Danfoss VLT MSD 510 User manual

Operating Guide

VLT® Multiaxis Servo Drive MSD 510 System

Contents

1 Introduction 14

1.1 Purpose of the Operating Guide 14

1.2 Additional Resources 14

1.3 Copyright 14

1.4 Approvals and Certifications 15

1.5 Areas of Application 16

1.6 Software 16

1.7 Terminology 17

2 Safety 18

2.1 Safety Symbols 18

2.2 Safety Instructions and Precautions 18

2.2.1 Operational Safety 19

2.3 Important Safety Warnings 19

2.4 Qualified Personnel 21

2.5 Due Diligence 21

2.6 Intended Use 21

2.6.1 Prohibited Application Areas 22

2.7 Forseeable Misuse 22

2.8 Service and Support 22

3 System Description 23

3.1 Overview of the VLT® Multiaxis Servo Drive System MSD 510 23

3.1.1 Application Examples 24

3.1.2 Maximum Number of Modules 25

3.2 Power Supply Module PSM 510 25

3.2.1 Overview 25

3.2.2 Connectors on the Top of PSM 510 27

3.2.3 Connectors on the Bottom of PSM 510 27

3.3 Servo Drive Module SDM 511/SDM 512 27

3.3.1 Overview 27

3.3.2 SDM 511/SDM 512 Types 28

3.3.3 Components 29

3.3.3.1 Cooling 29

3.3.4 Connectors on SDM 511 29

3.3.4.1 Connectors on the Top of SDM 511 30

3.3.4.2 Connectors on the Bottom of SDM 511 30

3.3.5 Connectors on SDM 512 31

3.3.5.1 Connectors on the Top of SDM 512 31

3.3.5.2 Connectors on the Bottom of SDM 512 32

ContentsOperating Guide | VLT® Multiaxis Servo Drive MSD 510 System

3.4 Decentral Access Module DAM 510 32

3.4.1 Overview 32

3.4.2 Connectors on the Top of DAM 510 33

3.4.3 Connectors on the Bottom of DAM 510 34

3.5 Auxiliary Capacitors Module ACM 510 34

3.5.1 Overview 34

3.5.2 Connectors on the Top of ACM 510 35

3.6 Expansion Module EXM 510 36

3.7 Local Control Panel (LCP) 37

3.7.1 Overview of the Local Control Panel 37

3.7.2 Layout of the Local Control Panel 37

3.7.2.1 A: Display Area 37

3.7.2.2 B: Display menu keys 40

3.7.2.3 C: Navigation keys and indicator lights (LEDs) 41

3.7.2.4 D: Operation keys and reset 41

3.8 Cables 42

3.8.1 Hybrid Cable 42

3.8.2 Ethernet Cable 42

3.8.3 LCP Cable 43

3.9 Cable Layout and Routing 43

3.9.1 Maximum Cable Lengths 43

3.9.2 Wiring of Output Filter 44

3.9.3 Standard Cabling Concept for 2 Decentral Access Modules (DAM 510) 44

3.10 Software 44

3.11 Fieldbus 45

3.11.1 EtherCAT® 45

3.11.2 Ethernet POWERLINK® 47

3.11.3 PROFINET® 47

4 Mechanical Installation 48

4.1 Items Supplied 48

4.2 Transport 48

4.3 Inspection on Receipt 48

4.4 Safety Measures during Installation 48

4.5 Installation Environment 49

4.5.1 System Components 49

4.6 Preparation for Installation 49

4.6.1 System Modules 49

4.6.2 Drilling Templates 50

4.7 Installation Procedure 50

4.7.1 Space Requirements for System Modules 50

4.7.2 Installation Aids and Tools Required 52

ContentsOperating Guide | VLT® Multiaxis Servo Drive MSD 510 System

4.7.3 Fitting Instructions for System Modules 52

5 Electrical Installation 57

5.1 Warnings for Electrical Installation 57

5.2 Electrical Environmental Conditions 57

