SIGMATEK MDD 111-2 Instruction Manual

SIGMATEK MDD 111-2 Instruction Manual

Axis module 400 v/480 v
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MDD 111-2
Axis Module 400 V/480 V
MDD 111-2

1 Overview

The MDD 111-2 is an axis module for one axis with a
Rated output current of 6 A at 230 V and 4 A at 400/480 V
and a peak output current of 15 A at 230 V and 9 A at
400/480 V. This module has an amplified brake output,
which allows a higher cut-off energy.
MDD 100 is a small to midsize power range servo drive
system, especially developed for multi-axial applications
in the low, middle and high performance range.
It is fully integrated in the Lasal operating system and has
1 to 8 servo axes.
Depending on the supply module used and the motor
type, the system is a 1-phase 230 VAC or a 3-phase
400-480 VAC system.
Four axis modules are available, two single-axis modules
for 230 V and 400 V and two dual-axes module for 230 V
and 400 V, which have a scalable output current range of
the 2 axes.
The supply module and the axes modules are put on a
module carrier, which is mounted on the mounting plate of the cabinet.
The current, speed, and position control of the up to 8 axes work with a cycle time
of 62.5 µs. MDD 100 has a high flexibility in connection of various feedback systems.
VARAN connects the servo drive system to the machine controller.
Integrated safety functions "Safe Torque off" STO and "Safe Stop 1" SS1 with a high safety
level ease the integration into the safety concept of the machine.
10.03.2021
Page 1

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Summary of Contents for SIGMATEK MDD 111-2

  • Page 1: Overview

    MDD 111-2 1 Overview The MDD 111-2 is an axis module for one axis with a Rated output current of 6 A at 230 V and 4 A at 400/480 V and a peak output current of 15 A at 230 V and 9 A at 400/480 V.
  • Page 2: Table Of Contents

    MDD 111-2 1 Overview ..................1 Components of a servo system ........... 4 2 General ..................5 About this manual ............... 5 Symbols used in this manual............6 Safety Instructions ..............7 Conformity with European Directives ........10 Prescribed use ................11 Non-prescribed use ..............
  • Page 3 MDD 111-2 Feedback (X12, X22) ..............47 5.2.1 Resolver Feedback ................48 ® 5.2.2 EnDat Feedback .................. 49 ® 5.2.3 Hiperface Feedback ................52 5.2.4 Sine Encoder Feedback ................ 53 5.2.5 Sanyo Denki Motor ................54 5.2.6 Panasonic Feedback ................55 5.2.7...
  • Page 4: Components Of A Servo System

    MDD 111-2 1.1 Components of a servo system Page 4 10.03.2021...
  • Page 5: General

    MDD 111-2 2 General 2.1 About this manual The manual describes the MDD 111-2 axis module 400 V/480 V. The information provided is: • Technical Data for the axis module 400 V/480 V • Description of the safety function •...
  • Page 6: Symbols Used In This Manual

    MDD 111-2 2.2 Symbols used in this manual Danger! Shock current Danger to personnel from electricity Caution! General General warning, see document Caution! Hot surface Hot surface more than 80 °C (176 °F) Important note See document Page 6 10.03.2021...
  • Page 7: Safety Instructions

    MDD 111-2 2.3 Safety Instructions The safety instructions must be read before installation and set-up of the servo drive system, to prevent injury or material damage. It is fundamental that the technical data and information for connection requirements be followed (on the nameplate and in the documentation).
  • Page 8 MDD 111-2 Never remove the electrical connections to the servo drive system while it is under voltage. There is a danger of electrical arcing with damage to contacts and danger to personnel. If a leakage current sensor is used in the mains supply of the servo drive system, a leakage current sensor RCD type B must be used.
  • Page 9 MDD 111-2 Caution! Hot surface During operation, the housing of the servo drive can become hot and may reach temperatures above 80 °C (176 °F). Especially the rear side of the module carrier will get hot, if the system is not mounted on a mounting plate in the cabinet.
  • Page 10: Conformity With European Directives

    MDD 111-2 2.4 Conformity with European Directives Servo drives are components, which are built into electrical equipment and machines for industrial use. The operation is forbidden, until the machine or plant fulfils the requirements defined by the EC Directive on Machines 2006/42/EC and the Electromagnetic Compatibility (EMC) directive 2014/30/EU.
  • Page 11: Prescribed Use

