Keba D3-DA 3 Series Installation and operation manual

KeDrive
D3-DA 3xx/x
Axis module
Project engineering manual V 1.07
Translation of the original manual

Document:V 1.07 / Document No.: 1008665
Filename: da3xx_pjen.pdf
Pages: 120
© KEBA
Specifications are subject to change due to further technical developments. Details presented may be
subject to correction.
All rights reserved.
KEBA AG Headquarters: Gewerbepark Urfahr, 4041 Linz, Austria, Phone: [phone],
Fax: [phone], [email protected]
For information about our subsidiaries please look at www.keba.com.

D3-DA 3xx/x Record of Revision
Project engineering manual V1.07 3
© KEBA
Record of Revision
Version Date Changed in chapter Descritpion Changed
by
1.00 10-2014 - Newly created ekt, ekr
1.01 08-2015 Various chapter Adaption to new version hasl
1.02 10-2016 Various chapter Several corrections and additions hasl, ekt
1.03 12-2016 Various chapter Several corrections and additions swb
1.04 05-2017 Various chapter Several corrections and additions, UL added swb, hasl
1.05 07-2017 EG directives and
standards UL added hasl
1.06 04-2018 Various chapter Several corrections (Type plate, Mounting, tech.
data, ...) hasl
1.07 10-2018 Various chapter Several updates (Mounting, Tech. data, ...) hasl, hli

D3-DA 3xx/x
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D3-DA 3xx/x Table of contents
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Table of contents
1 Introduction ................................................................................................................ 9
1.1 Purpose of the document................................................................................. 9
1.2 Preconditions ................................................................................................... 9
1.3 Intended use .................................................................................................... 10
1.4 Notes on this document ................................................................................... 11
1.4.1 Content of this document................................................................... 12
1.4.2 Not contained in this document ......................................................... 12
1.5 Documentation for further reading ................................................................... 12
1.6 EtherCAT declaration....................................................................................... 13
2 Safety notes ................................................................................................................ 14
2.1 Representation................................................................................................. 14
2.2 General safety instructions .............................................................................. 15
2.3 Safety instructions for personal safety ............................................................. 18
2.4 Safety instructions for device maintenance ..................................................... 18
2.5 ESD information............................................................................................... 19
3 Description of module ............................................................................................... 20
3.1 Front view ........................................................................................................ 20
3.2 Bottom view ..................................................................................................... 20
3.3 Type plate ........................................................................................................ 21
3.4 Overview D3-DA 3xx/x variants ....................................................................... 22
3.5 Accessories...................................................................................................... 23
3.5.1 Connector set .................................................................................... 23
4 Displays and operating elements ............................................................................. 25
4.1 Status LEDs of the axis.................................................................................... 25
4.2 EtherCAT LEDs (RJ45).................................................................................... 25
5 Mounting and installation instructions .................................................................... 27
5.1 EMC requirements ........................................................................................... 29
5.1.1 Requirements to the connectors........................................................ 30
5.2 Space requirements......................................................................................... 33
5.3 Mounting the module ....................................................................................... 36
5.3.1 For wall mounting .............................................................................. 37
5.3.2 For cooling element ........................................................................... 37
5.4 Dismantling of the module ............................................................................... 38
5.5 Air conditioning and ventilation ........................................................................ 39

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6 Connections and wiring............................................................................................. 40
6.1 Single-axis module........................................................................................... 42
6.2 Double-axis module ......................................................................................... 44
6.3 Triple-axis module............................................................................................ 48
6.4 Grounding ........................................................................................................ 51
6.5 Electrical isolation method ............................................................................... 54
6.6 Connection of supply voltages via busbars...................................................... 56
6.6.1 24 V voltage supply ........................................................................... 57
6.6.2 D.c. link .............................................................................................. 57
6.6.3 Overview busbars .............................................................................. 58
6.7 Control connections ......................................................................................... 58
6.7.1 Digital inputs on X25A (standard functions)....................................... 58
6.7.2 Safe digital input (terminal X26A) ...................................................... 60
6.7.3 Specification of terminals................................................................... 60
6.8 Motor connection ............................................................................................. 61
6.8.1 Connection diagram motor connections ............................................ 61
6.8.2 Monitoring output motor holding brake .............................................. 63
6.8.3 Specification of motor connections .................................................... 64
6.8.4 Switching in the motor cable.............................................................. 64
6.9 Specification of EtherCAT connection interface............................................... 65
6.9.1 Pin assignment .................................................................................. 65
6.10 Encoder connections ....................................................................................... 66
6.10.1 Matching motor/encoder cables......................................................... 66
6.10.2 Connection for high-resolution encoder............................................. 67
6.11 Operation on special systems.......................................................................... 68
6.12 DIP-Switch (S-ADR)......................................................................................... 68
7 Configuration.............................................................................................................. 69
8 Safety functions ......................................................................................................... 70
8.1 STO (Safe Torque OFF) .................................................................................. 70
8.1.1 Configuration of STO safety function................................................. 71
8.2 SBC (Safe Brake Control)................................................................................ 72
8.2.1 Configuration SBC safety function..................................................... 73
8.3 Diagnosis via cross circuit test......................................................................... 74
8.4 Recommended connection examples.............................................................. 75
8.4.1 Example: STO and SBC control via safety control ............................ 75
8.4.2 Example: STO without SBC control via safety control....................... 77
8.4.3 Example: STO and SBC control via light grid .................................... 78
8.4.4 Example: STO and SBC control directly via supply module .............. 78
8.5 Validation of safety functions ........................................................................... 79
8.6 Validation of STO safety function..................................................................... 79
8.7 Validation of SBC safety function..................................................................... 80

