Metronix DIS-2 310/2 FB FS STO User manual

General Page 1
Decentral Intelligent Servo DIS-2 310/2 FB
Mounting Instructions
Version 1.4
Metroni Meßgeräte und Elektronik GmbH Telefon: [phone]
Kocherstraße 3 Telefa : [phone]
D-38120 Braunschweig E-mail: vertrieb@metroni .de
Germany

Page 2 General
1 General
1.1 Documentation
This installation information serves the purpose of a safe use of the DIS-2 310/2 FB series servo
positioning controller. It contains safety notes, which must be complied with.
Further information can be found in the following manuals of the DIS-2 product range:
Product Manual “DIS-2 310/2 FB”: Description of the device functionality as well as notes of the
operation of the servo positioning controller DIS-2 310/2 FB.
ANopen Manual “DIS-2”: Description of the implemented CANopen protocol as per DSP402.
Profibus Manual “DIS-2”: Description of the implemented PROFIBUS-DP protocol.
Ether AT Manual “DIS-2”: Description of the implemented EtherCAT protocol.
Software Manual: Description of the device functionality and the software functions of the
firmware including RS232 communication. Description of the parameterisation program DIS-2
ServoCommanderTM with instructions of the commissioning of an DIS-2 series servo positioning
controller
1.2 Order numbers DIS-2 310/2 FB
DIS-2 310/2 FB CANopen: 9019-3103-00
DIS-2 310/2 FB PROFIBUS: 9019-3103-04
DIS-2 310/2 FB EtherCAT: 9019-3103-05
Auxiliary equipment
Brake resistor: 9519-0002-00 Connector set: 9019-3120-00
Input line filter: 9504-0005 RS232-cable: 9019-0221-00
Control panel: 9019-0330-00

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2 Safety notes for electrical drives and
controllers
2.1 Used symbols
Information
Important information and notes.
Caution!
Non observance may result in severe property damages.
DANGER!
Non observance may result in property damages and in personal injuries.
aution! Dangerous voltages.
The safety note indicates a possible perilous voltage.
2.2 General notes
In the case of damage resulting from non-compliance of the safety notes in this manual Metroni
Meßgeräte und Elektronik GmbH will assume any liability.
Sound and safe operation of the servo drive controller requires proper and professional transportation,
storage, assembly and installation as well as proper operation and maintenance. Only trained and
qualified personnel may handle electrical devices:
TRAINED AND QUALIFIED PERSONNEL
in the sense of this product manual or the safety notes on the product itself are persons who are
sufficiently familiar with the setup, assembly, commissioning and operation of the product as well as all
warnings and precautions as per the instructions in this manual and who are sufficiently qualified in
their field of e pertise:
Education and instruction or authorisation to switch devices/systems on and off and to ground
them as per the standards of safety engineering and to efficiently label them as per the job
demands.
Education and instruction as per the standards of safety engineering regarding the maintenance
and use of adequate safety equipment.
First aid training.
The following notes must be read prior to the initial operation of the system to prevent personal injuries
and/or property damages:
These safety notes must be complied with at all times.
Do not try to install or commission the servo drive controller before carefully reading all safety
notes for electrical drives and controllers contained in this document. These safety instruct-
ions and all other user notes must be read prior to any work with the servo drive controller.

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In case you do not have any user notes for the servo drive controller, please contact your
sales representative. Immediately demand these documents to be sent to the person
responsible for the safe operation of the servo drive controller.
If you sell, rent and/or otherwise make this device available to others, these safety notes must
also be included.
The user must not open the servo drive controller for safety and warranty reasons.
Professional control process design is a prerequisite for sound functioning of the servo drive
controller!
DANGER!
Inappropriate handling of the servo drive controller and non-compliance of the
warnings as well as inappropriate intervention in the safety features may result in
property damage, personal injuries, electric shock or in extreme cases even death.
2.3 Danger resulting from misuse
DANGER!
High electrical voltages and high load currents!
Danger to life or serious personal injury from electrical shock!
DANGER!
High electrical voltage caused by wrong connections!
Danger to life or serious personal injury from electrical shock!
DANGER!
Surfaces of device housing may be hot!
Risk of injury! Risk of burning!
DANGER!
Dangerous movements!
Danger to life, serious personal injury or property damage due to unintentional
movements of the motors!

