Emerson Digitax st series User manual

Installation Guide

Part Number: 0475-0000-02

Issue: 2

www.controltechniques.com

General Information

The manufacturer accepts no liability for any consequences resulting from inappropriate, negligent

or incorrect installation or adjustment of the optional parameters of the equipment or from

mismatching the variable speed drive with the motor.

The contents of this guide are believed to be correct at the time of printing. In the interests of

commitment to a policy of continuous development and improvement, the manufacturer reserves the

right to change the specification of the product or its performance, or the content of the guide without

notice.

means, electrical or mechanical including, photocopying, recording or by an information storage or

retrieval system, without permission in writing from the publisher.

Drive software version

This product is supplied with the latest version of user-interface and machine control software. If this

product is to be used in a new or existing system with other drives, there may be some differences

between their software and the software in this product. These differences may cause the product

to function differently. This may also apply to drives returned from the Control Techniques Service

Centre.

If there is any doubt, please contact your local Control Techniques Drive Centre or Distributor.

Environmental Statement

Control Techniques is committed to minimising the environmental impacts of its manufacturing

operations and of its products throughout their life cycle. To this end, we operate an Environmental

Management System (EMS) which is certified to the International Standard ISO 14001. Further

information on the EMS, our Environment Policy and other relevant information is available on

request, or can be found at www.greendrives.com.

The electronic variable speed drives manufactured by Control Techniques have the potential to save

energy and (through increased machine/process efficiency) reduce raw material consumption and

scrap throughout their long working lifetime. In typical applications, these positive environmental

effects far outweigh the negative impacts of product manufacture and end-of-life disposal.

Nevertheless, when the products eventually reach the end of their useful life, they can very easily be

dismantled into their major component parts for efficient recycling. Many parts snap together and can

be separated without the use of tools, while other parts are secured with conventional screws.

Virtually all parts of the product are suitable for recycling.

Product packaging is of good quality and can be re-used. Large products are packed in wooden

crates, while smaller products come in strong cardboard cartons which themselves have a high-

recycled fibre content. If not re-used, these containers can be recycled. Polythene, used on the

protective film and bags from wrapping product, can be recycled in the same way. Control

Techniques' packaging strategy favours easily recyclable materials of low environmental impact,

and regular reviews identify opportunities for improvement.

When preparing to recycle or dispose of any product or packaging, please observe local legislation

and best practice.

Issue: 2

Digitax ST Installation Guide 3

Issue: 2 www.controltechniques.com

Contents

1 Safety Information ...............................................................5

1.1 Warnings, Cautions and Notes ................................................................5

1.2 Electrical safety - general warning ..........................................................5

1.3 System design and safety of personnel ..................................................5

1.4 Environmental limits ................................................................................6

1.5 Compliance with regulations ...................................................................6

1.6 Motor .......................................................................................................6

1.7 Adjusting parameters ..............................................................................6

1.8 Electrical installation ................................................................................6

2 Introduction .........................................................................8

2.1 Features of the drive ...............................................................................9

2.2 Items supplied with the drive ...................................................................9

3 Mechanical Installation .....................................................11

3.1 Drive ......................................................................................................11

3.2 Braking ..................................................................................................13

3.3 External EMC filter ................................................................................14

4 Electrical Installation ........................................................15

4.1 Power terminal connections ..................................................................15

4.2 Ground leakage .....................................................................................17

4.3 EMC ......................................................................................................18

4.4 Control terminals ...................................................................................21

4.5 Recommended simple start-up .............................................................27

4Digitax ST Installation Guide

www.controltechniques.com Issue: 2

Declaration of Conformity

Control Techniques Ltd

The Gro

Newtown

Powys

SY16 3BE

The AC variable speed drive products listed above have been designed and manufactured in

accordance with the following European harmonised standards:

EN 61000-3-2: Applicable where input current <16A. No limits apply for professional equipment where

input power >1kW.

These products comply with the Low Voltage Directive 2006/95/EC, the Electromagnetic

Compatibility (EMC) Directive 89/336/EEC and the CE Marking Directive 93/68/EEC.

These electronic drive products are intended to be used with appropriate motors,

controllers, electrical protection components and other equipment to form complete end

products or systems. Compliance with safety and EMC regulations depends upon installing

and configuring drives correctly, including using the specified input filters. The drives must

be installed only by professional assemblers who are familiar with requirements for safety

and EMC. The assembler is responsible for ensuring that the end product or system

complies with all the relevant laws in the country where it is to be used. Refer to the User

Guide. An EMC Data Sheet is also available giving detailed EMC information.

