Keba D3-DA 3 Series Installation and operation manual

D3DA3xx/x
Axismodule
ProjectengineeringmanualV1.00
Translationoftheoriginalmanual

Document:V1.00/ArticleNo.:1008665
Filename:da3xx_pjen.pdf
Pages:112
©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:+4373270900,Fax:+43732730910,
[email protected]
Forinformationaboutoursubsidiariespleaselookatwww.keba.com.

D3DA3xx/x RecordofRevision
ProjectengineeringmanualV1.00 3
©KEBA
RecordofRevision
Version Date ChangesinChapter Description changedby
1.00 102014  newlycreated ekt,ekr

D3DA3xx/x
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D3DA3xx/x TableofContents
ProjectengineeringmanualV1.00 5
©KEBA
TableofContents
1 Introduction ................................................................................................................ 9
1.1 Purposeofthedocument................................................................................. 9
1.2 Preconditions ................................................................................................... 9
1.3 Intend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 Systemoverview ........................................................................................................ 20
3.1 Typeplate ........................................................................................................ 21
4 Displaysandoperatingelements ............................................................................. 23
4.1 StatusLEDsoftheaxis.................................................................................... 23
5 Mountingandinstallationinstructions .................................................................... 24
5.1 EMCrequirements ........................................................................................... 26
5.1.1 Requirementstotheconnectors........................................................ 26
5.2 Spacerequirements......................................................................................... 30
5.3 Airconditioningandventilation ........................................................................ 32
5.4 Installationofthedevicesforwallmounting .................................................... 33
5.4.1 Dimensionsandmountingclearances............................................... 33
5.5 Installationofthedevicesforcoldplate ........................................................... 36
5.5.1 Dimensionsandmountingclearances............................................... 36

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5.5.2 Mountingonthecooler ...................................................................... 38
5.5.3 Sizingthecooler ................................................................................ 40
6 Connectionsandwiring............................................................................................. 41
6.1 Singleaxismodule........................................................................................... 43
6.2 Doubleaxismodule ......................................................................................... 45
6.3 Tripleaxismodule............................................................................................ 49
6.4 Grounding ........................................................................................................ 52
6.5 Electricalisolationconcept............................................................................... 55
6.6 Connectionofsupplyvoltagesviabusbars...................................................... 55
6.6.1 24Vvoltagesupply(busbars) ........................................................... 56
6.6.2 Intermediatecircuit ............................................................................ 57
6.6.3 Overviewofbusbars .......................................................................... 58
6.7 Controlconnections ......................................................................................... 58
6.7.1 DigitalinputsonX25A(standardfunctions)....................................... 59
6.7.2 Safedigitalinputs(terminalX26A) .................................................... 60
6.7.3 Specificationoftheterminals............................................................. 60
6.8 Motorconnection ............................................................................................. 61
6.8.1 Connectiondiagrammotorconnections ............................................ 62
6.8.2 Monitoringoutputmotorholdingbrake .............................................. 64
6.8.3 Specificationofmotorconnections .................................................... 64
6.8.4 Switchinginthemotorcable.............................................................. 65
6.9 SpecificationofEtherCATinterface ................................................................. 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 Connectiondiagram......................................................................................... 69
6.12 Operationonspecialsystems.......................................................................... 70
6.13 DIPSwitch(SADR)......................................................................................... 70
7 Configuration.............................................................................................................. 71
8 Safetyfunctions ......................................................................................................... 72
8.1 STO(SafeTorqueOFF) .................................................................................. 72

