SIGMA TEK DIAS-Drive 335-23 User manual

DIAS-Drive 335-23
Date of creation: 01.10.2013
Current version: 27.09.2017
Article No.: 10-501-351-23E

Publisher: SIGMATEK GmbH & Co KG
A-5112 Lamprechtshausen
Tel.: [phone]
Fax: [phone]
e-mail: [email protected]
WWW.SIGMATEK-AUTOMATION.COM
Copyright © 2013
SIGMATEK GmbH & Co KG
Translation from German
All rights reserved. No part of this work may be reproduced in any form whatever (printing, photocopying,
microfilm or any other process), or processed, duplicated or distributed by means of electronic systems, without
express permission.
We reserve the right to make changes to the content without notice. SIGMATEK GmbH & Co KG shall not be held
responsible for technical or printing errors in this manual and shall accept no liability for damages caused as a
result of using this manual.

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DIAS-Drive 335-23
The manual describes the servo amplifier of the DIAS-Drive
series. Additional information on the safety functions and the
existing inputs and outputs in the installed VAC 013 interface
module can be found in the corresponding chapter.
Individual chapters:
•Technical Data of the servo amplifier
•Assembly and Installation
•Interface description
•Setup of the servo amplifier
•Accessories
•Transport, storage, maintenance, disposal
Abbreviations used in this manual
Abbreviation
Definition
AWG
American Wire Gauge (American cable coding)
BGND
Mass for the 24V auxiliary and braking supply
CE
Communité Europeenne
CLOCK
Clock signal
EMC
Electromagnetic Compatibility
EN
European Norm
IGBT
Insulated Gate Bipolar Transistor
LED
Light Emitting Diode
PELV
protected Extra Low Voltage
RES
Resolver
Rint.
Internal regen resistor connection
Rtr
Brake chopper connection
V AC
Alternating Current
V DC
Direct current

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Contents
1General .................................................................................... 6
1.1 Symbols used in this manual ......................................................6
1.2 Safety Guidelines..........................................................................7
1.3 Servo Amplifier Components....................................................10
1.4 European Guidelines and Norms..............................................11
1.5 Designated Use...........................................................................12
1.6 Non-designated Use...................................................................13
1.7 Nameplate....................................................................................14
1.8 Block Diagram.............................................................................15
1.8.1 Hardware...........................................................................................16
1.8.2 DIAS-Drive Concept ..........................................................................17
1.8.3 Software Functions............................................................................18
1.9 Technical Data ............................................................................19
1.10 Environmental Conditions, Ventilation and Mounting............21
1.11 Auxiliary Supply Voltage............................................................21
2Installation..............................................................................22
2.1 Important Instructions................................................................22
2.2 Construction of the Control Cabinet ........................................24
2.2.1 Wiring Diagram and Pin Assignment.................................................24
2.2.2 Mechanical Construction and Mounting.............................................26
2.2.3 Laying the Motor and Control Cables................................................28
2.2.4 Connector Models .............................................................................29
2.2.5 Cable Types ......................................................................................29
2.2.6 External Fusing..................................................................................30

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2.2.7 Voltage Supply Options .................................................................... 31
2.2.8 Usage of Cooling Devices................................................................. 32
2.2.9 Turn on/off Response of the Servo Amplifier .................................... 34
2.2.10 Holding Brake Control....................................................................... 35
3Connections...........................................................................36
3.1 Main Power supply (X1B)...........................................................36
3.2 24 V Auxiliary supply –Holding Brake supply (X1A)..............37
3.3 DC-link (X1B)...............................................................................38
3.4 External Regen Resistor (X1B)..................................................38
3.5 Motor Connection (X3, X4, X5) ..................................................39
3.5.1 Standard configuration...................................................................... 39
3.5.2 Classic Emergency Stop Functions (Stop Category 0)..................... 40
3.5.3 Personnel-Safe Holding Brake Control............................................. 41
3.6 Feedback (X6, X7, 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
4Maintenance...........................................................................47
4.1 Replace 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

