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

[e-mail]

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

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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

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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

>>>

UNITEK

DS205, DS403,
DPCxx

Analog three-phase servo-amplifiers
TVD3, TVD6, AS

>>>

UNITEK

Series

Analog dc servo-amplifiers
TV3, TV6, TVQ6

>>>

UNITEK

Series

Thyristor current converters
1Q, 4Q, Servo

>>>

UNITEK

Series Classic
200W to 800kW

DC and ac servo-amplifiers for battery operation
A2, A3, D3

Series BAMO

Analog and digital

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

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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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DS 400.2

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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DS 400.2

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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Technical data

Ambiant conditions

Protection rating

IP20, VGB4

Standards

EN60204, EN61800, IEC60146

Protection rating

Power protection class I (with PE firmly connected)

(protection - low voltage)

Over-voltage

Class 2 (EN61800-5-1)

Operating temperature range

0 to +45°C

Extended operating temperature range

from +45°C to +60°C performance reduced by 2 %/°C

Storage and transport

-30°C to +80°C EN60721

Site of installation

≤ 1000m above sea level 100 %,
>1000m performance reduced by 1.5 % / 100 m

Cooling

Internal ventilator

Mounting position

vertical, performance reduced by 20 % when
mounted horizontally

Contamination

Contamination degree 2 acc. to EN61800-5-1

Oscillation

10 Hz to 58 Hz amplitude 0.075 mm (IEC 60068-2-3)
58 Hz to 200 Hz 1g

Shock

15 g for 11ms

Environmental conditions

Not permissible:

spray, water

Humidity range

class 3K3 humidity < 85 %

no condensation allowed!

DS4/Strom-reduktion-Höhe-2

DS4/Strom-reduktion-IGBT-Taktfrequenz

Electronics protection class III

Stromreduktion Umgebung

condensation (dew), ice formation, oil mist, salt

DS4/Strom-reduktion-Umgebung-Temperatur-2

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Technical data

Blank page (for printing reasons)

Mechanical Installation

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Important advices

3 Mechanical Installation

3.1 Important advices

Pay attention to the ESD advices.
Blank mounting surface, no lacquer (EMC surface-to-surface contact)
The unit must be safely protected in the switch cabinet against mist and water and the intrusion
of metallic dust.

Check the device for mechanical damage.
Only devices in perfect working order can be mounted.

Disconnect the power supply prior to any assembly.

For installations connected to an electric power supply install the
shorting plug and affix the warning signs.
The device must only mounted by suitably trained personnel.

Vertical mounting position.
Please note that there will be a performance reduction when the devices are mounted
horizontally.

Ensure that there is enough space for the discharged ventilation air (min. 100mm).

Any bore hole dimensions for the fixation of the device must be taken from the dimension
diagrams or from the drilling plan, not from the device.
Drill the mounting bore holes into the mounting plate.
Insert the device and fasten the screws.

Note: Protect the device against intrusion of foreign particles (bore chips, screws, etc.)!

The filter and the choke have to be mounted near to the device

The line shields and the mounting plate must have surface-to-surface contact.
Unshielded cable heads must be kept as short as possible.

Braking resistors may become very hot (200°C).
Install the resistors such that neither persons will be injured (burns) nor
damage will occur due to the heat.

Use vibration-proof screw connections.

Inside temperature of the switch cabinet: max. 45°C

For internal mounting ensure that the switch cabinet ventilation is sufficient.
Use an air conditioning unit if the room temperatures are too high (>30°C).

Note: The operation of bedewed devices is not permissible.

Mechanical Installation

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Dimensions DS 405 – DS 420

3.2 Dimensions DS 405 – DS 420

Size 2:

DS405.xx bis DS420.xx

Mounting depth: without connector 190 mm
with connector max. 250 mm
Fixing screws: M5x10 (recommended DIN 912)

DS/DS-400-2-publi

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Dimensions - accessories

EMV-Filter

Type

Voltage

Current

Dimensions

Weight

V~

A~

HxBxT mm

kg

F250-V-B90-16

1x250

1x16

45x90x40

0,4

F400-V-B108-16

3x480

3x16

90x140x55

0,8

F400V-B150-25

3x480

4x25

130x180x80

2,4

Moto choke

DS/DS-400-Drossel

Type

Voltage

Induction

Dimension

Weight

A mH

HxBxT mm

kg

MDD 1.6a-5

5

1.9

95x54x108

MDD 1.6b-10

10 1 95x58x108

MDD 2b-20

20

0.8

128x80x140

Regenerative discharge resistor in IP65
protection standard aluminium housing

Weight 1.1 kg
mounting screws M5x12

Caution:

The ballast resistor can get as hot as 200°C. Protect

BAWID-300-996

3.3 Dimensions - accessories

In residential and commercial areas or unknown locations.

DS/DS-400-Filter1 Grounding on case back

Filters at high EMC requirements.

Mount filter directly on the device.

Bus filter and input filter capacitors

are installed in the device.

Motor choke only for cable - shield capacitances > 5 nF.

Cable length approx. 25 m.

the resistor against accidental touch when installing it.
Do not place any heat-sensitive components
directly at the resistor or in the hot airflow.
Mount resistor outside

Mechanical Installation

21

04/2019 - V01

DS 400.2

Installation

Installation instruction

DS-400-schrank2-block

Recommended fixing screw
DIN 912 M5x12 with safety washer

Bore the threaded M5 holes at a right angle

Turn in the M5x12 screws.

approx. 4 mm.

Enough space for the discharged ventilation air
Power line

size 1

size 2

signal line

Signal line

3.4 Installation

DS-400-montage-2

Supply air temperature 0 to max. 45°C

In order to achieve good EMC values, it is recommended to use bright, unpainted
mounting plates. The bright surface of the device's rear panel ensure a good surface-to­surface contact.

The signal lines and the power supply lines must be routed in separate trunkings with rectangular
crossings (spatial separation of the disturbance coupling).

distance of 312 mm

Distance to the rear panel of the switch cabinet

Position the upper edge of the device (1) and
push it up against the stop (2). Then push the
lower part of the device against the switch
cabinet's rear panel (3) and lower it (4).

Fasten the screws.

Electrical installation

DS 400-2

04/2019 - V01

22

Important advice

Adhere to:

4 Electrical installation

4.1 Important advice

The order of the connections to the connector or terminal numbers is obligatory.
All further advice is non-obligatory.
The input and output conductors may be altered or
supplemented in accordance with the electrical standards
and guidelines.

