SIGMA TEK DIAS-Drive 2000 User manual

Date of creation: 24.09.2021 Version date: 24.09.2021 Article number: XX-XXX-XXXX-E
DIAS-Drive 2000
Power/Axes & Axes Modules
Operating Manual

Publisher: SIGMATEK GmbH & Co KG
A-5112 Lamprechtshausen
Tel.: [phone]
Fax: [phone]
Email: [email protected]
WWW.SIGMATEK-AUTOMATION.COM
Copyright © 2021
SIGMATEK GmbH & Co KG
Translation from German
All rights reserved. No part of this work may be reproduced, edited using an electronic system, duplicated or
distributed in any form (print, photocopy, microfilm or in any other process) without express permission.
We reserve the right to make changes in the content without notice. SIGMATEK GmbH & Co KG is not responsible
for technical or printing errors in this handbook and assumes no responsibility for damages that occur through
its use.

POWER/AXES & AXES MODULES DIAS-DRIVE 2000
Power/Axes & Axes Modules DIAS-Drive 2000
The DIAS-Drive 2000 series contains the power/axis modules and axis modules for a power
input voltage of 400/480 V AC. The system is currently available in 3 different sizes. In the
following document, the MDP/MDD 21XX series are referred to as “size 1”, devices of the
MDP/MDD 22XX series as “size 2” and MDP 23xx series devices as “size 3”.
In the power/axis modules (MDP), as well as the axis modules (MDD), up to 3 servo amplifiers
are integrated. With a power/axis module, several axis modules can be powered.
The DIAS-Drive 2000 is a complete servo drive system for the low to mid power range, which
can also be used for applications high control performance. It is completely integrated into the
LASAL design environment.
The power/axis module and axis modules are mounted directly onto the control cabinet wall.
No mounting plate is required.
The current, speed and position control operates with a cycle time of 62.5 µs. DIAS-Drive
2000 is highly flexible when it comes to the connection to various feedback systems. VARAN
connects the drive systems with the machine control.
Baugröße 1 Baugröße 2 Baugröße 3
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DIAS-DRIVE 2000 POWER/AXES & AXES MODULES
Table of Contents
1 Introduction 10
1.1 Target Group/Purpose of this Operating Manual 10
1.2 Important Reference Documentation 10
1.3 Contents of Delivery 11
2 General Instructions 12
2.1 Abbreviations 12
2.2 Brief Descriptions Used 13
2.3 Available Models 13
2.3.1 Upon Request 13
3 Basic Safety Guidelines 14
3.1 Symbols Used 14
3.2 Disclaimer 16
3.3 General Safety Guidelines 17
3.4 Designated Use 19
3.5 Danger Electrical Shock 21
3.5.1 5 Safety Rules 21
3.6 Hot Surface Warning 22
3.7 Operation Modes 22
3.8 Safe State 22
3.9 Safe Inputs and Outputs 23
3.10 Software/Training 23
4 Standards and Guidelines 24
4.1 Residual Risks 24
4.2 Safety of the Machine or Equipment 25
4.3 Guidelines 25
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4.3.1 Norms 25
4.3.2 EU Conformity Declaration 26
4.4 Safety-Relevant Parameters 26
5 Description of Multi-Converter Systems 27
5.1 System Components 27
5.2 Concept 28
5.3 Function Power/Axis Module 29
5.4 Function Axis Module 29
5.5 Software Function 29
6 Safety Functions 31
6.1 Overview 31
6.2 Description of the Safety Functions 32
6.2.1 Stop Functions 32
6.2.1.1 Safe Torque Off (STO) 32
6.2.1.2 Safe Stop 1 (SS1) 33