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8.1.1 ConfigurationofSTOsafetyfunction................................................. 73
8.2 SBC(SafeBrakeControl)................................................................................ 74
8.2.1 ConfigurationSBCsafetyfunction..................................................... 75
8.3 Diagnosisviacrosscircuittest......................................................................... 76
8.4 Recommendedconnectionexamples.............................................................. 77
8.4.1 Example:STOandSBCcontrolviasafetycontrol ............................ 77
8.4.2 Example:STOwithoutSBCcontrolviasafetycontrol....................... 79
8.4.3 Example:STOandSBCcontrolvialightgrid .................................... 80
8.4.4 Example:STOandSBCcontroldirectlyviasupplymodule .............. 80
8.5 Validationofsafetyfunctions ........................................................................... 81
8.6 ValidationofSTOsafetyfunction..................................................................... 81
8.7 ValidationofSBCsafetyfunction..................................................................... 82
8.8 Validatecrosscircuittest ................................................................................. 82
9 Diagnosis .................................................................................................................... 84
9.1 Flashingcode................................................................................................... 84
10 Maintenance................................................................................................................ 85
10.1 Periodicalfunctionaltest .................................................................................. 85
11 Disposal ...................................................................................................................... 86
11.1 Disposalofthemodule .................................................................................... 86
11.2 Disposalofthebattery ..................................................................................... 86
12 TechnicalData ........................................................................................................... 87
12.1 D3DA3x0/x01xx,D3DA3x0/x03xx............................................................. 87
12.1.1 CurrentdataD3DA3x0/x01xx........................................................ 88
12.1.2 CurrentdataD3DA3x0/x03xx........................................................ 88
12.2 D3DA3x0/x06xx,D3DA3x0/x12xx............................................................. 89
12.2.1 CurrentdataD3DA3x0/x06xx........................................................ 90
12.2.2 CurrentdataD3DA3x0/x12xx........................................................ 91
12.3 D3DA310/x24xx,D3DA320/x16xx ............................................................ 92
12.3.1 CurrentdataD3DA310/x24xx ....................................................... 93
12.3.2 CurrentdataD3DA320/x16xx ....................................................... 93
12.4 Generalsafetyspecifications ........................................................................... 94

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12.5 Safedigitalinputs............................................................................................. 94
12.6 Ambientconditions........................................................................................... 95
13 ECdirectivesandstandards ..................................................................................... 97
13.1 ECdirectives.................................................................................................... 97
13.2 Standards......................................................................................................... 97
13.2.1 Machinesafetyandfunctionalsafety................................................. 97
13.2.2 EMCdirectives................................................................................... 97
13.2.3 Electricalsafetyandfireprotection.................................................... 97
13.2.4 Environmentalandsurroundingconditions........................................ 98
13.3 CEmarking ...................................................................................................... 98
13.4 ULcertification ................................................................................................. 98
13.5 Loadsonthemainsduetoharmonics ............................................................. 98
14 Declarationofconformity.......................................................................................... 99
15 Appendix ..................................................................................................................... 103
15.1 Accessories...................................................................................................... 103
15.2 Connectiontechnology .................................................................................... 103
15.2.1 ConnectioncableXWP0xxxx .......................................................... 104
15.2.2 ConnectioncableXWH0xxxx .......................................................... 104
15.2.3 SignalcableXWE10xxx .................................................................. 105
15.2.4 SignalcableXWR10xxx .................................................................. 106
15.2.5 SignalcableXW020 ......................................................................... 107
15.3 Selectionofmainsfilter.................................................................................... 108
Glossary ...................................................................................................................... 109
Index ............................................................................................................................ 111

D3DA3xx/x Introduction
ProjectengineeringmanualV1.00 9
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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adressed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,
● Specialriskpotentialofthemachine/systemandthepro
ductionprocess
● Specificprotectivemeasurestoavertmachinespecific
hazards(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according
tonationalandinternationalguidelines.
Programmers
Technicaltraining(UniversityofAppliedScience,engineering
degreeorcorrespondingprofessionalexperience).
Knowledgeabout:
● Currentvalidsafetyregulations,
● MethodofoperationofaPLC,
● Programmingofasafe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,
● 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 Intend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.
Requirementsforacorrectoperationwithfunctionalsafety:
● Correctprojectingofthesystem
● Correctandcompleteinstallationofallcomponentsincompliancewith
thespecifiedconditions
● Correctandcompletewiringofallcomponents
● Verificationandvalidationofallsafetyfunctions
● ComplianceofrequirementsofMachineryDirectiveandifnecessarylo
callawsforacompletemaschine
Information
ThecompilanceofEMCdirectivescanonlybeassumedunderattentionof
chapterCECertificationaswellastheinformationofconnectionandwiring,
alsothecableandadditionalcomponentsareused(specfiedinchapter15
Appendix)andathedimension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.