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2.4 Safety notes
2.4.1 General safety notes
The servo drive controller corresponds to IP54 class of protection as well as pollution level 1.
Make sure that the environment corresponds to this class of protection and pollution level.
Only use replacements parts and accessories approved by the manufacturer.
The devices must be connected to the supply as per EN regulations, so that they can be cut
off the mains supply by means of corresponding separation devices (e.g. main switch,
contactor, power switch).
The servo drive controller may be protected using an AC/DC sensitive 300mA fault current
protection switch (RCD = Residual Current protective Device).
Gold contacts or contacts with a high contact pressure should be used to switch the control
contacts.
Preventive interference rejection measures should be taken for control panels, such as
connecting contactors and relays using RC elements or diodes.
The safety rules and regulations of the country in which the device will be operated must be
complied with.
The environment conditions defined in the product documentation must be kept. Safety-
critical applications are not allowed, unless specifically approved by the manufacturer.
The compliance with the limits required by national regulations is the responsibility of the
manufacturer of the machine or system.
The technical data and the connection and installation conditions for the servo drive controller
are to be found in this product manual and must be met.
DANGER!
The general setup and safety regulations for work on power installations (e.g. DIN, VDE,
EN, IEC or other national and international regulations) must be complied with.
Non-compliance may result in death, personal injury or serious property damages.
Without claiming completeness, the following
regulations and others apply:
VDE 0100
EN 60204-1
EN 50178
EN ISO 12100
EN 1050
EN 1037
EN 954-1 Safty-related parts of control systems

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2.4.2 Safety notes for assembly and maintenance
The appropriate DIN, VDE, EN and IEC regulations as well as all national and local safety regulations
and rules for the prevention of accidents apply for the assembly and maintenance of the system. The
plant engineer or the operator is responsible for compliance with these regulations:
The servo drive controller must only be operated, maintained and/or repaired by personnel
trained and qualified for working on or with electrical devices.
Prevention of accidents, injuries and/or damages:
Additionally secure vertical a es against any kinde of dangerous movementsor
loweringfragwürdige Formulierung falling down after the motor has been switched off, e.g.
by means of:
Mechanical locking of the vertical a le,
E ternal braking, catching or clamping devices or
Sufficient balancing of the a le.
The motor holding brake supplied the whole timell das heißen?was soby default or an
e ternal motor holding brake driven by the drive controller alone is not suitable for personal
protection!
Render the electrical equipment voltage-free using the main switch and protect it from being
switched on again until the DC bus circuit is discharged, in the case of:
Maintenance and repair work
Cleaning
long machine shutdowns
Prior to carrying out maintenance work make sure that the power supply has been turned off,
locked and the DC bus circuit is discharged.
The e ternal or internal brake resistor carries dangerous DC bus voltages during operation of
the servo drive controller and up to 5 minutes thereafter. Contact may result in death or
serious personal injury.
Be careful during the assembly. During the assembly and also later during operation of the
drive, make sure to prevent drill chips, metal dust or assembly parts (screws, nuts, cable
sections) from falling into the device.
Also make sure that the e ternal power supply of the controller (24V) is switched off.
The DC bus circuit or the mains supply must always be switched off prior to switching off the
24V controller supply.
Carry out work in the machine area only, if AC and/or DC supplies are switched off. Switched
off output stages or controller enablings are no suitable means of locking. In the case of a
malfunction the drive may accidentally be put into action.
Initial operation must be carried out with idle motors, to prevent mechanical damages e.g. due
to the wrong direction of rotation.
Electronic devices are never fail-safe. It is the user’s responsibility, in the case an electrical
device fails, to make sure the system is transferred into a secure state.
The servo drive controller and in particular the brake resistor, e ternally or internally, can
assume high temperatures, which may cause serious burns.

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General Page 8
2.4.3 Protection against contact with electrical parts
This section only concerns devices and drive components carrying voltages e ceeding 50 V. Contact
with parts carrying voltages of more than 50 V can be dangerous for people and may cause electrical
shock. During operation of electrical devices some parts of these devices will inevitably carry
dangerous voltages.
DANGER!
High electrical voltage!
Danger to life, danger due to electrical shock or serious personal injury!
The appropriate DIN, VDE, EN and IEC regulations as well as all national and local safety regulations
and rules for the prevention of accidents apply for the assembly and maintenance of the system. The
plant engineer or the operator is responsible for compliance with these regulations:
Before switching on the device, install the appropriate covers and protections against
accidental contact. Rack-mounted devices must be protected against accidental contact by
means of a housing, e.g. a switch cabinet. The regulations VGB4 must be complied with!
Always connect the ground conductor of the electrical equipment and devices securely to the
mains supply. Due to the integrated line filter the leakage current e ceeds 3.5 mA!
Comply with the minimum copper cross-section for the ground conductor over its entire length
as per EN60617!
Prior to the initial operation, even for short measuring or testing purposes, always connect the
ground conductor of all electrical devices as per the terminal diagram or connect it to the
ground wire. Otherwise the housing may carry high voltages which can cause electrical
shock.
Do not touch electrical connections of the components when switched on.
Prior to accessing electrical parts carrying voltages e ceeding 50 Volts, disconnect the device
from the mains or power supply. Protect it from being switched on again.
For the installation the amount of DC bus voltage must be considered, particularly regarding
insulation and protective measures. Ensure proper grounding, wire dimensioning and
corresponding short-circuit protection.
The device comprises a rapid discharge circuit for the DC bus as per EN60204 section 6.2.4.
In certain device constellations, however, mostly in the case of parallel connection of several
servo drive controllers in the DC bus or in the case of an unconnected brake resistor, this
rapid discharge may be rendered ineffective. The servo drive controllers can carry voltage
until up to 5 minutes after being switched off (residual capacitor charge).