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8.8 Validate cross circuit test ................................................................................. 80
9 Diagnosis .................................................................................................................... 82
9.1 Blink code ........................................................................................................ 82
10 Maintenance................................................................................................................ 83
10.1 Update firmware............................................................................................... 83
11 Disposal ...................................................................................................................... 84
11.1 Disposal of the module .................................................................................... 84
12 Technical data ........................................................................................................... 85
12.1 D3-DA 3x0/x-01xx, D3-DA 3x0/x-03xx............................................................. 85
12.1.1 Current data D3-DA 3x0/x-01xx ........................................................ 86
12.1.2 Current data D3-DA 3x0/x-03xx ........................................................ 87
12.2 D3-DA 3x0/x-06xx, D3-DA 3x0/x-12xx............................................................. 87
12.2.1 Current data D3-DA 3x0/x-06xx ........................................................ 89
12.2.2 Current data D3-DA 3x0/x-12xx ........................................................ 89
12.3 D3-DA 320/x-16xx, D3-DA 310/x-18xx ............................................................ 90
12.3.1 Current data D3-DA 320/x-16xx ....................................................... 92
12.3.2 Current data D3-DA 310/x-18xx ....................................................... 92
12.4 D3-DA 310/x-24xx, D3-DA 310/x-32xx ........................................................... 93
12.4.1 Current data D3-DA 310/x-24xx ....................................................... 94
12.4.2 Current data D3-DA 310/x-32xx ....................................................... 94
12.5 General safety specifications ........................................................................... 95
12.6 Ambient conditions........................................................................................... 95
12.7 Safe digital inputs............................................................................................. 97
12.8 Digital inputs .................................................................................................... 98
12.9 Dimensions, weight.......................................................................................... 99
13 EC directives and standards ..................................................................................... 103
13.1 EC directives.................................................................................................... 103
13.2 Standards......................................................................................................... 103
13.2.1 Machine safety and functional safety................................................. 103
13.2.2 EMC directives................................................................................... 103
13.2.3 Electrical safety and fire protection.................................................... 103
13.2.4 Environmental and surrounding conditions........................................ 104
13.3 CE marking ...................................................................................................... 104
13.4 UL certification ................................................................................................. 104
13.5 Loads on the mains due to harmonics ............................................................. 105
14 Declaration of conformity.......................................................................................... 106
14.1 With safety ....................................................................................................... 106

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15 Appendix: Estimation of system performance........................................................ 109
16 Appendix: Further components................................................................................ 111
16.1 Cooling plate and cooling element................................................................... 111
16.1.1 Cooling Element D3-XM 310-055 ...................................................... 111
16.1.2 Cooling plate D3-XM 300-060 ........................................................... 112
16.1.3 Cooling plate D3-XM 300-080 ........................................................... 113
16.2 Accessories...................................................................................................... 113
16.3 Connection technology .................................................................................... 114
16.3.1 Connection cable XW P0x-xxx .......................................................... 114
16.3.2 Connection cable XW H0x-xxx .......................................................... 115
16.3.3 Signal cable XW E10-xxx .................................................................. 116
16.3.4 Signal cable XW R10-xxx .................................................................. 117
16.3.5 Signal cable XW 020 ......................................................................... 117
16.3.6 Signal cable XW 021 ......................................................................... 118
Index ............................................................................................................................ 120