5.3 Grounding 58

5.3.1 Grounding for Electrical Safety 58

5.3.2 Grounding for EMC-Compliant Installation 60

5.4 Mains Supply Requirements 61

5.4.1 Fuses 61

5.4.2 Circuit Breakers 62

5.5 Auxiliary Supply Requirements 62

5.5.1 Fuses 62

5.6 Safety Supply Requirements 62

5.7 UL Requirements 63

5.8 Connecting the Servo Drive Module SDM 511/SDM 512 64

5.8.1 Connecting the Motor Cable 64

5.8.2 Connecting the Brake/Thermistor Cable 66

5.8.3 Connecting the Cables on the Top of the Servo Drive Modules SDM 511/SDM 512 67

5.9 Connecting the Power Supply Module PSM 510 68

5.9.1 AC Line Choke 68

5.9.1.1 Connecting 1 PSM 510 to the AC Choke 68

5.9.1.2 Connecting 2 PSM 510 Modules to the AC Choke 69

5.9.1.3 Connecting 2 PSM 510 Modules to the AC Choke with System Splitting 70

5.9.2 Connecting the Cables on the Power Supply Module PSM 510 71

5.9.2.1 Connecting the Cables on the Top of the Power Supply Module PSM 510 71

5.9.2.2 Connecting the Cables on the Bottom of the Power Supply Module PSM 510 72

5.10 Connecting the Decentral Access Module (DAM 510) 73

5.10.1 Connecting the Cables on the Top of the Decentral Access Module DAM 510 73

5.10.2 Connecting the Feed-In Cable 73

5.11 Connecting the Auxiliary Capacitors Module ACM 510 75

5.12 Connecting the Expansion Module EXM 510 76

5.13 Connecting the Brake Resistor on the PSM 510 77

6 Commissioning 80

6.1 Warnings for Commissioning 80

6.2 Pre-Commissioning Checklist 80

6.3 SDM 511/SDM 512 Configuration Parameter and Drive Commissioning 80

6.3.1 Configuration Parameter Subtool 80

6.3.2 Drive Commissioning Subtool 81

6.4 EtherCAT® ID Assignment 82

6.5 Ethernet POWERLINK® ID Assignment 82

ContentsOperating Guide | VLT® Multiaxis Servo Drive MSD 510 System

6.5.1 Overview 82

6.5.2 Single Device ID Assignment 82

6.5.2.1 Setting the Node ID Directly on a Servo Drive or on the System Modules 82

6.5.2.2 Setting the Node ID for a Single Servo Drive via the Power Supply Module (PSM 510) or Decentral Access

Module (DAM 510) via the LCP 82

6.5.3 Multiple Device ID Assignment 83

6.5.3.1 Setting the Node IDs of all Servo Drives and System Modules on a Decentral Access Module (DAM 510)/

Power Supply Module (PSM 510) Line 84

6.6 PROFINET® ID Assignment 84

6.7 Power-Up Time 85

6.8 System Module Charging Time 85

6.9 Switching on the MSD 510 System 86

6.9.1 Procedure for Switching on the MSD 510 System 86

6.10 Libraries 86

6.11 Programming with Automation Studio™ 87

6.11.1 Requirements for Programming with Automation Studio™ 87

6.11.2 Creating an Automation Studio™ Project 87

6.11.3 Including the Servo Motion Libraries into an Automation Studio™ Project 88

6.11.4 Constants within the DDS_Drive Library 88

6.11.5 Instantiating AXIS_REF_DDS in Automation Studio™ 90

6.11.6 Instantiating PSM_REF in Automation Studio™ 90

6.11.7 Instantiating DAM_REF in Automation Studio™ 91

6.11.8 Instantiating ACM_REF in Automation Studio™ 91

