Danfoss VLT Integrated Servo Drive ISD 510 System User manual

Operating Guide
VLT® Servo Drive System ISD 510/DSD 510
drives.danfoss.com

1
1.1
1.2
1.3
1.4
1.5
1.6
2
2.1
2.2
2.3
2.3.1
2.4
2.5
2.6
2.6.1
2.7
2.8
3
3.1
3.1.1
3.2
3.2.1
3.2.2
3.2.3
3.2.4
3.2.4.1
3.2.4.2
3.2.4.3
3.2.4.4
3.2.4.5
3.2.5
3.2.5.1
3.3
3.3.1
Contents
Introduction 16
Purpose of the Operating Guide 16
Additional Resources 16
Copyright 16
Approvals and Certications 16
Firmware Updates 18
Terminology 18
Safety 20
Safety Symbols 20
Important Safety Warnings 20
Safety Instructions and Precautions 22
Operational Safety 22
Qualied Personnel 23
Due Diligence 23
Intended Use 23
Prohibited Application Areas 23
Forseeable Misuse 24
Service and Support 24
System Description 25
Overview of the ISD 510/DSD 510 System 25
Application Examples 26
VLT® Integrated Servo Drive ISD 510 27
Overview of the ISD 510 Servo Drive 27
Motor and Flange Sizes 27
ISD 510 Servo Drive Types 27
Motor Components 28
Shaft 28
Brake (Optional) 29
Cooling 29
Thermal Protection 29
Built-in Feedback Devices 29
Drive Components 29
Connectors on the ISD 510 Servo Drives 29
VLT® Decentral Servo Drive DSD 510 30
Overview of the DSD 510 Servo Drive 30
AQ262449648484en-000101/175R1135 | 3Danfoss A/S © 2020.08
Contents
VLT® Servo Drive System ISD 510/DSD 510
Operating Guide

3.3.2
3.3.3
3.4
3.4.1
3.5
3.5.1
3.6
3.6.1
3.7
3.8
3.8.1
3.8.2
3.8.2.1
3.8.2.2
3.8.2.3
3.8.2.4
3.9
3.9.1
3.9.1.1
3.9.2
3.9.2.1
3.9.2.2
3.9.3
3.9.4
3.9.5
3.10
3.10.1
3.11
3.12
3.12.1
3.12.2
3.12.3
4
4.1
4.2
4.3
4.4
DSD 510 Servo Drive Types 30
Connectors on the DSD 510 Servo Drives 31
Power Supply Module (PSM 510) 32
Overview 32
Decentral Access Module (DAM 510) 33
Overview 33
Auxiliary Capacitors Module (ACM 510) 34
Overview 34
Expansion Module EXM 510 35
Local Control Panel (LCP) 37
Overview of the Local Control Panel 37
Layout of the Local Control Panel 37
A: Display area 37
B: Display menu keys 39
C: Navigation keys and indicator lights (LEDs) 39
D: Operation keys and reset 40
Cables 40
Hybrid Cable 40
Minimum Bending Radius for Hybrid Cable 41
Motor and Feedback Cable 42
Minimum Bending Radius for Motor Cable 42
Minimum Bending Radius for Feedback Cable 42
I/O and/or Encoder Cable 43
Fieldbus Extension Cable 43
LCP Cable 43
Cable Layout and Routing 43
Standard Cabling Concept for 2 Lines 43
Software 44
Fieldbus 44
EtherCAT® 45
Ethernet POWERLINK® 46
PROFINET® 46
Mechanical Installation 48
Items Supplied 48
Transport 48
Inspection on Receipt 48
Safety Measures during Installation 48
AQ262449648484en-000101/175R11354 | Danfoss A/S © 2020.08
Contents
VLT® Servo Drive System ISD 510/DSD 510
Operating Guide

