SIGMA TEK MDP 102-1 User manual

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Power Supply Module 230 V MDP 102-1
1 Overview
The MDP 102-1 is a supply module that has a 2 kVA rating
with an input voltage of 230 V. The supply module is de-
signed for the 1-phase connection, with an input voltage of
115 V, it can be powered with a 3-phase connection.
It is fully integrated in the Lasal operating system and has 1
to 8 servo axes. The MDP 102 supply module is a 1-phase
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 Prescribed use...........................................................................10
2.5 Non-prescribed use....................................................................12
2.6 Nameplate .................................................................................13
2.7 Block Diagram and Concept ......................................................14
2.8 Technical Data Power Supply Module 230 V .............................19
2.9 Safety conformity.......................................................................20
2.10 Ambient conditions, ventilation and mounting ............................21
2.11 Auxiliary Power Supply ..............................................................21
3Installation................................................................................22
3.1 Important instructions.................................................................22
3.2 Important instructions for the Safety Function............................24
3.3 Planning of the switchgear cabinet.............................................26
3.3.1 Connection diagram and pin assignment of power supply module.........26
3.3.2 Ground ...................................................................................................29
3.3.3 Mechanical construction and mounting ..................................................31
3.3.4 Connector properties..............................................................................33
3.3.5 Wire sizing..............................................................................................33
3.3.6 External Fusing.......................................................................................34
3.3.7 MDP 102-1 Mains Supply Options..........................................................35
3.3.8 Usage of cooling units............................................................................36
3.3.9 Turn on/off response of the servo amplifier............................................38
3.3.10 Holding brake control..............................................................................39
4Safety Function........................................................................40
4.1 Implementation..........................................................................41
4.1.1 Block IN..................................................................................................41
4.1.2 Blocks AMV, OPTO 01 and OPTO 02....................................................42
4.1.3 Blocks CONTR 01, CONTR 02, AMP 01, AMP 02 and TR ....................42
4.1.4 Blocks G01 and REL01..........................................................................42
4.2 Function.....................................................................................43
4.3 Function Test.............................................................................45
4.3.1 Test conditions .......................................................................................45
4.4 Example Connection with Switching Contacts............................46
4.5 Example: Safety PLC Application...............................................47
5Interfaces..................................................................................51
5.1 Mains input (X2).........................................................................51

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5.2 Auxiliary 24 V and Holding Brake supply (X2)............................53
5.3 DC-link (X2)...............................................................................54
5.4 Motor connector (X11, X21).......................................................55
5.4.1 Standard configuration............................................................................55
4.4.2 Classic emergency stop function (stop category 0).................................56
4.4.3 Personnel safe holding brake control......................................................57
5.5 Feedback (X12, X22).................................................................58
5.5.1 Resolver Feedback.................................................................................59
5.5.2 EnDat®Feedback ...................................................................................60
5.5.3 Hiperface®Feedback..............................................................................63
5.5.4 Sine Encoder Feedback..........................................................................64
5.5.5 Sanyo Denki Motor .................................................................................65
5.5.6 Panasonic Feedback ..............................................................................66
5.5.7 BiSS C Feedback....................................................................................67
6Maintenance ............................................................................ 68
6.1 Replace and repair ....................................................................68
7Appendix.................................................................................. 70
7.1 Transport, storage and disposal.................................................70
7.2 Troubleshooting and Fault Elimination.......................................72
7.2.1 Seven segment display...........................................................................72
7.2.2 LED Indication.........................................................................................72
7.2.3 Malfunction of the drive...........................................................................73
7.2.4 Status Register .......................................................................................74
8VARAN Recommended Shielding.......................................... 78
8.1 Wiring from the Control Cabinet to an External VARAN
Component................................................................................ 79
8.2 Wiring Outside of the Control Cabinet........................................80
8.3 Shielding for Wiring Within the Control Cabinet .........................81
8.4 Connecting Noise-Generating Components...............................82
8.5 Shielding Between Two Control Cabinets..................................83

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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 MDP 102-1 power supply module 230 V.
The information provided is:
•Technical Data for the power supply module 230 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 Wire Gauge
BGND
Earth of 24V 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 fun-
damental that the technical data and information for connection re-
quirements 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 per-
sons are those who are familiar with the transport, assembly, installa-
tion, 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 equip-
ment damage.
Inappropriate handling of the servo drive system or ignoring the warn-
ings below and inappropriate engagement in the safety arrangement
can result in equipment damage, personal injury, electric shock or
death in an extreme situation.

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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 volt-
ages 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 be-
low 40 V.
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 sys-
tem, 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, seri-
ous 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, de-
pending on their degree of enclosure protection. Control and power connec-
tions may be live, even if the motor is not rotating.
The leakage current of the servo drive system is higher than 3.5 mA. There-
fore particular attention has to be taken on the grounding of the servo drive
system. See technical data of the power supply modules.

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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 volt-
age according to EN 60950.
Failure to observe these precautions can result in severe injury and
equipment damage.
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 dissi-
pated 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 Prescribed use
The safety module "Safe Restart Lock" in an integral component of the DIAS Drive MDP
102-1 and is already installed with delivery; it meets the conditions required for safe opera-
tion according to SIL 3 in compliance with IEC 62061 and according to PL e in compliance
with EN 13849-1.
Safety modules can only be powered by supplies that meet the requirements for
PELV in compliance with EN60294.
Installation, mounting, programming, initial start-up, operation, maintenance and
discarding of safety modules 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 com-
pliance with the strict guidelines and standards of safety technology.
For your own safety and the safety of others, use safety modules for their
designated purpose.
Designated use also applies to correct EMV installation.
Non-designated use in this context applies to
•Any changes made to the Safety modules or the use of damaged mod-
ules
•The use of the Safety modules outside of technical framework described
in these operating instructions
•The use of the Safety modules outside of the technical data described in
these operating instructions (see the "Technical data" sections of the re-
spective production).
In addition, observe the warnings in the other sections of these instruc-
tions. These instructions are visibly emphasized with a symbol.

