Danfoss VLT ISD 511 User manual

Operating Guide
VLT® Servo Drive System ISD 511
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
3.2.3.1
3.2.3.2
3.2.3.3
3.2.3.4
3.2.3.5
3.3
3.3.1
3.4
3.4.1
3.5
Contents
Introduction 13
Purpose of the Operating Guide 13
Additional Resources 13
Copyright 13
Approvals and Certifications 13
Firmware Updates 14
Terminology 14
Safety 16
Safety Symbols 16
Important Safety Warnings 16
Safety Instructions and Precautions 18
Operational Safety 18
Qualified Personnel 19
Due Diligence 19
Intended Use 19
Prohibited Application Areas 19
Forseeable Misuse 20
Service and Support 20
System Description 21
Overview of the ISD 511 System 21
Application 22
VLT® Integrated Servo Drive ISD 511 22
Overview of the ISD 511 Servo Drive 22
ISD 511 Servo Drive Types 23
Motor Components 24
Shaft 24
Flange 24
Cooling 24
Thermal Protection 24
Built-In Feedback Devices 24
Power Supply Module (PSM 510) 24
Overview 24
Decentral Access Module (DAM 510) 25
Overview 25
Auxiliary Capacitors Module (ACM 510) 26
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Contents
VLT® Servo Drive System ISD 511
Operating Guide

3.5.1
3.6
3.7
3.8
3.8.1
3.9
3.9.1
3.9.2
3.9.3
3.10
3.10.1
3.10.2
3.10.2.1
3.10.2.2
3.10.2.3
3.10.2.4
4
4.1
4.2
4.3
4.4
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
4.7.2
4.7.3
4.7.4
4.7.4.1
4.7.4.2
Overview 26
Expansion Module EXM 510 27
Software 28
Fieldbus 29
Ethernet POWERLINK® 29
Cables 29
Feed Cables 29
Loop Cable 29
LCP Cable 30
Local Control Panel (LCP) 30
Overview of the Local Control Panel 30
Layout of the Local Control Panel 30
A: Display area 30
B: Display menu keys 32
C: Navigation keys and indicator lights (LEDs) 32
D: Operation keys and reset 33
Mechanical Installation 34
Items Supplied 34
Transport 34
Inspection on Receipt 34
Safety Measures during Installation 34
Installation Environment 34
Overview 34
ISD 511 Servo Drive 34
System Modules 35
Preparation for Installation 35
ISD 511 Servo Drive 35
System Modules 35
Drilling Templates 36
Installation Procedure 36
Space Requirements for ISD 511 36
Minimum Distance for M23 Angled Connector 36
Space Requirements for System Modules 37
Installation Aids and Tools Required 38
Fitting Instructions for ISD 511 Servo Drive 38
Overview 38
Mounting the ISD 511 to the Roundtable 39
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Contents
VLT® Servo Drive System ISD 511
Operating Guide

4.7.4.3
4.7.5
5
5.1
5.2
5.3
5.3.1
5.3.2
5.4
5.5
5.5.1
5.5.2
5.6
5.6.1
5.7
5.8
5.9
5.9.1
5.9.1.1
5.9.1.2
5.9.1.4
5.9.2
5.9.2.1
5.9.2.2
5.9.3
5.9.3.1
5.9.3.2
5.9.4
5.9.5
5.9.6
6
6.1
6.2
6.2.1
6.3
6.4
6.4.1
Tightening Torques for Fixing Screws 40
Fitting Instructions for System Modules 40
Electrical Installation 45
Warnings for Electrical Installation 45
Electrical Environmental Conditions 45
Grounding for Electrical Safety 46
Grounding the ISD 511 Servo Drive 46
Grounding the System Modules 47
Grounding for EMC-Compliant Installation 48
Mains Supply Requirements 50
Fuses 50
Circuit Breakers 50
Auxiliary Supply Requirements 51
Fuses 51
Safety Supply Requirements 51
UL Requirements 52
Connecting the Components 52
Connecting the ISD 511 Servo Drive 52
Electrical Installation Warnings for ISD 511 Servo Drive 52
General Instructions for Cable Installation 52
Disconnecting Hybrid Cables 56
Connecting the Power Supply Module PSM 510 56
AC Line Choke 56
Connecting the Cables on the Power Supply Module PSM 510 58
Connecting the Decentral Access Module (DAM 510) 59
Connecting the Cables on the Top of the Decentral Access Module DAM 510 59
Connecting the Feed-In Cable 60
Connecting the Auxiliary Capacitors Module ACM 510 61
Connecting the Expansion Module EXM 510 63
Connecting the Brake Resistor on the PSM 510 64
Commissioning 66
Pre-Commissioning Checklist 66
Switching on the ISD 511 System 66
Procedure for Switching on the ISD 511 System 66
Warnings for Commissioning 66
ID Assignment 66
Overview 66
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Contents
VLT® Servo Drive System ISD 511
Operating Guide

