SIGMA TEK MDD 111-2 User manual

MDD 111-2
10.03.2021 Page 1
Axis Module 400 V/480 V MDD 111-2
1 Overview
The MDD 111-2 is an axis module for one axis with a
Rated output current of 6 A at 230 V and 4 A at 400/480 V
and a peak output current of 15 A at 230 V and 9 A at
400/480 V. This module has an amplified brake output,
which allows a higher cut-off energy.
MDD 100 is a small to midsize power range servo drive
system, especially developed for multi-axial applications
in the low, middle and high performance range.
It is fully integrated in the Lasal operating system and has
1 to 8 servo axes.
Depending on the supply module used and the motor
type, the system is a 1-phase 230 VAC or a 3-phase
400-480 VAC system.
Four axis modules are available, two single-axis modules
for 230 V and 400 V and two dual-axes module for 230 V
and 400 V, which have a scalable output current range of
the 2 axes.
The supply module and the axes modules are put on a
module carrier, which is mounted on the mounting plate of the cabinet.
The current, speed, and position control of the up to 8 axes work with a cycle time
of 62.5 µs. MDD 100 has a high flexibility in connection of various feedback systems.
VARAN connects the servo drive system to the machine controller.
Integrated safety functions “Safe Torque off” STO and “Safe Stop 1” SS1 with a high safety
level ease the integration into the safety concept of the machine.

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1Overview.....................................................................................1
1.1 Components of a servo system...................................................4
2General.......................................................................................5
2.1 About this manual.......................................................................5
2.2 Symbols used in this manual.......................................................6
2.3 Safety Instructions ......................................................................7
2.4 Conformity with European Directives ........................................10
2.5 Prescribed use..........................................................................11
2.6 Non-prescribed use...................................................................12
2.7 Nameplate ................................................................................13
2.8 Block Diagram and Concept......................................................14
2.9 Technical Data Axis Module 400 V/480 V.................................19
2.10 Ambient conditions, ventilation and mounting ...........................20
2.11 Auxiliary Power Supply .............................................................20
3Installation................................................................................21
3.1 Important instructions................................................................21
3.2 Important instructions for the Safety Function ...........................22
3.3 Planning of the switchgear cabinet............................................24
3.3.1 Connection diagram and pin assignment of the axis module................24
3.3.2 Ground ..................................................................................................26
3.3.3 Mechanical construction and mounting .................................................28
3.3.4 Connector properties.............................................................................30
3.3.5 Wire sizing.............................................................................................30
3.3.6 External Fusing .....................................................................................31
3.3.7 Usage of cooling units...........................................................................32
3.3.8 Turn on/off response of the servo amplifier...........................................34
3.3.9 Holding brake control ............................................................................35
4Safety Function........................................................................36
4.1 Implementation .........................................................................37
4.1.1 Block IN.................................................................................................37
4.1.2 Blocks AMV, OPTO 01 and OPTO 02...................................................38
4.1.3 Blocks CONTR 01, CONTR 02, AMP 01, AMP 02 and TR ...................38
4.1.4 Blocks G01 and REL01.........................................................................38
4.2 Function....................................................................................39
4.3 Function Test............................................................................41
4.3.1 Test conditions......................................................................................41
4.4 Example Connection with Switching Contacts...........................42
4.5 Example: Safety PLC Application..............................................43
5Interfaces..................................................................................45
5.1 Motor connector (X11, X21)......................................................45
5.1.1 Standard configuration ..........................................................................45
4.4.2 Classic emergency stop function (stop category 0)...............................46

