control wiring complies with the standards.
It must be paid attention to the equipotential bonding for components which are connected to
the unit and which do not have isolated inputs and outputs (equalizing connection GND). The
equalizing currents may destroy components and parts.
When measuring the isolation the units must be disconnected or the power connections must be
bridged together and the control connections must be bridged together. Non-observance will
cause damage to the semi-conductors in the unit.
Repeating circuits to earth and short circuits the values of which are all below the response
threshold for short circuits may cause damage to the output stages (conditionally short-circuit
proof acc. to standard EN 50178, EN61800-5-1).
Impermissible applications
- in life-sustaining medical devices or machines
- across unearthed or asymmetrical power supplies
- on ships
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Regulations and guidelines
EU Guidelines
2004/108/EG, 2006/95/EG, 2006/42/EG, 2002/96/EG
EU Standards
EN60204-1, EN292, EN 50178, EN60439-1, EN61800-3,
ECE-R100
International standards
ISO 6469, ISO 26262, ISO 16750, ISO 20653, ISO 12100
IEC/UL Regulations
IEC 61508, IEC364, IEC 664, UL508C, UL840
VDE Regulations and
TÜV Regulations
VDE 100, VDE 110, VDE 160
Regulations of the statutory accident
insurance and prevention institution
VGB4
Standard
Description
Version
EN 60146-1,-2
Semiconductor converters
2010
EN 61800-1,-2,-3
Speed-variable electrical drives
2010
EN 61800-5-1
Electric power drive systems - safety
2010
EN 60664-1
Isolation coordinates - low voltage
2012
EN 61010
Safety regulations - control units
2011
EN 61508-5
Functional safety of electric, electronic systems
2011
EN 60068-1,-2
Environmental influences
2011
ISO 20653
Type of protection of the electrical equipment of vehicles
ECE-R100
Conditions for battery-driven electric vehicles
UL 508 C
UL Regulations - converter
2002
UL 840
UL Regulation - clearance and creepage distances
2005
Standard
Description
Version
EN 60204
Safety and electrical equipment of machines
2011
EN 50178
Equipment of power plants
1998
EN 61800-3
Speed-variable electric drives - EMC
2010
EN 60439
Low voltage switching device combinations
2011
EN 1175-1
Safety of electric industrial trucks
2011
ISO 6469
Electric road vehicles
2009
ISO 26262
Functional safety of electric road vehicles
2011
ISO 16750
Elektrical components - vehicles
2010
ISO 12100
Safety of machines
2011
ISO 13849
Safety of machines and controls
2011
IEC 364
Protection against electric shocks
2010
IEC 664
Isolation coordinates - low voltage
2011
- in explosive environments
- in environments with acrid fumes
2.13 Regulations and guidelines
The device and its associated components can only be installed and switched on where the local
regulations and technical standards have been strictly adhered to:
EU standards and regulations observed for the components of the unit
EU standards and regulations which must be observed by the user
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Risks
2.14 Risks
The manufacturer aims to keep the remaining risks emanating from the unit
as low as possible by means of constructive, electrical, and software measures.
In the field of drive engineering the following known remaining risks must be
considered regarding the risks arising from machines, vehicles, and installations.
Impermissible movements
caused by:
• failure of safety watchdogs or switched-off safety watchdogs during commissioning or
repair works
• software errors in upstream controls, errors in bus systems
• non-monitored hardware and software errors in actuating elements and connecting
cables
• inverted sense of control
• faults during the parameter setting and wiring
• limited response time of the control features. Ramps, limits
• operations not permitted in the specifications
• electromagnetic interferences
• electrostatic interferences, lightning strikes
• failure of components
• failure in the brakes
Dangerous temperatures
caused by:
• faults during the installation
• faulty connections, bad contacts, aging
• faults in the electric safety system, incorrect types of fuses
• operations not permitted in the specifications
• negative climatic conditions, lightning strikes
• failure of components
Dangerous voltages
caused by:
• faulty earthing of the unit or motor
• faulty connections, bad contacts, aging
• faulty potential isolation, failure of components
• conductive contamination, condensation
Dangerous fields
The units, the inductive and capacitive accessories as well as the power wiring can
generate strong electric and electromagnetic fields. These fields may be dangerous
for persons having electronic medical aids or appliances (e.g. cardiac pacemakers).
Sufficient distance to these electrical parts must be observed.
The switch cabinet must be labeled accordingly.
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Technical data
up to 1 kW
up to 18 kW
1/3 x 30 V~ to 480 V~
3 x 30 V~ to 480 V~
+10 % 50/60 Hz
+10 % 50/60 Hz
24 V= ±10 % / 2A residual ripple < 10 %
regenerating fuse
Data
Unit
DS-405.2
DS-412.2
DS-420.2
Supply voltage - rated value
Max. power loss
Clock frequency
Input fuse
Switch-off integral
A
A²s
10
150
20
200
40
300
Dimensions h x w x d
mm
320x85x190
Size 2 2 2
Control signals
V
A
Funktion
ON
OFF
10-30
<6
0.010
---
optically decoupled
optically decoupled
optically decoupled
optically decoupled
optically decoupled
2.15 Technical data
Power supply connection DVC
Auxiliary voltage connection EVL
V~ 3x400 (480)
Max. output voltage - rated value V~eff 3x390( (470)
Bus circuit voltage V= 560 (675)
Max. connection power S1 kVA 3.4 8.2 14
Max. power output S1 kW 3 7.5 13.5
Permanent current Aeff 5 12 20
Max. peak current Alo 10 24 40
W 80 150 250
kHz 8
Ballast switch-on voltage V= 750 ± 10
Over-voltage switching threshold V= 860 ± 10
Min. external ballast resistance Ω 8 51 40
Weight kg 3 3 3
Installation pattern mm 100
Analog inputs ± 10 0.005 differential input
Digital inputs
Digital outputs +24 0.03
Resolver differential input
Encoder input >3.6V
Encoder output >4.7
CAN interface
RS232 interface 115200 (or 9600) Baud
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