SIGMA TEK DIAS-DRIVE 210-23 User manual

DIAS-DRIVE 210-23
30.03.2021 Page 1
1 General
1.1 About this Handbook
This handbook describes the servo amplifiers for the DIAS-Drive
series. You will find additional information on the safety functions
and the existing inputs and outputs in the used VAC 013 inter-
face module in the according chapter.
The individual chapters:
•Technical Data
•Assembly and Installation
•Description of interfaces
•Servo Amplifier settings
•Accessories
•Transport, Storage, Maintenance, Disposal
Abbreviations used in this handbook
Abbreviation
Definition
AWG
American Wire Gauge
BGND
Mass for the 24 V auxiliary and braking supply
CE
Communité Europeenne
CLOCK
Clock signal
EMV
Electromagnetic tolerance
EN
European Norm
IGBT
Insulated Gate Bipolar Transistor
LED
Light emitting diode
PELV
protected Extra Low Voltage
RES
Resolver
Rint.
Internal brake resistor connection
Rtr
Brake chopper connection
V AC
Alternating current
+24 V DC
Direct current

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1General 1
1.1 About this Handbook 1
1.2 Abbreviations used in this handbook 4
1.3 Safety Guidelines 5
1.4 Servo Amplifier Components 8
1.5 European Guidelines and Standards 9
1.6 Designated Use 10
1.7 Non-Designated Use 11
1.8 Block Diagram 12
1.9 Technical Data 16
1.10 Environmental conditions, Ventilation and Mounting19
1.11 Auxiliary supply voltage 19
2Installation 20
2.1 Important Guidelines 20
2.2 Configuration of the Control Cabinet 22
2.2.1 Wiring Diagram and Pin Layout 22
2.2.2 Mechanical Construction and Mounting 24
2.2.3 Laying the motor and control cables 26
2.2.4 Connector Layout 27
2.2.5 Cable Types 27
2.2.6 External Fuse 28
2.2.7 Voltage Supply Options 29
2.2.8 Using Cooling Devices 31
2.2.9 Turn on/off response of the servo amplifier 33
2.2.10 Stop Brake Control 34
3Connections 35
3.1 Main Power supply (X1B) 35
3.2 24 V Auxiliary supply –Stop Brake Supply (X1A) 36
3.3 DC-link (X1B) 37
3.4 External brake resistance (X1B) 38
3.5 Motor connections (X3, X5) 39
3.5.1 Standard configuration 39
3.5.2 Classic Emergency-Stop (Stop-Category 0) 40
3.5.3 Personnel-Safe Stop Brake Control 41
3.6 Feedback (X6, X8) 42
3.6.1 Resolver Feedback 43
3.6.2 EnDAT®Signal Encoder 44
3.6.3 Hiperface®Signal Encoder 45
3.6.4 Sine/Cosine & TTL Encoder feedback 46

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4Maintenance 47
4.1 Exchange and Repair 47
5Appendix 49
5.1 Transport, Storage and Disposal 49
5.2 Correcting Errors 51
5.2.1 LED Display 51
5.2.2 Amplifier Malfunctions 52
5.2.3 Status Register 53
6DIAS Drive Accessories 57
6.1 Shielding Plate with Strain Relief 57
6.1.1 Mounting Instructions 57
6.2 Mounting Set 58
6.2.1 Mounting Instructions 59
6.3 Dimensions 60
7VARAN Interface for the DIAS Drive 3xx (VAC 013)
61
7.1 Technical Data 62
7.2 Mechanical Dimensions 65
7.3 Connector Layout 66
7.4 Status Displays 68
7.5 Additional Safety Information 69
7.6 Additional Information 71
7.6.1 "Safe Restart" STO (Safe Torque Off) 71
7.7 Addressing 82
7.8 Recommended Shielding for VARAN 86
7.8.1 Wiring from the Control Cabinet to an External VARAN Component87
7.8.2 Wiring Outside of the Control Cabinet 88
7.8.3 Shielding for Wiring Within the Control Cabinet 89
7.8.4 Connecting Noise-Generating Components 90
7.8.5 Shielding Between Two Control Cabinets 91