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5.2.3 Status Register..................................................................................53
6DIAS Drive 300 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
6.2.2 Dimensions incl. Mounting Set ..........................................................60
7VARAN Interface for the DIAS Drive 3xx (VAC 013)............61
7.1 Technical Data ............................................................................62
7.1.1 General..............................................................................................62
7.1.2 Electrical Requirements.....................................................................62
7.1.3 Input Specifications ...........................................................................62
7.1.4 Relay Specifications ..........................................................................63
7.1.5 Safety Conformity..............................................................................63
7.1.6 Miscellaneous....................................................................................63
7.1.7 Environmental Conditions..................................................................64
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 Lock" STO (Safe Torque Off) ......................................71
7.7 Addressing..................................................................................81
7.8 Recommended Shielding for VARAN.......................................85
7.8.1 Wiring from the Control Cabinet to an External VARAN Component.86

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7.8.2 Wiring Outside of the Control Cabinet............................................... 87
7.8.3 Shielding for Wiring within the Control Cabinet................................. 88
7.8.4 Connecting Noise-Generating Components...................................... 89
7.8.5 Shielding Between Two Control Cabinets......................................... 90

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1 General
1.1 Symbols used in this manual
Danger! Electric shock Danger to personal from
electricity and its effects
Caution! General Danger to machines
General warning
Caution! Hot surface Hot surface more than 80 °C (176 °F)
Important note See Manual

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1.2 Safety Guidelines
The safety instructions must be read before installation and initial start-
up of the servo amplifier. Improper handling of the servo amplifier can
lead to personal injury or material damage. Compliance with the
technical data and connection specifications (nameplate and
documentation) mandatory.
Only qualified personnel may perform tasks such as transportation,
assembly, Initial startup and maintenance. Qualified personnel are
those who are familiar with the transport, assembly, installation, setup
and operation of the product, and have the appropriate qualifications
for their task.
The machine manufacturer must perform a safety analysis for the entire
machine. With the appropriate measures, the manufacturer ensures that
no injuries or damage can be caused by unexpected movements.
Improper operation of the servo amplifier or failure to follow the
following guidelines and improper handling of the safety equipment can
result in damage to the machine, personnel injury, electrical shock or in
extreme cases, death.
Annotations
Danger! Shock current
After disconnecting the servo amplifier from the voltage supply, a wait-time of
at least 5 minutes is required before current conducting components of the
amplifier (e.g. clamps) can be touched or connectors removed. After turning
off the voltage supply, the internal capacitors can have dangerous voltage
levels for up to 5 minutes. For safety purposes, measure the voltage in the
intermediate circuit and wait until the voltage is below 40 V.
The electrical connectors of the servo amplifier can never be removed while
voltage is applied. The danger of electrical arcing exists, which could cause
personal 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 an FI switch of Type A is used, a DC ground fault could cause it to
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 living areas, this
product can cause EMC interference problems. In such a case, the user must
take additional filtering 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
conductive surface. Contact with highly insulated material (synthetic fiber,
plastic foil etc.) must be avoided. The servo amplifier must be placed on a
conductive surface.
Opening the device is not allowed. During operation, keep all covers and
control cabinet doors closed. The danger of severe damage to health or
material, as well as death exists.
During operation, servo amplifiers –according to their protection type –may
have bare, voltage-carrying components. Control and power connections
may be live, even if the motor is not turning.
The main voltage supply for the DIAS-Drive requires a fixed connection. If the
servo amplifier is mounted on a moveable part of a machine with a connector
plug, the ground connection must have a minimum cross-section of 10 mm²
(8 AWG) because of the high leakage current of the servo amplifier
(> 3.5 mA).
The +24 V auxiliary power supply and the power supply for the
+24V-BR holding brake supply must be galvanically separated as protective
extra-low voltage (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 has fallen below 40 °C (104
°F).
Failure to follow the above safety measures can lead to severe injuries.
Caution! Electromagnetic Fields (EMF)
Risk of death!
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 taken to ensure that such persons maintain
the necessary safety distance of at least 2 m.

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1.3 Servo Amplifier Components