4.5
4.5.1
4.5.2
4.5.3
4.6
4.6.1
4.6.2
4.6.3
4.7
4.7.1
4.7.1.1
4.7.1.2
4.7.2
4.7.2.1
4.7.2.2
4.7.3
4.7.4
4.7.5
4.7.5.1
4.7.5.2
4.7.5.3
4.7.5.4
4.7.6
4.7.6.1
4.7.7
5
5.1
5.2
5.3
5.4
5.4.1
5.4.2
5.5
5.5.1
5.5.2
5.6
5.6.1
Installation Environment 48
Overview 48
ISD 510/DSD 510 Servo Drive 49
System Modules 49
Preparation for Installation 49
ISD 510/DSD 510 Servo Drive 49
System Modules 49
Drilling Templates 50
Installation Procedure 50
Space Requirements for ISD 510 Servo Drive 50
Minimum Distance for M23 Straight Connector on ISD 510 50
Minimum Distance for M23 Angled Connector on ISD 510 51
Space Requirements for DSD 510 Servo Drive 51
Minimum Distance for M23 Straight Connector on DSD 510 52
Minimum Distance for M23 Angled Connector on DSD 510 52
Space Requirements for System Modules 52
Installation Aids and Tools Required 54
Fitting Instructions for ISD 510 Servo Drive 54
Overview 54
Clamping the ISD 510 Servo Drive 54
Coupling the ISD 510 Servo Drive 55
Tightening Torques for Fixing Screws 56
Fitting Instruction for DSD 510 Servo Drive 56
Clamping the DSD 510 Servo Drive 56
Fitting Instructions for System Modules 57
Electrical Installation 61
Warnings for Electrical Installation 61
Electrical Environmental Conditions 61
EMC-Compliant Installation 62
Grounding 62
Grounding for Electrical Safety 62
Grounding for EMC-Compliant Installation 62
Mains Supply Requirements 64
Fuses 64
Circuit Breakers 64
Auxiliary Supply Requirements 65
Fuses 65
AQ262449648484en-000101/175R1135 | 5Danfoss A/S © 2020.08
Contents
VLT® Servo Drive System ISD 510/DSD 510
Operating Guide

5.7
5.8
5.9
5.9.1
5.9.2
5.9.3
5.9.4
5.9.5
5.9.5.1
5.9.5.2
5.9.5.3
5.9.5.4
5.9.6
5.10
5.10.1
5.10.1.1
5.10.1.2
5.10.1.3
5.10.2
5.10.2.1
5.10.2.2
5.11
5.11.1
5.11.2
5.12
5.13
5.14
6
6.1
6.2
6.3
6.4
6.4.1
6.4.2
6.4.2.1
6.4.2.2
6.4.3
Safety Supply Requirements 65
UL Requirements 66
Connecting the ISD 510/DSD 510 Servo Drive 66
Electrical Installation Warnings for ISD 510/DSD 510 Servo Drive 66
General Instructions for Cable Installation 66
Connecting Hybrid Cables 67
Disconnecting Hybrid Cables 69
Connecting Cables to Ports X3, X4, and X5 69
Cable Routing Recommendations 69
Connecting I/O and/or Encoder Cables to Port X3 70
Connecting the LCP Cable to Port X5 71
Connecting the 3rd Ethernet Device Cable to Port X3 72
Disconnecting Cables from Ports X3, X4, and X5 72
Connecting the Power Supply Module PSM 510 72
AC Line Choke 72
Connecting 1 PSM 510 to the AC Choke 73
Connecting 2 PSM 510 Modules to the AC Choke 73
Connecting 2 PSM 510 Modules to the AC Choke with System Splitting 74
Connecting the Cables on the Power Supply Module PSM 510 75
Connecting the Cables on the Top of the Power Supply Module PSM 510 75
Connecting the Cables on the Bottom of the Power Supply Module PSM 510 76
Connecting the Decentral Access Module (DAM 510) 77
Connecting the Cables on the Top of the Decentral Access Module DAM 510 77
Connecting the Feed-In Cable 77
Connecting the Auxiliary Capacitors Module ACM 510 79
Connecting the Expansion Module EXM 510 79
Connecting the Brake Resistor on the PSM 510 80
Commissioning 83
Warnings for Commissioning 83
Pre-Commissioning Checklist 83
EtherCAT® ID Assignment 83
Ethernet POWERLINK® ID Assignment 83
Overview 83
Single Device ID Assignment 83
Setting the Node ID Directly on a Servo Drive or on the System Modules 83
Setting the Node ID for a Single Servo Drive via the Power Supply Module (PSM 510) or Decentral Access
Module (DAM 510) via the LCP 84
Multiple Device ID Assignment 84
AQ262449648484en-000101/175R11356 | Danfoss A/S © 2020.08
Contents
VLT® Servo Drive System ISD 510/DSD 510
Operating Guide