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1.2 Abbreviations used in this handbook
Danger! Electric Shock Danger of electric shock
Warning! General Danger posed by machines,
general warning
Warning! Hot Surface Temperatures over 80°C (176°F)
Important Note See handbook

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1.3 Safety Guidelines
Before installation and startup, it is important to read the documenta-
tion provided. Incorrect handling of the servo amplifier can lead to per-
sonnel injury or material damage. The technical data and connection
instructions (specification label and documentation) must be followed.
Only qualified personnel may perform tasks such as transportation, as-
sembly, Initial startup and maintenance. Qualified personnel are per-
sons familiar with the transportation, setup, assembly, initial startup
and operation of motors and possess the corresponding qualifications
for their specific job.
The machine manufacturer must perform a safety analysis for the entire
machine. The manufacturer must take appropriate measures to ensure
that no injuries or damage can be caused by unexpected movements.
Improper operation of the servo amplifier or failure to follow the follow-
ing guidelines and improper handling of the safety equipment can
cause damage to the machine, personnel injury, electrical shock or in
extreme cases, death.
Notes
Danger! Electrical shock
After disconnecting the servo amplifier from the voltage supply, a wait-time of
5 minutes is required before current conducting components in the amplifier
(i.e. clamps) can be touched or connectors removed. After turning off the
voltage supply, the internal capacitors can remain at dangerous voltage lev-
els for up to 5 minutes. For safety purposes, measure the voltage in the in-
termediate circuit and wait until the voltage is below 40 V.
The electrical connectors of the servo amplifier cannot be removed while
voltage is still applied. The possibility for arcing exists and could cause injury
as well as damage to the contacts.

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When using a ground fault interrupter in the circuit, a type B FI-switch must
be used. If a type "A" FI-switch of is used, a DC ground fault could cause a
malfunction.
Failure to follow these instructions can lead to death, serious injury or
damage to the machine.
Warning General
The use of the servo amplifier is defined by EN61800-3. In residential areas,
EMI problems can arise. In such a case, the user must take additional filter-
ing measures.
The servo amplifier contains electrostatic-sensitive components, which can
be damaged by improper handling. Before touching the servo amplifier, the
user must discharge their body by touching a grounded object with a conduc-
tive surface. Contact with highly insolated material (synthetic fiber, plastic foil
etc.) must be avoided. The servo amplifier must be placed on a conductive
surface.
The device cannot be opened. During operation, all covers and cabinet doors
must be closed to avoid the danger of death, serious health risks or material
damage.
According to their protection type, servo amplifiers can contain blank com-
ponents that are conductive. Control and power connections can have a volt-
age even when the motor is not turning.
The main voltage supply for the DIAS-Drive requires a fixed connection. If the
servo amplifier is mounted with a connector terminal to a moving machine
part, the earth connection must have a cross section of at least 10 mm2(8
AWG) due to the high residual current (>3.5 mA) of the amplifier.
The +24 V auxiliary supply voltage as well as the +24 V-BR voltage supply
for the holding brake must be galvanically separated as PELV according to
EN 60950.
Failure to follow the above safety measures can lead to severe injuries
and machine damage.

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CAUTION! Hot surface
During operation, the heat sink of the servo amplifier can reach temperatures
of over 80° C (176° F). The heat sink temperature should be checked before
handling and it may be necessary to wait until it is below 40° C (104° F).
Failure to follow the above safety measures can lead to severe injuries.
Caution! Electromagnetic Fields (EMF)
Mortal danger!
Due to the electromagnetic fields generated during operation of the servo
amplifier, people with pacemakers or implants are particularly at risk if they
are in the immediate vicinity of the device.
Caution must therefore be take to ensure that such persons maintain
the necessary safety distance of at least 2 m.