6.2.2 Wiring Examples Safety 34
7 Technical Data 37
7.1 DC-link Circuit 37
7.2 +24 V Auxiliary Voltage 37
7.3 Axis/Motor Connection 38
7.4 Safe/Capture Inputs 38
7.5 Signal Output for Cross-Circuit Detection 38
7.6 Encoder Interface 39
7.7 Expanded MDP 2XXX Specifications 40
7.7.1 Power Supply 40
7.7.2 Ballast Resistance 40
7.8 Communication 41
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7.9 Motor Holding Brake 41
7.10 Mechanics 41
7.11 Environmental Conditions 42
7.12 Miscellaneous 42
8 Mechanical Dimensions 43
8.1 Size 1 43
8.2 Size 2 44
8.3 Size 3 45
9 Connectors and Cables 46
9.1 Size 1 Overview 46
9.1.1 Size 1 Front Interfaces 46
9.1.2 Size 1 Top Interfaces 47
9.1.3 Size 1 Bottom interfaces (Power/Axis Module) 48
9.2 Size 2 Overview 49
9.2.1 Size 2 Front Interfaces 49
9.2.2 Size 2 Top Interfaces 50
9.2.3 Size 2 Bottom interfaces (Power/Axis Module) 51
9.3 Size 3 Overview 52
9.3.1 Size 3 Front Interfaces 52
9.3.2 Size 3 Top Interfaces 53
9.3.3 Size 3 Bottom Interfaces (Power/Axis Module) 54
9.4 Connector Layout 54
9.4.1 X1, X2 X3: Motor Connection 54
9.4.1.1 Pin Assignment Hiperface DSL Cable 55
9.4.1.2 Motor Temperature Cable Pin Assignment 55
9.4.2 X30 BG1: Power Supply (MDP 2102) 55
9.4.3 X30 BG1: Power Supply (MDP 2100) 56
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9.4.4 X30 BG2: Power Supply (MDP 2200) 56
9.4.5 X30 BG3: Power Supply (MDP 2300) 56
9.4.6 X31: Ballast Resistance (MDP 210X, MDP 2200, MDP 2300) 57
9.4.7 X20: +24 V Supply 57
9.4.8 X21: STO Diagnostic Relays 57
9.4.9 X22: Safe Inputs/Capture Inputs 57
9.4.10 X23: Safe Inputs/Capture Inputs/Clock Signal Outputs 58
9.4.11 VARAN Bus (Industrial Mini I/O) 58
9.4.12 X11, X12 X13: Optional Encoder Module 59
9.4.12.1 EnDat Cable Pin Assignment 60
9.4.12.2 Resolver Cable Pin Assignment 61
9.4.12.3 Hiperface Cable Pin Assignment 61
9.4.13 X10: Battery Terminal 62
9.5 Status LEDs 63
9.6 Cable Cross Sections 64
9.6.1 X1, X2, X3 (motor connection) 64
9.6.2 X30 BG1 (power supply), X31 (ballast resistor), X20 (+24 V supply) 65
9.6.3 X30 BG2 (power supply) 66
9.6.4 X30 BG3 (power supply) 66
9.6.5 X21 (STO diagnostic relay), X22 (inputs), X23 (signal output), X10 (battery
connector) 67
9.7 Cable Lengths 68
9.8 Cable Strain Relief 68
9.9 Applicable Cable Types 69
9.9.1 +24 V power supply 69
9.9.2 VARAN 69
9.9.3 DC-link Circuit 70
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9.9.4 Motor cable 70
9.9.5 Encoder Cables 70
10 Configuration and Setting 71
10.1 Training Opportunities 71
11 Electrical Configuration 72
11.1 Motor Selection 72
11.1.1 Internal 72
11.1.2 With Encoder Interface 72
11.1.3 Supplementary Specifications Encoder 73
11.2 Electrical Installation 73
11.2.1 Fuse 74
11.2.2 Guidelines for Installation and Wiring 74
11.2.3 Protective Earth Connection 75
11.2.4 Protective Earth Connection between Multiple Modules 76
11.2.5 Ground Fault Interrupter 77
11.2.6 Shield Connector Clamps 78
11.3 Guidelines for Correct EMC Control Cabinet Construction 78
11.3.1 Configuration of the Control Cabinet 79
11.3.2 Wiring 79
11.4 Using Cooling Devices 80
11.5 Pre-Start Check List 82
12 Assembly/Installation 83
12.1 Check Contents of Delivery 83
12.2 Safety Guideline 83
12.3 Position of the Mounting Holes 84
12.3.1 Size 1 84
12.3.2 Size 2 85
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12.3.3 Size 3 85