D3-DA 3xx/x Introduction
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© KEBA
1 Introduction
1.1 Purpose of the document
This document describes the structure of the axis module D3-DA 3xx/x.
Information
This manual is not addressed to end customers! Necessary safety notes for
the end customer have to be taken into the customer manual in the respec-
tive national language by the machine builders and system providers.
1.2 Preconditions
This document contains information for persons with the following skills:
Target group Prerequisite knowledge and abilities
Safety engineer for "Func-
tional Safety"
Basic technical training (technical college, engineer training or
corresponding professional experience).
Knowledge about:
● principles of functional safety,
● relevant standards and safety regulations for the machine/
system, particularly knowledge about validation according
to EN ISO 13849-2,
● special risk potential of the machine/system and the pro-
duction process,
● specific protective measures to avert machine-specific haz-
ards (based on hazard and risk analysis),
● functioning and application limits of the safety components
(including safety PLC),
● in-depth knowledge of national accident prevention regula-
tions.
Project engineer
Basic technical training (technical college, engineer training or
corresponding professional experience).
Knowledge about:
● current valid safety regulations,
● fundamental validation concepts according to EN ISO
13849,
● method of operation of a PLC,
● the application.

D3-DA 3xx/xIntroduction
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Target group Prerequisite knowledge and abilities
Electrician
Professional training in electrical engineering (based on indus-
try- standard training guidelines).
Knowledge about:
● current valid safety regulations,
● wiring guidelines,
● circuit diagrams,
● professional installation of electrical connections.
Programmer
Basic technical training (technical college, engineer training or
corresponding professional experience).
Knowledge about:
● current valid safety regulations,
● method of operation of a PLC,
● programming of an safety PLC.
Start-up operator
Basic technical training (technical college, engineer training or
corresponding professional experience).
Knowledge about:
● current valid safety regulations,
● fundamental validation concepts according to EN ISO
13849,
● the method of operation of the machine or system,
● fundamental functions of the application, system analysis
and troubleshooting,
● setting options on the operating devices.
Service technician
Basic technical training (technical college, engineer training or
corresponding professional experience).
Knowledge about:
● Method of operation of a PLC,
● current valid safety regulations,
● fundamental validation concepts according to EN ISO
13849,
● method of operation of the machine or system,
● diagnostic options,
● systematic fault analysis and remedial action.
1.3 Intended use
The D3-DA 3xx/x is intended for installation in stationary electrical systems
or machines and was developed for controlling of drives.

D3-DA 3xx/x Introduction
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The D3-DA 3xx/x may only be used for the types of use described in the
technical descriptions and in compliance with described technical general
conditions. The D3-DA 3xx/x may only be used in conjunction with recom-
mended/ approved third-party equipment/installations.
The D3-DA 3xx/x has been developed, manufactured, tested and docu-
mented in accordance with the appropriate directives and standards. There-
fore, the products do not pose any danger to the health of persons or a risk
of damage to other property or equipment under normal circumstances, pro-
vided that the instructions and safety precautions are properly observed.
The intended use also includes the attention of the notes and informations
described in this document.
The D3-DA 3xx/x provides safety functions. For more information see
"Safety functions".
For safety relevant control tasks in combination with axis module D3-DA 3xx/
x it is recommended to use the control module D3-DU 3xx/x in the variant
D3-DU 3x5/x.
Caution
Also take care of the information in the safety manual "Functional safety"
provided by KEBA.
Information
The compliance of EMC directives can only be assumed under attention of
chapter "CE Certification" as well as the information of cahpter "Connection
and wiring", also the cable and additional components are used as speci-
fied in chapter "Connection technology" and the correct dimensioning of the
mains filter is done.
1.4 Notes on this document
This manual is an integral part of the product. It is to be retained over the en-
tire life cycle of the product and should be forwarded to any subsequent
owners or users of the product. For end user necessary safety information
and information must be integrated in the instruction manual for end users in
the specific national language by the engine builder or the system provider.
This documentation must be legible and available to the specified persons
and must be read and understood from them.