- connection and operating instructions

- local regulations

- EU EG regulations such as the 2006/42/EG machine directive

- VDE and TÜV regulations and Trade body guidelines

Electrical installation should only be carried out
when all voltages have been removed!

Ensure that the device is safely disconnected from the power supply

- place the short-circuit bracket

- affix warning signs
The installation should only be carried out by suitably trained
personnel for electrical engineering.

Compare the connection data with those indicated on the type plate.

Ensure that the correct fuses have been provided for the power supply, the
auxiliary voltage, and the external ballast resistors.

Use a pre-charging circuit (UNITEK Inrush limiter).

Power supply conductors and control lines must be routed separately from each other.
Connection shields and grounding must be carried out in compliance with the EMC guidelines.
Use the correct line cross-sections.

Note: Always connect the BTB contact into the safety circuit!
Note: The PE connection must comply with the standard EN61800-5-1.

Operation without a PE-connection is not allowed!

Electrical installation

23

04/2019 - V01

DS 400.2

Circuit diagram

4.2 Circuit diagram

DS-400-blockbild-2-tms

Electrical installation

DS 400-2

04/2019 - V01

24

Circuit diagram

Circuit diagram

DS-400-blockbild-digi-1-5

Electrical installation

25

04/2019 - V01

DS 400.2

Connection diagram

1
2

6

3
4
5

7
8
9

10
11

K1

Fx

-UB
+UB

PE

L1
L2
L3

M1
M2
M3

Bin

Bex

EC

MOTOR

3

Geber

X3-1

X3-2

X3-3

X3-4

X7

X10

X9

X8

X1-1

X1-2

1
2
3
4
5
6
7
8
9
10

11
12
13
14
15
16
17
18

BTB
GND24

+24
END1
END2
FRG

GNDE

AIN2+
AIN2­DOUT3
RFE

DIN1
DIN2
DOUT1
DOUT2

AIN1+
AIN1-

INC-OUT

CAN-BUS

RS232

CAN-

MASTER

GND

System­GND

L1
L2
L3
PE

+24V
GND24

PC

COMx

DS 400.2

39

32 34

37

37

40

37

29

37

39

33

40

38

40

48

42

28

43
47

41

19
20
21

+24
AOUT
GND

Master
connector

Line
protection

Mains

filter

ext. regen
resistor

Auxiliary voltage

Mains voltage maximum 3x480V+10%

24V=

Safety
circuit

Control

Protective earth PE connection

EMC earth connections

Connector with shielded cable

Drive enable

Analog
setpoint 1

Logic GND

Logic
input

Digital
output

Analog
output

System
GND

Enable

Analog
input 1

Digital-GND

Digital
input

Digital
output

Analog
input 2

Analog
output 3

Limit
switch

Auxiliary
voltage

Ready

Detail
Page

Limit

switch

Encoder output

Counter
input

Rotation
enable
+24V

Digital
output 3

Analog
setpoint 2

Digital
output
RFE
input

Encoder input

Feedback

Feedback

Logic
input

bridge for int. regen

resistor

Inrush Limiter

Power on

tv

4.3 Connection diagram

Connections DS405.2, DS412.2, DS420.2

Zeichnungen- DS4 / E-DS-400-anschlussplan3-1

Electrical installation

DS 400-2

04/2019 - V01

26

Connections DS405.2, DS412.2, DS420.2

1

2

6

3

4

5

7

8

9

10
11

-UB
+UB

PE

L1
L2
L3

M1
M2
M3

Bin

Bex

EC

MOTOR

3

X3-1

X3-2

X3-3

X3-4

X7

PE
+24V

GND24

-UB

+UB

X3: 3, 4 ,5

+UB

-UB

Geber

X10

X9

X8

X1-1

X1-2

1
2
3
4
5
6
7
8
9
10

11
12
13
14
15
16
17
18

BTB
GND24

+24
END1
END2
FRG

GNDE

AIN2+
AIN2­DOUT3
RFE

DIN1
DIN2
DOUT1
DOUT2

AIN1+
AIN1-

INC-OUT

CAN-BUS

RS232

CAN-

MASTER

GND

PC

COMx

DS 400.2

19
20
21

+24
AOUT
GND

DC-BUS
input

DC-BUS fuses

Auxiliary voltage

DC-BUS maximal 650=

24V=

Safety
circuit

Control

Protective earth PE connection

EMC earth connections

Connector with shielded cable

Drive enable

Analog
setpoint

Logic GND

Logic
input

Digital
output

Analog
output

System
GND

Enable

Analog
input 1

Digital-GND

Digital
input

Digital
output

Analog
input 2

Analog
output 3

Limit
switch

Auxiliary
voltage

Ready

Limit

switch

Encoder output

Counter
input

Rotation
enable
+24V

Digital
output 3

Analog
setpoint 2

Digital
output
RFE
input

output
Modul

not connected

Feedback

Feedback

Encoder input

Logic
input

4.4 Connections DS405.2, DS412.2, DS420.2

For DC BUS with energy input and recovery module

E-DS-400-anschpl-MoAC-DCBus-2

Electrical installation

27

04/2019 - V01

DS 400.2

Connectors DS405.2/DS412.2/DS420.2

DC Bus

Main Power

Motor Power

Regen Resistor

11

10

7
9

8

5

3
4

6

2

1

Bin

Bex

M3

M1
M2

L3

L2

L1

PE

+UB

-UB

X3

Bex
Bin

M3

L3

M2

M1

L2

L1

PE

+UB

-UB

Earth Contact

Cannel N
Cannel B
Cannel A

GND

+5V

Encoder

output

6

7

9
8

33

M

11

22

44

5

X8

CAN-V+

CAN-H

1

3
4

FM

5

2

nc

9

8

nc

6
7

CAN-GND

nc

nc

CAN-L

nc

CAN-BUSX9

12

DIN2

AIN2­DOUT3
RFE

DOUT1

AIN2+

DOUT2

16

18

17

14
15

13

4

+24
END1/LMT1
END2/LMT2

AIN1+
AIN1-

DIN1

GNDE

FRG/RUN

8

10
11

9

6
7

5

GND24

BTB/RDY

BTB/RDY

2
3

1

X1

Resolver

Motor

Temperatur

nc
nc

nc

10
9

11

REF1

COS1

SIN2

13
12

14

15

REF2

4

M

nc

1

2

3

COS2
SIN1

Motor (GND)

