Keba KeDrive D3-DU 3 A Series Installation and operation manual

KeDrive
D3-DU 3xx/A, /B
Control module
Project engineering manual V 1.09
Translation of the original manual

Document:V 1.09
Pages: 146
© KEBA 2021
Specifications are subject to change due to further technical developments. Details presented may be
subject to correction.
All rights reserved.
KEBA Industrial Automation GmbH Reindlstraße 51, 4040 Linz, Austria
[phone], [phone], [email protected]
For information about KEBA and our subsidiaries please look at www.keba.com.

D3-DU 3xx/A, /B Record of Revision
Project engineering manual V1.09 3
© KEBA 2021
Record of Revision
Version Date Change in chapter Description Changed
by
1.00 07-2014 - Newly created swb, ekr,
hasl
1.01 08-2014 Various chapters Updates, documented review TÜV swb, ekr,
hasl
1.02 12-2016 Various chapters Chapter part update added, Technical data updated hasl
1.03 10-2018 Various chapters
Type plate updated, Overview variants updated,
Technical data updated, Mounting the module up-
dates
raud, hli,
hasl
1.04 05-2019
Description of the
module, Technical
data
Type plate updated, Technical data updated hli, hasl
1.05 05-2020
Technical data, Ap-
pendix: Response
Time
Updated Technical data to IEC61131, update re-
sponse times hasl
1.06 10-2021 Various chapters
Version 2.1.100 added, EL1918 and EP1908
added, alarms and serious errors updated, points
from package 3 added, adding modules added,
change to new company structure, UKCA, stan-
dards restructured
hasl
1.07 03-2022 Update Error list
safety control Addition of new alarms and fatal errros ext_pflueg l
1.08 09-2022
Operating behav-
ior; Various chap-
ters; UKCA
Display menu updated; FW 2.0.0.9 integrated;
UKCA declaration of conformity inserted hasl
1.09 04-23
Operating behav-
iour, Displays and
operating elements
Behaviour with missing license added, Status LED
updated hasl, rmr

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D3-DU 3xx/A, /B Table of contents
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Table of contents
1 Introduction................................................................................................................ 11
1.1 Purpose of the document................................................................................. 11
1.2 Preconditions ................................................................................................... 11
1.3 Intended use .................................................................................................... 13
1.4 Notes on this document ................................................................................... 14
1.4.1 Contents of the document................................................................. 15
1.4.2 Not contained in this document......................................................... 15
1.5 Documentation for further reading ................................................................... 15
1.6 Conformity of safety fieldbusses...................................................................... 16
1.6.1 EtherCAT declaration........................................................................ 16
1.6.2 PROFINet / PROFISafe declaration ................................................. 17
2 Safety notes ............................................................................................................... 18
2.1 Representation................................................................................................. 18
2.2 General safety instructions .............................................................................. 19
2.3 Safety instructions for personal safety............................................................. 20
2.4 Safety instructions for device maintenance ..................................................... 21
2.5 ESD information............................................................................................... 21
3 Description of the module ........................................................................................ 22
3.1 Front view ........................................................................................................ 23
3.2 Bottom view ..................................................................................................... 24
3.3 Top view........................................................................................................... 25
3.4 Type plate ........................................................................................................ 25
3.5 Overview variants ............................................................................................ 27
3.6 Storage media.................................................................................................. 28
3.6.1 Proper handling of flash storage media ............................................ 28
3.6.2 CFast card......................................................................................... 28
3.7 Accessories...................................................................................................... 30
3.7.1 CFast card......................................................................................... 30
3.7.2 Connector set.................................................................................... 30
4 Displays and operating elements ............................................................................ 32
4.1 Operating panel ............................................................................................... 32
4.1.1 LCD display....................................................................................... 32
4.1.2 Operating buttons ............................................................................. 32
4.2 Status-LEDs..................................................................................................... 33
4.2.1 Status LEDs of functional control...................................................... 33