6.4.3.1
6.5
6.6
6.7
6.8
6.8.1
6.9
6.10
6.10.1
6.10.2
6.10.3
6.10.4
6.10.5
6.10.6
6.10.7
6.10.8
6.10.9
6.10.9.1
6.10.9.2
6.10.10
6.10.10.1
6.10.10.2
6.10.11
6.10.12
6.10.13
6.11
6.11.1
6.11.2
6.11.3
6.11.4
6.11.5
6.11.6
6.11.7
6.11.8
6.11.9
6.11.10
6.11.11
Setting the Node IDs of all Servo Drives and System Modules on a Decentral Access Module (DAM 510)/
Power Supply Module (PSM 510) Line 84
PROFINET® ID Assignment 85
Power-Up Time 85
System Module Charging Time 86
Switching on the ISD 510/DSD 510 System 86
Procedure for Switching on the ISD 510/DSD 510 System 86
Libraries 86
Programming with Automation Studio™ 87
Requirements for Programming with Automation Studio™ 87
Creating an Automation Studio™ Project 87
Including the Servo Motion Libraries into an Automation Studio™ Project 87
Constants within the DDS_Drive Library 88
Instantiating AXIS_REF_DDS in Automation Studio™ 89
Instantiating PSM_REF in Automation Studio™ 90
Instantiating DAM_REF in Automation Studio™ 90
Instantiating ACM_REF in Automation Studio™ 90
Importing a Servo Drive into Automation Studio™ 91
Version V3.0.90 91
Version V4.x 91
Importing PSM 510, DAM 510 and ACM 510 into Automation Studio™ 92
Version V3.0.90 92
Version V4.x 92
I/O Conguration and I/O Mapping 93
Setting the PLC Cycle Time 95
Connecting to the PLC 95
Programming with TwinCAT® 96
Requirements for Programming with TwinCAT® 96
Creating a TwinCAT® Project 96
Including the TwinCAT® Library into a TwinCAT® Project 96
Constants within the DDS_Drive Library 88
Instantiating AXIS_REF_DDS in TwinCAT® 98
Instantiating PSM_REF in TwinCAT® 99
Instantiating DAM_REF in TwinCAT® 99
Instantiating ACM_REF in TwinCAT® 99
Adding a PLC Project to TwinCAT® System Manager 99
Importing Devices to TwinCAT® 99
I/O Conguration and I/O Mapping 102
AQ262449648484en-000101/175R1135 | 7Danfoss A/S © 2020.08
Contents
VLT® Servo Drive System ISD 510/DSD 510
Operating Guide

6.11.12
6.11.13
6.11.14
6.11.15
6.11.15.1
6.11.16
6.12
6.13
6.13.1
6.13.2
6.13.3
6.13.4
6.13.5
6.13.6
6.13.7
6.13.8
6.13.9
6.13.9.1
6.13.9.2
6.13.10
6.13.11
6.13.12
6.13.13
6.13.14
6.13.15
6.13.16
6.13.17
6.14
6.15
6.15.1
6.15.2
6.15.3
6.15.4
6.15.5
6.16
6.17
6.17.1
6.17.2
Attaching the Input and Output Variables to the Physical Data Points 103
Transferring the Mappings back to the PLC Program 104
Setting the PLC Cycle Time in TwinCAT® PLC Control 105
Conguration as a TwinCAT® NC Axis 105
I/O Conguration for Servo Drives used as NC Axes 105
Connecting to the PLC 106
Programming Guidelines for Automation Studio™ and TwinCAT® 106
Programming with SIMOTION SCOUT® 106
Requirements for Programming with SIMOTION SCOUT® 106
Connecting to the PLC 107
Creating a SIMOTION SCOUT® Project 107
Including the Servo Motion Libraries into a SIMOTION SCOUT® Project 107
Importing Devices into SIMOTION SCOUT® 109
Assigning IP Conguration and Device Name 110
Creating a Sync Domain 113
Conguring a Topology 116
Dening Send Clock and Update Time 117
Conguring the Send Clock Time 117
Conguring the Update Time 117
Accessing Inputs and Outputs 118
Programming using the Danfoss VLT® Servo Motion Library 119
Instantiating AXIS_REF_DDS in SIMOTION SCOUT® 119
Instantiating PSM_REF in SIMOTION SCOUT® 119
Instantiating DAM_REF in SIMOTION SCOUT® 119
Instantiating ACM_REF in SIMOTION SCOUT® 120
Global Compiler Settings 120
Assigning Tasks 121
Programming Guidelines for SIMOTION SCOUT® 123
Programming with TIA 123
Requirements for Programming with TIA 123
Creating a TIA Project 124
Including the Servo Motion Libraries into a TIA Project 124
Importing Devices into TIA 125
Creating a Network 126
Programming Guidelines for TIA 130
VLT® Servo Toolbox Software 131
Overview 131
System Requirements 131
AQ262449648484en-000101/175R11358 | Danfoss A/S © 2020.08
Contents
VLT® Servo Drive System ISD 510/DSD 510
Operating Guide