Temperatur

nc
nc

nc

7
5

6

8

X7

CTS

RTS

5

GND

FM

X10

1
2

4

3

nc

nc

8
9

7

6

RS232

TX
DTR

RX

nc

RTS
CTS

GND

7

nc

9

8

3
4
5

DTR

TX

nc

6

nc

2

1

RX

RS232X10

FM

nc
nc

CAN-V+

CAN-H

3

8
9

5

4

nc
nc

7

6

2

1

nc

CAN-GND

CAN-L

CAN-BUSX9

FM

+24
AOUT
GND

input

AGND

Cannel A
Cannel B
Cannel N
Select

Ready

Auxiliary voltage
Limit Switch

Enable
Analog Input 1

Logic GND
Digital Input

Digital Output
Analog Input 2

Analog output

Digital Output
Rotation enable

further feedback connections

see page 37 to 40

Incrementel TTL, SINCOS, Rotor

4.5 Connectors DS405.2/DS412.2/DS420.2

E-DS-400-steckerübersicht-1

Electrical installation

DS 400-2

04/2019 - V01

28

EMC

After having been mounted in machines and installations the

4.6 EMC

The devices adhere to the EU guidelines 2004/108/EC and the technical standard EN 61800-3
provided that the following conditions are observed:

Mounting:

The device is conductively mounted on a 500x500x5 mm bright mounting plate.
The mounting plate must be connected to PE using a 10 mm² wire.
The motor housing must be connected to PE using a 10 mm² wire.
The device ground X-AGND must be connected to the mounting plate using a 2.5 mm² wire.
The device PE screw X:3:6 must be connected to the mounting plate using a 4 mm² line.

Connection of the control conductors:
All control conductors must be shielded. Analogue signal lines must be twisted and shielded.

Three-phase mains connection:

3 x 400 V~ with protective earth conductor

Motor connection:

Motor lines must be shielded and must have surface-to-surface contact with the earth.

operation of the device must not be started until the machine
or the installation has been approved of the regulations of the
EC machine guideline 2006/42/EC and the EMC guideline
2004/108/EC, for vehicles ECE-R83 and ECE-R100.
A manufacturer's declaration can be asked for.

Electrical installation

29

04/2019 - V01

DS 400.2

Mains connection

DS400-Netzanschluss-T-NC-Trafo

4.7 Mains connection

Connection to earthed three-phase power supply system (TN-C mains supply).
Asymmetrically earthed supply systems must be connected via an isolating
transformer!

Connection to the T-NC mains

The max. supply voltage of 528 V~ must not
be exceeded at any time (not even for short
intervals)!
Danger of damage!

F1 = device protection
safety fuses FF, F, or semi-conductor
automatic fuses

DS400-Netzanschluss-T-NC

Install an additional power line filter for high
EMC requirements.
Bus filter and input capacitors are installed.
Leakage current > 60 mA

Connection to the T-NC mains using an auto-transformer

The max. secondary voltage of the
transformer of 528 V~ must not be exceeded
at any time (not even for short intervals)!

Danger of damage!!

Slow-acting transformer fuses

F1 = device protection:
safety fuses FF, F, or semi-conductor
automatic fuses

Install an additional over-voltage protective
device for protecting against switching surges
of the transformer.

Install an additional power line filter for high
EMC requirements.
Bus filter and input capacitors are installed.
Leakage current > 60 mA.

If the supply voltage is < 30 V the output stage is electronically de-activated.

Electrical installation

DS 400-2

04/2019 - V01

30

Mains connection

Connection to the TT mains

TT-mains

Connection to the IT mains

IT-mains

Typ

AC connection

Three-phase current

3x480V +10% 50/60Hz

min.

mm2 AWG

Fuse

Drive

Power line

405

L1=X3:3, L2=X3:4, L3=X3:5

1

18

10 AFF

DL00

F250V-B90-16

412

L1=X3:3, N=X3:4

L1=X3:3, L2=X3:4, L3=X3:5

1.5

16

20 AFF

DL0

420

not possible

L1=X3:3, L2=X3:4, L3=X3:5

2.5

14

10 AFF

DL0

F400V-B150-25

PE-connection to X3:9 (Any operation without a PE connection is not allowed!)

Separating transformer

Power line filter

Separating transformer

Power line filter

Note: For power supply systems without a PE conductor please note
that the connection must be made via an isolating transformer.

Connection data

Asymmetric three or four
conductor three-phase mains
with direct earthing.

Device PE via a ground
connection

Asymmetric three or four
conductor three-phase mains
without direct earthing.

Device PE via a ground
connection.

1x30V -10% to
1x480V +10% 50/60Hz

L1=X3:3, N=X3:4

connection
3x30V -10% to

connecting
cross-section

contactor
size

filter type

F400V-B108-16

Electrical installation

31

04/2019 - V01

DS 400.2

Pre-charging

4.8 Pre-charging

Inrush current

With the first switching-on the inrush current is internally limited to a 10-fold rated current value
(approx. 2 ms) by means of a NTC resistor.
The effect persists when between switching off and switching on again a waiting time interval of
180s is adhered to. The NTC resistor is placed in the cooling air flow of the device ventilator.

Note: Always check the switching capacity K1

Fast switching off/on

If the switch off-on sequence is fast the inrush current may rise to a 30-fold higher value (1ms)

Attention:

The drive contactor K1 and the input rectifier may be damaged.

A pre-charging unit must be installed.

Pre-charging with inrush limiter

The charging current is limited to < 10 A by means of the UNITEK Inrush Limiter. The power
contactor K1 is switched on after a delay time.

Attention:

The drive contactor must not be switched
under load.
Switching on-off only when the enable is blocked.
No voltage applying across FRG/RUN (X1:7).

Electrical installation

DS 400-2

04/2019 - V01

32

Auxiliary voltage connection

Input voltage

24 V DC X1:4

GND24 X1:3

Residual ripple

10 %

Inrush current

2 A

Nominal current

0.8 A

In addition to the internal supply current (0.8 A) the sum of the

If the auxiliary voltage is inferior to 20 V - even in case of short-time

The LED signal for the state "OK" is dark.

+15L
GNDL

VCC
+15

-15
GND

100n100u100n

100n

100n

+24 DOUTx

X1:4

X1:3

X4:27,28

X4:29,30

intern

5u

+24V=

GND24

DSxx / DPCxx / BAxx

Power supply 24V=

self-resseting
fuse

DC/DC-converter

Connector X4

4.9 Auxiliary voltage connection

Mains potential-free auxiliary dc voltage 24 V= ±10 % / 2 A
The auxiliary voltage

- is galvanically connected with the logic voltage

- is galvanically isolated from all internal supply voltages of the device

- has internal regenerating fuses

- has an EMC filter

DS-BAx-DPC/E-DS-400-Hilfsspannung

External fuse only for line protection.

