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KeDrive D3 Axis Controller BG1 and BG2 Operation Manual Compact multi-axis system KeDrive D3...
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Date: 01/2022 Information and specifications may be subject to change at any time. Please obtain information on the latest version at www.keba.com Applicable as from firmware version V1.1 The German version is the original of this documentation.
Table of contents Mechanical installation ............... 15 Notes for installation ..................... 15 3.1.1 Order and arrangement ................15 Mounting clearances .................... 16 General ..................7 Cooling the devices ....................17 Target group ......................7 Installation of the devices for wall mounting ............17 Prerequisites ......................
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Operation Manual KeDrive D3-DA Axis Controller BG1 and BG2 ID no.: 1404.200B.0-00 Date: 01/2022 Control connections ..................... 38 Standard operation on the KeDrive D3-DU controller ........... 57 4.7.1 Digital inputs on X25A (standard functions) ..........39 5.4.1 Configuration of the KeDrive D3-DU controller......... 57 4.7.2 Digital inputs on X26A (safe digital inputs) ..........
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Connection system ....................77 A.7.1 Encoder cables ..................77 A.7.2 Motor cable ....................77 A.7.3 Connector sets ..................77 Glossary .................... 79 Operation Manual KeDrive D3-DA Axis Controller BG1 and BG2 ID no.: 1404.200B.0-00 Date: 01/2022...
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Operation Manual KeDrive D3-DA Axis Controller BG1 and BG2 ID no.: 1404.200B.0-00 Date: 01/2022...
To obtain stated performance features and product characteristics. Prerequisites for usage of the devices from KEBA: KEBA does not accept any liability for injuries, damage or financial losses that result from The documentation on the devices is to be stored so it is legible, accessible at the failure to follow the documentation.
The table below shows the type, device and short designations. All three designations can be used in the operation manual in different contexts with the same meaning. Type designation Device designation Short designation KeDrive D3-DA Axis controller D3 DA KeDrive D3-DP Supply unit D3 DP KeDrive D3-DC...
Date: 01/2022 Scope of supply 1.11 Support The scope of supply includes: Address: KEBA Industrial Automation Germany GmbH Gewerbestrasse 5-9 KeDrive D3-DA BG1 and BG2 axis controller 35633 Lahnau Ready-made data cables for EtherCAT If you have any questions about the project planning for your machine or the...
Safety Protection against magnetic and/or electromagnetic fields during installation and operation. Persons fitted with heart pacemakers, metallic implants or hearing aids, etc. must not be allowed access to the following areas: Overview • Areas in the immediate vicinity of electrical equipment! •...
(see previous sections). The warranty provided by Pay attention to special safety instructions and warnings that are given here in the document before a KEBA will be rendered void. specific action and that warn the user about a specific hazard!
Not approved for usage outside a switch cabinet. Not approved for the generation of high-frequency onboard For information about laws, standards and directives applied by KEBA, refer to the networks for which the devices are not designed. declaration of conformity.
Safety Safety Operation Manual KeDrive D3-DA Axis Controller BG1 and BG2 ID no.: 1404.200B.0-00 Date: 01/2022 Declaration of conformity According to Machinery Directive 2006/42/EC:...
Mechanical installation 3.1.1 Order and arrangement The following basic guidelines apply to the arrangement and installation of the axis controller or supply unit: Notes for installation Butt mounting and alignment The devices can be mounted directly beside each other without any spacing. During the installation work it is imperative you avoid ...
Mechanical installation Mechanical installation Operation Manual KeDrive D3-DA Axis Controller BG1 and BG2 ID no.: 1404.200B.0-00 Date: 01/2022 WARNING! Risk of injury due to hot surfaces on the device (heat sink)! Carelessness may result in serious burns or damage. ≥ 300 ≥...
Cooling the devices 3.4 Installation of the devices for wall mounting Cooling air must be able to flow through the device (interior and heat sink) without Step Action Comment restriction. For installation in switch cabinets with convection (= heat loss is dissipated to the outside via the switch cabinet walls), always fit an internal fan.
3.5 Installation of the devices for cold plate Step Action Comment Arrange the devices on the backing plate as per Figure 3.1. This action is necessary to be able to couple the DC link using the busbars. Please also provide enough space to the left of the supply unit for the KeDrive D3-DU controller.
3.5.2 Installation on the cooler For the optimal transfer of heat from the rear wall of the device to the cooler provided, a thermally conductive film is already bonded to the cooling plate on the device. The film is laminated with aluminium toward the cooler. The device can be mounted and also removed with the film.
Mechanical installation Mechanical installation Operation Manual KeDrive D3-DA Axis Controller BG1 and BG2 ID no.: 1404.200B.0-00 Date: 01/2022 Hole spacings in the group A = 27.5 mm A1= 55 mm Figure 3.8 Hole spacing in BG1 and BG2 group...
Use only shielded cables with double copper braiding with 60 % to 70 % coverage. To connect KEBA servomotors we recommend the usage of ready- made motor and encoder cables from KEBA, as all EMC tests have been undertaken successfully with these cables.