D3-DA 3xx/xIntroduction
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Information
This manual also applies to identically constructed and functionally identical
customer variants of the D3-DA 3xx/x.
Because of the fact that customer variants may differ in their appearance
(e.g. with a different front cover) from the KEBA standard variant, the pic-
tured devices used in this manual may differ in their appearance from the
devices used by you.
1.4.1 Content of this document
● Description of the module
● Mounting and installation instructions
● Description of interfaces including EMC directives
● Diagnostics functions
● Maintenance
● Technical data
1.4.2 Not contained in this document
● Programming instruction
● Application diagnosis
● Firmware description
● General functional safety information
● Examples for safety applications
1.5 Documentation for further reading
Depending on the using system solution the following documents are to be
observed:
Doc.No. Name Target group
System manual
● Project engineer
● Electrician
● Programmer
● Start-up operator
● Service technician

D3-DA 3xx/x Introduction
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© KEBA
Doc.No. Name Target group
DE: 1008535
EN: 1008536
KEBA - Functional safety
safety manual
● Safety engineer for "functional safety"
● Project engineer
● Electrician
● Programmer
● Start-up operator
● Service technician
DE: 1008773
EN: 1008774
KeDrive Firmware for drive
control devices
● Electrician
● Programmer
● Start-up operator
● Service technician
Onlinehelp DriveManager
● Programmer
● Start-up operator
● Service technician
DE: 1008643
EN: 1008666
D3-DP 3xx/x Project engi-
neering manual
● Project engineer
● Electrician
● Start-up operator
● Service technician
Information
This project engineering manual exclusively describes the D3-DA 3xx/x.
You can find information about further components in the respective project
engineering manual.
1.6 EtherCAT declaration
EtherCAT® is registered trademark and
patented technology, licensed by Beckhoff
Automation GmbH, Germany.

D3-DA 3xx/xSafety notes
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2 Safety notes
2.1 Representation
At various points in this manual, you will see notes and precautionary warn-
ings regarding possible hazards. The symbols used have the following
meaning:
DANGER!
indicates an imminently hazardous situation, which will result in death or se-
rious bodily injury if the corresponding precautions are not taken.
WARNING!
indicates a potentially hazardous situation, which can result in death or seri-
ous bodily injury if the corresponding precautions are not taken.
CAUTION!
means that if the corresponding safety measures are not taken, a potentially
hazardous situation can occur that may result in slight bodily injury.
Caution
means that damage to property can occur if the corresponding safety mea-
sures are not taken.
ESD
This symbol reminds you of the possible consequences of touching electro-
statically sensitive components.
Safety information
Describes important safety-related requirements or informs about essential
safety-related coherences.
Information
Identifies practical tips and useful information. No information that warns
about potentially dangerous or harmful functions is contained.

D3-DA 3xx/x Safety notes
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2.2 General safety instructions
WARNING!
Safety and operating instructions for drive converters (acc. to: Low
voltage directive 2014/35/EU):
● During operation, drive power converters can, in accordance with their
degree of protection, have life, bare, possibly even moving or rotating
parts, as well as hot surfaces.
● Inadvertently removing the necessary covering, inappropriate use, incor-
rect installation or operation causes the risk of severe personal injuries,
material damage or even fatal injuries.
● Further information can be found in the product documentation. Com-
missioning is not permitted if the product documentation is missing. In
this case you should immediately ask for a new product documentation.
● Commissioning is only permitted for persons, who understand the lan-
guage of the enclosed product documentation.
● All work concerning transportation, installation and commissioning as
well as repair and maintenance must only be carried out by qualified ex-
pert personnel.

D3-DA 3xx/xSafety notes
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WARNING!
● It is absolutely essential that you also observe the safety instructions in
the system manual and the "Functional safety" manual for your automa-
tion system.
● The following application areas are expressly excluded for the D3-DA
3xx/x without completing a special evaluation relating to the application
and implementing the necessary measures in the installation relating to
the operating conditions:
● Use in areas where there is a risk of explosion or fire
● Use in the mining sector
● Use in outdoor areas
● Use in wet rooms or rooms with the risk of splashing water
● Use in environments with heavily polluted air
● Use in environments with harmful solutions, steams or radiations
● Use in non-stationary applications
● Usage in environments with constant vibrations
● Direct use on a DC motor
● The module is defined as "open type equipment" (UL 508) or as "open
equipment" (EN 61131-2) and must therefore be installed in a control
cabinet.
● The D3-DA 3xx/x contains safety-relevant functions (e.g. STO). For
safety-relevant control tasks and personnel security a control of KEBA in
the variant D3-DU 3x5/x with correspondent safety related peripheral de-
vices must be used. Details can be found in the safety manual "Func-
tional safety".
● At the developement of the D3-DU 3x0/x the standard EN ISO 13849-1
or other standards for description of the functional safety were not con-
sidered.
WARNING!
Danger of personal injury due to loss of security!
Correct operation and safety of damaged components cannot be guaran-
teed. Damaged products must never be installed or put into operation. De-
fective products must be replaced immediately.