6.17.3
6.17.4
6.17.4.1
6.17.4.2
6.17.4.3
6.17.4.4
6.17.5
6.17.5.1
6.17.5.2
6.17.5.3
6.18
6.18.1
6.18.2
7
7.1
7.1.1
7.2
7.2.1
7.2.2
7.2.3
7.2.4
8
8.1
8.2
8.3
8.4
8.5
8.6
8.6.1
8.7
8.8
8.8.1
8.8.2
8.9
8.9.1
8.9.2
8.10
Installing the VLT® Servo Toolbox Software 132
VLT® Servo Toolbox Communication 132
Overview 132
Firewall 132
Indirect Communication 132
Direct Communication 135
VLT® Servo Toolbox Commissioning 138
Step 1: Opening the Main Window 138
Step 2: Connecting to Network 139
Step 3: Scanning for Devices 140
Motion Library 140
Function Blocks 140
Simple Programming Template 140
Operation 141
Operating Modes 141
Motion Functions 141
Operating Status Indicators 142
Operating LEDs on the ISD 510/DSD 510 Servo Drive 142
Operating LEDs on the PSM 510 143
Operating LEDs on the DAM 510 144
Operating LEDs on the ACM 510 145
Functional Safety Concept 147
Functional Description 147
Safety Precautions 147
Qualied Personnel for Working with Functional Safety 148
Applied Standards and Compliance 148
Abbreviations and Conventions 148
Installation 149
Protective Measures 150
Application Example 150
Commissioning Test 150
Commissioning Test using Libraries 151
Commissioning Test using PROFINET® Devices 152
Operation of the STO Function 153
Error Codes 153
Fault Reset 153
Functional Safety Characteristic Data 153
AQ262449648484en-000101/175R1135 | 9Danfoss A/S © 2020.08
Contents
VLT® Servo Drive System ISD 510/DSD 510
Operating Guide

8.11
9
9.1
9.2
9.2.1
9.2.1.1
9.2.1.2
9.2.1.3
9.2.1.4
9.2.1.5
9.2.1.6
9.2.1.7
9.2.1.8
9.2.1.9
9.2.1.10
9.2.1.11
9.2.1.12
9.2.1.13
9.2.1.14
9.2.1.15
9.2.1.16
9.2.2
9.2.2.1
9.2.2.2
9.2.2.3
9.2.2.4
9.2.2.5
9.2.2.6
9.2.2.7
9.2.2.8
9.2.2.9
9.2.2.10
9.2.2.11
9.2.2.12
9.2.2.13
9.2.2.14
9.2.2.15
Maintenance, Security, and User Accessibility 154
Diagnostics 155
Faults 155
Troubleshooting 155
Troubleshooting for the ISD 510/DSD 510 Servo Drives 155
Drive not Running/Starting Slowly 155
Drive Hums and Draws High Current 155
Drive Stops Suddenly and Restart is not Possible 155
Motor Rotating in Wrong Direction 156
Motor not Generating Expected Torque 156
Drive Screaming 156
Uneven Running 156
Vibration 156
Unusual Running Noises 156
Drive Speed Drops Sharply under Load 157
Brake not Releasing 157
Holding Brake not Holding the Servo Drive 157
Delayed Brake Engagement 157
Noises when Power-O Brake is Engaged 157
LEDs not Lighting Up 157
Drive Protection Trips Immediately 157
Troubleshooting for the Servo System 158
LCP Display is Dark/Not Functioning 158
Open Power Fuses or Circuit Breaker Trip 158
DC-link Voltage Too Low (Error 0x3220/0x104) 158
Current Overload Trip (Error 0x2396/0x15C) 158
High Cont. Power Overload (Error 0x2313/0x161) 159
Continuous Power Overload (Error 0x2314/0x162) 159
AUX Overcurrent (Error 0x2391/0x125) 159
AUX Overvoltage (Error 0x3292/0x133) 159
AUX Undervoltage (Error 0x3294/0x135) 159
Mains Phase Loss (Error 0x3130/0x12F) 160
Generic Application Error (Error 0x1000/ 0x100) 160
Grounding Fault 160
Brake Resistor Error 160
Brake Chopper Error 160
Internal Fan Error 160
AQ262449648484en-000101/175R113510 | Danfoss A/S © 2020.08
Contents
VLT® Servo Drive System ISD 510/DSD 510
Operating Guide