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1.4 Servo Amplifier Components

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1.5 European Guidelines and Standards
Servo amplifiers and components, which are designed for installation in electrical sys-
tems/machines for industrial use. With the installation into machines/systems, the servo
amplifier should not be operated until it has been determined that the machine/system
meets the requirements of the machine guideline 2006/42/EC and the EMV guideline
2014/30/EU.
Note: The machine manufacturer must perform a safety analysis for the
entire machine. With the appropriate measures, the manufacturer en-
sures that no injuries or damage can be caused by unexpected move-
ments.
− Conformity
With the supply of servo amplifiers within the European Union, compliance with the EMC
2014/30/EU and low voltage 2014/35/EU guidelines is mandatory.
With this servo amplifier, the harmonized standard EN 61800-5-1 (Electrical Power Amplifi-
er Systems with Adjustable Speed - part 5-1: Requirements for the Safety of Electrical,
Thermal and Energetic Demands) was used for the 2014/35/EU low voltage guideline.
With this servo amplifier, the harmonized standard EN 61800-3 (Electrical Power Amplifier
systems with Adjustable Speed - Part 3: EMC product standard including special test meth-
ods) was used for the 2014/30/EU guideline.
To meet the EMI conditions for the installation, the documentation contains detailed infor-
mation on:
•shielding
•grounding
•wiring in the control cabinet
•filters (if necessary)
The servo amplifier from the DIAS-Drive series was tested with the systems components
and the corresponding configuration described in this document.
Any change in the configuration and installation described in this document requires new
measurements to ensure that standards are met.

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1.6 Designated Use
The servo amplifier from SIGMATEK GmbH & Co KG was designed and produced with
state of the art technology. The product was tested for reliability before delivery. It is an
installed component for electrical systems and can only be operated as an integral part.
Before installation, the following conditions for designated use must be met:
•Each user of the product must read and understand the safety instructions for
designated and non-designated use.
•The machine manufacture must perform a safety analysis of the machine in or-
der to ensure that no injury or damage is caused to personnel and equipment by
unexpected movements.
•The servo amplifier must be operated under the assembly and installation condi-
tions described in this document. The environmental conditions (temperature,
protection class, humidity, voltage supply, EMI and mounting position) must be
especially observed.
•The amplifier can only be operated in a control cabinet.
•The Servo amplifier must be operated in the original condition without any me-
chanical or electrical changes.
•Mechanical or electrical defects or defective servo amplifiers may be not be
mounted or operated.
•The servo amplifier is provided for the control of synchronous servo, linear and
torque motors, as well as frequency, torque, speed or position control of asyn-
chronous motors.
•The specified rated voltage of the motor must be at least as high as the power
supply voltage of the servo amplifier (230V, 400V or 480V).
•Only motors with star-connection may be used.
•This product can lead to EMI disruptions in residential areas. In such a case, the
user must take additional filtering measures.

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1.7 Non-Designated Use
If a servo amplifier is operated according to the environmental conditions described in this
document, it is "designated use".
•Single-phase operation is not authorized as standard use, but is al-
lowed for initial startup and demonstration purposes.
•Because of salt-containing and conductive contamination, the servo
amplifier cannot be used on ships (sea operation) or in offshore ap-
plications.
•The servo amplifier cannot be operated under any environmental
conditions other than those described in this documentation (mean-
ing without a control cabinet, incorrect assembly etc.)
Special care is needed for production facilities, in which conductive material such as carbon
fiber, graphite, and cast iron chips or similar material is used. In such cases, the control
cabinet must be hermetically sealed (no ventilation with fan filters) or placed outside of the
contaminated area. Especially during the initial start-up, the danger posed by open control
cabinet doors is extremely high. Contaminated servo amplifiers may no longer be used.

