SIGMATEK MDP 101-1 Instruction Manual

SIGMATEK MDP 101-1 Instruction Manual

Power supply module 400 v/480 v
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MDP 101-1
Power Supply Module 400 V/480 V
MDP 101-1

1 Overview

The MDP 101 is a power supply module with a
3 kVA rating at an input voltage of 400/480 V.
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.
05.06.2020
Page 1

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Summary of Contents for SIGMATEK MDP 101-1

  • Page 1: Overview

    MDP 101-1 Power Supply Module 400 V/480 V MDP 101-1 1 Overview The MDP 101 is a power supply module with a 3 kVA rating at an input voltage of 400/480 V. 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.
  • Page 2: Table Of Contents

    3.3.5 Wire sizing ..................... 31 3.3.6 External Fusing ..................32 3.3.7 MDP 101-1 Mains Supply Options ............33 3.3.8 Usage of cooling units ................35 3.3.9 Turn on/off response of the servo amplifier ........... 37 3.3.10 Holding brake control ................38 4 Safety Function ................
  • Page 3 MDP 101-1 Mains input (X2) ............... 50 Auxiliary 24 V and Holding Brake supply (X2) ......51 DC-link (X2) ................52 Motor connector (X11, X21) ............53 5.4.1 Standard configuration ................53 4.4.2 Classic emergency stop function (stop category 0) ....... 54 4.4.3...
  • Page 4: Components Of A Servo System

    MDP 101-1 1.1 Components of a servo system Page 4 05.06.2020...
  • Page 5: General

    MDP 101-1 2 General 2.1 About this manual The manual describes the MDP 101-1 power supply module 400 V/480 V. The information provided is: • Technical Data for the power supply module 400 V/480 V • Description of the safety function •...
  • Page 6: Symbols Used In This Manual

    MDP 101-1 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 05.06.2020...
  • Page 7: Safety Instructions

    MDP 101-1 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 MDP 101-1 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 MDP 101-1 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: Prescribed Use

    MDP 101-1 2.4 Prescribed use The safety module "Safe Restart Lock" in an integral component of the DIAS Drive MDP 101-1 and is already installed with delivery; it meets the conditions required for safe operation according to SIL 3 in compliance with IEC 62061 and according to PL e in compliance with EN 13849-1.
  • Page 11 MDP 101-1 The servo amplifier from SIGMATEK GmbH & Co KG was designed and produced with state of the art technology. Before delivery, the products are completely tested for reliability. It is a built-in component for electrical systems, which can only be operated as an integral part of such systems.
  • Page 12: Non-Prescribed Use

    MDP 101-1 2.5 Non-prescribed use “Prescribed use” means, that the servo drive system is used according to the environmental conditions described in this documentation. • It must not be used in electrical equipment on ships (service afloat) or in offshore applications because of the conductive pollution.
  • Page 13: Nameplate

    MDP 101-1 2.6 Nameplate 05.06.2020 Page 13...
  • Page 14: Block Diagram And Concept

    MDP 101-1 2.7 Block Diagram and Concept Block diagram of the Power Supply Module Page 14 05.06.2020...
  • Page 15 MDP 101-1 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 05.06.2020 Page 15...
  • Page 16: Hardware

    MDP 101-1 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: Concept Of The Mdd 100

    MDP 101-1 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 MDP 101-1 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 62.5µs) • Spline interpolator and position controller (update time 62.5 µs) •...
  • Page 19: Technical Data Power Supply Module 400 V/480 V

    MDP 101-1 2.8 Technical Data Power Supply Module 400 V/480 V MDP101-1 Article number 09-403-101-1 Hardware version Rated Data Rated mains voltage (symmetrically to , 45 – 65 Hz ground) maximum 5000 rms symmetrical 3 x 230 V - 480 V...
  • Page 20 MDP 101-1 Peak power of the internal regen resistor (max. 1sec) Safety Input Input voltage between ENABLE_H (+) and Typically 24, max 30 V ENABLE_L (-) Signal level between ENABLE_H (+) and Low ≤ +5, High ≥ +15 ENABLE_L (-)
  • Page 21: Safety Conformity