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5.2 Feedback (X12, X22)................................................................47
5.2.1 Resolver Feedback................................................................................48
5.2.2 EnDat®Feedback..................................................................................49
5.2.3 Hiperface®Feedback.............................................................................52
5.2.4 Sine Encoder Feedback ........................................................................53
5.2.5 Sanyo Denki Motor................................................................................54
5.2.6 Panasonic Feedback.............................................................................55
5.2.7 BiSS C Feedback ..................................................................................56
6Maintenance ............................................................................ 57
6.1 Replace and repair ...................................................................57
7Appendix.................................................................................. 59
7.1 Transport, storage and disposal................................................59
7.2 Troubleshooting and Fault Elimination......................................61
6.2.1 LED Indication .......................................................................................61
6.2.2 Malfunction of the drive..........................................................................62
6.2.3 Status Register......................................................................................63
8VARAN Recommended Shielding.......................................... 66
8.1 Wiring from the Control Cabinet to an External VARAN
Component............................................................................... 67
8.2 Wiring Outside of the Control Cabinet.......................................68
8.3 Shielding for Wiring Within the Control Cabinet ........................ 69
8.4 Connecting Noise-Generating Components..............................70
8.5 Shielding Between Two Control Cabinets.................................71

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1.1 Components of a servo system

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2 General
2.1 About this manual
The manual describes the MDD 111-2 axis module 400 V/480 V.
The information provided is:
•Technical Data for the axis module 400 V/480 V
•Description of the safety function
•Assembly and Installation
•Interface description
•Setup of the servo drive
•Accessories
•Transport, storage, maintenance, disposal
Abbreviations used in this manual
Abbreviation
Meaning
AWG
American gauge wire
BGND
Earth of 24 V help and break supply voltage
CE
Communité Européenne
CLOCK
Clock pulse signal
EMV
Electromagnetic compatibility
EN
European standard
IGBT
Insulated Gate Bipolar Transistor
LED
Light Emitting Diode
PELV
Protected extra low voltage
RES
Resolver
V AC
AC voltage
V DC
DC voltage

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2.2 Symbols used in this manual
Danger! Shock current Danger to personnel from electricity
Caution! General General warning, see document
Caution! Hot surface Hot surface more than 80 °C (176 °F)
Important note See document

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2.3 Safety Instructions
The safety instructions must be read before installation and set-up of
the servo drive system, to prevent injury or material damage. It is
fundamental that the technical data and information for connection
requirements be followed (on the nameplate and in the documentation).
Only qualified personnel are permitted to perform activities such as
transport, installation, setup and maintenance. Properly qualified
persons are those who are familiar with the transport, assembly,
installation, setup and operation of the product.
The manufacturer of the machine must generate a safety analysis for
the entire machine. The manufacturer has to take appropriate measures
to ensure that unforeseen movements cannot cause injury or
equipment damage.
Inappropriate handling of the servo drive system or ignoring the
warnings below and inappropriate engagement in the safety
arrangement can result in equipment damage, personal injury, electric
shock or death in an extreme situation.
Annotations
Danger! Shock current
Wait at least 7 minutes after disconnecting the servo drive system from the
mains supply voltage before touching live sections of the equipment (e.g.
contacts) or undoing connections. Capacitors can still have dangerous
voltages levels for up to 7 minutes after switching off the supply voltages. To
be sure, measure the voltage in the DC-link circuit and wait until it has fallen
below 40 V.

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Never remove the electrical connections to the servo drive system while it is
under voltage.
There is a danger of electrical arcing with damage to contacts and danger to
personnel.
If a leakage current sensor is used in the mains supply of the servo drive
system, a leakage current sensor RCD type B must be used.
If a RCD type A or AC is used, there is a risk, that the DC ground current of
the servo drive will inhibit the leakage current sensor.
Failure to follow any one of these instructions will result in death,
serious injury or equipment damage.
Caution General
The availability of the servo drive system is limited according to EN61800-3.
This product can cause radio interference problems in living quarters. In this
case, it may be necessary for the operator to take adequate measures.
The servo drive system contains components that are sensitive to electro
static, which can be damaged by incorrect handling. Ground yourself before
touching the servo drive system by touching any grounded unpainted metal
surface. Avoid contact with highly insulating materials (artificial fabrics, plastic
film etc.). Place the servo drive on a conductive surface.
Do not open the units. Keep all covers and switchgear cabinet doors closed
during operation. Otherwise there are deadly hazards that pose a severe
danger to health or could cause material damage.
During operation, servo amplifiers may have uncovered live components,
depending on their degree of enclosure protection. Control and power
connections may be live, even if the motor is not rotating.
The leakage current of the servo drive system is higher than 3.5 mA.
Therefore particular attention has to be taken on the grounding of the servo
drive system. See technical data of the power supply modules.
The +24 V auxiliary power supply and also the power supply for the +24 V-
BR holding brake supply must be galvanically isolated with SELV output
voltage according to EN 60950.
Failure to observe these precautions can result in severe injury and
equipment damage.