Attention:

output currents (DOUT) must be provided by the mains module
24 V.

voltage drop-outs - the internal mains module is switched off.
Any data of the RAM are deleted!
The speed and the position command values are set to zero
and any calibrated data are deleted.

Electrical installation

33

04/2019 - V01

DS 400.2

Motor connection

Cable

PE

M1

M2

M3

Motor cable

min. cross-section see below table

Connecting terminal

X3:6

X3:7

X3:8

X3:9

Type DS

405

412

420

Motor choke

of > 5 nF. Approx. 25 m motor cable

Cross-section mm²

1.5

2.5 4 AWG

16

14

10

Connection of the shield

4.10 Motor connection

Only electronically commutating synchronous motors (brushless dc motors, EC motors, AC
motors) must be used.
These motors must be approved of by the manufacturer prior to any use.

DS400 / DS-400-Motor-3

3-core + protective earth,
single-shielded for 600 V~, 1000 V=,

Only one correct connecting sequence is possible!!!

Attention: Any motor cable cores which are not used must be connected to earth.
Dangerous voltages due to capacitive coupling of the clocked motor cores.

DS-400-emv-motor

shield capacity = 150 pF/m

Only necessary for a shield capacity

Surface-to-surface connection
to the switch cabinet input.
Surface-to-surface connection
as short as possible to the
motor side

Use multiple shield earthing for long motor cables.

Electrical installation

DS 400-2

04/2019 - V01

34

Ballast circuit DS405 / DS412 / DS420

Type DS 405

412

420

Installed resistor

Ohm

80

51

42

Continuous power

W

50

100

Pulse power 1s

kW 1 2.5

External resistor min.

Ohm

80

51

40

Fuse F2

AF

10

16

25

-UB

+UB

BAL

X3:1

X3:2

X3:10

X3:11

F2-1

F2-2

DSxx/BAxx

Power-Modul

ext. regen
resistor

bridge
with internal
regen resistor

regen
fuses

4.11 Ballast circuit DS405 / DS412 / DS420

DS-BAx-DPC / E-DS-400-ballast-3

The energy arising during the braking operation is fed back into the dc bus circuit. The bus circuit
Elkos can store only little energy.
Any surplus of energy is transformed into heat in the ballast resistor.
The internal ballast resistance is rated for drives without centrifugal mass.

Always use external resistors for centrifugal masses or in case of uncertainties concerning the
rating.

Note:

For DS420:

Observe the motor centrifugal mass (rotor moment of inertia).
The power of the internal ballast resistance is only 100 W.
Install an external ballast resistor.

Caution: Ballast resistors may become very hot!

Electrical installation

35

04/2019 - V01

DS 400.2

Ballast – dimensioning

Dimensioning

91 x tB

Ballast resistance power

Jg

=

Motor torque and reduced load

kgm²]

Braking time

Cooling time

4.12 Ballast – dimensioning

External ballast resistance

Maximum value of the braking power

Pmax [W] = Jg x n x n

n

=

max. Speed

n

=

Speed difference

tB

=

Braking time

[min -1]

-1

[min
[s]

]

P Ballast [W] = ___Pmax___
K1 x K2

Warning:

The ballast resistor may be up to 200 ° C hot. Resistance shockproof mount. Do not place
any heat-sensitive parts directly to the resistance or heat air flow. Note enclosure
temperature rise, resistance mounted outside as possible.

Control connection

DS 400-2

04/2019 - V01

36

Digital input

DS-BAx-DPC/E-DS-400-digi-in-2

Input voltage

H-level (On)

+10 bis +30 V

L-level (Off)

<+6 V

Ratet voltage / cure

24 V/6 mA

Reference ground

GNDE

(X1:10)

Input

Connection

Function

State

FRG/RUN

X1:7

Enable

fixed

RFE

X1:18

Rotating field enable

fixed

END1/LMT1

X1:5

Output stage switch 1/Digital
input

programmable

END2/LMT2

X1:6

Output stage switch 2/Digital
input

programmable
DIN1

X1:11

Digital input 1

programmable

DIN2

X1:12

Digital input 2

programmable

X1:5 END1/LMT1
X1:6 END2/LMT2
X1:7 FRG/RUN
X1:11 DIN1
X1:12 DIN2

VCC

PAx

3k9

1k5

100nF

100nF

Digital

10...30V=

Input

DSxx/BAxx

X1:18 RFE

Digital input

Limit switch 1
Limit switch 2
Enable
Digital Input 1
Digital Input 2
Rotation-enable

(X1:E)
(X1:F)
(X1:G)
(X1:L)
(X1:M)
(X1:T)

(IP65)

+24V for the logic and the auxiliary

GNDE logic ground

5 Control connection

5.1 Digital input

6 Opto-input

Input current Max. 7,5 mA

The enable input (FRG/RUN) and the input for the rotating field enable (RFE) are fixed, they
cannot be programmed.
Without the enable FRG/RUN the servo-drive is electronically disabled (no PWM pulses).
Without the rotating field enable RFE the rotating field of the output stage is additionally
electronically disabled (2

nd

disable channel). The drive is free of torque (no holding torque).

The remaining four digital inputs can be programmed.
The inputs LMT1 (X1:5) and LMT2 (X1:6) are preferably to be used as inputs of the output stage
switch.

External voltage supply for the inputs and outputs

DS-BAx-DPC/E-DS-400-Logi

voltage

Control connection

37

04/2019 - V01

DS 400.2

Safety input RFE (rotating field enable)

Warning!

there is no mechanical brake or block provided.

from the mains power supply.

Operation with RFE input

Two-channel disable of the enable via a
Enable input FRG/RUN + rotating field

enable input RFE

Switching on

Contacts of the safety device closed.

Enable FRG/RUN 0.5s after RFE

Safety switch-off

Contacts of the safety device open:

Restart

Release the safety switching device.

enable RFE).

Operation without RFE input

The input RFE must be bridged with the
logic voltage.

If the logic voltage corresponds to the

with +24V.

