Unitek DS-405.2 User manual

Hans-Paul-Kaysser-Straße 1
Ausgabe / Version
71397 Leutenbach-Nellmersbach
04/2019 - V01
Tel.: 07195 / 92 83 - 0
Fax: 07195 / 92 83 - 129
[e-mail]
www.unitek.eu
M A N U A L
Digitale three-phase Servo Amplifier
DS-400.2
for EC/AC-Servo Motors

Basic information
1
04/2019 - V01
DS 400.2
1Contents
2 Basic information ....................................................................................................................... 3
2.1 History ................................................................................................................................ 3
2.2 Further UNITEK products ................................................................................................... 3
2.3 Engineering instructions (MANUAL) .................................................................................. 3
2.4 Validity................................................................................................................................ 4
2.5 Designations and symbols.................................................................................................. 4
2.6 Scope of delivery ................................................................................................................ 4
2.7 General product information ............................................................................................. 5
2.8 Application/build/features................................................................................................. 6
2.9 Safety regulations............................................................................................................... 8
2.10 Commissioning ................................................................................................................. 10
2.11 Safety advices................................................................................................................... 11
2.12 Intended applications....................................................................................................... 12
2.13 Regulations and guidelines .............................................................................................. 13
2.14 Risks.................................................................................................................................. 14
2.15 Technical data .................................................................................................................. 15
3 Mechanical Installation ............................................................................................................ 18
3.1 Important advices ............................................................................................................ 18
3.2 Dimensions DS 405 – DS 420............................................................................................ 19
3.3 Dimensions - accessories.................................................................................................. 20
3.4 Installation........................................................................................................................ 21
4 Electrical installation ................................................................................................................ 22
4.1 Important advice.............................................................................................................. 22
4.2 Circuit diagram ................................................................................................................. 23
4.3 Connection diagram ......................................................................................................... 25
4.4 Connections DS405.2, DS412.2, DS420.2......................................................................... 26
4.5 Connectors DS405.2/DS412.2/DS420.2 ......................................................................... 27
4.6 EMC .................................................................................................................................. 28
4.7 Mains connection............................................................................................................. 29
4.8 Pre-charging ..................................................................................................................... 31
4.9 Auxiliary voltage connection............................................................................................ 32
4.10 Motor connection ............................................................................................................ 33
4.11 Ballast circuit DS405 / DS412 / DS420............................................................................. 34
4.12 Ballast – dimensioning ..................................................................................................... 35
5 Control connection................................................................................................................... 36
5.1 Digital input...................................................................................................................... 36

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5.2 Safety input RFE (rotating field enable) Stopp-Class 0..................................................... 37
5.3 Digital outputs (open emitter) ......................................................................................... 38
5.4 Serial interface RS 232...................................................................................................... 40
5.5 CAN-BUS ........................................................................................................................... 41
5.6 Resolver connection......................................................................................................... 42
5.7 Encoder TTL connection ................................................................................................... 43
5.8 SIN COS 1Vss CONNECTION.............................................................................................. 45
5.9 Rotor position encoder – connection via a bl-tacho ....................................................... 46
5.10 X8 TTL-Encoder output or input (2).................................................................................. 47
5.11 X8 as TTL Encoder output................................................................................................. 48
5.12 Display .............................................................................................................................. 49
5.13 Error display on the servo ................................................................................................ 50
5.14 Warning signals ................................................................................................................ 51
6 Warranty .................................................................................................................................. 52
6.1 Warranty .......................................................................................................................... 52

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History
2Basic information
2.1 History
Version
Modification
Date
04/2013 - V04
new English version
13.06.2013
04/2013 - V05
drawing news, fault list
Nov 2013
04/2019 - V01
CAN BUS data / Inrush Limiter updated
April 2019
2.2 Further UNITEK products
Digital servo-amplifiers for small power values
>>>
UNITEK
DS205, DS403,
DPCxx
Analog three-phase servo-amplifiers
TVD3, TVD6, AS
>>>
UNITEK
Series
Analog dc servo-amplifiers
TV3, TV6, TVQ6
>>>
UNITEK
Series
Thyristor current converters
1Q, 4Q, Servo
>>>
UNITEK
Series Classic
200W to 800kW
DC and ac servo-amplifiers for battery operation
A2, A3, D3
Series BAMO
Analog and digital
Series BAMOBIL
Series BAMOCAR
2.3 Engineering instructions (MANUAL)
1.
MANUAL
DS xxx
Hardware
2.
MANUAL
NDrive2
Software
3.
MANUAL
DS, DPC
Commissioning -
Troubleshooting
Use all three MANUALs for the engineering, the installation, and the commissioning!
CD (UNITEK-DOKU-SOFT) supplied with the delivery of the units.
Online: www.unitek-online.eu
The hardware MANUAL comprises warning and safety advices, explanations of standards,
mechanical and electrical installation advices.
The MANUAL must be available for all persons who are concerned with the unit.