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Caution! Hot surface
During operation, the housing of the servo drive can become hot and may
reach temperatures above 80 °C (176 °F).
Especially the rear side of the module carrier will get hot, if the system is not
mounted on a mounting plate in the cabinet. This is due to the related
dissipated breaking energy in the ballast resistor. See technical data of
module carrier.
Check (measure) the housing and the module rack temperature and wait until
it has cooled down below 40 °C (104 °F) before touching it.
Failure to observe this precaution can result in severe injury
Caution! Electromagnetic Fields (EMF)
Mortal danger!
Due to the electromagnetic fields generated during operation of the servo
drive system, 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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2.4 Conformity with European Directives
Servo drives are components, which are built into electrical equipment and machines for
industrial use.
The operation is forbidden, until the machine or plant fulfils the requirements defined by the
EC Directive on Machines 2006/42/EC and the Electromagnetic Compatibility (EMC)
directive 2014/30/EU.
Note: To ensure unforeseen movement, which can cause injury or
damage to personnel or property, the manufacturer of the machine
must generate a safety analysis for the machine.
−Conformity
The conformance to the Electromagnetic Compatibility (EMC) directive 2014/30/EU and the
Low voltage directive 2014/35/EU is mandatory for the supply of servo drives within the
European Community.
The harmonized standard EN 61800-5-1 (Adjustable speed electrical power drive systems -
Part 5-1: Safety requirements - Electrical, thermal and energy) is applied to the servo drive
in connection with the Low voltage directive 2014/35/EU.
The harmonized standard EN 61800-3 (Adjustable speed electrical power drive systems -
Part 3: EMC product standard including specific test methods) is applied to the servo drive
in connection with the Electromagnetic Compatibility (EMC) directive 2014/30/EU.
The correct installation to meet the EMC regulations can be found in this documentation,
particularly information on:
•shielding
•grounding
•layout of the cabinet cabling
•filters (if necessary)
The servo drives of the MDD 100 series have been tested in a defined configuration with
the system components that are described in this documentation.
Any divergence from the configuration and installation described in this documentation
means that new measurements must be made to ensure that the regulatory requirements
are met.

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2.5 Prescribed use
The servo drives of SIGMATEK GmbH & Co KG are developed and produced according to
the actual prior art. The products are fully tested before delivery, especially in terms of fail-
safe conditions.
They are components, which are built into electrical equipment and can only be used as
integral components of such equipment.
Before the products are installed, the following requirements must be fulfilled to meet the
prescribed use.
•Everyone who is working in any way with the products has to read and
understand the safety instructions, the prescribed use and the not prescribed
use.
•The machine builder has to generate a safety analysis for the machine to ensure
that unforeseen movements cannot cause injury or damage to any person or
property.
•The servo drive has to run under the mounting and installation conditions
described in this documentation, especially the environmental conditions
(temperature, protection class, humidity, mains input, EMC and the mounting
position)
•It must be mounted in a closed switchgear cabinet with minimum IP54.
•The servo drive has to be used in the way they are delivered (without any
mechanical or electrical modification).
•Do not mount or start-up mechanical or electrical damaged or faulty servo drives.
•The servo drive is intended to control synchronous servo motors in closed loop
control of torque, speed or position.
•The rated voltage of the motor must be at least as high as the setting of the
mains input voltage (230 V, 400 V or 480 V) of the servo drive.
•Only motors with star-connection may be used.
•The servo drive is developed for usage in industrial environment. If it is used in
residential areas, then an additional filter must be installed in the mains input
line.