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1.8 Block Diagram

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Hardware
•The main supply is connected to a rectifier, input filter and a load cir-
cuit, which reduces the load current for the electrical torque.
•IGBT –Power output stage with separate current measurement (short
circuit protected).
•Short circuit protected brake chopper with internal brake resistor. With
insufficient power, the internal resistor can be disconnected and re-
placed by an external one.
•DC link for connection to additional amplifiers.
•Auxiliary voltage for the internal supply.
•Separate voltage supply for the holding brake.
•Evaluation from the Resolver, EnDAT and Hiperface sensors.
•Micro controller system with communication for the interface

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DIAS-Drive Concept
•1 and 3-axis amplifiers to reduce machine costs. 3-axis amplifiers
have advantages through components savings
•Auto-range function to optimize the resolution of the actual current of
10 A axes, in various configurations.
•Two different mounting options.
- On a mounting plate in the control cabinet
Through-hole technology
•Large input voltage range; 3 x 230VAC-10% … 3 x 480VAC+10%
powered by TN or TT supplies with grounded neutral lines and a max-
imum symmetrical current of 5000 Aeff.
•TT supplies without grounded neutral wires require additional
measures.
•Load circuit for limiting the maximum load current in the electrical
torque.
•Fuse installed by user (phase failure is monitored by the amplifier)
•1-phase operation is possible, i.e. initial start-up
•24 V auxiliary supply, galvanically isolated for independent power.
•Separate 24 Volt connection to power the holding brakes.
•Noise filter for the main, 24V auxiliary and holding brake supplies,
class A (industrial use)
•Housing with connection for the cable shielding
•Protective functions against:
-Under or over voltage in the intermediate circuit.
-Several short circuit conditions
-Phase error in the main supply
-Brake resistance over heating
-Over temperature (heat sink, environment and motor)

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Software functions
•Modified space vector modulation (SVM) technology to reduce power
output loss.
•Field oriented current regulator (update every 62.5 µs)
•Feedback evaluation and speed controller (update every 62.5µs)
•Spline interpolation and position controller (update every 62.5µs)
•Full synchronization up to the output stage to the control frequency
with cycle times of 250µs, 500µs and 1ms to 8 ms
•The servo amplifier has a volatile data storage medium. After power-
up, the parameters are loaded to the servo amplifier through the host.
•Since FW version 1.82 the electrical rotary field frequency is limited to
599 Hz. Error bit 18 is set, if the frequency is higher than 599 Hz for
longer than one second. The drive then goes to error status. Reason
might be a too high rotational speed of the motors with a high pole
number.

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1.9 Technical Data
DIM
DIAS-Drive
SDD 210-23
Rated values
Rated input voltage (symmetrical
opposite to earth) max. 5000 Aeff.
(L1, L2, L3)
VAC
3 x 230V-10% - 480V 10% , 45 –65 Hz
Max. peak current in electrical
torque (limited by the load circuit)
A
2.5
Rated power in S1 mode
kVA
14
Rated intermediate circuit voltage
VDC
290 - 680
Over voltage protection - limit for the
intermediate circuit
VDC
450 - 900
Additional voltage supply +24V
VDC
22 - 30
Power from the additional +24
supply
W
35
Holding brake supply +24V-BR
VDC
25 - 27
Max. Holding brake current per axis
ADC
2
Holding brake voltage drop with a
load +24V-BR
VDC
Max. 1 (at 2 x 2 A Stop brake current)
Max. holding brake switching
energy
mJ
100
Rated current for axis 1 (eff. +/- 3%)
Arms
10
Max. standstill current axis 1 from
500 ms
Arms
7
Rated current for axis 2 (eff. +/- 3%)
Arms
10
Max. standstill current axis 2 from
500 ms
Arms
7
Max. total continuous current of all
axis (heat sink)
Arms
20
Peak output current axis 1 for a
max. 5s (eff. +/- 3%)
Arms
20
Peak output current axis 2 for a
max. 5s (eff. +/- 3%)
Arms
20
The loss in the power output stage
(add the average current of the 2
axes and multiply by the factor)
without brake unit loss
W /
Arms
10
Output frequency of the power
output stage
kHz
8
Maximum output current for 8 V -
feedback systems at X6, X8
mA
250
Minimum output current for 8 V -
feedback systems at X6, X8
mA
0
Maximum output current for 5 V -
feedback systems at X6, X8
mA
250
Minimum output current for 5 V -
feedback systems at X6, X8
mA
50
Maximum residual current
mA
15