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Validity
2.4 Validity
Hardware state:
Firmware state:
2.5 Designations and symbols
Unit DS xxx (BDM)
User:
Manufacturers or operators of machines or installations in the industrial
sector (B2B, secondary environment)
Manufacturer: UNITEK Industrie Elektronik GmbH
Dealer:
Caution - Danger to life!
High voltage
Warning!
Important
Dangerous electric fields
2.6 Scope of delivery
Divece DS405-x, DS412-x or DS420-x
documentation DS400, NDrive, CD Unitek-Docu-Soft
Connector plug Phönix 10pin. and 11pin.
D-connector X7 15pin., X8 9pin
In the shipping container
Not in the delivery
D-connectorr X9, X10 9pin.

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General product information
2.7 General product information
The digital 3-phase current servo amplifiers DS/DPC xxx as component (BDM) in combination with
the synchronous servo motor (EC motor) or the asynchronous servo motor (ac motor) provide a
drive solution (PDS) free of maintenance and with a wide dynamic control range.
The drive displays the well-known good control characteristics of dc drives without the
disadvantages of the carbon brushes' wear and the commutation limits.
For synchronous motors the generated heat in the motor only occurs in the stator, the rotor
remains cold. The motors can easily be cooled via the surface (efficiency up to 96%).
The physical characteristics correspond to those of dc motors, i.e., the current is proportional to
the torque and the voltage is proportional to the speed. The speed is steadily controlled up to the
current limit (max. torque. In case of an overload the speed drops and the current remains
constant.
The speed/torque characteristic is rectangular.
Current, speed, and position are precisely measured. The field frequency is not controllable, it is
automatically adjusted.
The rotor moment of inertia is notably smaller and the limiting performance is higher which
results in up to 5 times higher acceleration values.
Asynchronous servo motors are less expensive and do not require solenoids in the rotor.
The control characteristics are very good due to the space-vector control, the performance and
the efficiency are lower. Due to the heated rotor it is necessary to use a motor fan for large
control ranges.
The EC and ac motors have the protection rating IP65.
The motor voltages and the motor currents are sinusoidal. A maximum motor efficiency is
achieved by means of a compensating current control.
DS/DPCxx drives can be used as single-axis position amplifiers or torque or speed amplifiers.
The position and speed actual value is generated in the encoder unit (resolver, incremental, or
SIN/COS encoder). The encoder pulses are emitted from the amplifier for a superordinate
PLC/CNC control.
The control circuits of current, speed, and position are PID controllers which are easy to program.
They can be programmed by means of the PC Software NDrive2.
The communication with superordinate controls is effected by means of BUS systems (standard
CAN-BUS, RS232) or by analogue interfaces.
Note:
For dc, ac, or EC servo amplifiers which are supplied by a bus circuit, it must be checked that the
energy is fed back into the bus during brake operation (lift drives, winding machines, great
centrifugal masses).
An internal or possibly external ballast resistor is necessary.