12.4 Mounting and Connecting the MDP and MDD Modules 85
12.4.1 Connecting DC-Link and VARAN 87
12.5 Installing Universal Encoder Modules 87
13 Monitoring and Warning Functions 89
13.1 Error Configuration 89
13.2 Over Temperature Protection 89
13.3 Motor Overload Protection 89
14 Decommissioning and Maintenance 90
14.1 Repairing Individual Devices 90
14.2 Maintenance 90
14.3 Exchanging the Fan 90
14.4 Forming 91
14.4.1 Forming of Capacitors 92
14.5 Restarting 93
15 Transport/Storage 94
15.1 Packaging, Transport and Storage Specifications 94
16 Maintenance 95
16.1 Repair 95
17 Accessories 96
17.1 Cable Type Key 96
17.1.1 Motor Cables 96
17.1.2 Encoder Cables 98
17.2 Encoder Modules 99
17.3 Replacement Fan 99
18 Disposal 100
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DIAS-DRIVE 2000 POWER/AXES & AXES MODULES
1 Introduction
1.1 Target Group/Purpose of this Operating Manual
This operating manual contains all information required for the operation of the product.
This operating manual is intended for:
lProject planners
lTechnicians
lCommissioning engineers
lMachine operators
lMaintenance/test technicians
General knowledge of automation technology is required.
Further help and training information, as well as the appropriate accessories can be found on
our website www.sigmatek-automation.com.
Our support team is happily available to answer your questions.
Please see our website for our hotline number and business hours.
1.2 Important Reference Documentation
This and additional documents can be downloaded from our website or obtained through
SIGMATEK Support.
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1.3 Contents of Delivery
1x DIAS-Drive 2000 Component
Power/Axis Module MDP:
l2x VARAN Mini-I/O-Block (VARAN IN/VARAN OUT)
l2x DC-link covers
lUniversal encoder module (optional)
lrequired opposing connector
Axis Module MDD:
l1x Bus Connection Block
l1x DC Connection Block
lUniversal encoder module (optional)
lrequired opposing connector
The required cables are not included with delivery (see chapter 17.1 Cable Type Key).
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DIAS-DRIVE 2000 POWER/AXES & AXES MODULES
2 General Instructions
2.1 Abbreviations
AWG American Wire Gauge
CE Communauté Européenne (Symbol for conformity with EU guidelines (manufacturer's
self-declaration))
CLOCK Clock signal
EMC Electromagnetic Compatibility
ESD Electrostatic Discharge
EN European Norm
IGBT Insulated Gate Bipolar Transistor
LED Light emitting diode
PE Protective Earth
PELV Protective Extra Low Voltage
SELV Safety Extra Low Voltage
V AC Alternating current
V DC Direct current
ISO International Organization for Standardization
IEC International Electrotechnical Commission
SIL Safety Integrity Level (safety integrity level according to IEC 62061)
PL Safety performance level according to EN ISO 13849-1
PDS Power Drive System
Cat. Safety category according to ISO 13849-1
Rx Receive
Tx Transmit
PWM Pulse width modulation
Size Construction
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BCB Bus Connection Block
DCB DC Connection Block
2.2 Brief Descriptions Used
Power/Axis Module MDP 210X, MDP 2200, MDP2300
Axis Module MDD 210X, MDD 2200
Axis Combination of control and power electronics for a motor within a module.