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2.4.4 Protection against electrical shock by means of protective extra-low
voltage (PELV)
All connections and terminals with voltages between 5 and 50 Volts at the servo drive controller are
protective e tra-low voltage, which are designed safe from contact in correspondence with the
following standards:
International: IEC 60364-4-41
European countries within the EU: EN 50178/1998, section 5.2.8.1.
DANGER!
High electrical voltages due to wrong connections!
Danger to life, risk of injury due to electrical shock!
Only devices and electrical components and wires with a protective e tra low voltage (PELV) may be
connected to connectors and terminals with voltages between 0 to 50 Volts.
Only connect voltages and circuits with protection against dangerous voltages. Such protection may
be achieved by means of isolation transformers, safe optocouplers or battery operation.
2.4.5 Protection against dangerous movements
Dangerous movements can be caused by faulty control of connected motors, for different reasons:
Improper or faulty wiring or cabling
Error in handling of components
Error in sensor or transducer
Defective or non-EMC-compliant components
Error in software in superordinated control system
These errors can occur directly after switching on the device or after an indeterminate time of
operation.
The monitors in the drive components for the most part rule out malfunctions in the connected drives.
In view of personal protection, particularly the danger of personal injury and/or property damage, this
may not be relied on e clusively. Until the built-in monitors come into effect, faulty drive movements
must be taken into account; their magnitude depends on the type of control and on the operating state.
DANGER!
Dangerous movements!
Danger to life, risk of injury, serious personal injuries or property damage!
For the reasons mentioned above, personal protection must be ensured by means of monitoring or
superordinated Was ist das? measures on the device. These are installed in accordance with the
specific data of the system and a danger and error analysis by the manufacturer. The safety
regulations applying to the system are also to be taken into consideration.. ?? (Are also to be taken?)
Random movements or other malfunctions may be caused by switching the safety installations off, by
bypassing them or by not activating them.

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2.4.6 Protection against contact with hot parts
DANGER!
Housing surfaces may be hot!
Risk of injury! Risk of burning!
Do not touch housing surfaces in the vicinity of heat sources! Danger of burning!
Before accessing devices let them cool down for 10 minutes after switching them off.
Touching hot parts of the equipment such as the housing, which contain heat sinks and
resistors, may cause burns!
2.4.7 Protection during handling and assembly
Handling and assembly of certain parts and components in an unsuitable manner may under adverse
conditions cause injuries.
DANGER!
Risk of injury due to improper handling!
Personal injury due to pinching, shearing, cutting, crushing!
The following general safety notes apply:
Comply with the general setup and safety regulations on handling and assembly.
Use suitable assembly and transportation devices.
Prevent incarcerations and contusions by means of suitable protective measures.
Use suitable tools only. If specified, use special tools.
Use lifting devices and tools appropriately.
If necessary, use suitable protective equipment (e.g. goggles, protective footwear, protective
gloves).
Do not stand underneath hanging loads.
Remove leaking liquids on the floor immediately to prevent slipping.