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Application/build/features
2.8 Application/build/features
Application in machines and installations for all types of industrial use with a drive power of
13.5 kW under hard application conditions especially as 4Q-servo-drive
- highly dynamic acceleration and braking cycles
- a wide control range
- a high efficiency
- small motor dimensions
- a uniform, accurate and smooth running
For speed or torque control or combined speed/torque control incorporated within or
independent of position control loops.
Suitable for:
Machines and installations
as well as component inserting machines, testing machines, sheet-metal working machines,
machine tools, plastic working machines, assembly machines,
knitting and sewing machines, textile working machines, grinding machines,
wood and stone working machines, metal working machines, food processing machines, robots
and handling systems, conveyors, extruders, calenders, and many other machines and
installations for industrial applications.
Build:
- Robust units for switch cabinet mounting, steel housing,
according to the VDE, DIN and EC regulations,
protection rating IP20, VGB4
- Standard digital control electronics
- Power electronics of 5 and 20 A (S1 operation)
- Power input voltage 30V~ to 480 V~ (40 V= to 500 V=)
- Independent 24 V chopper power supply unit for the internal auxiliary voltages
Galvanic isolation
- between the housing and all electric parts
- between the auxiliary voltage connection and the power section and the control electronics
- between the power section and the control electronics
- between the control electronics and the logic inputs/logic outputs
The distance of air gaps and leakage paths adhere to the EU standards.
Components used:
- completely isolated IGBT power semi-conductors, comfortably over-dimensioned
- only components customary in trade and industrially standardised are used
- SMD equipment
- LED displays , 7-segment displays

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Application/build/features
Features:
EMC protected steel housing
Shock and vibration-proof build
Direct mains connection 230 V~ to 480 V~
Independent auxiliary voltage connection 24 V=
Digital interfaces RS232, CAN-BUS (further option)
Analog inputs, programmable differential inputs
Digital inputs/outputs, programmable, optically de-coupled
Output for brake 24 V/3 A with load watchdog
logic for enable and the output stage switch, emergency stop function, safety
BTB ready for operation, solid state relay
Position, speed and torque control
Encoder systems: resolver, TTL incremental encoder, SINCOS 1Vss, rotor position
Encoder output
Static and dynamic current limiting
Uniform, completely digital control unit
Intrinsically safe and short-circuit proof power section (EN50178)
Anti-interference choke in the bus circuit
Integrated ballast circuitry
DC power bus
Processor-independent hardware switch-off in case of short-circuits, circuits to earth, over-
voltage, under-voltage, and over-temperature of the amplifier or the motor

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Safety regulations
2.9 Safety regulations
Electronic equipment is not fault proof!
Caution - High voltage
> 900V AC/DC ~/=
Shock hazard! / Danger to life!
Discharge time of the bus circuit > 4 min!
Before installation or commissioning begins, this manual must be thoroughly read and
understood by the skilled technical staff involved. It must be ensured that the documentation
(manuals) and thus, the knowledge of the unit and especially the safety advices must be available
for all persons who are concerned with the unit
If any uncertainty arises or if any function is not or not sufficiently described in the
documentation, the manufacturer or dealer should be contacted.
Any incorrect installation/connection may damage the device!
Any incorrect programming may cause dangerous movements!
Intended applications:
The devices of the DSxx series are power electric parts used for regulating energy flow.
They are designed as components (BDM) to control EC synchronous motors and ac asynchronous
motors in stationary machines or installations for industrial applications.
For applications in residential areas additional EMC measures are necessary.
Any other type of application must be approved by the manufacturer.
The user must draw up a hazard analysis for his end product.
Protection rating IP20 for stationary switch cabinet mounting.
Power supply connection only to an earthed three-phase current system!
Protective conductor PE must be firmly connected!
Operation only allowed when the switch cabinet is closed or
locked!
The control and power connections may be voltage-carrying
without the axis operating!
The discharge time of the bus circuit is superior to 4 min!
Measure the voltage before any disassembly!

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Safety regulations
The user must draw up a hazard analysis for his machine, vehicle, or installation.
The user must ensure that in the event of:
- device failure
- incorrect operation,
- loss of regulation or control
the axis will be safely de-activated.
It must also be ensured that the machines, equipment, or
vehicles are fitted with device independent monitoring and
safety features.
The user must take appropriate measures so that man as well as
property are not exposed to danger due to incorrect or improper
movements at any time!
During operation the switch cabinet must be closed and the
safety systems must be enabled.
When the switch cabinet is open and/or the safety systems are
de-activated, it must be ensured by the operator that only skilled
and suitably trained personnel has access to the units.
Assembly
- should only be carried out when all voltages have been removed and the units are secured
- should only be carried out by suitably trained personnel
Installation
- should only be carried out when all voltages have been removed and the units are secured
- should only be carried out by suitably trained personnel for electrics
- should only be carried out in accordance with health and safety guidelines
Adjustments and programming
- should only be carried out by suitably trained personnel with knowledge in electronic drives and
their software
- should only be carried out in accordance with the programming advice
- should only be carried out in accordance with health and safety guidelines