    MDP 101-1 General Article number 09-403-101-1 Standard UL 508C, NMMS.E336350 2.9 Safety conformity Safety Integrity Level according to IEC EN 62061 SIL 3 Performance Level according to EN ISO 13849-1 Probability of failure per hour Mean time to dangerous failure...
  • Page 22: Installation

    MDP 101-1 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 23 MDP 101-1 b) Variable machine mains supply connection: Mains connection with industry connector according to EN 60309 and a minimum wire cross section of the protective conductor of 2.5 mm² (AWG 13) as part of a multi-conductor supply cable. Use an adequate pull relief.
  • Page 24: Important Instructions For The Safety Function

    MDP 101-1 3.2 Important instructions for the Safety Function • All control components (switches, relays, PLC, etc.) and the control cabinet must comply with the requirements of the ISO 13849. This includes: – Door – switches, etc. with protection class IP54 as minimum –...
  • Page 25: Planning Of The Switchgear Cabinet

    MDP 101-1 3.3 Planning of the switchgear cabinet 3.3.1 Connection diagram and pin assignment of power supply module 05.06.2020 Page 25...
  • Page 26 MDP 101-1 Connector layout of X1, X2, X3, X4 and X6 Varan 1 TX/RX+ Safety Input TX/RX- RX/TX+ RX/TX- 4,5,7,8 reserved TX/RX+ Enable_L TX/RX- Enable_H RX/TX+ RX/TX- 4,5,7,8 Varan 2 Supply Input Digital Input BGND 12 V_BAT +24V 11 V_BAT_GND...
  • Page 27: Ground

    MDP 101-1 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. 05.06.2020 Page 27...
  • Page 28 MDP 101-1 The entire MDD System is grounded over the module carrier in the control cabinet. Page 28 05.06.2020...
  • Page 29: Mechanical Construction And Mounting

    MDP 101-1 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 05.06.2020...
  • Page 30 MDP 101-1 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 31: Connector Properties

    MDP 101-1 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 32: External Fusing

    MDP 101-1 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.
  • Page 33: Mdp 101-1 Mains Supply Options

    MDP 101-1 3.3.7 MDP 101-1 Mains Supply Options The servo drive system MDD 100 has a high leakage current higher than 3.5 mA. Therefore particular attention has to be taken on the grounding of the servo drive system: a) Stationary machine mains supply connection: –...
  • Page 34 MDP 101-1 • Transient over voltages (<50µs) must not exceed 1000 V (peak value) between the phases and 2000 V against ground. Note: Ungrounded mains always need additional surge protection in the mains input. High voltage mains If the mains voltage exceeds the maximum allowed input voltage of the power supply module, a transformer has to be used to bring it into the specified range.
  • Page 35: Usage Of Cooling Units

    MDP 101-1 3.3.8 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 36 MDP 101-1 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 37: Turn On/Off Response Of The Servo Amplifier

    MDP 101-1 3.3.9 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 38: Holding Brake Control

    MDP 101-1 3.3.10 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 39: Safety Function

    MDP 101-1 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 40: Implementation

    MDP 101-1 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 41: Blocks Amv, Opto 01 And Opto 02

    MDP 101-1 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 42: Function

    MDP 101-1 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 43 MDP 101-1 Controlled shut down (K-EN = 0): If the actual speed reaches < 1% of min(N-NMAX, V-NMAX) or the ramp time exceeds 1 second, the brake is activated and the pre-set speed (I-NCMD) is immediately set to 0 (to support the braking effect).
  • Page 44: Function Test

    MDP 101-1 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 45: Example Connection With Switching Contacts

    MDP 101-1 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 46: Example: Safety Plc Application

    MDP 101-1 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 47 MDP 101-1 05.06.2020 Page 47...
  • Page 48 MDP 101-1 Two-channel error-proof relay output, with which the + output is connected to ENABLE_H and the – output to ENABLE_L. Page 48 05.06.2020...
  • Page 49 MDP 101-1 05.06.2020 Page 49...
  • Page 50: Interfaces