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•Power supply modules MDP101-1 and MDP 102-1 are to be used with axis
modules MDD111-2 and MDD121-1 only.
•Drives must to be used with motors provided with over temperature sensing.
2.6 Non-prescribed use
“Prescribed use” means, that the servo drive system is used according to the environmental
conditions described in this documentation.
•It must not be used in electrical equipment on ships (service afloat) or in offshore
applications because of the conductive pollution.
•It must not be used in environmental conditions that do not meet the conditions
described in this documentation (too hot, without closed switchgear cabinet,
wrong mounting position, etc.)
Be very careful in plants, were conductive material (carbon fiber, graphite with machining of
graphite cast iron or similar) is easily purgeable in the factory floor. In this case, the
switchgear cabinet has to be sealed very carefully (no forced ventilation with blower filter) or
be placed outside the factory floor. Especially during start-up of the machine, the risk is high
because of open switchgear cabinet doors. Servo drives, which become contaminated,
cannot be used anymore.

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2.7 Nameplate

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2.8 Block Diagram and Concept
Block diagram of the Power Supply Module

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MC –system real-time control
Internal Bus Interface
Control and Communication Unit
Axis ModuleModule
Carrier
DC-link
Internal
Bus
+24V-BR
Internal
Supply
U_Treiber
Feedback –Converter
Res
En-
coder
X12, X22
Feedback
2x3
2 x 6
M
X11, X21
Motor and brake
2x2
Block diagram of the Axis Module

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Hardware
•Mains input is fed to the power rectifier, the input filter and the inrush
circuit
•DC-link connection for connecting the DC-link to other drives for power
distribution
•Regen unit with internal regen resistor.
•Auxiliary power supply input for the internal supply
•Separate power supply input for the holding brake for safety reasons
•Integrated safety functions
•Micro controller system with communication unit
•IGBT –power stage with isolated current measurement (short circuit
protected)
•Feedback converter for resolver and high resolution feedback devices
•8 digital Capture-inputs to record the momentary actual position of the
selected axis.

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Concept of the MDD 100
•Servo drive system contains of different components
- Power supply module for up to eight logical axes
- Axis module in different configurations
- Single axis module
- Dual axis module
- Module carrier in different configurations for one to 4 axis
modules
•Auto range function to optimize the resolution of the actual current
•Wide mains input voltage range 3 x 230 VAC-10% … 3 x 480 VAC+10%
directly from TN-system or TT-system with grounded neutral point
mains. TT-systems with ungrounded or missing neutral point need
additional circuitry.
•Inrush circuitry to limit the maximum charge current at switch on of the
mains contactor
•Fusing provided by the user (phase failure detection in the drive)
•24 V auxiliary supply input, electrically isolated for internal supply
•Separate 24 V input for holding brake supply
•Input EMI –filter for AC-input, 24 V auxiliary supply and holding brake
supply for class A (industrial environment)
•Safety functionality STO (Safe Torque off) and SS1 (Safe Stop 1) with
performance level „e“ according to ISO 13849 and SIL3 according to
EN 62061
•All shield connections at the housing
•Protection functions against:
-DC-link under/over voltage
-Several short circuit conditions
-Phase failure of the mains input
-Overheating of the regen resistor
-Over temperature protection (heat sink, ambient and
motor)
The overload protection is provided internally by the drive. The load current is limited to
100 % of peak output current. For the thermal protection of the motor the I²T regulation is
used.
Integral solid state short circuit protection does not provide branch circuit
protection. Branch circuit protection must be provided in accordance with the
Manufacturer Instructions, National Electrical Code and any additional local codes.

