SIGMATEK DIAS Drive 310-23 servo amplifier

SIGMATEK DIAS Drive 310-23 servo amplifier

Overall safety regulations

Key safety warning

Power off and wait for 5 minutes: After cutting off the main power, the intermediate circuit capacitor still carries dangerous high voltage. It is necessary to wait for ≥ 5 minutes and measure the DC bus voltage to be less than 40V before touching the terminals and plugging in the connectors.

High temperature of heat dissipation shell: The operating heat sink can reach above 80 ℃, and it should be cooled to below 40 ℃ before treatment.

Leakage protection: B-type leakage protector must be used; Type A may malfunction due to DC leakage.

PE grounding: minimum 10   mm ² (8AWG) copper conductor for protective earth wire; The minimum size for mobile devices is ≥ 10 mm ², as the residual leakage of the device is greater than 3.5 mA.

ESD anti-static: Before touching the equipment, touch the cabinet floor to release static electricity. It is forbidden to touch the circuit board with bare hands.

It is strictly prohibited to dismantle the casing without authorization, as dismantling will result in the loss of all warranty.

People with pacemakers should maintain a safe distance of at least 2 meters from the device to avoid electromagnetic radiation risks.

Only qualified electrical technicians are allowed to perform installation, power on, maintenance, and repair.

Compliance Standards

Low voltage: 2014/35/EU (EN 61800-5-1)

EMC Electromagnetic Compatibility: 2014/30/EU (EN 61800-3)

Machinery Directive 2006/42/EC; UL 508C (E336350).

Permitted/Prohibited Use

Design purpose: for use in control cabinet IP54 environment; Drive star connected servo, asynchronous, linear, and torque motors; Support speed, torque, and position control.   

Prohibited scenarios: Ship offshore/marine offshore environment; Bare machine operation without control cabinet; Salt spray conductive dust environment (carbon fiber, graphite, etc., requiring sealed cabinets); Standard mode prohibits single-phase input (single-phase is only used for demonstration and debugging).

Overall hardware architecture and performance parameters

DIAS Drive 310-23 is a three-axis integrated servo amplifier, with 3 axes and a rated 10A per axis, with a peak value of 20A (up to 5 seconds); The maximum continuous output of the three-axis system is 20   A.

Electrical core parameters

Project parameters

Main power supply three-phase AC 3 × 230   V~3 × 480   V, 45-65   Hz

Auxiliary 24V (X1A) 22-30 VDC, power 35 W, PELV isolation

Brake power supply+24V BR 25-27 VDC; Each axle brake has a maximum of 2 A

DC bus DC-link 290-680 VDC; Bus capacitor 700 µ F

PWM carrier frequency of 8 kHz; Regulator frequency 16   kHz

Output maximum electrical frequency 599   Hz (firmware ≥ V1.82, over limit reporting fault 18)

The brake unit is equipped with an internal regenerative resistor of 25 Ω/200W; Can be connected with an external regenerative resistor of 25-50 Ω; 230V/400V/480V busbars correspond to different switching thresholds

Software control characteristics

Improved space vector modulation; The update period for the magnetic field oriented current loop, velocity loop, and position loop is 62.5 µ s.

Support system cycle: 250 µ s/500 µ s/1 ms~8 ms;

No local storage: The drive RAM is volatile, and the power on parameters are downloaded by the upper controller (CPU). When replacing the drive, the parameters are automatically downloaded.

Environment and Machinery

Operating temperature: 0-45 ℃ at full power; For every 1 ℃ increase between 45-55 ℃, the rated power decreases by 2.5%; Temperature derating is required for altitudes greater than 2000m.

Storage temperature: -25~+70 ℃; If stored for more than 1 year, the bus capacitance needs to be reformed before powering on: connect to a single-phase 230V and power on for 30 minutes.

Protection level IP20; Pollution level 2; Overvoltage category III.

Dimensions: Width 158mm x Depth 240mm; Height 378mm (without plug)/472mm (with plug); Weight 10   kg.

Two types of installation: vertical DIN installation inside a regular cabinet; Through hole wall installation kit, place the fan part outside the cabinet to enhance heat dissipation.

All interface descriptions

X1A (3-pin Phoenix): 24V auxiliary+brake power supply

+24V: Internal power supply for the controller; +24V BR: Independent power supply for motor brake; BGND: Reference location.

+24V and+24V BR must use PELV isolated power supply.

X1B (8-pin high-power terminal): main power supply, DC bus, regenerative resistor

L1, L2, L3 three-phase AC input; PE protected area;

+DC, DC: DC bus parallel interface, multiple drivers can share the bus; When sharing the busbar, the main power supply must also be synchronized and parallel connected;

Rint, Rtr: internal regenerative resistors; When connecting an external regeneration resistor, the Rint Rtr short circuit should be removed, and the external resistor should be connected to+DC and Rtr. The external resistor must be connected in series with a slow melting fuse.

X3/X4/X5 (motor terminals for each axis, 6-pin)

W V U motor three-phase, PE protection ground; B+B - Motor brake output.