6.11.9 Importing a Servo Drive into Automation Studio™ 91

6.11.9.1 Version V3.0.90 92

6.11.9.2 Version V4.x 93

6.11.10 Importing PSM 510, DAM 510 and ACM 510 into Automation Studio™ 93

6.11.10.1 Version V3.0.90 94

6.11.10.2 Version V4.x 95

6.11.11 I/O Configuration and I/O Mapping 96

6.11.12 Setting the PLC Cycle Time 98

6.11.13 Connecting to the PLC 99

6.12 Programming with TwinCAT® 99

6.12.1 Requirements for Programming with TwinCAT® 99

6.12.2 Creating a TwinCAT® Project 99

6.12.3 Including the TwinCAT® Library into a TwinCAT® Project 100

6.12.4 Constants within the DDS_Drive Library 101

6.12.5 Instantiating AXIS_REF_DDS in TwinCAT® 103

6.12.6 Instantiating PSM_REF in TwinCAT® 103

6.12.7 Instantiating DAM_REF in TwinCAT® 103

6.12.8 Instantiating ACM_REF in TwinCAT® 104

6.12.9 Adding a PLC Project to TwinCAT® System Manager 104

6.12.10 Importing Devices to TwinCAT® 104

ContentsOperating Guide | VLT® Multiaxis Servo Drive MSD 510 System

6.12.11 I/O Configuration and I/O Mapping 108

6.12.12 Attaching the Input and Output Variables to the Physical Data Points 108

6.12.13 Transferring the Mappings back to the PLC Program 110

6.12.14 Setting the PLC Cycle Time in TwinCAT® PLC Control 110

6.12.15 Configuration as a TwinCAT® NC Axis 111

6.12.15.1 I/O Configuration for Servo Drives used as NC Axes 111

6.12.16 Connecting to the PLC 112

6.13 Programming Guidelines for Automation Studio™ and TwinCAT® 112

6.14 Programming with SIMOTION SCOUT® 113

6.14.1 Requirements for Programming with SIMOTION SCOUT® 113

6.14.2 Connecting to the PLC 113

6.14.3 Creating a SIMOTION SCOUT® Project 113

6.14.4 Including the Servo Motion Libraries into a SIMOTION SCOUT® Project 114

6.14.5 Importing Devices into SIMOTION SCOUT® 116

6.14.6 Assigning IP Configuration and Device Name 118

6.14.7 Creating a Sync Domain 121

6.14.8 Configuring a Topology 124

6.14.9 Defining Send Clock and Update Time 126

6.14.9.1 Configuring the Send Clock Time 126

6.14.9.2 Configuring the Update Time 127

6.14.10 Accessing Inputs and Outputs 127

6.14.11 Programming using the Danfoss VLT® Servo Motion Library 128

6.14.12 Instantiating AXIS_REF_DDS in SIMOTION SCOUT® 129

6.14.13 Instantiating PSM_REF in SIMOTION SCOUT® 129

6.14.14 Instantiating DAM_REF in SIMOTION SCOUT® 130

6.14.15 Instantiating ACM_REF in SIMOTION SCOUT® 130

6.14.16 Global Compiler Settings 131

6.14.17 Assigning Tasks 131

6.15 Programming Guidelines for SIMOTION SCOUT® 133

6.16 VLT® Servo Toolbox Software 134

6.16.1 Overview 134

6.16.2 System Requirements 134

6.16.3 Installing the VLT® Servo Toolbox Software 134

6.16.4 VLT® Servo Toolbox Communication 135

6.16.4.1 Overview 135

6.16.4.2 Firewall 135

6.16.4.3 Indirect Communication 135

6.16.4.4 Direct Communication 139

6.17 VLT® Servo Toolbox Commissioning 142

6.17.1 Step 1: Opening the Main Window 142

6.17.2 Step 2: Connecting to Network 144

6.17.3 Step 3: Scanning for Devices 145

ContentsOperating Guide | VLT® Multiaxis Servo Drive MSD 510 System

