Keba D3DP 3 Series Installation and operation manual

D3DP3xx/x
Supplymodule
ProjectengineeringmanualV1.00
Translationoforiginalmanual

Document:V1.00/ArticleNo.:1008666
Filename:dp3xx_pjen.pdf
Pages:82
©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DP3xx/x RecordofRevision
ProjectengineeringmanualV1.00 3
©KEBA
RecordofRevision
Version Date Changeinchapter Description changedby
1.00 102014  Newlycreated ekt,ekr

D3DP3xx/x
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D3DP3xx/x TableofContents
ProjectengineeringmanualV1.00 5
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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 .................................................................................................... 11
1.4 Notesonthisdocument ................................................................................... 11
1.4.1 Contentsofthe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 ............................................................. 17
2.4 Safetyinstructionsformaintenance................................................................. 17
2.5 ESDInformation............................................................................................... 18
3 Systemoverview ........................................................................................................ 19
3.1 Typeplate ........................................................................................................ 20
4 Displaysandoperatingelements ............................................................................. 22
4.1 StatusLEDs ..................................................................................................... 22
5 Mountingandinstallationinstructions .................................................................... 23
5.1 EMCrequirements ........................................................................................... 25
5.1.1 Requirementstotheconnectors........................................................ 25
5.2 Spacerequirements......................................................................................... 29
5.3 Airconditioningandventilation ........................................................................ 31
5.4 Installationofthedevicesforwallmounting .................................................... 32
5.4.1 Dimensionsandmountingclearances............................................... 32
5.5 Installationofthedevicesforcoldplate ........................................................... 34
5.5.1 Dimensionsandmountingclearances............................................... 35

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5.5.2 Mountingonthecooler ...................................................................... 36
5.5.3 Sizingthecooler ................................................................................ 38
6 Connectionsandwiring............................................................................................. 39
6.1 Grounding ........................................................................................................ 40
6.2 Electricalisolationconcept............................................................................... 42
6.3 Busbarsforthesupplyvoltages....................................................................... 43
6.3.1 24Vvoltagesupply(busbars) ........................................................... 43
6.3.2 Intermediatecircuit ............................................................................ 44
6.3.3 Overviewofbusbars .......................................................................... 45
6.4 Controlconnections(frontpanel)..................................................................... 45
6.5 SpecificationofEtherCATinterface ................................................................. 46
6.6 Specificationconnection"State"(X20A) .......................................................... 47
6.7 SpecificationrelaycontactRELOutput(X23A) ............................................... 48
6.8 Connectiondiagram......................................................................................... 49
6.9 ACmainsconnectionpowersupply................................................................. 50
6.9.1 TerminalpositionbottomsideX01A(LineIN)andX01B(LineIN
Aux) ................................................................................................... 50
6.9.2 Operationonspecialsystems............................................................ 53
6.10 ACmainsconnection24Vswitchedmodepowersupply ............................... 53
6.10.1 TerminalpositiontopsideX30A(BR)andX01C(24VDC).............. 55
6.11 Brakingchopperconnection ............................................................................ 55
6.11.1 ConnectionofanexternalbrakingresistorX30A(BR) ...................... 56
6.11.2 Brakingchopperconnectionexample................................................ 57
6.12 24VDCoutputX01C(24VDC) ..................................................................... 57
7 Configuration.............................................................................................................. 59
8 Diagnosis .................................................................................................................... 60
8.1 Flashingcode................................................................................................... 60
9 Maintenance................................................................................................................ 61
10 Disposal ...................................................................................................................... 62
10.1 Disposalofthemodule .................................................................................... 62
10.2 Disposalofthebattery ..................................................................................... 62
11 Options........................................................................................................................ 63