Enable FRG/RUN at least 0.5s after the RFE

21

20

19

18

17

16

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

CNC/SPS

Hardware

PNOZ

Hardware

FRG / RUN

RFE

+24V=

GND24

X1

DSxx, BAxx

GNDE

GND24

+24V=

+24

GND24

Enable

Safity
Device

Enable

Rotation
enable

Logic-GND

24V- Voltage

21

20

19

18

17

16

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

CNC/SPS

Hardware

PNOZ

Hardware

FRG / RUN

RFE

+24V=

GND24

X1

DSxx, BAxx

GNDE

Enable

Safity
Device

Enable

Rotation
enable

Logic-GND

Logik - Voltage

21

20

19

18

17

16

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

CNC/SPS

Hardware

Hardware

FRG / RUN

RFE

+24V=

GND24

X1

DSxx, BAxx

GNDE

Enable

Enable

Rotation
enable

Logic-GND

Logic - Voltage

5.2 Safety input RFE (rotating field enable)

Stopp-Class 0

If the input of the enable or of the rotating field enable are
switched off, the drive is free of torque. The drive could move if

The motor conductors are not dead. Only the rotating field is
disabled. Prior to any work or maintenance on the motor or
servo-drive, the servo-drive must be completely disconnected

safety switching device.

There is no FRG/RUN signal in the 1st disable
channel to disable the PWM pulses in the
processor,
There is no RFE signal in the 2
channel to disable the PWM pulses at
the output of the processor.

Contacts of the safety device closed.
The motor can only move after a second
disable FRG/RUN (after the rotating field

supply voltage, the RFE input is bridged

signal.

nd

disable

DS-BAxDPC/E-DS-400-REF-1-1/1-2/1-3

Control connection

DS 400-2

04/2019 - V01

38

Digital outputs (open emitter)

Output voltage

ON level

max.

+24 V=

OFF level

<1 V=

Output current

nom

1 A

Output current

max.

2 A Reference voltage

+24

(X1:4)

Reference ground

GNDE

(X1:10)

DS-BAx-DPC/E-DS-400-BTB-3

Contact for

max. 48 V/0.5 A

(not short-circuit proof)

Capacitive load

max. 1 myF

Contact resistance

max. 2 Ohm

The contact is closed

means of 0.5A!

Output

Connection

Function

State

Parameter

BTB/RDY

X1:1, X1:2

ready

fixed/relay

DOUT1

X1:13

Digital output 1

programmable

DOUT2

X1:14

Digital output 2

programmable

DOUT3

X1:17

Digital output 3

programmable

DOUT4

Xx:Xx

Digital output 4

programmable

+ 24 V for logic and auxiliary voltage

X1:13 DOUT1
X1:14 DOUT2

+24

F_AUSx

100nF

24V/1A

DSxx/BAxx

X1:17 DOUT3

Digital output

Digital output 1
Digital output 2
Digital output 3

Digital
output

(X1:N)
(X1:O)
(X1:S)

(IP65)

BTB/RDY

Solid State Relais

F_BTB

100nF

X1:1

X1:2

DSxx/BAxx

Safity

Circuit

5.3 Digital outputs (open emitter)

DS-BAx-DPC/E-DS-400-digi-out-2

The logic outputs 1 to 3 are rated for 24 V and 1A (short-time: 2 A).

Signal contact "Ready BTB/RDY" (Solid state relay)/ Ready BTB / RDY

when the device is ready
for operation.
State signal via seven­segment LED display.
In case of failures the contact is open.

Always install the BTB/RDY contact in
the safety circuit!
Protect the BTB/RDY signal path by

Ready for operation opens

in case of error messages
in case of under-voltage of the auxiliary voltage (<20 V)
The message "under-voltage in the bus circuit" can be programmed. (Manual NDrive)

(red LED, open relay contact)

Observe the total current of all outputs

GNDE logic ground
_____________________

DS-BAx-DPC/DS-400-lgoiksp

Control connection

39

04/2019 - V01

DS 400.2

Digital outputs (open emitter)

Input

Connection

Basic function

Voltage

State

Parameter

AIN1+, AIN1-

X1:8, X1:9

Speed command value

+/- 10 V

prog.

AIN2+, AIN2-

X1:15, X1:16

Current limit

+/- 10 V

prog.

Differential input

AIN1+ / AIN1-

AIN2+ / AIN2-

Input resistance

70 k

Threshold voltage

± 12 V

Resolution

11Bit + sign

Output

Connection

Function

Voltage

State

Parameter

AOUT1

X2:20

measurement

±10 V

prog.

GND

X2:21

Signal zero

0 V

fixed

Sollx

REF150

10k 100k

100k 100nF

15k

10k 100k

15k

IN+

IN-

DSxx/BAxx

1.5V +/- 1.36V

analog inputs

Analoge Eingang ±10 V

DSx-BAx-DPC/E-DS-400-Ana-1-2

Features

The direction of rotation of the motor can either be changed by swapping the ± connections at
the differential input, or by means of a logic input or by programming.

The analog inputs can be assigned to different functions.

With a digital command value (RS232, x-bus) the analog input AIN1 can be programmed as
external analog speed limit and the analog input AIN2 can be programmed as external analog
current limit.

Analog output +/- 10V

The analog input can be assigned to different functions.

Control connection

DS 400-2

04/2019 - V01

40

Serial interface RS 232

The controller (D connector X10) and the serial interface (COMx) of the pc must only be

The interface is hard-coded to 115200 Baud.

Null modem connecting cable

E-DS-400-RS232-Verb-1

FM = socket

E-DS-400-RS232-FI-1

Schirm am Steckergehäuse

6

2

5

FM

4

3

7
8
9

1

6

FM

7
8
9

2

5

4

3

1

RxD
TxD

GND GND

TxD

RxD

RS232 PC

DSxx/BAxx

X10

Shield at connector housing

6

2

5

FM

4

3

7
8
9

1

6

FM

7
8
9

2

5

4

3

1

RxD
TxD

GND GND

TxD

RxD

RS232 PC

Schirm entkoppelt von X10

DSxx/BAxx

X10

2k2

2k2

1k

100n

Shield disconnected from X10

Schirm am Steckergehäuse

2

3

4

T2OU

7

8
R2IN

5

RS232

RxD

TxD

2

3

5GND

Stecker am PC

RxD

TxD

DSxx/BAxx

Connector at PC

Shield at Connector housing

5.4 Serial interface RS 232

Via the serial pc interface RS232 the device is programmed and operated during commissioning.
There is a software description in the Manual DS NDrive.

The interface is galvanically connected with

the device zero (GND/AGND).

DS-BAx-DPC/E-DS-400-rs232-2

connected using a null modem cable.
Do not use a null modem link cable!
Install the cable only after disconnecting the device from the mains.

View to the soldered side,
Shield on the housing,
Max. cable length 10m

A line filter should be installed in
case of strong interferences at the
interface.
Notebooks with a USB-RS232
converter are usually susceptible
to interference.

Control connection

41

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DS 400.2

CAN-BUS

Designation

Connector
no.