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4.2.2 (Only for D3-DU 3x5/x) Status LEDs of safety control ...................... 34
4.3 Ethernet Gbit status LEDs ............................................................................... 34
4.4 Master fieldbus interface status LEDs ............................................................. 35
4.5 RT Ethernet slave interface LEDs.................................................................... 36
4.6 (Only for D3-DU 3x5/x) Signal indications ....................................................... 40
4.7 (Only for D3-DU 3x5/x) Acknowledge button................................................... 40
5 Mounting and installation instructions ................................................................... 42
5.1 EMC requirements........................................................................................... 42
5.2 Space requirements......................................................................................... 43
5.2.1 Dimensional drawing......................................................................... 45
5.3 Adding modules ............................................................................................... 46
5.4 Mounting the module ....................................................................................... 47
5.4.1 For wall mounting.............................................................................. 48
5.4.2 For cooling element .......................................................................... 48
5.5 Dismantling of the module ............................................................................... 49
5.6 Air conditioning and ventilation ........................................................................ 50
5.6.1 Use of air filters ................................................................................. 50
6 Connections and wiring............................................................................................ 51
6.1 General wiring information............................................................................... 51
6.2 Power supply ................................................................................................... 51
6.2.1 Connection example ......................................................................... 52
6.3 Grounding ........................................................................................................ 54
6.4 Graphic interface (DVI) .................................................................................... 56
6.4.1 Pin assignment.................................................................................. 57
6.4.2 KEBA operating panel pin assignment ............................................. 57
6.4.3 Cable and plug specification ............................................................. 58
6.5 EtherCAT interface .......................................................................................... 58
6.5.1 Pin assignment.................................................................................. 58
6.5.2 Cable and plug specification ............................................................. 58
6.6 Gigabit Ethernet interface ................................................................................ 59
6.6.1 Pin assignment.................................................................................. 59
6.6.2 Cable and plug specification ............................................................. 59
6.7 Master interface ............................................................................................... 59
6.7.1 Pin assignment.................................................................................. 60
6.7.2 Cable and plug specification ............................................................. 60
6.8 RT ethernet slave interface.............................................................................. 60
6.8.1 EtherCAT .......................................................................................... 60
6.8.2 PROFINET IO ................................................................................... 61
6.8.3 EtherNet/IP........................................................................................ 61
6.8.4 Pin assignment.................................................................................. 61
6.9 USB ports......................................................................................................... 62

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6.9.1 Cable and plug specification ............................................................. 63
6.10 (Only for D3-DU 3x5/x) Safe digital inputs (SDI) and Test outputs (TDO)....... 63
6.10.1 Pin assignment.................................................................................. 64
6.10.2 Current / Voltage curve ..................................................................... 64
6.11 (Only for Du 3x5/x) Safe digital outputs ........................................................... 65
6.11.1 Pin assignment.................................................................................. 66
6.12 (Only for D3-DU 3x5/x) Safe relay outputs ...................................................... 66
6.12.1 Pin assignment.................................................................................. 67
6.13 (Only for D3-DU 3x5/x) Digital outputs............................................................. 68
6.13.1 Pin assignment.................................................................................. 68
6.14 EMC and wiring guidelines .............................................................................. 68
7 Configuration ............................................................................................................. 69
7.1 Address settings .............................................................................................. 69
8 Operating behavior.................................................................................................... 70
8.1 Start-up ............................................................................................................ 70
8.1.1 Display during start-up ...................................................................... 70
8.2 Operating states............................................................................................... 71
8.3 Display menu ................................................................................................... 71
8.4 Operating mode of the module ........................................................................ 90
8.4.1 Failure of supply voltage ................................................................... 90
8.4.2 Response to module errors............................................................... 91
8.4.3 Switch off........................................................................................... 91
8.4.4 USB overload switch-off.................................................................... 91
8.4.5 Behavior with missing license ........................................................... 91
8.5 Battery monitoring............................................................................................ 92
8.6 Fan monitoring................................................................................................. 92
8.7 Temperature monitoring................................................................................... 92
8.8 (Only for D3-DU 3x5/x) Temperature monitoring............................................. 93
9 Diagnosis ................................................................................................................... 94
9.1 Status report .................................................................................................... 94
9.2 Crashreport...................................................................................................... 94
10 Maintenance............................................................................................................... 96
10.1 Battery.............................................................................................................. 96
10.1.1 Battery type and service life.............................................................. 96
10.1.2 Change battery ................................................................................. 96
10.2 Fan................................................................................................................... 99
10.2.1 Service life fan................................................................................... 99
10.2.2 Changing the fans............................................................................. 99
10.3 (Only for D3-DU 3x5/x) Regular function check............................................... 104