    MDD 111-2 2.5 Prescribed use The servo drives of SIGMATEK GmbH & Co KG are developed and produced according to the actual prior art. The products are fully tested before delivery, especially in terms of fail- safe conditions. They are components, which are built into electrical equipment and can only be used as integral components of such equipment.
  • Page 12: Non-Prescribed Use

    MDD 111-2 • Power supply modules MDP101-1 and MDP 102-1 are to be used with axis modules MDD111-2 and MDD121-1 only. • Drives must to be used with motors provided with over temperature sensing. 2.6 Non-prescribed use “Prescribed use” means, that the servo drive system is used according to the environmental conditions described in this documentation.
  • Page 13: Nameplate

    MDD 111-2 2.7 Nameplate 10.03.2021 Page 13...
  • Page 14: Block Diagram And Concept

    MDD 111-2 2.8 Block Diagram and Concept Block diagram of the Power Supply Module Page 14 10.03.2021...
  • Page 15 MDD 111-2 Module Axis Module Carrier Feedback – Converter Internal coder DC-link +24V-BR Internal Supply 2 x 6 U_Treiber Block diagram of the Axis Module 10.03.2021 Page 15...
  • Page 16 MDD 111-2 Hardware • Mains input is fed to the power rectifier, the input filter and the inrush circuit • DC-link connection for connecting the DC-link to other drives for power distribution • Regen unit with internal regen resistor. •...
  • Page 17 MDD 111-2 Concept of the MDD 100 • Servo drive system contains of different components - Power supply module for up to eight logical axes - Axis module in different configurations - Single axis module - Dual axis module - Module carrier in different configurations for one to 4 axis modules •...
  • Page 18 MDD 111-2 Software functionality • Modified space vector modulation (SVM) technique to reduce the power stage losses • Field oriented current controller (update time 62.5 µs) • Feedback converter and speed controller (update time 62.5 µs) • Spline interpolator and position controller (update time 62.5 µs) •...
  • Page 19: Technical Data Axis Module 400 V/480 V

    MDD 111-2 2.9 Technical Data Axis Module 400 V/480 V MDD 111-2 Article number 09-404-111-2 Rated Data Nominal allowed mains voltage 230/ 400 / 480 Max. holding brake current per axis Holding brake voltage drop from Max. 1 (at 1 A holding brake current)
  • Page 20: Ambient Conditions, Ventilation And Mounting

    MDD 111-2 Plug types Feedback (X12, X22)) Sub-D 25-pole (female) Motor (X11, X21) Phoenix GMSTB 2,5HCV/ 6-ST-7,62 Mechanics Height Width Depth with module carrier (without/with 152/195 plugs) Weight General Article number 09-404-111-2 Standard UL 508C, NMMS.E336350 Is limited to the equivalent continuous sum current depending on axis 2 Is limited to the equivalent peak sum current depending on axis 2 2.10 Ambient conditions, ventilation and mounting...
  • Page 21: Installation

    MDD 111-2 3 Installation 3.1 Important instructions • If a leakage current sensor is used in the mains supply of the servo drives, a leakage current sensor RCD type B has to be used in any case. If a RCD type A or AC is used, there is a risk, that the DC ground current of the servo drive inhibits the leakage current sensor.
  • Page 22: Important Instructions For The Safety Function

    MDD 111-2 • Route the motor and control cables separately (distance about 100 mm). This improves the noise level of the control signals because of the high radiation of the motor cables. Use only screened motor and feedback cable with shield connections on both ends.
  • Page 23 MDD 111-2 • When an external force is likely to act with the function ”safe restart lock” (e.g. force to the load by hanging load) additional measures have to be provided (e.g. double-disc spring set brake, instead of permanent magnetic-excited brake) Failure to observe this precaution can result in severe injury and equipment damage.
  • Page 24: Planning Of The Switchgear Cabinet

    MDD 111-2 3.3 Planning of the switchgear cabinet 3.3.1 Connection diagram and pin assignment of the axis module Module Axis Module Carrier Sine Sine encoder encoder Resolver Motor 2 Motor 2 Sine Sine encoder encoder Resolver Resolver Motor 1 Motor 1...
  • Page 25 MDD 111-2 10.03.2021 Page 25...
  • Page 26: Ground

    MDD 111-2 3.3.2 Ground On the MDD module a mounting bracket is found, which serves as stress relief as well as shielding. Here, the cable shield is connected. Page 26 10.03.2021...
  • Page 27 MDD 111-2 The entire MDD System is grounded over the module carrier in the control cabinet. 10.03.2021 Page 27...
  • Page 28: Mechanical Construction And Mounting