DST1201 DST1202 DST1203 DST1204

DST1401 DST1402 DST1403 DST1404 DST1405

EN 61800-5-1 Adjustable speed electrical power drive systems - safety requirements -

electrical, thermal and energy

EN 61800-3 Adjustable speed electrical power drive systems. EMC product standard

including specific test methods

EN 61000-6-2 Electromagnetic compatibility (EMC). Generic standards. Immunity standard for

industrial environments

EN 61000-6-4 Electromagnetic compatibility (EMC). Generic standards. Emission standard for

industrial environments

EN 61000-3-2 Electromagnetic compatibility (EMC), Limits, Limits for harmonic current

emissions (equipment input current <16A per phase)

EN 61000-3-3 Electromagnetic compatibility (EMC), Limits, Limitation of voltage fluctuations

and flicker in low-voltage supply systems for equipment with rated current <16A

W. Drury

Executive VP Technology

Date: 2nd May 2007

Safety Information

Introduction Mechanical Installation Electrical Installation

Digitax ST Installation Guide 5

Issue: 2 www.controltechniques.com

1 Safety Information

1.1 Warnings, Cautions and Notes

1.2 Electrical safety - general warning

The voltages used in the drive can cause severe electrical shock and/or burns, and

could be lethal. Extreme care is necessary at all times when working with or adjacent to

the drive.

Specific warnings are given at the relevant places in this guide.

1.3 System design and safety of personnel

The drive is intended as a component for professional incorporation into complete

equipment or a system. If installed incorrectly, the drive may present a safety hazard.

The drive uses high voltages and currents, carries a high level of stored electrical

energy, and is used to control equipment which can cause injury.

Close attention is required to the electrical installation and the system design to avoid

hazards either in normal operation or in the event of equipment malfunction. System

design, installation, commissioning and maintenance must be carried out by personnel

who have the necessary training and experience. They must read this safety information

and this guide carefully.

The STOP and SAFE TORQUE OFF functions of the drive do not isolate dangerous

voltages from the output of the drive or from any external option unit. The supply must

be disconnected by an approved electrical isolation device before gaining access to the

electrical connections.

With the sole exception of the SAFE TORQUE OFF function, none of the drive

functions must be used to ensure safety of personnel, i.e. they must not be used

for safety-related functions.

Careful consideration must be given to the functions of the drive which might result in a

hazard, either through their intended behaviour or through incorrect operation due to a

fault. In any application where a malfunction of the drive or its control system could lead

to or allow damage, loss or injury, a risk analysis must be carried out, and where

necessary, further measures taken to reduce the risk - for example, an over-speed

protection device in case of failure of the speed control, or a fail-safe mechanical brake

in case of loss of motor braking.

A Warning contains information, which is essential for avoiding a safety hazard.

WARNING

A Caution contains information, which is necessary for avoiding a risk of damage to the

product or other equipment.

CAUT ION

A Note contains information, which helps to ensure correct operation of the product.

NOTE

6Digitax ST Installation Guide

www.controltechniques.com Issue: 2

The SAFE TORQUE OFF function has been approved1as meeting the requirements of

EN954-1 category 3 for the prevention of unexpected starting of the drive. It may be

used in a safety-related application. The system designer is responsible for ensuring

that the complete system is safe and designed correctly according to the relevant safety

standards.

1Independent approval by BGIA is pending.

1.4 Environmental limits

Instructions regarding transport, storage, installation and use of the drive must be

complied with, including the specified environmental limits. Drives must not be

subjected to excessive physical force. Refer to the Technical Data Guide.

1.5 Compliance with regulations

The installer is responsible for complying with all relevant regulations, such as national

wiring regulations, accident prevention regulations and electromagnetic compatibility

(EMC) regulations. Particular attention must be given to the cross-sectional areas of

conductors, the selection of fuses or other protection, and protective ground (earth)

connections.

Within the European Union, all machinery in which this product is used must comply

with the following directives:

98/37/EC: Safety of machinery.

89/336/EEC: Electromagnetic Compatibility.

1.6 Motor

Ensure the motor is installed in accordance with the manufacturer’s recommendations.

Ensure the motor shaft is not exposed.

The values of the motor parameters set in the drive affect the protection of the motor.

The default values in the drive should not be relied upon.

It is essential that the correct value is entered in Pr 0.46 Motor rated current. This affects

the thermal protection of the motor.

1.7 Adjusting parameters

Some parameters have a profound effect on the operation of the drive. They must not

be altered without careful consideration of the impact on the controlled system.

Measures must be taken to prevent unwanted changes due to error or tampering.

1.8 Electrical installation

1.8.1 Electric shock risk

The voltages present in the following locations can cause severe electric shock and may

be lethal:

• AC supply cables and connections

• DC bus, dynamic brake cables and connections

• Output cables and connections

• Many internal parts of the drive, and external option units

Unless otherwise indicated, control terminals are single insulated and must not be

touched.

1.8.2 Isolation device

The AC supply must be disconnected from the drive using an approved isolation device

before any cover is removed from the drive or before any servicing work is performed.