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10.4 Create backup.................................................................................................. 105
10.5 Restore backup / update firmware................................................................... 106
10.6 Part update selected components ................................................................... 108
10.7 Replacing the device........................................................................................ 109
11 Disposal...................................................................................................................... 111
11.1 Disposal of the module .................................................................................... 111
11.2 Disposal of the battery ..................................................................................... 111
12 Technical data............................................................................................................ 112
12.1 General ............................................................................................................ 112
12.2 (Only for D3-DU 3x5/x) General safety specifications ..................................... 112
12.3 Environmental conditions................................................................................. 113
12.4 Computer kernel .............................................................................................. 113
12.5 Interfaces ......................................................................................................... 113
12.6 (Only for D3-DU 3x5/x) Safe digital inputs (SDI).............................................. 114
12.7 (Only for D3-DU 3x5/x) Safe digital outputs (SDO) 0.5 A ................................ 115
12.8 (Only for D3-DU 3x5/x) Safe digital outputs (SDO) 2 A ................................... 115
12.9 (Only for D3-DU 3x5/x) safe relais outputs (SRO)........................................... 116
12.10 (Only for D3-DU 3x5/x) Test digital outputs (TDO) .......................................... 117
12.11 (Only for D3-DU 3x5/x) Digital outputs (DO).................................................... 117
12.12 Dimensions, weight.......................................................................................... 118
13 Directives, standards and regulations .................................................................... 120
13.1 EU Directives ................................................................................................... 120
13.2 Standards for checking the conformity............................................................. 120
13.3 Other standards ............................................................................................... 121
13.4 Regulations...................................................................................................... 121
13.5 Standards for the American market ................................................................. 122
14 EU Declaration of conformity ................................................................................... 123
15 UKCA .......................................................................................................................... 128
15.1 UKCA Declaration of Conformity ..................................................................... 129
16 System-wide error response characteristics.......................................................... 134
17 Appendix: Response time ........................................................................................ 136
18 Appendix: Further components ............................................................................... 139
18.1 Cooling plate and cooling element................................................................... 139
18.1.1 Cooling Element D3-XM 310-055 ..................................................... 139
18.1.2 Cooling plate D3-XM 300-060........................................................... 140

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18.1.3 Cooling plate D3-XM 300-080........................................................... 141
Index ........................................................................................................................... 142

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D3-DU 3xx/A, /B Introduction
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© KEBA 2021
1 Introduction
1.1 Purpose of the document
This document describes the structure of the control DU 3xx/x.
The product variants without enclosure (type "C") are no part of this docu-
ment, these variants are described in a separate project engineering man-
ual.
The structure of the optional integrated safety control (variant D3-DU 3x5/x)
is described also in this manual.
Additionally, the installation and configuration is described enough to obtain
an operationally ready module (except safety module). "Ready for operation"
means that the assembly is ready for the synchronization of the application.
Information
The manual is written exclusively for the target groups listed in this manual.
The machine manufacturer or system supplier must incorporate the safety
information required for end customers into the operating manual for end
customers in the applicable national language.
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.

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Target group Prerequisite knowledge and abilities
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.
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 regulations.
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.

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1.3 Intended use
The DU 3xx/x is inteded for installation stationary in electrical plants or ma-
chines and was developed to control drives.
The DU 3xx/x may only be used for the types of use described in the techni-
cal descriptions and in compliance with described technical general condi-
tions. The DU 3xx/x may only be used in conjunction with recommended/ ap-
proved third-party equipment/installations.
The DU 3xx/x has been developed, manufactured, tested and documented
in accordance with the appropriate directives and standards. Therefore, the
products do not pose any danger to the health of persons or a risk of dam-
age to other property or equipment under normal circumstances, provided
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.
CAUTION!
The DU 3xx/x in the variant D3-DU 3x0/x is not designed for safety-relevant
control tasks and is not subject to the machine directive!
For eventual safety relevant control operations use a control in the variant
D3-DU 3x5/x. The integrated safety control is programmable and determined
for the following use:
● As Emergency Stop facilities
● As safety component as defined by the EC machine directive 2006/42/
EC
● As Programmable Electronic System (PES) for risk reduction as defined
by EN 61508
● As PES for functional safety as defined by EN 62061
● As Safety-Related Parts of Control System (SRP/CS) as defined by EN
ISO 13849
● As device for establishing the safety functions acc. to EN 61800-5-2
● As logic unit for converting and processing signals in two-hand control
acc. to EN 574
Caution
For this also take care of the information in the safety manual "KEBA -
Functional safety" provided by KEBA and the SafeEdit programming manual
(online help).
Requirements for a correct operation with functional safety:
● Correct project engineering of the system

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● Correct and complete installation of all components in compliance with
the specified conditions.
● Correct and complete wiring of all components
● Creation of a complete safety application
● Verification and validation of all safety functions
● Compliance of requirements of Machinery Directive and if necessary lo-
cal laws for a complete machine
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 users, necessary safety notes and
information must be integrated in the instruction manual for end users in the
specific national language by the mechanical engineer or the system
provider.
This documentation must be legible and available to the specified persons
and must be read and understood by them.
The manual corresponds to the current state of knowledge at the time of
publication. Due to further technical developments, it is subject to changes in
content. So it is recommended to check with KEBA regularly (e.g. via web-
side), if an updated manual version suitable to the product is available.
Information
This manual also applies to the customer variants that are identical in con-
struction and function.
Because these types of customer variants occasionally differ from the
KEBA standard variant in their appearance (e.g. due to a different front
membrane), the devices pictured in this manual may differ in appearance
from the devices you are using.
This document refers to the following version of safety control:
HW-Version: 07-05
FW-Version:
● 2.0.0.2L
● 2.0.0.3
● 2.0.0.9
● 2.1.100
● 3.0.0