    MDD 111-2 3.3.3 Mechanical construction and mounting The mechanical dimensions of the servo drive system above are: depends on the selected module carrier 120 mm for MDM 011 180 mm for MDM 021 240 mm for MDM 031 300 mm for MDM 041 Page 28 10.03.2021...
  • Page 29 MDD 111-2 The mechanical dimensions of the module carrier and the fastening on the mounting plate of the cabinet above are: depends on the selected module carrier 100 mm for MDM 011 160 mm for MDM 021 220 mm for MDM 031...
  • Page 30: Connector Properties

    MDD 111-2 3.3.4 Connector properties All connections of the servo drive system (except the ground bolt) are plugging style connectors. This makes it easier to install the cables and to replace a drive. Never the less it also opens the possibility to create cable sets for high volume machines.
  • Page 31: External Fusing

    MDD 111-2 3.3.6 External Fusing The AC-mains and 24 V – fuses are calculated depending on customer needs. Signal Fuses, time delay AC mains input (L1-L3) Size fuses to the average power, needed by the servo drives, connected to the circuit. Maximum rating is 12 A time delay corresponding to cable diameter of 2.5 mm²...
  • Page 32: Usage Of Cooling Units

    MDD 111-2 3.3.7 Usage of cooling units The servo drive system operates up to 45 °C (55 °C with power reduction) ambient temperature. This means, that there could be a need to use a cooling unit. Note: Principally, the usage of a cooling unit can and will produce condensation water.
  • Page 33 MDD 111-2 Avoid condensation also by observing the following rules: • Set the set point of the temperature control of the cooling unit minimal to the temperature of the factory building. • Use only properly sealed switchgear cabinets to avoid condensation by the moist external air.
  • Page 34: Turn On/Off Response Of The Servo Amplifier

    MDD 111-2 3.3.8 Turn on/off response of the servo amplifier The turn on/off response of the servo amplifier is shown below. 24V – Auxiliary supply Max. 15 s Amplifier drive ready “ Main con tact L1, L2, L3 Under voltage Max.
  • Page 35: Holding Brake Control

    MDD 111-2 3.3.9 Holding brake control +24V_BR Min. 0.2 sec Min. 0.1 sec Enable Speed Setpoint Host Speed Setpoint Emergency ramp internally Brake enable delay time Max. 1 sec Actual Speed Speed threshold Enable internally Brake disable delay time Brake...
  • Page 36: Safety Function

    MDD 111-2 4 Safety Function The MDD 100 servo drive system supports the safety functions SS1 (Safe Stop 1) and STO (Safe Torque Off), and meets the requirements for Category 4 Performance Level "e" according to EN ISO 13849-1 and SIL3 according to EN 62061.
  • Page 37: Implementation

    MDD 111-2 4.1 Implementation The following block diagram gives an overview of the internal switching circuit. REL 01 G 01 OPTO 01 CONTR 01 AMP 01 Super visor Astable Multi- U_Treiber vibrator OPTO 02 Super 0.5s visor AMP 02 Control...
  • Page 38: Blocks Amv, Opto 01 And Opto 02

    MDD 111-2 4.1.2 Blocks AMV, OPTO 01 and OPTO 02 As long as the AMV block is powered by the IN input block, it generates a pulse with a constant frequency that is transmitted to the sequential electronics through blocks OPTO 01 and OPTO 02.
  • Page 39: Function

    MDD 111-2 4.2 Function The safety functions in the DIAS Drive are controlled over two digital inputs. The following table shows the status that the ENABLE_L and ENABLE_H inputs must assume to enable normal operation or trigger the safety function.
  • Page 40 MDD 111-2 Software Enable ENABLE_H – ENABLE_L >= 15V STO aktivated SS1 aktivated Enable (internally) Speed set point of the controller G-EMRAMP Actual speed max. 1 s Timing Diagram If the ENABLE_L and ENABLE_H are changed from any status to the "Drive Ready" status, the servo amplifier is not immediately enabled.
  • Page 41: Function Test

    MDD 111-2 4.3 Function Test The safety function test is required to ensure correct operation. The entire safety circuit must be tested for full functionality. Tests must be performed at the following times: • After installation • In regular intervals, or at least once a year.
  • Page 42: Example Connection With Switching Contacts

    MDD 111-2 4.4 Example Connection with Switching Contacts To meet the requirements of safety category 4, performance level "e" for EN 13849-1 and SIL3 according to EN 62061, a two-channel control must be provided for the safety functions. The wiring for both connections must be provided with protective insulation (to avoid the "external voltage supply"...
  • Page 43: Example: Safety Plc Application