6.4.2
6.4.2.1
6.4.2.2
6.4.3
6.4.3.1
6.4.3.2
6.4.3.3
6.4.3.4
6.5
6.5.1
6.5.2
6.5.3
6.5.4
6.5.5
6.5.6
6.5.7
6.5.8
6.5.9
6.5.10
6.5.11
6.5.12
6.5.13
6.5.14
6.6
6.6.1
6.6.2
6.6.3
6.6.4
6.6.4.1
6.6.4.2
6.6.4.3
6.6.4.4
6.7
6.7.1
6.7.2
Single Device ID Assignment 67
Setting the Node ID for a Single Servo Drive Manually using the VLT® Servo Toolbox 67
Setting the Node ID for a Single Servo Drive Manually using the LCP 67
Multiple Device ID Assignment 67
Setting the Node IDs Automatically for Multiple Servo Drives and System Modules using the VLT® Servo
Toolbox 68
Setting the Node IDs Automatically for Multiple Servo Drives using the LCP 68
Setting the Node IDs Automatically for Multiple Servo Drives and System Modules using the LCP 68
Setting the Node ID Automatically for Multiple Servo Drives using the PLC with an Automation Studio
Dedicated Library Function Block 69
Programming with Automation Studio 69
Requirements for Programming with Automation Studio™ 69
Creating an Automation Studio™ Project 69
Including the Servo Motion Libraries into an Automation Studio™ Project 69
Constants within the DDS_Drive Library 70
Instantiating AXIS_REF_DDS in Automation Studio™ 71
Instantiating PSM_REF in Automation Studio™ 72
Instantiating DAM_REF in Automation Studio™ 72
Instantiating ACM_REF in Automation Studio™ 72
Importing a Servo Drive into Automation Studio™ 73
Importing PSM 510, DAM 510 and ACM 510 into Automation Studio™ 73
I/O Configuration and I/O Mapping 74
Setting the PLC Cycle Time 76
Connecting to the PLC 76
Programming Guidelines for Automation Studio™ 77
VLT® Servo Toolbox Software 77
Overview 77
System Requirements 78
Installing the VLT® Servo Toolbox Software 78
VLT® Servo Toolbox Communication 78
Overview 78
Firewall 78
Indirect Communication 78
Direct Communication 80
Motion Library 82
Function Blocks 82
Simple Programming Template for Automation Studio 82
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Contents
VLT® Servo Drive System ISD 511
Operating Guide

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
8.9
8.9.1
8.9.2
8.10
8.11
9
9.1
9.2
9.2.1
9.2.2
9.2.3
9.2.4
9.2.5
9.2.6
9.2.7
9.2.8
9.2.9
9.2.10
Operation 83
Operating Modes 83
Motion Functions 83
Operating Status Indicators 83
Operating LEDs on the ISD511 Servo Drive 84
Operating LEDs on the PSM 510 85
Operating LEDs on the DAM 510 86
Operating LEDs on the ACM 510 87
Safety Concept 89
Functional Description 89
Safety Precautions 89
Qualified Personnel for Working with Functional Safety 90
Applied Standards and Compliance 90
Abbreviations and Conventions 90
Installation 91
Protective Measures 92
Application Example 92
Commissioning Test 92
Commissioning Test using Libraries 92
Operation of the STO Function 93
Error Codes 94
Fault Reset 94
Functional Safety Characteristic Data 94
Maintenance, Security, and User Accessibility 95
Diagnostics 96
Faults 96
Troubleshooting for the ISD 511 Servo Drive 96
Drive not Running/Starting Slowly 96
Drive Hums and Draws High Current 96
Drive Stops Suddenly and Restart is not Possible 96
Motor Rotating in Wrong Direction 97
Motor not Generating Expected Torque 97
Drive Screaming 97
Uneven Running 97
Vibration 97
Unusual Running Noises 97
Drive Speed Drops Sharply under Load 98
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Contents
VLT® Servo Drive System ISD 511
Operating Guide