D3-DA 3xx/x Safety notes
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Caution
Improper use of the assembly or the control system leads to irreparable
damage!
● Turn off the power supply before inserting or removing the module. Oth-
erwise, the module can be destroyed or undefined signal states can lead
to damage of the control system.
● If there are further power supply units in the system, they must also be
turned off, to ensure that no electrical voltages are present at the inputs
(and possibly the relay outputs) of the safety control.
KEBA shall assume no liability or warranty for consequential losses, which
may arise of:
● Disregard of directives and standards
● Illegal changes
● Improper use
● Disregard of instructions in this document
Information
If information about potentially dangerous incidents of the machine or sys-
tem is obtained in the course of product monitoring obligation, which could
be related to products delivered by KEBA, report these promptly to KEBA.
Furthermore, it is asked to send all safety-oriented products that have failed
due to a defect for purposes of analysis to KEBA, even if they are consid-
ered as non-repairable.

D3-DA 3xx/xSafety notes
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2.3 Safety instructions for personal safety
WARNING!
Danger of personal injury due to electric shock
● Cut-off control from all power supplies during installation and service. If
the D3-DA 3xx/x is supplied by a D3-DP 3xx/x whose both supply termi-
nals (Line IN and Line IN Aux) must be separated from power (e.g. via
switching a joint main switch mechanism).
● If the D3-DA 3xx/x is supplied by a D3-DP 3xx/x 3 minutes have to be
waited after switching-off due to dangerous residual voltage at the d.c.
link. Afterwards the absence of voltage has to be verified. Only then the
supply rails and the remaining covers may be opened.
● Protective low voltage circuits must always be installed safely insulated
separated from circuits with dangerous voltage.
WARNING!
Dangerous voltage may be applied to the device, even if the device does
not emit any visual or audible signals/indications!
CAUTION!
Protection against magnetic and/or electromagnetic fields during in-
stallation and operation!
Persons fitted with heart pacemakers, metallic implants and hearing aids
etc. must not be allowed access to the following areas:
● Areas where drive systems are installed, repaired and operated.
● Areas where motors are installed, repaired and operated. Motors with
permanent magnets pose a particular hazard.
If it is necessary to access such areas, suitability to do so must be deter-
mined beforehand by a doctor.
2.4 Safety instructions for device maintenance
WARNING!
● If this device is damaged, the device must be taken out of commission
and repaired or replaced by trained specialized personnel.
● The device must only be opened by trained specialized personnel. They
must only carry out maintenance work that is explicitly permitted by
KEBA (see chapter "Maintenance").

D3-DA 3xx/x Safety notes
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Any other manipulations to the device will result in loss of warranty.
2.5 ESD information
Electronic component are generally put at risk by electro-static discharges
(Electro Static Discharge). An electro-static charge can occur during any ac-
tivity involving movement. ESD can occur with any touch.
Most discharges are so low that they are not noticeable. However, they can
nevertheless put unprotected electronic components at risk or even destroy
them. Therefore, any handling with open electronics is only permissible with
the application of effective ESD protection.
When handling open electronics, please follow the following ESD measures:
● Only touch open electronics if this is absolutely necessary.
● Wear a conductive ESD wristband.
● Use conductive mats.
● Establish a conductive connection between device/system, mat, wrist-
band, and grounding connection.
● Cotton work clothes are preferred over synthetic fiber materials.
● Keep work area free of highly isolating materials (e.g. Styrofoam, plas-
tics, nylon, ...).
● Use ESD protection even for defective modules.
Generally avoid, for modules which are mounted in an enclosure, direct con-
tact with any accessible electronic components, such as non-equipped ter-
minals.

D3-DA 3xx/xDescription of module
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3 Description of module
The D3-DA 3xx/x is an axis module and is available in different performance
ranges and variants.
3.1 Front view
The following graphic shows the full expansion of each size, depending on
variant less interfaces can be on the module.
Fig.3-1: Front side D3-DA 3xx/x
1 ... D3-DA 3xx/x size 1 2 ... D3-DA 3xx/x size 2
3 ... Status-LEDs of axis 4 ... EtherCAT interface
5 ... Digital inputs 6 ... Encoder interface
7 ... Digital inputs safety function
3.2 Bottom view
The following graphic shows the full expansion of each size, depending on
variant less interfaces can be on the module.