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The servo amplifier from SIGMATEK GmbH & Co KG was designed and produced with
state of the art technology. Before delivery, the products are completely tested for reliability.
It is a built-in component for electrical systems, which can only be operated as an integral
part of such systems. Before the products are installed, the following requirements must be
fulfilled to meet the prescribed use.
•Anyone who works with the products in any way has to read and understand the
safety instructions, the prescribed use and the non-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 personnel or
property.
•The servo drive has to operate under the mounting and installation conditions
described in this documentation, especially the environmental conditions (tem-
perature, protection class, humidity, mains input, EMC and the mounting posi-
tion)
•It must be mounted in a closed switchgear cabinet with minimum IP54.
•The servo drive has to be used in the way in which they are delivered (without
any mechanical or electrical modification).
•Do not mount or start-up mechanically or electrically damaged or faulty compo-
nents.
•The servo drive is intended to control synchronous servo, linear, torque and
asynchronous 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) of the servo drive system.
•Only motors with star-connection may be used.
•The servo drive is developed for usage in an industrial environment. If it is used
in residential areas, then an additional filter must be installed in the mains input
line
•Power supply modules MDP101-1 and MDP 102-1 are to be used with axis
modules MDD111-1 and MDD121-1 only.
•Drives must to be used with motors provided with over temperature sensing.

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2.5 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 switch-
gear 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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2.6 Nameplate

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2.7 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 1 x 115 VAC-10% … 3 x 480 VAC+10%
directly from TN-system or TT-system with grounded neutral point.
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 mo-
tor)
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 protec-
tion. Branch circuit protection must be provided in accordance with the Manufacturer
Instructions, National Electrical Code and any additional local codes.
a

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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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2.8 Technical Data Power Supply Module 230 V
DIM
MDP 102-1
Article number
09-403-102-1
Hardware version
3.x
Rated Data
Rated mains voltage (symmetrically to
ground) maximum 5000 rms symmetrical
amps (L1, L2, L3)
VAC
1 or 3 x 115 V-10% / 1 x 230 V+10%,
45 - 65 Hz
Maximum peak current at switch on of the
mains contactor (limited by the inrush
circuit)
A
2
Rated installed power for S1 operation
kVA
2
Rated installed power for S1 operation for
input voltage < 230 V
VA
2 kVA –8.7 W * (230 –input voltage/V)
Rated DC-link voltage
VDC
150 - 360
Over voltage protection threshold of DC-link
voltage
VDC
450
Auxiliary supply voltage +24 V
VDC
22 - 30
Maximum leakage current
mA
30
Power of additional supply voltage +24 V
W
Max. 50
Holding brake supply voltage +24 V-BR
VDC
23 - 26
(depending on type of selected holding brake)
Regen Circuit
DC-Link capacitance
µF
540
G-VMAINS = 230 (rated mains voltage = 230 V)
Switch-on threshold
VDC
420
Switch-off level
VDC
400
Over voltage protection
VDC
450
Peak power of the internal regen resistor
(max. 1sec)
kW
5.3
Safety Input
Input voltage between ENABLE_H (+) and
ENABLE_L (-)
V
Typically 24, max 30 V
Signal level between ENABLE_H (+) and
ENABLE_L (-)
V
Low ≤ +5, High ≥ +15
Input current
mA
Typically 10 at 24 V
Switching delay times of the inputs
s
Switch-on about 0.02
Switch-off minimum 0.5, maximum 1 s
Relay output (S1, S2)
-
NO
Switching capacity
-
Max. 30 VDC , 42 VAC, 100µA to 0.5 A
Digital Input
Input voltage Dig_IN1 to Dig_IN8
V
Typically 24, max 30 V
Signal level
V
Low ≤ +5, High ≥ +15
Input current
mA
Typically 10 at 24 V
Switching delay times of the inputs
ms
Typically 0.1

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Internal fusing
Auxiliary supply 24 V (+24 V to BGND)
-
Electronic fuse
Holding brake supply 24V-BR (+24 V-BR to BGND)
-
Electronic fuse
Regent resistor
-
Electronic protection
Resolver specification
Exciter frequency ferr
kHz
8
Exciter voltage URef
Ueff
2,8
Number of poles m
-
2, 4, 6, .., 32
Resolver voltage Usin/cos, max
Ueff
1,9
Plug types
Safety Inputs (X1)
-
Phoenix FK-MCP1,5/ 5-ST-3,5
Power Supply (X2)
-
Phoenix GMSTB 2,5HCV/ 9-ST-7,62
VARAN Bus (X3, X4)
(maximum length: 100 m)
-
RJ 45
Digital Inputs (X6)
-
Phoenix FK-MCP1,5/ 12-ST-3,5
Mechanics
Height
mm
155
Width
mm
60
Depth with module carrier (without/with plugs)
mm
152/195
Weight
kg
1.2
General
Article number
09-403-102-1
Standard
UL 508C, NMMS.E336350
2.9 Safety conformity
Safety Integrity Level according to IEC EN 62061
SIL 3
Performance Level according to EN ISO 13849-1
PLe
Probability of failure per hour
PFHD[10-9]
0,3
Mean time to dangerous failure
MTTFD symmetrized [Years]
High
Proof Test Interval [Years]
20