9.2.11
9.2.12
9.3
9.3.1
9.3.2
9.3.3
9.3.4
9.3.5
9.3.6
9.3.7
9.3.8
9.3.9
9.3.10
9.3.11
9.3.12
9.3.13
9.3.14
9.3.15
9.4
9.4.1
9.4.2
9.4.3
9.4.4
9.4.5
9.4.6
9.4.7
9.4.8
9.4.9
9.4.10
9.4.11
9.4.12
9.4.13
9.4.14
9.4.15
9.4.16
9.4.17
9.4.18
9.4.19
LEDs not Lighting Up 98
Drive Protection Trips Immediately 98
Troubleshooting for the Servo System 98
LCP Display is Dark/Not Functioning 98
Open Power Fuses or Circuit Breaker Trip 98
DC-link Voltage Too Low (Error 0x3220/0x104) 99
Current Overload Trip (Error 0x2396/0x15C) 99
High Cont. Power Overload (Error 0x2313/0x161) 99
Continuous Power Overload (Error 0x2314/0x162) 99
AUX Overcurrent (Error 0x2391/0x125) 99
AUX Overvoltage (Error 0x3292/0x133) 100
AUX Undervoltage (Error 0x3294/0x135) 100
Mains Phase Loss (Error 0x3130/0x12F) 100
Generic Application Error (Error 0x1000/ 0x100) 100
Grounding Fault 100
Brake Resistor Error 100
Brake Chopper Error 101
Internal Fan Error 101
Error Codes for ISD 511 Servo System 101
No error (0x0000 / 0x0) 101
Generic application error (0x1000 / 0x100) 101
High cont. power overload (0x2313 / 0x161) 101
Continuous power overload (0x2314 / 0x162) 101
Overcurrent short circuit (0x2320 / 0x163) 102
Ground fault (0x2330 / 0x151) 102
AUX overcurrent (0x2391 / 0x125) 102
AUX user limit current (0x2393 / 0x127) 102
AUX user limit current warning (0x2394 / 0x128) 102
AUX supply failure (0x2395 / 0x129) 103
Current overload trip (0x2396 / 0x15C) 103
Power overload trip (0x2397 / 0x12B) 103
Mains phase loss (0x3130 / 0x12F) 103
DC link overvoltage (0x3210 / 0x103) 103
DC link undervoltage (0x3220 / 0x104) 104
DC link charging error (0x3230 / 0x152) 104
DC Link unbalanced (0x3280 / 0x153) 104
UAUX high voltage (0x3291 / 0x132) 104
UAUX overvoltage (0x3292 / 0x133) 104
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Contents
VLT® Servo Drive System ISD 511
Operating Guide