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1.4 European Guidelines and Norms
Servo amplifiers are components designed for installation in electrical systems/machines for
industrial use. During 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 EG-machine guideline 2006/42/EG and the EG-EMC guideline 2004/108/EG.
Note: The machine manufacturer must perform a safety analysis for
the entire machine. With the appropriate measures, the
manufacturer ensures that no injuries or damage can be
caused by unexpected movements.
−Conformity
With the delivery of servo amplifiers within the European community, compliance with the
EG-EMC 2004/108/EG and low voltage 2006/95/EG guidelines is mandatory.
The harmonized standard EN 61800-5-1 (Electrical Power Amplifier Systems with
Adjustable Speed - part 5-1: Requirements for the Safety of Electrical, Thermal and
Energetic Demands) was included with the 2006/95/EG low voltage guideline for this servo
amplifier.
The harmonized standard EN 61800-3 (Electrical Power Amplifier systems with Adjustable
Speed - Part 3: EMI Product Norm including Special Test Processes) was included with the
2004/108/EG for this servo amplifier.
To meet the EMC conditions for the installation, the documentation contains detailed
information on:
•Shielding
•Ground connection
•Control cabinet wiring
•Filters (as required)
The servo amplifier from the DIAS-Drive series was tested with the system components and
the corresponding configuration defined in this document. Any change in the configuration
and installation described in this document requires new measurements to ensure the
standards are met.

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1.5 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, especially
in terms of fail-safe conditions. 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 order to
ensure that no injuries or damage is caused to personnel and equipment by
unexpected movements.
•The servo amplifier must be operated under the assembly and installation conditions
described in this document. The environmental conditions (temperature, protection
class, humidity, voltage supply, EMC and mounting position) must be observed in
particular.
•The amplifier can only be operated in a control cabinet with minimum IP54.
•The Servo amplifier must be operated in the original condition without any mechanical
or electrical changes.
•Mechanically or electrically defective or faulty servo amplifiers may be not installed 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 asynchronous
motors.
•The specified rated voltage of the motor must be at least as high as the power supply
voltage of the servo amplifier (230 V, 400 V or 480 V).
•Only motors with star circuit may be used.
•This product can lead to EMC disruptions in living areas. In such a case, the user must
take additional filtering measures.

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1.6 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 allowed for initial
startup and demonstration purposes.
•Because of saline and therewith, conductive contamination, the servo amplifier cannot
be used on ships (sea operation) or in offshore applications.
•The servo amplifier cannot be operated under any environmental conditions other than
those described in this documentation (meaning without a control cabinet, incorrect
assembly etc.)
Particular caution is required in production facilities, in which conductive material such as
carbon fiber, graphite, and cast iron or similar material is used. In such cases, the control
cabinet must be hermetically sealed (no forced 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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1.7 Nameplate
The name plate is attached to the side of the amplifier heat sink. The information in the
individual fields depends on the various amplifier types.

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1.8 Block Diagram

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1.8.1 Hardware
•The main supply is connected to a rectifier, input filter and a charging circuit, which
reduces the load current for the power-up moment.
•IGBT –Power output stage with separate current measurement (short circuit protected).
•Short circuit proof brake chopper with internal brake resistor. For insufficient power, the
internal resistor can be disconnected and replaced 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 to the interface

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1.8.2 DIAS-Drive Concept
•1 and 3-axis amplifiers to reduce machine costs. 3-axis amplifiers have advantages
reducing components
•Auto-range function to optimize the resolution of the actual current value of 10 A axes,
in various configurations.
•Two different mounting options.
➢On a mounting place in the control cabinet
➢Through-hole technology
•Broad input voltage range from 3 x 230 VAC-10% … 3 x 480 VAC+10% supplied from TN-
supply or TT-supply with grounded neutral point, with a maximum current of
symmetrical 5000 ARMS.
•TT supplies without grounded neutral lines require additional measures.
•Charging circuit for limiting the maximum load current at the power-up moment.
•Fuse installed by user (phase failure is monitored by the amplifier)
•1-phase operation is possible, e.g. for 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, 24 V 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 DC-link circuit.
➢Several short circuit conditions
➢Phase error in the main supply
➢Brake resistance over heating
➢Over temperature (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.

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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.
1.8.3 Software Functions
•Modified space vector modulation (SVM) technique to reduce the power stage losses
•Field oriented current controller (update time 62.5 µs)
•Feedback evaluation and speed controller (update time 62.5 µs)
•Spline interpolation and position controller (update time 62.5 µs)
•Full synchronisation up to the output stage to the control frequency with cycle times of
250 µs, 500 µs and 1 ms to 8 ms
•The servo amplifier has a volatile data storage medium. After power-up, the parameters
are loaded into the servo amplifier via the host
•Starting with FW version 1.82, the electrical rotary field frequency is limited to 599 Hz.
The error bit 18 is set when the frequency is above 599 Hz for more than one second.
The amplifier then changes to error status. The cause could be a high rotation speed
with motors that have a high number of poles.