    MDD 111-2 4.5 Example: Safety PLC Application To meet the requirements of safety category 4, performance level "e" for EN 13849-1 and SIL 3 according to EN 62061, an error-proof output of a safety PLC must be used. There are two Types of error-safe outputs.
  • Page 44 MDD 111-2 Two-channel error-proof relay output, with which the + output is connected to ENABLE_H and the – output to ENABLE_L. Page 44 10.03.2021...
  • Page 45: Interfaces

    MDD 111-2 5 Interfaces 5.1 Motor connector (X11, X21) 5.1.1 Standard configuration The motor cable length is limited to 20 m. If a longer motor cable is required, use an addition motor choke in the output of the servo drive.
  • Page 46: Classic Emergency Stop Function (Stop Category 0)

    MDD 111-2 4.4.2 Classic emergency stop function (stop category 0) The motor cable length is limited to 20 m. If a longer motor cable is required, use an addition motor choke in the output of the servo drive. Note: The contactor K has to be switched on, before the servo drive is enabled and to be switched off minimal 1ms after disable.
  • Page 47: Feedback (X12, X22)

    MDD 111-2 5.2 Feedback (X12, X22) The servo drive has feedback inputs for several different feedback devices. • Resolver Feedback with thermal contact in the motor winding • ® EnDat encoder (single and multiturn) • Hiperface® encoder (single and multiturn) •...
  • Page 48: Resolver Feedback

    MDD 111-2 5.2.1 Resolver Feedback The standard feedback system for servomotors is resolver feedback. The servo drive allows evaluation of single speed (2-pole) and also multi speed resolvers (up to 32-pole). The maximum cable length is limited to 50 m.
  • Page 49: Endat ® Feedback

    MDD 111-2 ® 5.2.2 EnDat Feedback One of the high-resolution feedback systems for servomotors is the encoder with EnDat interface. The maximum cable length is limited to 10 m. If a thermal contact is used in the motor, the signal is also connected via the encoder cable.
  • Page 50 MDD 111-2 The Maximum cable length is 10 m, with the exception of the following encoders: Type code Motor type Encoder Type Max. Length description AKM2 – AKM3 ECI 1118 8,2 m AKM2 – AKM3 EQI 1130 6,9 m AKM2 – AKM4...
  • Page 51 MDD 111-2 Cabel length is halved since the supply and GND line form the entire length. Cable wire Legend: U = Voltage drop ( 5 V supply – minimum encode supply) R = Wire resistance I = Maximum required encoder current ρ...
  • Page 52: Hiperface Feedback

    MDD 111-2 ® 5.2.3 Hiperface Feedback ® An encoder with Hiperface interface is a high-resolution interface for servomotors. The maximum cable length is limited to 25 m. If a thermal contact is used in the motor, the signal is also connected via the encoder cable.
  • Page 53: Sine Encoder Feedback

    MDD 111-2 5.2.4 Sine Encoder Feedback A sine encoder is a high-resolution feedback system, used with linear or torque servomotors. The maximum cable length is limited to 10 m. If a thermal contact is used in the motor, the signal is also connected via the encoder cable.
  • Page 54: Sanyo Denki Motor

    MDD 111-2 5.2.5 Sanyo Denki Motor A Sanyo Denki motor with an absolute encoder with no battery can be connected to the MDD 100. The maximum cable length is limited to 25 m. The battery type is in preparation. Sanyo Denki Motor, R Series...
  • Page 55: Panasonic Feedback

    MDD 111-2 5.2.6 Panasonic Feedback The Panasonic feedback analysis is supported starting with FW version 1.84 in combination with the MDD FPGA version v22 (see parameter I-HC). The maximum cable length is 25 m. 10.03.2021 Page 55...
  • Page 56: Biss C Feedback

    MDD 111-2 5.2.7 BiSS C Feedback The BiSS C analysis is supported starting with FW version 1.84 in combination with the MDD FPGA version v22 (see parameter I-HC). The maximum cable length is 10 m. If a thermos contact is used the signal is wired via the feedback cable.
  • Page 57: Maintenance

    MDD 111-2 6 Maintenance The servo drive does not require any maintenance. Note: Opening the enclosure invalidates the warranty If the casing is dirty, clean with Isopropanol or similar cleaning agent. • Dirt inside the unit must be cleaned by the manufacturer •...
  • Page 58 MDD 111-2 Disassemble the servo drive. Check the replacement component and compare it to the disassembled one. Install only the same type! Plug the connectors. Be careful not to swap connectors. Install the fuses supplying the servo drive system, switch on the main switch of the switchgear cabinet.
  • Page 59: Appendix