Cable colour
CAN-V+

9

brown

CAN-GND

3

white

CAN-H

7

green

CAN-L

2

yellow

CAN BUS connection with several devices

Master

Address xx

Address xx

Address xx

DS-BAx-DPC / E-DS-400-CAN-3x3

Terminating resistor at the end of the bus line > 120 Ohm between CAN-H and CAN-L

1

3
4

FM

5

2

9

8

6
7

1

3
4

FM

5

2

9

8

6
7

CAN-V+

CAN-H

1

3
4

FM

5

2

9

8

6
7

CAN-GND

CAN-L

(PE)

Schirm am Steckergehäuse

X9 X9 X9

CAN-BUS

DSxx/BAxx

DSxx/BAxx

DSxx/BAxx

120

Shield at connector housing

The BUS interface is galvanically isolated

5.5 CAN-BUS

The CAN-BUS is a digital connection to the CNC control.
Optimum conditions are achieved with CNC controls and CAN components of LABOD electronic or
CAN Open.
Programming and operation by means of the control panel via the CAN-BUS.
Interface complies with the standard ISO 11898.
Adjustment and programming see Manual DS-CAN.

from the internal device voltage.

CAN BUS cable

Use a shielded bus conductor with a low shielding capacity.
Signal plus GND.
D-connector with a metal or metallized housing.
LiYCY 4x0.25+shield.

The voltage is supplied via an internal
isolated DC-DC converter.
CAN-V +9 to 15 V=
CAN-Bus isoliert /
CAN-GND auf gemeinsames Potential
bringen.

FM=jack

Control connection

DS 400-2

04/2019 - V01

42

Resolver connection

The resolver is an absolute

Use only motors with a 2-,4-,6-, or 8-pole resolver which have been approved by the
manufacturer. Observe the motor specific connection data sheet (RS)!

Connector

X7

15-pole D-connector

Connecting cable

4 x 2 cores, twisted in pairs and shielded, additional overall shield.
For link chains use appropriate cables!

cable length

for >25m only use high-quality resolver cables with adequate shielding
properties.

Shield connection

across connector X7

combine all shields and
connect them to the housing

across the motor connector

connect the overall shield tot he
connector housing

Setting parameters

see Software-Manual DS

Steckerbelegung
Lötseite

REF1

REF2

13

4

2

15

14

3

COS2

COS1

SIN1

SIN2

REF1

REF2

10nF

10nF

2x2u2

2x2u2

1k

100nF

47

47

TEMP

Motor-Stecker
Resolver

12

6

Motor
Temperatur

REF1

REF2

SIN1

SIN2

COS1

COS2

R1

R2

S2

S4

S1

S3

DSxx/BAxx

Schirm am Steckergehäuse

Shield at connector housing

Schirm am Steckergehäuse

Shield at connector housing

Motor-connector

D-Stecker X7

D-connector X7

5.6 Resolver connection

Only for version RS

DSx-BAx-DPC/E-DS-400-Reso-anschluss-3

measuring system for a motor
revolution.
It is robust and not impaired by high
motor temperatures.
Its build corresponds to a revolving
transformer. The rotor is supplied by
the reference (10kHz). The stator
supplies the sine and cosine signals
modulated by the rotational
frequency. The amplitudes of these
signals are analyzed and digitalized in
the servo-drive. The resolution is
automatically and optimally adjusted
to 10, 12, or 14 bit.
The max. possible speed is 50 000
(10bit).
The digitalized signals are used for
the polar wheel angle, the position
and speed control, and the
incremental output.

DS/BAx/DPC - DS-400-stecker-reso

Control connection

43

04/2019 - V01

DS 400.2

Encoder TTL connection

DSx-BAx-DPC/E-DS-400-Enco-TTL-Anschluss-400

Use only motors with TTL incremental encoders and rotor position tracks which have been
approved by the manufacturer. Observe the motor specific connection data sheet (IN)!

Connector

X7

15 pole D-connector

Connecting cable

10 signal conductors, shielded

min. cross-section 0,14 mm

2 supply lines

min. cross-section 0,5 mm

For link chains use appropriate cables!

Cable length

for >25m the cross-section fot he cable used must be increased by one
grade

Shield connection

across the connector X7

connect the shield tot he
connector housing

across the motor connector

connect the shield tot he
connector housing

Setting parameter

see Software-Manual DS

Steckerbelegung

Temperatur

Motor

5

12

TEMP

Motor-Stecker

D-Stecker X7

TMS

Encoder TTL

10
VCC +5V

1

A

4

A

2

B

11

B

3

N

9

N

13

ROTOR1

14

ROTOR2

15

ROTOR3

TEMP

6

DS xx/BAxx

VCC +5V

GND

GND

4k7

VCC +5V

D-connector X7

Motor-connector

Schirm am Steckergehäuse

Shield at connector housing

Schirm am Steckergehäuse

Shield at connector housing

5.7 Encoder TTL connection

Only for Version IN

ITTL Incremental encoder (Encoder)
with 2 counter tracks and 1 zero track
plus 3 rotor position tracks. Counter
tracks with or without push-pull

.

output

Without a push-pull pulse a connecting
adapter must be used.

The counter input corresponds to
RS485.
Max. counting frequency 500kHz.

The incremental encoder is
galvanically connected with the device
zero (GND).
Supply voltage 5V is provided by the
servo.

Lötseite

DS/BAx/DPC - DS-400-stecker-encoin

Control connection

DS 400-2

04/2019 - V01

44

Encoder TTL connection

clockwise

side of motor INC-Encoder-Adapter side of device

Adapter for INC- encoder with A,B,N channel without push-pull signals

The device input for the incremental counter signals

requires the push-pull counter pulses for a reliable
detection.
Encoders without push-pull signals (e.g. position
encoders) with different supply voltages are used for
many simple applications. For these applications the INC
adapter must be installed.
The adapter converts the counter signals A, B, N to he
push-pull signals A, /A, B, /B, N, /N.

For supply voltages which differ from 5V the voltage
must be specified on order and externally be connected.

Checking the correct connection

Rotor sequence

The correct sequence of

Numerical value

Turn motor clockwise for one revolution without
enable.
One motor revolution corresponds to a position value
of Num65536. In case of different results the input of
Feedback Inc-Mot (0xa6) is incorrect.

Zero angle

Motor turning clockwise and anti-clockwise at 10%­100% speed.
The value of zero-capture must remain constant.

the rotor signals with a
motor turning clockwise is
1,3,2,6,4,5.