Safety Information

Introduction Mechanical Installation Electrical Installation

Digitax ST Installation Guide 7

Issue: 2 www.controltechniques.com

1.8.3 STOP function

The STOP function does not remove dangerous voltages from the drive, the motor or

any external option units.

1.8.4 Stored charge

The drive contains capacitors that remain charged to a potentially lethal voltage after the

AC supply has been disconnected. If the drive has been energised, the AC supply must

be isolated at least ten minutes before work may continue.

Normally, the capacitors are discharged by an internal resistor. Under certain, unusual

fault conditions, it is possible that the capacitors may fail to discharge, or be prevented

from being discharged by a voltage applied to the output terminals. If the drive has failed

in a manner that causes the display to go blank immediately, it is possible the capacitors

will not be discharged. In this case, consult Control Techniques or their authorised

distributor.

1.8.5 Equipment supplied by plug and socket

Special attention must be given if the drive is installed in equipment which is connected

to the AC supply by a plug and socket. The AC supply terminals of the drive are

connected to the internal capacitors through rectifier diodes which are not intended to

give safety isolation. If the plug terminals can be touched when the plug is disconnected

from the socket, a means of automatically isolating the plug from the drive must be used

(e.g. a latching relay).

1.8.6 Permanent magnet motors

Permanent magnet motors generate electrical power if they are rotated, even when the

supply to the drive is disconnected. If that happens then the drive will become energised

through its motor terminals.

If the motor load is capable of rotating the motor when the supply is disconnected, then

the motor must be isolated from the drive before gaining access to any live parts.

8Digitax ST Installation Guide

www.controltechniques.com Issue: 2

2 Introduction

The Digitax ST family of servo drives are available with four levels of intelligence:

• Digitax ST Base

• Digitax ST Indexer

• Digitax ST Plus

• Digitax ST EZMotion

The Digitax ST Base drive operates in velocity or torque modes and is designed to

operate with a centralised motion controller or as a standalone drive.

The Digitax ST Indexer drive performs point-to-point motion profiling including relative,

absolute, rotary plus, rotary minus, registration and homing motion. The Digitax ST

Indexer will operate as a single standalone system controller. Alternatively, the Digitax

ST Indexer can form part of a distributed system where commands are sent over a

fieldbus or through digital input/output signals.

The Digitax ST Plus drive offers all the features available on the Digitax ST Indexer

drive with the addition of performing complex motion as a single axis or synchronised to

a reference axis. This offers digital lock and electronic camming via a virtual master

reference.

The Digitax ST EZMotion drive is part of the Motion Made Easy family of servo drives

and allows the user to create programs to sequence motion, I/O control, and other

machine operations in one environment. Digitax ST EZMotion also supports advanced

functions such as a Position Capture Object, Multiple Profile Summation, Queuing, and

Program Multitasking.

All variants provide a SAFE TORQUE OFF function. This function is identical to that

referred to as "SECURE DISABLE" in the Control Techniques Unidrive SP product

range. The name has been changed in accordance with draft standard prEN 61800-5-2

(future IEC 61800-5-2, EN 61800-5-2)

Figure 2-1 Model code explanation

Model: Digitax ST

Frame size

Voltage rating

200V to 240V

380V to 480V

Current rating step

Variant

DST 1 2 01 B

Base

Indexer

Plus

EZMotion

Safety Information

Introduction

Mechanical Installation Electrical Installation

Digitax ST Installation Guide 9

Issue: 2 www.controltechniques.com

2.1 Features of the drive

Figure 2-1 Features of the drive

2.2 Items supplied with the drive

The drive is supplied with the following items:

• Installation Guide

• SMARTCARD

• Safety Information booklet

• Certificate of Quality

• CD ROM containing all appropriate drive and option module documentation, and

software tools

An accessory box containing the items illustrated in Figure 2-2 is also provided.

Solutions

Module

slot 2

cover

Solutions

Module

slot 1

cover

Buffered

encoder output

Encoder In

connection

Motor

connections

Line to

ground

varistor

screw

AC supply

48V connection

(for low voltage

DC operation)

Braking

resistor

connections

SMARTCARD

slot

Serial port

connector

Control

terminals

Relay

terminal

Keypad

connection

EMC bracket Ground

EMC bracket

Ground

screw

Status LED

Marker tag

location

Internal

EMC

filter

screw

Rating

label

Approvals

label

Brake

resistor slot

Reset

button

Fan

Control cable

strain relief

Product

identifier

The drive is supplied with a SMARTCARD installed. Do not remove until after first power-

up, as defaults are stored on the SMARTCARD.

NOTE

Static precautions must be taken when removing the Solutions Module slot covers.

CAUT ION

10 Digitax ST Installation Guide

www.controltechniques.com Issue: 2

Figure 2-2 Accessory box contents

Ground screws

Grounding

bracket

Cable

guides

ontrol

connectors

Relay

connecto

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