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The term "safe" used in the following text in any case refers to the functional
safety classification for applications up to PL acc. to EN ISO 13849-1 or SIL
acc. to EN 62061 and EN 61508. The signal level "Low" is defined as a safe
condition.
The term "not safe" refers to functions and data interfaces which do not meet
requirements of the above named standards completely or partially.
In case of ambiguity or further required information, please contact KEBA.
1.4.1 Contents of the document
● Description of the module
● Mounting and installation instructions
● Description of interfaces including EMC guidelines
● Configuration
● Operating behavior
● Diagnostics functions
● Maintenance
● Technical data
Information
Chapters and paragraphs which apply exclusively for control module vari-
ants with safety function, are separately highlighted with "only for D3-DU
3x5/x".
1.4.2 Not contained in this document
● Programming instruction
● Application description and application diagnosis
● Firmware description
● General functional safety information
● Examples for safety applications
1.5 Documentation for further reading
The following documents are to be observed:
Doc.No. Name Target group
System manual
● Project engineer
● Electrician
● Programmer
● Commissioning foreman
● Service technician

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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
● Commissioning foreman
● Service technician
Onlinehelp SafeEdit operating instruc-
tions
● Safety engineer for "functional
safety"
● Project engineer
● (Electrician)
● Programmer
● Commissioning foreman
● Service technician
1.6 Conformity of safety fieldbusses
The safety firmware of the KEBA safety control contains so-called "safety
stacks" (for FSoE, ProfiSafe), which are installed together with the underly-
ing functional stacks (for EtherCat, ProfiNet) of the original KEBA control
packages and which have been tested and certified for their conformity with
the applicable communication standards.
If the original bus stacks of the KEBA control package are not to be used for
functional fieldbus communication, the alternatively used bus stacks must
also have passed a conformance test of the respective responsible user or-
ganizations (ETG, PNO). This is the responsibility of the integrating party
(OEM).
In the absence of functional fieldbus conformity, the respective "safety stack"
is also excluded from all certificates and must not be used as a safe commu-
nication system.
1.6.1 EtherCAT declaration
EtherCAT® is registered trademark and
patented technology, licensed by Beckhoff
Automation GmbH, Germany.
Safety over EtherCAT® is a registered trade-
mark and patented technology, licensed by
the Beckhoff Automation GmbH, Germany.

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1.6.2 PROFINet / PROFISafe declaration
PROFINet® and PROFISafe® logos are registered trade marks. The use is restricted only
for members of "PROFIBUS & PROFINET International". More detailed terms for the use
can be found on the web page www.profibus.com.
Ffor the following PROFISafe Stack protocol versions integrated in the
firmware of the KEBA safety controller certificates from the PNO are avail-
able:
PROFIsafe protocol CRCs (of object files) Firmware
V 2.2
● Channel A:
0x7CDB9786
● Channel B:
0x6D57944C
● V 2.0.0.3
● V 2.1.100
● V 3.0.0
V 2.4
● Channel A:
0x4ED5D3A7
● Channel B:
0xC315AC0A
● V 2.0.0.9

D3-DU 3xx/A, /BSafety 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 correlations.
Information
Identifies practical tips and useful information. No information that warns
about potentially dangerous or harmful functions is contained.

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2.2 General safety instructions
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 DU 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 DU 3xx/x contains safety-relevant functions (e.g. STO). For safety-
relevant control tasks and personnel security a control of KEBA in the
variant with correspondent safety related peripheral devices must be
used. Details can be found in the safety manual "Functional safety".
● At the developement of the the standard EN ISO 13849-1 or other stan-
dards for description of the functional safety were not considered.
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 all connec-
tions of the module.
KEBA shall assume no liability or warranty for consequential losses, which
may arise of:
● Disregard of directives and standards

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● 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
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 DU 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 DU 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.
● Supply the control with a D3-DP 3xx/x or exclusively from power sources
that have a protective low voltage (e.g. SELV or PELV according to EN
61131-2). If a SELV power source is used, it has to be carried out as
PELV power source through grounding of the minus pole (grounding!)
● Protective low voltage circuits must always be installed safely insulated
separated from circuits with dangerous voltage.
CAUTION!
Note fire hazard during module failure
If an external power supply instead of D3-DP 3xx/x is used for 24 V DC sup-
ply of the DU 3xx/x, a 20 A fuse for the 24 V DC power supply for the final
application must be provided!