9.4.20
9.4.21
9.4.22
9.4.23
9.4.24
9.4.25
9.4.26
9.4.27
9.4.28
9.4.29
9.4.30
9.4.31
9.4.32
9.4.33
9.4.34
9.4.35
9.4.36
9.4.37
9.4.38
9.4.39
9.4.40
9.4.41
9.4.42
9.4.43
9.4.44
9.4.45
9.4.46
9.4.47
9.4.48
9.4.49
9.4.50
9.4.51
9.4.52
9.4.53
9.4.54
9.4.55
9.4.56
9.4.57
UAUX low voltage (0x3293 / 0x134) 105
UAUX undervoltage (0x3294 / 0x135) 105
DC link high voltage (0x3295 / 0x136) 105
DC link low voltage (0x3296 / 0x137) 105
UAUX charging error (0x3297 / 0x154) 105
DC link shutdown error (0x3298 / 0x165) 106
UAUX shutdown error (0x3299 / 0x155) 106
UAUX undervoltage hardware (0x329A / 0x156) 106
Automated fault reset failure (0x329B / 0x168) 106
Device overtemperature (0x4210 / 0x157) 106
Device under temperature (0x4220 / 0x138) 107
Overtemperature: Control card (0x4291 / 0x106) 107
Overtemperature: Power card (0x4292 / 0x107) 107
Inrush overtemperature DC link (0x4293 / 013C) 107
Inrush overtemperature AUX line (0x4294 / 0x13D) 107
Overtemperature: Motor (0x4310 / 0x108) 108
UAUX undervoltage (0x5112 / 0x109) 108
Charge switch failure voltage (0x5121 /0x158) 108
Output phase U failure (0x5411 / 0x123) 108
Output phase V failure (0x5412 / 0x124) 108
Output phase W failure (0x5413 / 0x125) 109
EE Checksum Error (parameter missing) (0x5530 / 0x10A) 109
Parameter error (0x6320 / 0x10B) 109
Conf par ver (0x6382 / 0x15D) 109
Configuration parameters limits error (0x6383 / 0x164) 109
Power EEprom configuration error (0x6384 / 0x166) 110
Brake chopper failure (0x7111 / 0x141) 110
Brake chopper overcurrent (0x7112 / 0x167) 110
Brake chopper module overload (0x7181 / 0x142) 110
External brake chopper overload (0x7182 / 0x143) 110
Brake mains voltage too high (0x7183 / 0x159) 111
Internal position sensor error (0x7320 / 0x10C) 111
External position sensor error (0x7380 / 0x10D) 111
Communication error (0x7500 / 0x169) 111
Following error (0x8611 / 0x10E) 112
Homing error on entering homing mode (0x8693 / 0x10F) 112
Homing error on start homing method (0x8694 / 0x110) 112
Homing error distance (0x8695 / 0x111) 112
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Contents
VLT® Servo Drive System ISD 511
Operating Guide

9.4.58
9.4.59
9.4.60
9.4.61
9.4.62
9.4.63
9.4.64
9.4.65
9.4.66
9.4.67
9.4.68
9.4.69
9.4.70
9.4.71
9.4.72
9.4.73
9.4.74
9.4.75
9.4.76
9.4.77
9.4.78
9.4.79
9.4.80
9.4.81
9.4.82
10
10.1
10.2
10.2.1
10.2.2
10.3
10.4
10.5
10.5.1
10.5.2
10.6
10.6.1
Communication interrupted (0xFF10 / 0x14F) 112
Fan feedback inconsistent (0xFF21 / 0x145) 112
Fan lifetime critical (0xFF22 / 0x15A) 113
Timing violation 1 (0xFF60 / 0x115) 113
Timing violation 2 (0xFF61 / 0x116) 113
Timing violation 3 (0xFF62 / 0x117) 113
Timing violation 4 (0xFF63 / 0x118) 113
Timing violation 5 (0xFF64 / 0x119) 113
Timing violation 6 (0xFF65 / 0x11A) 114
Timing violation 7 (0xFF66 / 0x168) 114
Timing violation 8 (0xFF67 / 0x16B) 114
Timing violation 9 (0xFF68 / 0x16C) 114
Firmware: Package description mismatch (0xFF70 / 0x11B) 114
Firmware: Power cycle needed (0xFF71 / 0x11C) 114
Firmware: Update started (0xFF72 / 0x11D) 115
Firmware: Update invalid (0xFF73 / 0x15B) 115
STO active while drive enabled (0xFF80 / 0x11E) 115
STO mismatch (0xFF81 / 0x11F) 115
P_STO error (0xFF85 / 0x120) 115
Guide value reversed (0xFF90 / 0x121) 116
Guide value implausible (0xFF91 / 0x122) 116
UDU GV out of range (0xFF92 / 0x291) 116
UDU GV offset out of range (0xFF93 / 0x292) 116
UDU Min Blending distance out of range (0xFF94 / 0x293) 116
Sign of life error (0xFF95 / 0x14E) 117
Maintenance, Decommissioning and Disposal 118
Warnings 118
Inspection during Operation 118
ISD 511 Servo Drives 118
System Modules 118
Maintenance Tasks 118
Repair 119
System Module Replacement 119
Dismounting the System Modules 119
Fitting and Commissioning the System Modules 121
Cable Replacement 121
Overview 121
AQ377148425069en-000101/130R1213
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Contents
VLT® Servo Drive System ISD 511
Operating Guide