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PWM frequency
kHz
8
Regulator frequency
kHz
16
Brake unit
Capacitance of the intermediate
circuit voltage
µF
700
External brake resistance
Ω
25 - 50
Internal brake resistance
Ω
25
Rated power of the internal brake
resistor
W
200
G-VMAINS =230 (rated supply voltage = 230V)
Start-up limit
VDC
420
Switch-off level
VDC
400
Over voltage protection
VDC
450
Max. rated power of the external
brake resistor
W
750
Peak internal brake resistance
power (max. 1s)
kW
6.5
G-VMAINS = 400 (rated supply voltage = 400V)
Start-up limit
VDC
730
Switch-off level
VDC
690
Over voltage protection
VDC
800
Max. rated power of the external
brake resistor
W
1200
Peak internal brake resistance
power (max. 1s)
kW
21
G-VMAINS = 480 (rated supply voltage = 480V)
Start-up limit
VDC
850
Switch-off level
VDC
810
Over voltage protection
VDC
900
Max. rated power of the external
brake resistor
W
1500
Peak internal brake resistance
power (max. 1s)
kW
27
Internal fuse
24V auxiliary supply voltage (+24V
to BGND)
-
Electronic fuse
Holding brake supply 24V-BR
(+24V-BR to BGND)
-
Electronic fuse
Brake resistance
-
Electronic protection
Resolver specfications
Exciter frequency ferr
kHz
8
Exciter voltage URef
Ueff
4
Number of poles m
-
2, 4, 6, .., 32
Resolver voltage Usin/cos, max
Ueff
2.2

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Connector types
Internal auxiliary power supply (X1A)
-
Combicon 5, 3-pin, 2.5mm²
Power supply (X1B)
-
Power Combicon 7.62, 8-pin, 4mm²
Feedback (X6, X8)
-
Sub-D 25-pin (female)
Motor (X3, X5)
-
Power Combicon 7.62, 6-pin, 4mm²
Dimensions
Height with/without connector plugs
mm
472 / 378
Width
mm
158
Depth
mm
240
Weight
KG
10

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1.10 Environmental conditions, Ventilation and Mounting
Storage conditions
Page 50
Transport conditions
Page 50
Operational environmental conditions
0 to +45°C (32 to 113°F) at rated values
+45 to 55°C (113 to 131°F) at power reduction by 2.5% / K
Humidity
Relative humidity 95%, no condensation
Installation altitude above sea level
0-2000 m without derating
> 2000 m with derating of the maximum environmental
temperature by 0.5 °C per 100 m
Pollution degree
2
Overvoltage category
III
Servo amplifier protection class
IP 20
Mounting position
Page 25
Ventilation
Forced ventilation with internal fan controller
1.11 Auxiliary supply voltage
The power supply mounted in the control cabinet, which provides the +24 V auxiliary and
brake voltage (+24V-BR), must output a galvanically isolated protective extra low voltage
(PELV) according to EN60950. Due to the start current of the electrical torque, the rated
current must be at least 5A.

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2 Installation
2.1 Important Guidelines
•When using a ground fault interrupter in the circuit, a type B FI-switch
is required. If an FI switch of type "A" is used, A DC ground fault could
cause it to malfunction. High-frequency leakage currents occur, which
must be taken into consideration when selecting the FI (e.g. Schrack
ID-B 4/XX/XX-B). Trigger diagram:
•The servo amplifier and motor must be grounded according to the
guidelines. Uncoated mounting plates must be used in the control
cabinet.
•The DIAS Drive must be connected to the ground terminal over a wire
with a cross section of at least 10 mm² (8 AWG).
•The main power supply for the DIAS Drive requires a fixed connection.
If the servo amplifier is mounted on a moving part over a connector
terminal, the ground wire must have a cross section of at least 10 mm²
(8 AWG) to avoid high leakage current (>3.5 mA).
•Before installation, the servo amplifier must be mechanically tested. If
damage resulting from transportation is determined, for example, the
amplifier cannot be used. Electronic components cannot be physically
handled.
•The rated voltage and current specifications of the servo amplifier and
motor must match. The electrical connection must correspond to the
schematicon page 35.