If the sequence of
numbers is different the
encoder connection of the
rotor position signals
Rotor1, Rotor2, Rotor3
(U,V,W) is not correct.

Use the connection
diagram!

Control connection

45

04/2019 - V01

DS 400.2

SIN COS 1Vss CONNECTION

DS-BAx-DPC/E-DS-400-SINCOS-Anschluss-3

Incremental encoder with 2 analog

Use only motors with SIN/COS encoders (SC) which have been approved by the manufacturer.
Observe the motor specific connection data sheet (SC)!

Connector

X7 15-pole D-connector

Connecting cable

4x signal conductors, twisted and shielded

min. cross-section 0.14 mm

2x signal conductors, shielded

min. cross-section 0.14 mm

4x supply lines, temp

min. cross-section 0.5 mm

Cable type

(4x(2x0,14)+(4x0,14)C+4x0,5)C
For link chains use appropriate cables!

Cable length

for >25m the cross-section of the cable used must be increased by one
grade

Shield connection

across connector X7

connect the shield to the connector
housing

across the motor connector

connect the shield to the connector
housing

Setting parameter

see software Manual DS

Steckerbelegung
M, Stiftkontakt

Temperatur

Motor

100nF

5

12

T-Motor

Motor-Stecker

D-Stecker X7

TMS

SIN/COS 1Vss

10 VCC +5V

1ka+

4ka-

TEMP

DS xx/BAxx

120

2kb+

11kb-

120

3kr+

9kr-

120

14kc+

15kc-

1000

7kd+

13kd-

1000

1k

VCC +5V

GND

6

VCC +5V

GND

GND

SF1
SF0
Faktor

D-connector X7

Motor-connector

Schirm am Steckergehäuse

Shield at connector housing

Schirm am Steckergehäuse

Shield at connector housing

5.8 SIN COS 1Vss CONNECTION

Only for version SC

sinusoidal counter tracks and 1 zero
track plus 2 commutating tracks.
Differential inputs 1Vss.

Max. counting frequency 500 kHz

The incremental encoder is galvanically
connected with device zero (GND).
Supply voltage 5 V, provided by the
servo.

The resolution is automatically adjusted
to an optimum.

Lötseite

DS/BAx/DPC – DS-400-stecker-sincos

Control connection

DS 400-2

04/2019 - V01

46

Rotor position encoder – connection via a bl-tacho

3 rotor position encoder signals (Hall sensors)

and 11. Connect the tacho center point to X7:1

Use only motors with rotor position encoders (bl) which have been approved by the
manufacturer. Observe the motor specific connection data sheet (bl)!

Connector

X7 15-pole D-connector

Connecting cable

12x signal conductors, supply lines, temp.

min. cross-section 0.25mm

For link chains use appropriate cables!

Cable length

for >25 m the cross-section of the cable used must be increased by one
grade

Shield connection

across connector X7

connect the shield to the connector
housing

across the motor connector

connect the shield to the connector
housing

Setting parameter

see software Manual
DSNDrive

Steckerbelegung

M, Stiftkontakt

13ROTOR1

14ROTOR2

15ROTOR3

6

Temperatur

Motor

100nF

5

12

T-Motor

Motor-Stecker

D-Stecker X7

TMS

Rotorlage + bl-Tacho

10 VCC +5V

2TR+

1T Mp

TEMP

DS xx/BAxx

100k

3TS+

9

100k

4TT+

11

100k

GND

+15V

GND

82k

82k

82k

82k

82k

82k

Tacho R

Tacho S

Tacho T

4k7

4k7

4k7

22k

22k

22k

4k7

Rotor U1

Rotor U2

Rotor U3

GND

VCC +5V

+15V

Rv

Rv

Rv

Rv

Rv

Rv

TR+

TR-

TS+

TS-

TT+

TT-

Adapter

13

14

15

6

5

12

10

2

1

3

9

4

11

D-connector X7

Motor-connector

Schirm am Steckergehäuse

Shield at connector housing

Schirm am Steckergehäuse

Shield at connector housing

5.9 Rotor position encoder – connection via a bl-tacho

Only for version bl

for the commutation; with or without a
brushless tacho.

The rotor position encoder is galvanically
connected with the device zero (GND).
The voltage of 15 V is supplied by the servo­drive.

Provide an adapter in case the tacho voltage at
rated speed is superior to 10 V∼.

For lower tacho voltages connect X7: pin 1, 9,

DS-BAx-DPC/E-DS400-X7-Roto

Lötseite

DS-400-stecker-rotor

Control connection

47

04/2019 - V01

DS 400.2

X8 TTL-Encoder output or input (2)

D-Stecker X8

1VCC-CNT

2

9

3

8

7

4

5GND-CNT

TMS

DSxx/BAxx

6Out-In

A

A

B

B

N

N

VCC-CNT

GND

LBR 1

Inc-In

Inc-Out

Zähler CNC-SPS oder

2. TTL- Incremental-Feedback

VCC

470

470

470

Schirm am Steckergehäuse

Shield at connector housing

D-connector X8

Counter CNC-SPS or

9 pol D-connector (M,pins)

5.10 X8 TTL-Encoder output or input (2)

The D-connector X8 is connected as input or output (default).

Output X8 Pin 6 not connected or bridged with GND
Input X8 Pin 6 bridged with +5 V (X8:1)

DSx-BAx-DPC/ E-DS-400-Enco-In-Out-TTL-Ansch3

DS-BAx-DPC/DS-400-Stecker-encoout

Connector assignment
solder side

Note:
X8 as input

Connect X8:6 (select IN) with
X8:1 (+5 V) in the D-connector.

Control connection

DS 400-2

04/2019 - V01

48

X8 as TTL Encoder output

DS-400-encoder-out

5.11 X8 as TTL Encoder output

The encoder signals supplied by the motor (feedback) are available at the output of the D­connector X8 TTL encoder signals for the CNC control.

The encoder output is internally isolated.
The voltage is supplied via the encoder line from the CNC/PLC control.
Voltage supply +5 V ±0.2 V.
The output signal corresponds to RS485.

Option: Internal supply from the servo-drive (LBR1 + LBR2)

For RS and SC the resolution can be programmed. (Parameter 0 x a4, Bit1),
for IN it corresponds to the encoder no. of pulses

Pulse signals

(motor revolving clockwise)

Output level low < 0,5 V
high >4.5 V

Slope < 0,1 µs

Zero pulse min. 0.2 µs

Output frequency max. 200 kHz

Pulse/rpm
for RS, SC programmable
for IN encoder no. of pulses

X8 as TTL encoder input

Note: X8 pin 6 (select IN) must be bridged with X8 pin 1 (+5V)!