D3DA3xx/xIntroduction
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Thisdocumentationmustbelegibleandavailabletothespecifiedpersons
andmustbereadandunderstoodfromthem.
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D3DA3xx/xstandardvariant,the
pictured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instructions
● 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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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
Onlinehelp DriveManager
● Programmer
● Startupoperator
● Servicetechnician
Information
ThisprojectengineeringmanualexclusivelydescribestheD3DA3xx/x.
Youcanfindinformations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.

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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propertyinjuryorslight
bodilyinjury.
Caution
CAUTIONusedwithoutthesafetyalertsymbolindicatesapotentiallyhaz
ardoussituationwhich,ifnotavoided,mayresultindamagetoproperty.
ESD
Thissymbolremindsyouofthepossibleconsequencesoftouchingelectro
staticallysensitivecomponents.
Information
Usefulpracticaltipsandinformationontheuseofequipmentareidentified
bythe“Information”symbol.Theydonotcontainanyinformationthatwarns
aboutpotentiallydangerousorharmfulfunctions.

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2.2 Generalsafetyinstructions
DANGER!
Safetyandoperatinginstructionsfordriveconverters(acc.to:Low
voltagedirective2006/95/EC).
● 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ifyouunderstandthelanguageofthe
productdocumentation.Otherwisecommissioningmustbeperformedby
aspecialistwhounderstandsthelanguage.
● Allworkconcerningtransportation,installationandcommissioningas
wellasrepairandmaintenancemustonlybecarriedoutbyqualifiedex
pertpersonnel.

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WARNING!
● Itisabsolutelyessentialthatyoualsoobservethesafetyinstructionsin
thesystemmanualandthesafetymanual"Functionalsafety"foryour
automationsystem.
● ThefollowingareasofapplicationareexpresslyexcludedfortheD3DA
3xx/x:
● 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
● UsewithadirectlyconnectedDCmotor
● Otherproductsaretobeusedfortheseapplications!
● 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DA3xx/xthestandardENISO138491
orotherstandardsfordescriptionofthefunctionalsafetywasnotconsid
ered.
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.
Otherwise,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
turnedoff,toensurethatnoelectricalvoltagesarepresentattheinputs
(andpossiblytherelayoutputs)ofthesafetycontrol.
Caution
● Correctoperationandsafetyofdamagedcomponentscannotbeguar
anteed.Damagedproductsmustneverbeinstalledorputintooperation.
Defectiveproductsmustbereplacedimmediately.

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Information
Duetoproductmonitoringobligationweaskyoutoreportpromptleyto
KEBAanypossiblepotentiallydangerousincidents,whicharerelatedto
KEBAsafetytechnology.
Furthermore,itisaskedtosendallsafeproductsthathavefailedduetoa
defectforpurposesofanalysistoKEBA,eveniftheyareconsideredasir
repairable.
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

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2.3 Safetyinstructionsforpersonalsafety
WARNING!
Dangerofpersonalinjuryduetoelectricshock!
● Cutoffmodulefrompowersupplyduringinstallationandservice.Ifthe
D3DA3xx/xissuppliedbyaD3DP3xx/xwhosebothsupplyterminals
(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youhavetowaitupto3
minutesafterswitchingoffuntilnomoredangerousresidualvoltageisat
theintermediatecircuit.Onlyafterverificationofabsenceofvoltagethe
supplyrailsmaybeopenedandtheremainingcoverscanbeopened.
● Protectivelowvoltagecircuitsmustalwaysbeinstalledsafelyinsulated
separatedfromcircuitswithdangerousvoltage.
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").

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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/xSystemoverview
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3 Systemoverview
Illustration31:Systemoverview
1...HMI(Operating) 2...D3DU3xx/xcontrolmodule
3...D3DP3xx/xsupplymodule 4...D3DA3xx/xaxismodulesize1
5...D3DA3xx/xaxismodulesize2
Assignmentnumberofaxes,nominalcurrentandsize
Axismodule
with...
Size1
RatedcurrentInenn,eff[A]
Size2
RatedcurrentInenn,eff[A]
1axis 1,5A 3A 6A 12A  16A 24A
In
prepa
ration:
32