2.3 Available Models
Short Description Type Safety Universal
Encoder Article Number
MDP2100-DDD-03 Power/axis module with 3 x 5/15 A yes yes 09-83-100-DDD-03
MDD2100-DDD-03 Axis module with 3 x 5/15 A yes yes 09-84-100-DDD-03
MDP2200-HHH-03 Power/axis module with 3 x 10/30 A yes yes 09-83-200-HHH-03
MDD2200-HHH-03 Axis module with 3 x 10/30 A yes yes 09-84-200-HHH-03
2.3.1 Upon Request
Short Description Type Safety Universal
Encoder Article Number
MDP2100-DDD-00 Power/axis module with 3 x 5/15 A yes no 09-83-100-DDD-00
MDD2100-DDD-00 Axis module with 3 x 5/15 A yes no 09-84-100-DDD-00
MDP2200-HHH-00 Power/axis module with 3 x 10/30 A yes no 09-83-200-HHH-00
MDD2200-HHH-00 Axis module with 3 x 10/30 A yes no 09-84-200-HHH-00
MDP2300-P-00 Power/axis module with 1 x 30/90 A yes no 09-83-300-P-00
MDP2300-P-01 Power/axis module with 1 x 30/90 A yes yes 09-83-300-P-01
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DIAS-DRIVE 2000 POWER/AXES & AXES MODULES
3 Basic Safety Guidelines
3.1 Symbols Used
The following symbols are used in the operator documentation for warning and danger
messages, as well as informational notes.
DANGER
Danger indicates that death or serious injury will occur, if the specified
measures are not taken.
To avoid death or serious injuries, observe the all guidelines.
Danger indique une situation dangereuse qui, faute de prendre les
mesures adéquates, entraînera des blessures graves, voire mortelles.
Respectez toutes les consignes pour éviter des blessures
graves, voire mortelles.
WARNING
Warning indicates that death or serious injury can occur, if the specified
measures are not taken.
To avoid death or serious injuries, observe the all guidelines.
Avertissement d’une situation dangereuse qui, faute de prendre les
mesures adéquates, entraînera des blessures graves, voire mortelles.
Respectez toutes les consignes pour éviter des blessures
graves, voire mortelles.
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CAUTION
Caution indicates that moderate to slight injury can occur, if the
specified measures are not taken.
To avoid moderate to slight injuries, observe the all guidelines.
Attention indique une situation dangereuse qui, faute de prendre les
mesures adéquates, peut entraîner des blessures assez graves ou
légères.
Respectez toutes les consignes pour éviter des blessures
graves, voire mortelles.
DANGER
Electrical voltage
Tension électrique
DANGER
Danger for persons with pacemakers, implanted defibrillators or other
active implants.
Danger pour les personnes portant un stimulateur cardiaque, un
défibrillateur implanté ou d'autres implants actifs
WARNING
Hot Surfaces
Surfaces chaudes
CAUTION
Danger for ESD-sensitive components.
Les signes de danger pour les composants sensibles aux décharges
électrostatiques.
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DIAS-DRIVE 2000 POWER/AXES & AXES MODULES
WARNING
Magnetic field warning
Alerte au champ magnétique
INFORMATION
INFORMATION
Provides important information on the product, handling or
relevant sections of the documentation, which require particular
attention.
3.2 Disclaimer
INFORMATION
The contents of this operating manual were prepared with the greatest
care. However, deviations cannot be ruled out. This operating manual is
regularly checked and required corrections are included in the subsequent
versions. The machine manufacturer is responsible for the proper
assembly, as well as device configuration. The machine operator is
responsible for safe handling, as well as proper operation.
The current operating manual can be found on our website. If necessary,
contact our support.
Subject to technical changes, which improve the performance of the
devices. The following operating manual is purely a product description. It
does not guarantee properties under the warranty.
Please thoroughly read the corresponding documents and this operating
manual before handling a product.
SIGMATEK GmbH & Co KG is not liable for damages caused
through, non-compliance with these instructions or applicable
regulations.
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3.3 General Safety Guidelines
The Safety Guidelines in the other sections of this operating manual must be observed. These
instructions are visually emphasized by symbols.