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11.1 24Vbackuponpowerfailure ......................................................................... 63
11.1.1 Purposeofthefunction...................................................................... 63
11.1.2 Functiondescription........................................................................... 63
11.2 Versionwithout24Vswitchedmodepowersupply......................................... 63
11.2.1 Purposeofthevariant........................................................................ 63
11.3 Versionwithintegratedbrakingresistor........................................................... 64
11.3.1 Purposeofthefunction...................................................................... 64
12 Technicaldata ............................................................................................................ 65
12.1 Ambientconditions........................................................................................... 65
12.2 Supplymodulesize1....................................................................................... 66
12.2.1 Technicaldatabrakechoppersize1 ................................................. 67
12.3 Supplymodulesize2....................................................................................... 69
12.3.1 Technicaldatabrakechoppersize2 ................................................. 70
13 ECdirectivesandstandards ..................................................................................... 72
13.1 ECdirectives.................................................................................................... 72
13.2 Standards......................................................................................................... 72
13.2.1 EMCdirectives................................................................................... 72
13.2.2 Electricalsafetyandfireprotection.................................................... 72
13.2.3 Environmentalandsurroundingconditions........................................ 72
13.3 CECertification ................................................................................................ 72
13.4 ULcertification ................................................................................................. 73
13.5 Loadsonthemainsduetoharmonics ............................................................. 73
14 Declarationofconformity.......................................................................................... 74
15 Appendix ..................................................................................................................... 78
15.1 Accessories...................................................................................................... 78
15.2 Connectiontechnology .................................................................................... 78
15.2.1 SignalcableXW020 ......................................................................... 78
15.3 Selectionofmainsfilter.................................................................................... 79
Glossary ...................................................................................................................... 80
Index ............................................................................................................................ 81

D3DP3xx/xTableofContents
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D3DP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supplymoduleD3DP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DP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.

D3DP3xx/x Introduction
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1.3 Intendeduse
TheD3DP3xx/xwasdevelopedassupplymodulefortheKEBAsystem
withatleastoneD3DA3xx/xandaappropriatemainsfilterforcontrolling
andregulatingdrives.Inmotoroperationmodethesupplymodeobtainsen
ergyofthemainspowersupplyandprovidesittotheconnectedmodulesvia
theintermediatecircuit.
TheD3DP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DP3xx/xmayonlybeusedinconjunctionwithrecom
mended/approvedthirdpartyequipment/installations.
TheD3DP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.
Requirementsforacorrectoperation:
● 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
● ComplianceofrequirementsofMachineryDirectiveandifnecessarylo
callawsforacompletemaschine
Information
CompliancewithEMCdirectivescanonlybeassumedifchapter14Decla
rationofconformityandthenotesaboutconnectionsandwiringwereob
served,andcablesandauxiliarycomponentsareusedaccordingto15.2
Connectiontechnologyanddimensioningofthemainsfilterwasimple
mented.
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.
Thisdocumentationmustbelegibleandavailabletothespecifiedpersons
andmustbereadandunderstoodfromthem.

D3DP3xx/xIntroduction
ProjectengineeringmanualV1.00
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Information
Thismanualalsoappliestoidenticallyconstructedandfunctionallyidentical
customervariantsoftheD3DP3xx/x.
Becauseofthefactthatcustomervariantsmaydifferintheirappearance
(e.g.withadifferentfrontcover)fromtheD3DP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 Contentsofthe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DP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DP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.

D3DP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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.

D3DP3xx/x Safetynotes
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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.
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DP
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
● Directuseona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.

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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.
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.
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
theD3DP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DP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.
● SupplythecontrolwiththeD3DP3xx/xorexclusivelyfrompower
sourcesthathaveaprotectivelowvoltage(e.g.SELVorPELVaccord
ingtoEN611312).
● 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maintenance
WARNING!
● Ifthisdeviceisdamaged,thedevicemustbetakenoutofcommission
andrepairedorreplaced.

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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.

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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

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Orderinformationsupplymodule
Thearticledesignationindicatesthedesignvariantofthesupplymodule
suppliedtoyou.Youwillfindthesignificanceoftheindividualcharactersof
theordercodeinthecolumnontheleft.
Example D3DP 3 0 0 / A  10 0 0
Product D3DP
Series 3
Version 0
Passiv 0
Powersupply 0
3x230480VAC 0
Cooling x
Coolingelement A
Coldplate B
Continouspower xx
10kW(size1) 10
22kW(size2) 22
Controlmodulesupply x
None 0
24VDC,20A 4
24VDC,20A;withintermediatecircuit
support 5
Brakingresistor 0
External 0
3.1 Typeplate
Thetypeplateislocatedontheleftbottomsideonthemodule.