The maximum allowable length for motor cables is 25 meters; if it exceeds 25 meters, an output suppression coil must be added. Support Class 0 emergency stop wiring scheme.

X6/X7/X8 (25 pin D-Sub, feedback port on each axis)

Supports 4 types of encoder feedback:

Resolver rotary transformer (standard): supports 2-32 poles; The cable is up to 50 meters long and supports motor temperature contacts;

EnDAT encoder;

Hiperface encoder;

Sin/Cos, TTL incremental encoder (Sin/Cos cable ≤ 25 μ m, TTL ≤ 10 μ m).

The maximum length of EnDAT/Hiperface cable is 25 meters.

Installation, wiring, and power on timing

Cabinet requirements: vertical installation; Reserved upper and lower air ducts; The physical separation between the motor power cable and feedback signal line is ≥ 100mm; all shielded cables have a 360 ° large-area grounding at both ends of the shielding layer.

Cable specifications: motor shielded cable, capacitance<150   pF/m; Feedback: The capacitance of the twisted pair cable is less than 120 pF/m.

External fuse: maximum 20A delay fuse for three-phase main circuit; 24V circuit 16A slow melting; External regenerative resistor 10A delay insurance.

Power supply system: The grounded TN system can be directly used; The IT ungrounded power grid must be equipped with isolation transformers or surge protection.

Power on timing: 1) Connect the 24V auxiliary power supply first, and after a maximum of 15 seconds, the driver outputs the "Drive Ready" ready signal; 2) Then connect the three-phase main power; Bus capacitor charging takes about 0.7 seconds; 3) When the main power is disconnected, the bus can be maintained for up to 7 minutes for motor feedback braking; The busbar discharge is completed after 5 minutes of power outage.

Brake timing: The driver has built-in brake logic, which only provides high reliability control and does not meet personal safety levels; To achieve safe braking, an external series safety relay is required to cut off the power supply of 24V BR.

Maintenance and replacement process

Drive body maintenance free; The shell can only be wiped with isopropanol; Do not spray or soak; Clean the grille of the cooling fan with a dry brush. Internal faults must be returned to the factory for repair.

Step 1 of replacing the driver: Cut off the main power supply, wait for 5 minutes, confirm that the bus voltage is less than 40V, and cool down the radiator; 2) Mark all connectors and unplug all connectors; 3) Dismantle the old drive; Install drivers of the exact same model; 4) Restore all wiring and strictly prohibit reverse connection; Install the fuse and close the main switch; 5) The upper computer automatically downloads parameters and verifies their correctness.

Fault diagnosis

1) Dual color LED status

Meaning of green LED and red LED status

Always on Boot mode, firmware damaged/missing

1Hz flashing off ready to enable

8Hz flashing, I ² T thermal overload current limiting

Constant on/off, normal operation

Always on 1Hz flashing warning status

Shutdown due to constant on/off fault

2) 32-bit status register I-STATUS

Each corresponding fault source: single-phase power supply fault, main power loss, bus overvoltage, bus undervoltage, brake failure, motor overheating, ambient temperature, radiator overheating, feedback fault, commutation error, overspeed, tracking error, upper communication fault, output stage fault, enable interlock, I2T overload, multi turn encoder fault, total power exceeding limit, etc; The manual provides reasons and solutions for each individual.

Optional accessories

Stress relief shielding plate (09-501-101-Z1): used for cable shielding clamping and fixing;

Wall through installation kit (09-501-101-Z2): The driver fan part extends outside the control cabinet to improve heat dissipation.

VAC 013 VARAN interface module

Inserted inside DIAS Drive for VARAN real-time bus communication, integrated with STO (Safe Torque Off) safety torque cutoff and SS1 safety deceleration stop, achieving SIL   3/PL   e/Cat.4 safety levels.

interface

X1 VARAN‑IN； X2 VARAN-OUT (RJ45, maximum bus length of 100m);

X3 (16 pin): 2-channel safety differential input ENABLE-H/ENABLE-L; 4-channel fast digital input; One non safety relay output S3-S4 is used for status feedback.

Power supply: Powered by 5V from within the driver; Typical 400 mA, maximum 500 mA.

Safety logic: Dual channel differential ENABLE-H/ENABLE-L, the driver must meet the level condition simultaneously to enable it;

STO: Directly block the output torque of power devices;

SS1: First slow down and stop the machine on the slope, then execute STO; Typical delay of 0.5s;

The motor brake is not in the safety circuit; Mechanical double spring brake must be added externally for suspended loads (lifting).

Wiring case: Supports ordinary safety contacts, single channel output of safety PLC, and dual channel relay output of safety PLC.

Addressing: VARAN bus register mapping, with independent read-write objects, control bytes, and status bytes on axes 1-3.

VARAN cabling specification: Recommended CAT5e S-FTP industrial Ethernet cable; Shielding grounding schemes for different cabinets, inside and outside cabinets, and around interference sources; Anti vibration fixing should be done within 20cm of the cable from the connector.

Transportation, storage, and disposal

Transportation must use original factory packaging; Maximum stacking capacity of 6 devices.

Scrap: It should be dismantled by electronic waste certification enterprises and cannot be discarded as household waste.