    MDD 111-2 7 Appendix 7.1 Transport, storage and disposal Transport: • Use only the manufacturer’s original recyclable packaging • Avoid shocks • Maximum temperature range –25 to +70 °C (-13...158 °F), maximum 20 K/h rate of change • Maximum 95 % relative humidity, not condensing •...
  • Page 60 MDD 111-2 • Storage duration: < 1 year: without restriction ≥ 1 year: capacitors must be re-formed before operating the servo drive. To re-form, remove all electrical connections, and supply the servo amplifier for about 30 min. from 230 VAC, single-phase, on terminals L1 / L2.
  • Page 61: Troubleshooting And Fault Elimination

    MDD 111-2 7.2 Troubleshooting and Fault Elimination Faults and warnings can be detected by LED and bus system. The list “Status Register” helps you eliminate the errors. 6.2.1 LED Indication Each axis module of the MDD 100 servo drive system has two LED’s for each axis, which display the status of the corresponding axis.
  • Page 62: Malfunction Of The Drive

    MDD 111-2 6.2.2 Malfunction of the drive Malfunction of the drive Cause Remedy ─ I-FPOS shows decrementing ─ Feedback system is not ─ Connect feedback system according values when the motor connected correctly to drawing rotates clockwise (view of the...
  • Page 63: Status Register

    MDD 111-2 6.2.3 Status Register The MDD 100 has a status register, read by I-STATUS. It is a 32-Bit variable that contains all error and status information. The internal behavior of the drive to the different bits can be set by G-MASKE1, G-MASKE2, G-MASKW and G-MASKD. According to the setting of the different masks, the drive detects an error, warning or does not react at all.
  • Page 64 MDD 111-2 ─ internal temperature too high ─ improve ventilation in the cabinet Ambient temperature and check mounting position according to this manual ─ heat sink temperature too high ─ improve ventilation in the cabinet, Heat sink temperature check mounting position according to this manual or use a cooling unit ─...
  • Page 65 MDD 111-2 Power stage fault: ─ motor cable has (ground) ─ replace motor cable short circuit ─ motor has (ground) short ─ replace motor circuit ─ power stage is damaged ─ replace drive Regen fault: ─ regen resistor has (ground) ─...
  • Page 66: Varan Recommended Shielding

    It is recommended that whenever possible, to avoid wiring VARAN-Bus lines parallel to power cables. SIGMATEK recommends the use of CAT5e industrial Ethernet bus lines. For the shielding variants, an S-FTP bus line is recommended, which is a symmetric, multi- wire cable with unshielded pairs.
  • Page 67: Wiring From The Control Cabinet To An External Varan Component

    MDD 111-2 8.1 Wiring from the Control Cabinet to an External VARAN Component If the Ethernet lines are connected from a VARAN component to a VARAN node outside the control cabinet, the shielding should be placed at the entry point to the control cabinet housing.
  • Page 68: Wiring Outside Of The Control Cabinet

    MDD 111-2 8.2 Wiring Outside of the Control Cabinet If a VARAN bus cable must be placed outside of the control cabinet only, no additional shield connection is required. This requires that only IP67 modules and connectors be used. These components are very robust and noise resistant. The shielding for all sockets in IP67 modules are internally connected to common bus or electrically connected to the housing, whereby the deflection of voltage spikes does not flow through the electronics.
  • Page 69: Shielding For Wiring Within The Control Cabinet

    MDD 111-2 8.3 Shielding for Wiring Within the Control Cabinet Sources of strong electromagnetic noise located within the control cabinet (drives, Transformers, etc.) can induce interference in a VARAN bus line. Spike voltages are deflected over the metallic housing of a RJ45 connector. Noise is conducted through the...
  • Page 70: Connecting Noise-Generating Components

    MDD 111-2 8.4 Connecting Noise-Generating Components With the connection of power components that generate strong electromagnetic noise, it is also critical to ensure correct shielding. The shielding should be placed before a power component (or a group thereof). Page 70...
  • Page 71: Shielding Between Two Control Cabinets

    MDD 111-2 8.5 Shielding Between Two Control Cabinets If two control cabinets must be connected over a VARAN bus, it is recommended that the shielding be located at the entry points to both cabinets. Noise can thereby be kept from reaching the electronics within the control cabinet.
  • Page 72 MDD 111-2 Page 72 10.03.2021...

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