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3 Technical data
Range DIS-2 310/2 FB
Ambient conditions and qualification:
Admissible temperature ranges Storage temperature:
Housing temperature:
Ambient temperature at nominal power:
Admissible installation height Up to 1000 m above a.m.s.l., 1000 to 4000 m above
a.m.s.l. with power derating
Humidity Relative humidity up to 0%, no bedewing
Protection class IP54, dependent on mounting IP67 may be achieved
Pollution degree 1
CE conformity:
Low-voltage directive
EMC regulation
Interference emission
Interference immunity
EN 50 178
EN 61 800 – 3 (only with external line filter END-
230-4; 504-0005)
Category C2
Category C3
Dimensions and eight:
Dimensions: H*W*D 56*80*112 mm (without
mounting plate and mating
plugs)
Weight approx. 550 g
Performance data po er supply [X1]:
Input supply voltage 230 Veff  10%, approx. 2 A
Single phase supply voltage
24 V logic supply 24 V DC [± 20%] / 0,20 A 1)
internal protected with poly-
switch, triggered at approx. 1 A
1) plus supply current of the
optional holding brake and
driven I/Os of approx. 0,7 A

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Performance data po er supply [X1]:
Brake Chopper
External brake resistor
Value / continuous / pulse power
Brake Chopper is integrated;
UChop  380 V
Screwed on mounting plate
(Type: PLR of Metallux; 51 -
0002-00)
100  / 30 W / 600 W

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Motor connection specifications [X6]:
Specifications for operation with 230 Veff / THousing = 80°C
Output nominal power 300 W
Output nominal current 2 Aeff
Max. output current for 1 s 6 Aeff
PWM frequency 10 kHz
Motor temperature monitoring
[X2]:
Digital Sensor Normally closed contact: Rcold < 500 
Analogue Sensor Silicon temperature sensors KTY series
KTY81-2x0; KTY82-2x0 R25 
2000 
KTY81-1x0; KTY81-2x0 R25 
1000 
KTY83-1xx R25 
1000 
KTY84-1xx R100 
1000 
Resolver evaluation [X2]:
Suitable resolver Industry standard, single speed
Transformation ratio 0.5
Carrier frequency 10 kHz
Resolution > 12 Bit ( typ. 15 Bit)
Delay time signal detection < 200 µs
Speed resolution ca. 4 min-1
Absolute accuracy of angle detection < 10´
Max. rotational speed 16.000 min-1
Evaluation of analogue Hall sensor signals [X2]:
Suitable Hall sensors HAL400 (Micronas), SS4 5A
(Honeywell) and others
Output type: differential
analogue output, VCM = 2.0
V...3.0 V
Signal amplitude: max. 4,8 Vss
differential 1)
Resolution > 12 Bit ( typ. 15 Bit)

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Delay time signal detection < 200 µs
Speed resolution ca. 10 min-1
Absolute accuracy of angle detection < 30´
Max. rotational speed 16.000 min-1
1) Other Signal levels on request as custom specific version, please contact your local supplier.

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Evaluation of Hiperface Encoders [X2]:
Suitable Encoder Stegmann Hiperface SCS /
SCM60 ; SRS / SRM50 ; SKS36
other types – please contact
supplier
Resolution Up to 16 Bit ( depends on
number of increments)
Delay time signal detection < 200 µs
Speed resolution ca. 4 min-1
Absolute accuracy of angle detection < 5´
Max. rotational speed 6.000 min-1, 3.000 min-1 with
lines / turn at 1024
Evaluation of Six-Step-Sensors (Hall) and block commutation mode [X2]:
Suitable Six-Step-Sensors HALL-Sensors with +5 V
supply; 120 ° phase shift
between phases; open collector
or push-pull output; iout > 5 mA;
Resolution 6 steps per electric turn
Delay time signal detection < 200 µs
Speed resolution Depends on number of poles of
the motor
Max. rotational speed 3.000 min-1 with a 4 pole motor
Evaluation of Incremental encoder [X2]:
Suitable encoder pulse counts Programmable 32 to 1024
periods per turn,
is equivalent to 128 to 40 6
lines/turn
Input signal level 5 V differential inputs / RS422-
standard
Power supply for encoder +5 V / 100 mA max.
Input impedance Ri  1600 
Max. input frequency fmax > 100 kHz (pulses/s)
Digital inputs and outputs [X1]:
Logic inputs general 24V (8V...30V) active high, conforming with EN
1131-2