6.18 Motion Library 145

6.18.1 Function Blocks 145

6.18.2 Simple Programming Template 146

7 Operation 147

7.1 Operating Modes 147

7.1.1 Supported Operating Modes 147

7.1.2 Motion Functions 148

7.2 Operating Status Indicators 148

7.2.1 Operating LEDs on SDM 511 and SDM 512 148

7.2.2 Operating LEDs on the PSM 510 149

7.2.3 Operating LEDs on the DAM 510 150

7.2.4 Operating LEDs on the ACM 510 152

8 Functional Safety Concept 153

8.1 Functional Description 153

8.2 Safety Precautions 153

8.3 Qualified Personnel for Working with Functional Safety 154

8.4 Applied Standards and Compliance 154

8.5 Abbreviations and Conventions 155

8.6 Installation 156

8.6.1 Protective Measures 156

8.7 Application Example 156

8.8 Commissioning Test 157

8.8.1 Commissioning Test using Libraries 157

8.8.2 Commissioning Test using PROFINET® Devices 159

8.9 Operation of the STO Function 160

8.9.1 Error Codes 160

8.9.2 Fault Reset 161

8.10 Functional Safety Characteristic Data 161

8.11 Maintenance, Security, and User Accessibility 161

9 Diagnostics 163

9.1 Faults 163

9.2 Troubleshooting 163

9.2.1 Troubleshooting for the Servo Drive Modules SDM 511/SDM 512 163

9.2.1.1 Drive not Running/Starting Slowly 163

9.2.1.2 Drive Hums and Draws High Current 164

9.2.1.3 Drive Stops Suddenly and Restart is not Possible 164

9.2.1.4 Motor Rotating in Wrong Direction 164

9.2.1.5 Motor not Generating Expected Torque 164

9.2.1.6 Drive Screaming 164

9.2.1.7 Uneven Running 165

ContentsOperating Guide | VLT® Multiaxis Servo Drive MSD 510 System

9.2.1.8 Vibration 165

9.2.1.9 Unusual Running Noises 165

9.2.1.10 Drive Speed Drops Sharply under Load 165

9.2.1.11 Brake not Releasing 165

9.2.1.12 Holding Brake not Holding the Servo Drive 166

9.2.1.13 Delayed Brake Engagement 166

9.2.1.14 Noises when Power-Off Brake is Engaged 166

9.2.1.15 LEDs not Lighting Up 166

9.2.1.16 Drive Protection Trips Immediately 166

9.2.2 Troubleshooting for the Servo System 167

9.2.2.1 LCP Display is Dark/Not Functioning 167

9.2.2.2 Open Power Fuses or Circuit Breaker Trip 167

9.2.2.3 DC-link Voltage Too High (Error 0x3210/0x103) 168

9.2.2.4 DC-link Voltage Too Low (Error 0x3220/0x104) 168

9.2.2.5 DC-link Overcurrent (Error 0x2396/0x15C) 168

9.2.2.6 DC link Overpower (Error 0x2313/0x161) 169

9.2.2.7 PT Power Overload (Error 0x2314/0x162) 169

9.2.2.8 UAUX Overcurrent (Error 0x2391/0x125) 169

9.2.2.9 UAUX Overvoltage (Error 0x3292/0x133) 169

9.2.2.10 UAUX Undervoltage (Error 0x3294/0x135) 170

9.2.2.11 Mains Phase Loss (Error 0x3130/0x12F) 170

9.2.2.12 Grounding Fault 170

9.2.2.13 Brake Resistor Error 170

9.2.2.14 Brake Chopper Error 171

9.2.2.15 Internal Fan Error 171

9.3 Error Codes 171

9.3.1 No error (0x0000 / 0x0) 171

9.3.2 Generic err (0x1000 / 0x100) 172

9.3.3 Overcurrent on output (0x2310 / 0x101) 172

9.3.4 High current overload (0x2311 / 0x15F) 172

9.3.5 I2T current overload (0x2312 / 0x160) 172