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Software functionality
•Modified space vector modulation (SVM) technique to reduce the
power stage losses
•Field oriented current controller (update time 62.5 µs)
•Feedback converter and speed controller (update time 62.5 µs)
•Spline interpolator and position controller (update time 62.5 µs)
•Full synchronization down to the power stage, to the beat of the host
controller with cycle times of 250 µs, 500 µs, 1 ms and every ms up to
8 ms
•The servo drive has no non-volatile data memory. So after switch-on,
the parameters have to be send via the host communication to the
servo drive

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2.9 Technical Data Axis Module 400 V/480 V
DIM
MDD 111-2
Article number
09-404-111-2
Rated Data
Nominal allowed mains voltage
VAC
230/ 400 / 480
Max. holding brake current per axis
ADC
1
Holding brake voltage drop from
+24 V-BR to output
VDC
Max. 1 (at 1 A holding brake current)
Maximum switching energy of the holding
brake at 100 ms cut-off time
mJ
1000
Maximum switching energy of the holding
brake at 10 ms cut-off time
mJ
130
Max. continuous sum current of all axes
(heat sink) at 230 V
Arms
-
Rated output current axis 1 (rms +/- 3 %)
at 230 V
Arms
6
Rated output current axis 2 (rms +/- 3 %)
at 230 V
Arms
-
Max. continuous sum current of all axes
(heat sink) at 400 V/480 V
Arms
-
Rated output current axis 1 (rms +/- 3 %)
at 400 V/480 V
Arms
4
Rated output current axis 2 (rms +/- 3 %)
at 400 V/480 V
Arms
-
Max. peak sum current of all axes at
230 V for max 5 sec.
Arms
-
Peak output current axis 1 for max 5 sec.
(rms +/- 3 %) at 230 V
Arms
15
Peak output current axis 2 for max 5 sec.
(rms +/- 3 %) at 230 V
Arms
-
Max. peak sum current of all axes at
400 V/480 V for max 5 sec.
Arms
-
Peak output current axis 1 for max 5 sec.
(rms +/- 3 %) at 400 V/480 V
Arms
9
Peak output current axis 2 for max 5 sec.
(rms +/- 3 %) at 400 V/480 V
Arms
-
Power stage losses (sum average
currents of the 3 axis and multiply with
factor), without regen losses
W /
Arms
10
Output frequency of the power stage
kHz
8
Regulator frequency
kHz
16
DC-Link capacitance
µF
60

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Plug types
Feedback (X12, X22))
-
Sub-D 25-pole (female)
Motor (X11, X21)
-
Phoenix GMSTB 2,5HCV/ 6-ST-7,62
Mechanics
Height
mm
155
Width
mm
60
Depth with module carrier (without/with
plugs)
mm
152/195
Weight
kg
1.2
General
Article number
09-404-111-2
Standard
UL 508C, NMMS.E336350
*) Is limited to the equivalent continuous sum current depending on axis 2
**) Is limited to the equivalent peak sum current depending on axis 2
2.10 Ambient conditions, ventilation and mounting
Storage conditions
page 59
Transport conditions
page 59
Ambient temperature in operation
0 to +45 °C (32 to 113 °F) at rated data
+45 to 55 °C (113 to 131°F) with power derating of
2.5 % / K
Humidity in operation
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
Servo drive enclosure protection class
IP 20
Mounting position
page 28
Ventilation
Forced ventilation by controlled internal fan
Replacement fan
09-404-111-Z3 (up to HW 1.10)
09-404-111-Z2 (starting from HW 1.20)
2.11 Auxiliary Power Supply
The power supply that is used for the +24 V auxiliary power supply voltage and the holding
brake supply (+24 V-BR) must be a power supply with a galvanically isolated SELV output
voltage according to EN60950. Due to the inrush current of the drive during switch-on, the
current rating must be at least 5 A.