INFORMATION
According to EU Guidelines, the operating manual is a component of a
product.
This operating manual must therefore be accessible in the vicinity of the
machine since it contains important instructions.
This operating manual should be included in the sale, rental or transfer of
the product, or its online availability indicated.
Maintain this operating manual in readable condition and keep it
accessible for reference.
Regarding the requirements for Safety and health connected to the use of
machines, the manufacturer must perform a risk assessment in
accordance with machine guidelines 2006/42/EG before introducing a
machine to the market. Before commissioning this product, check that
conformance with the provisions of the 2006/42/EG guidelines is correct.
As long as the machine with which the product should be used does not
comply with the guideline, operating this product is prohibited.
Operate the unit with devices and accessories approved by SIGMATEK
only.
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DIAS-DRIVE 2000 POWER/AXES & AXES MODULES
CAUTION
Handle the device with care and do not drop or let fall.
Prevent foreign bodies and fluids from entering the device.
The device must not be opened, otherwise it could be damaged!
Manipulez l’appareil avec précaution et ne le laissez pas tomber.
Empêchez les corps étrangers et les liquides de pénétrer dans l’appareil.
L’appareil ne doit pas être ouvert, sinon il risque d’être endommagé!
The module complies with EN 61800-5-1.
In combination with a machine, the machine builder must comply with EN
60204-1 standards.
For your own safety and that of others, compliance with the environmental
conditions is essential.
The control cabinet must be connected to ground correctly.
To perform maintenance or repairs, disconnect the system from the power
supply.
Le module est conforme à la norme EN61131-2.
En combinaison avec une machine, le constructeur de la machine doit
respecter la norme EN60204-1.
L’armoire de commande doit être raccordée correctement à la terre.
Pour l'entretien et les réparations, débranchez le système de
l'alimentation.
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3.4 Designated Use
The PDS of the DIAS-Drive 2000 series are designed exclusively for use in the control cabinet
with the supply /axis modules, of the same series. They are combined and installed as
components in electrical equipment and machines and can only be operated such machines
and equipment.
The Safety functions are designed for use with safety applications (functional safety) and
meet the required conditions for safe operation in compliance with EN 62061, EN ISO 13849-
1/2 and EN 61800-5-2.
For details of the safety figures achieved, see chapter 4.4 Safety-Relevant Parameters.
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DIAS-DRIVE 2000 POWER/AXES & AXES MODULES
CAUTION
The instructions contained in this operating manual must be followed.
Installation, mounting, programming, initial start-up, operation,
maintenance and decommissioning can only be performed by qualified
personnel.
Qualified personnel in this context are people, who have completed
training or have trained under supervision of qualified personnel and have
been authorized to operate and maintain safety-related equipment,
systems and facilities in compliance with the strict guidelines and
standards of safety technology (Functional Safety).
Les instructions contenues dans ce manuel technique doivent être suivies.
Pour un fonctionnement sans erreur, le transport et le stockage appropriés
sont essentiels.
L’installation, le montage, la programmation, la mise en service initiale,
l’exploitation, la maintenance et la mise hors service ne peuvent être
effectués que par une personne qualifiée.
Dans ce contexte, on entend par personnel qualifié les personnes qui ont
suivi une formation ou qui ont été formées sous la supervision d’un per-
sonnel qualifié et qui ont été autorisées à utiliser et à entretenir
l’équipement, les systèmes et les installations de sécurité conformément
aux directives et aux normes strictes de la technique de sécurité (Sécurité
fonctionnelle).
For your own safety and that of others, the safety modules should be used
for their designated purpose only.
Correct EMC installation is also included under designated use.
Pour votre propre sécurité et celle des autres, les modules de sécurité ne
doivent être utilisés qu’à des fins prévues.
Une installation CEM correcte est également incluse dans l’utilisation
prévue.
Non-designated use includes:
lany changes made to the device or the use of damaged devices
luse of the module inconsistent with the technical margins
described in this Operating Manual or the speciation's defined in
the technical data.
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