9.3.6 High power overload (0x2313 / 0x161) 172

9.3.7 PT power overload (0x2314 / 0x162) 173

9.3.8 Short circuit (0x2320 / 0x163) 173

9.3.9 Earth leakage (0x2330 / 0x151) 173

9.3.10 AUX overcurrent (0x2391 / 0x125) 173

9.3.11 AUX user limit current (0x2393 / 0x127) 174

9.3.12 AUX user limit current warning (0x2394 / 0x128) 174

9.3.13 AUX fuse failure (0x2395 / 0x129) 174

9.3.14 DC overcurrent trip (0x2396 / 0x15C) 174

9.3.15 Output power trip (0x2397 / 0x12B) 174

9.3.16 I2T overload motor (0x239B / 0x102) 175

ContentsOperating Guide | VLT® Multiaxis Servo Drive MSD 510 System

9.3.17 Mains phase loss (0x3130 / 0x12F) 175

9.3.18 DC link overvoltage (0x3210 / 0x103) 175

9.3.19 Overcurrent trip SW (0x3210 / 0x103) 175

9.3.20 DC link undervoltage (0x3220 / 0x104) 176

9.3.21 UDC charging error (0x3230 / 0x152) 176

9.3.22 DC Link Voltage unbalanced (0x3280 / 0x153) 176

9.3.23 UAUX high voltage (0x3291 / 0x132) 176

9.3.24 UAUX overvoltage (0x3292 / 0x133) 177

9.3.25 UAUX low voltage (0x3293 / 0x134) 177

9.3.26 UAUX undervoltage (0x3294 / 0x135) 177

9.3.27 UDC high voltage (0x3295 / 0x136) 177

9.3.28 UDC low voltage (0x3296 / 0x137) 178

9.3.29 UAUX charging error (0x3297 / 0x154) 178

9.3.30 UDC shutdown error (0x3298 / 0x165) 178

9.3.31 UAUX shutdown error (0x3299 / 0x155) 178

9.3.32 UAUX undervoltage hardware (0x329A / 0x156) 179

9.3.33 Automated fault reset failure (0x329B / 0x168) 179

9.3.34 Device overtemperature (0x4210 / 0x157) 179

9.3.35 Too low temperature (0x4220 / 0x138) 180

9.3.36 Overtemperature: Power module (0x4290 / 0x105) 180

9.3.37 Overtemperature: Control card (0x4291 / 0x106) 180

9.3.38 Overtemperature: Power card (0x4292 / 0x107) 180

9.3.39 Inrush overtemperature: DC link (0x4293 / 013C) 180

9.3.40 Inrush overtemperature AUX line (0x4294 / 0x13D) 181

9.3.41 Overtemperature: Motor (0x4310 / 0x108) 181

9.3.42 UAUX undervoltage (0x5112 / 0x109) 181

9.3.43 Charge switch failure voltage (0x5121 /0x158) 181

9.3.44 EE Checksum Error (parameter missing) (0x5530 / 0x10A) 182

9.3.45 Parameter error (0x6320 / 0x10B) 182

9.3.46 Conf par ver (0x6382 / 0x15D) 182

9.3.47 Configuration parameters limits error (0x6383 / 0x164) 182

9.3.48 Power EEprom configuration error (0x6384 / 0x166) 183

9.3.49 Brake chopper failure (0x7111 / 0x141) 183

9.3.50 Brake chopper overcurrent (0x7112 / 0x167) 183

9.3.51 Brake resistor maximum power limit (0x7181 / 0x142) 183

9.3.52 Brake resistor user power limit (0x7182 / 0x143) 184

9.3.53 Brake mains voltage too high (0x7183 / 0x159) 184

9.3.54 Internal position sensor error (0x7320 / 0x10C) 184

9.3.55 External position sensor error (0x7380 / 0x10D) 185

9.3.56 Following error (0x8611 / 0x10E) 185

9.3.57 Homing error on entering homing mode (0x8693 / 0x10F) 185

9.3.58 Homing error on start homing method (0x8694 / 0x110) 185

ContentsOperating Guide | VLT® Multiaxis Servo Drive MSD 510 System

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