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If connection cables from other suppliers are used, these cables must as a minimum be equivalent. However, an assurance of stable, reliable operation with such cables cannot be given by KEBA Industrial Automation Germany GmbH. Figure 4.2 Cu strap for improvement of EMC Earthing measures Control connections The devices are to be fastened to a conductive, earthed backing plate.
Overview of the connections Abbreviation Designation Details 24 V control supply See 4.6.1 on page 37 In the following you will find the layouts of the KeDrive D3-DA single-axis, double-axis Via busbars and triple-axis controllers with the corresponding positions of connectors and terminals. DC link supply (DC-Link +/-) See 4.6.2 on page 37 For improved clarity we have added an abbreviation (X...) to the designation of the...
Electrical installation Electrical installation Operation Manual KeDrive D3-DA Axis Controller BG1 and BG2 ID no.: 1404.200B.0-00 Date: 01/2022 4.3.1 Single-axis controller Abbreviation Designation Details rt-Ethernet coupler and cross- Can also be used as Ethernet interface X40A communication (IN0) for PC with DriveManager 5. rt-Ethernet coupler and cross- X40B communication (OUT0)
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Single-axis controller, encoder axis 1 X48A SinCos X48B SinCos Fig. EnDat / SSI Hiperface BISS Resolver Fig. Resolver and TTL and TTL A− REFCOS S3 / COS− (A−) A− S3 / COS− (A−) +COS S1 / COS+ (A+) S1 / COS+ (A+) +5 V (+5 V 3) 4)
Electrical installation Electrical installation Operation Manual KeDrive D3-DA Axis Controller BG1 and BG2 ID no.: 1404.200B.0-00 Date: 01/2022 4.3.2 Double-axis controller Abbreviation Designation Details rt-Ethernet coupler and cross-communication Can also be used as Ethernet interface X40A (IN0) for PC with DriveManager 5. rt-Ethernet coupler and cross-communication X40B (OUT0)
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Double-axis controller, encoder axis 1 X48A SinCos X48B SinCos Fig. EnDat / SSI Hiperface BISS Resolver Fig. Resolver and TTL and TTL A− REFCOS S3 / COS− (A−) A− S3 / COS− (A−) +COS S1 / COS+ (A+) S1 / COS+ (A+) +5 V (+5 V 3) 4)
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Electrical installation Electrical installation Operation Manual KeDrive D3-DA Axis Controller BG1 and BG2 ID no.: 1404.200B.0-00 Date: 01/2022 Double-axis controller, encoder axis 2 X48C SinCos X48D SinCos Fig. EnDat / SSI Hiperface BISS Resolver Fig. Resolver and TTL and TTL A−...
4.3.3 Triple-axis controller Abbreviation Designation Details rt-Ethernet coupler and cross- Can also be used as Ethernet interface for PC X40A communication (IN0) with DriveManager 5. rt-Ethernet coupler and cross- X40B communication (OUT0) Programmable, per axis three inputs and 2 X25A 9 digital and 2 fast control inputs touch probe inputs X48A...
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Electrical installation Electrical installation Operation Manual KeDrive D3-DA Axis Controller BG1 and BG2 ID no.: 1404.200B.0-00 Date: 01/2022 Triple-axis controller, encoder axis 1 X48A SinCos X48B SinCos Fig. EnDat / SSI Hiperface BISS Resolver Fig. Resolver and TTL and TTL A−...
Electrical installation Electrical installation Operation Manual KeDrive D3-DA Axis Controller BG1 and BG2 ID no.: 1404.200B.0-00 Date: 01/2022 Protective earth conductor connection 4.4.2 Connection principle 1. KeDrive D3-DU controller Step Action Comment 2. KeDrive D3-DP supply unit 3. KeDrive D3-DA axis Connect together the PE connections on the supply unit, the axis controller controllers and the controller in series.
Electrical isolation concept 1. KeDrive D3-DU controller 2. KeDrive D3-DP supply unit 3. KeDrive D3-DA axis The control terminals are designed as protective extra low voltage (PELV) circuits and controller must only be operated with such PELV voltages, as per the relevant specification. This 4.
If connection elements are used that do not meet the Mains filter (accessory) (17) Backing plate earthing requirements, KEBA does not provide any guarantee for stable, reliable operation. AC mains supply (power) (18) PE protective earth conductor connection...
Electrical installation Electrical installation Operation Manual KeDrive D3-DA Axis Controller BG1 and BG2 ID no.: 1404.200B.0-00 Date: 01/2022 Control connections 4.6.3 Overview of busbars in the group Step Action Comment Establish a connection between the EtherCAT interface X40A on the first axis controller and the controller D3-DU 3xx by connecting the EtherCAT output on the For EtherCAT interface specification, see controller to connector X40A on the supply module D3-...