The encoder input is internally isolated.
The voltage is supplied via the encoder line.
Option: Internal supply from the servo-drive
The input signal correspond to RS485.
Input frequency max. 200 kHz

Option: Internal supply from the servo-drive (LBR1 + LBR2)

The encoder input can be programmed for different functions;
see software Manual DS-NDrive

Control connection

49

04/2019 - V01

DS 400.2

Display

Display

Point/segment

State

State of NDrive

flashing

Processor active

flashing

dark

Starting state after reset (auxil. voltage 24V off-on).

Drive disabled (not enabled)

OK = 0

OK = 1, ENA = 0

flashing

Motor current reduced to continuous current Icns

limits

Icns = 1

bright for 0.1 s

A new command (value) was received from the BUS

Point flashes

=
active processor

Bottom segment
Right segment

= = drive enabled
motor turns clockwise

5.12 Display

The state "normal" is signalled by a bright green seven-segment display + decimal point (display
of the state).

The state "fault" is signalled by a bright red fault LED and the seven-segment display indicates the
error no.

The state "warning" is signalled by the flashing red fault LED and the seven-segment display
indicates alternately the state and the warning no.

Display of the servo-drive state

dark

bright

bright

bright

bright

bright

dark

Auxiliary voltage missing or inherent hardware failure

The first enable stops the flashing display.

Drive enable

Speed zero (standstill signal)

Drive revolves clockwise, N currently positive

Drive revolves anti-clockwise, N currently negative

Motor current at max. current limit I

Normal operation; Motor current within the current

max

OK = 1, ENA = 1

N0 = 1

N0 = 0

N0 = 0

Icns = 0

Icns = 0

Zeichnung_NDrive2_Bilder/7Segment……

Beispiel: Motor clockwise

or RS232.

Control connection

DS 400-2

04/2019 - V01

50

Error display on the servo

Display
controller

Fault display on the
NDrive

Meaning

0

BADPARAS

Damaged parameter

1*

POWER FAULT

Output stage error

2

RFE FAULT

Safety bus fault

3

BUS TIMEOUT

Transmission fault BUS

4

FEEDBACK

Encoder signal faulty

5

POWERVOLTAGE

No power supply voltage

6

MOTORTEMP

Motor temperature too high

7*

DEVICETEMP

Device temperature too high

8

OVERVOLTAGE

Overvoltage >1.8 x UN

9

I_PEAK

Over-current 300 %

A

RACEAWAY

Drive races
(without command value, wrong direction)

B

USER

User - choice of error

C

12R

Overload

D

RESERVE E

CPU-ERROR

Software error

F

BALLAST

Ballast circuit overloaded

Decimal point flashing

Processing unit active

Decimal point dark

Auxiliary voltage missing or inherent hardware failure

Beispiel:

FAULT LED rot

Fault no. 5

5.13 Error display on the servo

The red LED "fault" is bright and the fault no. is indicated by the green seven-segment display.

List of faults/errors

(device-dependent)

POWERVOLTAGE

Fault

* DEVICETEMP
For the DS405, 412, 420 the IGBT over-temperature is signaled as fault 1 POWER FAULT (output
stage fault).

Note: When applying the 24V auxiliary voltage with the enable closed (FRG/RUN X1:7 active) the
red LED signals an error. There is no fault signal displayed in the 7-segment display.

(Power voltage missing)

Control connection

51

04/2019 - V01

DS 400.2

Warning signals

Display
Controller

Warning signals
on the NDrive

Meaning

ID-Address

0x8f

0

WARNING_0

Device detection inconsistent

Bit 16

1

ILLEGAL STATUS

RUN Signal

Bit 17

2

WARNING_2

RFE Signal inactiv

Bit 18

3

Bit 19

4

Bit 20

5

POWERVOLTAGE

Power voltage too small or missing

Bit 21

6

MOTORTEMP

Bit 22

7

DEVICETEMP

Bit 23

8

OVERVOLTAGE

Bit 24

9

I_PEAK Bit 25

A

Bit 26

B

Bit 27

C

I2R

Overload >87 %

Bit 28

D

Bit 29

E

Bit 30

F(device-ependent)

BALLAST

Ballast circuit >87 % overloaded

Bit 31

:

5.14 Warning signals

The state "warning" is signalled by the flashing red fault LED and the seven-segment display
indicates alternately the state and the warning no.

List of warning signals

Example

flashing red,
The display swaps between the state and the warning no.,

Fault

Warning no. 5

Warranty

DS 400-2

04/2019 - V01

52

Warranty

6 Warranty

6.1 Warranty

UNITEK warranties that the device is free from material and production defects. Test results are

recorded and archived with the serial number.

The warranty time begins from the time the device is shipped, and lasts two years.

UNITEK undertakes no warranties for devices which have been modified for special applications.

During the warranty period, UNITEK will, at its option, either repair or replace products that prove
to be defective, this includes guaranteed functional attributes. UNITEK specifically disclaims the
implied warranties or merchantability and fitness for a particular purpose. For warranty service or
repair, this product must be returned to a service facility designated by UNITEK.

For products returned to UNITEK for warranty service, the buyer shall prepay shipping charges to
UNITEK and UNITEK shall pay shipping charges to return the product to the buyer.

However, the buyer shall pay all shipping charges, duties and taxes for products returned to
UNITEK from another country.

The foregoing warranty shall not apply to defects resulting from:

- improper or inadequate repairs effected by the buyer or a third party,

- non-observance of the manual which is included in all consignments,

- non-observance of the electrical standards and regulations,

- improper maintenance

- acts of nature.

All further claims on transformation, diminution and replacement of any kind of damage,
especially damage, which does not affect the UNITEK device, cannot be considered. Follow-on
damage within the machine or system, which may arise due to malfunction or defect in the device
cannot be claimed. This limitation does not affect the product liability laws as applied in the place
of manufacture (i.e. Germany).

UNITEK reserves the right to change any information included this MANUAL.
All connection circuitry described is meant for general information purposes and is not
mandatory.
The local legal regulations, and those of the standards authorities have to be adhered to. UNITEK
does not assume any liability, expressively or inherently, for the information contained in this
MANUAL, for the functioning of the device or its suitability for any specific application.

All rights are reserved.
Copying, modifying and translations lie outside UNITEK’s liability and thus are not prohibited.

UNITEK’s products are not authorised for use as critical components in the life support devices or

systems without express written approval.
The onus is on the reader to verify that the information here is current