    ( page 35). Note: If the DC-link of two or more MDD 100 systems are linked with the same supply voltage, the mains inputs must also be linked. 3-phase connection of the MDP 101-1 power supply module: Mains contactor Power supply Module Page 50 05.06.2020...
  • Page 51: Auxiliary 24 V And Holding Brake Supply (X2)

    MDP 101-1 5.2 Auxiliary 24 V and Holding Brake supply (X2) Note: Only use power supply with galvanic isolated SELV output voltage! If a 24 V auxiliary power supply is installed in the switchgear cabinet for relays, contactors or other devices, this 24 V can be used to supply also the servo drive (notice the current rating of the power supply).
  • Page 52: Dc-Link (X2)

    MDP 101-1 5.3 DC-link (X2) When several drives are connected together, the DC-link connection enables power sharing between different axes. Note: If the DC-link of several servo drives is connected together, the mains input must also be connected in parallel to the drives connected of the group.
  • Page 53: Motor Connector (X11, X21)

    MDP 101-1 5.4 Motor connector (X11, X21) 5.4.1 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. Axis Module...
  • Page 54: Classic Emergency Stop Function (Stop Category 0)

    MDP 101-1 4.4.2 Classic emergency stop function (stop category 0) The motor cable length is limited to 20m. 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 55: Personnel Safe Holding Brake Control

    MDP 101-1 4.4.3 Personnel safe holding brake control The servo drive has a high level of functional safety of the control of the holding brake. If it is necessary to have a personnel-safe control for the holding brake, this requires one or two additional safety contacts in compliance with the safety standards in the +24 V-BR - line.
  • Page 56: Feedback (X12, X22)

    MDP 101-1 5.5 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 57: Resolver Feedback

    MDP 101-1 5.5.1 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 58: Endat Feedback

    MDP 101-1 ® 5.5.2 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 59 MDP 101-1 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 60 MDP 101-1 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 61: Hiperface Feedback

    MDP 101-1 ® 5.5.3 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 62: Sine Encoder Feedback

    MDP 101-1 5.5.4 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 63: Sanyo Denki Motor

    MDP 101-1 5.5.5 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 64: Panasonic Feedback

    MDP 101-1 5.5.6 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. Page 64 05.06.2020...
  • Page 65: Biss C Feedback

    MDP 101-1 5.5.7 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 66: Maintenance

    MDP 101-1 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 67 MDP 101-1 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 68: Appendix

    MDP 101-1 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/hr rate of change • Maximum 95 % relative humidity, not condensing •...
  • Page 69 MDP 101-1 • 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 70: Troubleshooting And Fault Elimination

    MDP 101-1 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. 7.2.1 Seven segment display Display Description 8.8. Initialization of the display During start-up the FPGA version is shown...
  • Page 71: Malfunction Of The Drive

    MDP 101-1 7.2.3 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 72: Status Register

    MDP 101-1 7.2.4 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 73 MDP 101-1 ─ internal temperature too ─ improve ventilation in the Ambient temperature high cabinet and check mounting position according to this manual ─ heat sink temperature too ─ improve ventilation in the Heat sink temperature high cabinet, check mounting...
  • Page 74 MDP 101-1 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 ─ replace module rack (ground) short circuit ─...
  • Page 75 MDP 101-1 ─ When the sum output ─ Servo drive system meets not Max. Sum Power Limitation power of all axes exceeds the demands of the Application the power supply limitation reserved ─ The fan does not reach the ─ Exchange axis module.
  • Page 76: 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 77: Wiring From The Control Cabinet To An External Varan Component

    MDP 101-1 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 78: Wiring Outside Of The Control Cabinet

    MDP 101-1 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 79: Shielding For Wiring Within The Control Cabinet

    MDP 101-1 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 80: Connecting Noise-Generating Components

    MDP 101-1 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 80...
  • Page 81: Shielding Between Two Control Cabinets

    MDP 101-1 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.

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