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Digital inputs and outputs [X1]:
DIN0
DIN1
DIN2
DIN3
Bit 0 \
Bit 1, \ Target selection for positioning
Bit 2, / 16 targets selectable from target table
Bit 3 /
DIN4 (usable as encoder input A-signal) Bit 4 \ Target Group selection
\ Target selection for positioning
/ 4 target groups with separate positioning
parameters
Bit 5 / (speed, acceleration, positioning mode e.g.)
selectable
DIN5 (usable as encoder input B-signal)
DIN6 (usable as encoder input N-signal) Control signal Start positioning
DIN7 End switch input 0
DIN8 End switch input 1
DIN Controller enable at High, clear error high-low
transition at Low
Logic outputs general 24V (8V...30V) active high, short circuit rated to GND
DOUT0 Operational state / Ready
DOUT1 Freely configurable, usable as Encoder output A-
Signal
DOUT2 Freely configurable, usable as Encoder output B-
Signal
DOUT3 (on X3) Holding brake
Incremental encoder output [X1] (DOUT1, DOUT2):
Number of lines Programmable 32 / 64 / 128 /
256 / 512 / 1024 lines / turn
Connection level 24 V single ended / maximum
20 mA output current
Output impedance Ra  300 
Limit frequency fLimit > 100 kHz (lines/s); flimit
depends on line length, data
measured with RLoad = 1 k and
CLoad = 1 nF , which equals 5 m
cable length
Incremental encoder input [X1] (DIN4, DIN5, DIN6):
Number of lines Programmable 32 / 64 / 128 /
256 / 512 / 1024 lines / turn

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Connection level 24 V single ended / 24V
(8V...30V) active high,
conforming with EN 1131-2
Max. input frequency fLimit = 50 kHz (lines/s); flimit
depends on input filter, data
measured with RInput = 13,3 k
and CInput = 470 pF
Analogue inputs and outputs [X1]:
Analogue Inputs general 10V input range, 12 Bit
resolution , differential input
stage
< 250µs delay time, Input
protection up to 30 V
AIN0 / #AIN0 Analogue input, used as an input
for the current or speed setpoint;
Pins shared with DIN0 and
DIN1
AIN1 / #AIN1 Analogue input, used as an input
for the current or speed setpoint;
Pins shared with DIN2 and
DIN4
Analogue monitor output:
AMON0
0 V...10 V output range, 8 bit
resolution, fLimit  1kHz
4 Mechanical installation
4.1 Important notes
The DIS-2 310/2 FB was originally designed for direct mounting on one side of the motor.
Optimum cooling will be achieved, if the DIS-2 310/2 FB is mounted vertical, this means that
connector X1 is directed to the floor or to the sky.
Ma imum allowable housing temperature of the DIS-2 310/2 FB is 80 °C to achieve ensure the
specified lifetime of the electronic!
The connection cable to X1 should be fi ed (to some machine parts e.g.) close to the
DIS-2 310/2 FB to achieve the ma imum reliability of the wiring.
Installation spaces: Keep a minimum distance of 100 mm to other components / motors each
above and underneath the device to ensure sufficient venting.
4.2 Position and alignment of the connectors
The DIS-2 310/2 FB contains the following connectors:
Figure : DIS-2 view into the housing – location of the connectors

General Page 18
onnectors on the main board:
X1: The only IO connector led to the outside. It includes digital and analogue inputs and outputs, as
well as the power supply and some debug signals.
X2: Is used to connect the angle encoders. It is a multifunctional interface which support the following
angle sensors:
resolver (industry standard - 10kHz e citing frequency, transfer ration 1 : 0,5)
analogue hall sensors (SIN- and COS signals)
Stegmann HIPERFACE
Incremental encoders (with differential signals, programmable from 32 to 1024 periods / turn,
which is equivalent to 128 to 4096 lines/turn)
Digital Hall sensors (si -step-encoder)
X3: Connector for the holding brake at the motor (24 V, ma . 500 mA)
X300: Connector for the brake resistor which has to be screwed on the mounting plate
X6: Connector for the three motor phases U, V ,W and PE
X8: Is an e pansion interface for the fieldbus-modules
onnectors on the fieldbus-modules ( ANopen, PROFIBUS, Ether AT):
X5: Connector for the RS232 communication to parameterise or control the DIS-2 310/2 FB
X401: Fieldbus connector which can be used for bus IN or bus OUT
X402: Second fieldbus connector for bus IN or bus OUT

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4.3 Dimensions of the housing
Figure : DIS-2 dimensions of housing

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4.4 Mounting
The electronic will be mounted directly to the motor using a seal. The mounting flange at the motor
should have a smooth surface with a circular slot to achieve the highest protection against water. With
a good construction the protective class of IP67 will be achieved. ch kein besserer sein. Vielleicht Satz
ist Scheiße mir fällt aber auAchieving the protective class of IP67 is possible by using a good
mechanical construction. It is recommended that the brake resistor is screwed on the mounting plate.
Figure : DIS-2 310/2 FB mounting example – synchronous servo motor, mounting plate
with brake resistor and servo positioning controller DIS-2 310/2 FB
Figure : Example of a mounting plate for a motor from supplier DRIVETEC