4.7.1 Digital inputs on X25A (standard functions) Des. Term. Specification Electrical isolation DI00 The digital inputs are provided for axis-related tasks, e.g. limit switches. They can be Standard dig. inputs: DI01 programmed individually via the EtherCAT bus system. The inputs DI09 and DI10 are = +24 V DC +20 % Inmax DI02...
Electrical installation Electrical installation Operation Manual KeDrive D3-DA Axis Controller BG1 and BG2 ID no.: 1404.200B.0-00 Date: 01/2022 Motor connection 4.7.2 Digital inputs on X26A (safe digital inputs) Figure X26A/ Type Function Step Action Comment X26A/Safe-DI SDI0 Safe digital input STO 1 - CH1 SDI1 Safe digital input...
BRK_OUT BRK_GND made motor cable from KEBA. The cables available are listed in the appendix A.7. max. 2 A motor brake Hiperface DSL®+ Equivalent shielded cables must be used for the connection of motors from other...
Electrical installation Electrical installation Operation Manual KeDrive D3-DA Axis Controller BG1 and BG2 ID no.: 1404.200B.0-00 Date: 01/2022 4.8.3 Specification for motor connections 4.8.4 Switching in the motor cable The connections X31A/X31B/X31C are provided for up to three motors with motor CAUTION! Damage to the device due to switching in the motor cable! temperature monitoring and motor holding brake.
Document Contents ID no. Format To connect the LSN/LST and LSP synchronous motors, please use the ready-made motor and encoder cable from KEBA, see also A.7. KeDrive D3 Overview with notes on ordering and project planning information System 1404.205B.x for: KeDrive D3 including variants and accessories Catalogue 4.9.1...
Connection for high-resolution encoders NOTE: The usage of encoders not included in the range supplied by KEBA requires special approval from KEBA Industrial Automation Germany GmbH. The interfaces X48A, X48C and X48D make it possible to evaluate the encoder types listed in the following, depending on the model, as single-axis, double-axis or triple-axis The maximum signal input frequency is 500 kHz.
Only one resolver per axis! Table 4.22 Suitable encoder types on X48B and X48D The usage of encoders not included in the range supplied by KEBA requires special approval from KEBA Industrial Automation Germany GmbH. The maximum signal input frequency is 500 kHz.
Electrical installation Electrical installation Operation Manual KeDrive D3-DA Axis Controller BG1 and BG2 ID no.: 1404.200B.0-00 Date: 01/2022 4.10 Specification for motor temperature 4.10.2 Motor temperature monitoring on the encoder connection connections If connected to the encoder connector, the motor temperature sensor must be designed with reinforced insulation as per DIN EN 61800-5-1 in relation to the motor winding.
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Connection example Des. Term. Specification Figure X40A Input, EtherCAT® d e e d e e Connection via RJ45 connector OUT0 X40B Output, EtherCAT® LEDs Ethernet ports Green Port0 Link / Activity Green Device / EtherCAT RUN Green Port1 Link / Activity Device / EtherCAT ERROR Table 4.23 EtherCAT ports...
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Electrical installation Electrical installation Operation Manual KeDrive D3-DA Axis Controller BG1 and BG2 ID no.: 1404.200B.0-00 Date: 01/2022 Connection example, supply unit / axis controller Key to connection example Designation +24 V 24 V 24 V X01C X01C (1) (2) (3) (4) See Operation Manual KeDrive D3-DP Supply Unit (5) (6) (7) (8) DC Link+...
Commissioning This is possible in the EtherCAT group via the Ethernet-over-EtherCAT function or in the service and diagnostics mode by directly connecting the service PC to the connection X40A ECATin on the first axis controller. The chapter on commissioning is divided into the subject areas "Checking the motor- The cable assignment (1:1 or cross-over) is detected automatically.
Commissioning Commissioning Operation Manual KeDrive D3-DA Axis Controller BG1 and BG2 ID no.: 1404.200B.0-00 Date: 01/2022 5.1.3 Procedure for activating the service/diagnostics mode: NOTE: The function described in the following is available on KeDrive D3-DA axis controllers from firmware version V2.20. The service and diagnostics mode is CC-Master activated for all axes in the axis group.
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Switch off system. The next time after switching on up to three yellow LEDs on the first axis controller illuminate briefly, depending on the number of axes, and are then illuminated continuously for approx. 4 seconds after approx. 14 seconds. This process is repeated during each switch-on process. Only exception: after a firmware update, the upstream supply unit may also be updated during CC-Master 1 the restart in certain circumstances.
Commissioning Commissioning Operation Manual KeDrive D3-DA Axis Controller BG1 and BG2 ID no.: 1404.200B.0-00 Date: 01/2022 5.1.4 Exiting the service/diagnostics mode: 1. Service interface on the supply unit in the service and diagnostics After the conclusion of the commissioning, the service and diagnostics mode must be mode VOLTAGE left again.
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NOTE: The interface switchover selected is signalled by the yellow LEDs flashing quickly during To check the axes affected by the switchover, all are shown again in the the next power-up. following dialog box. Here it is possible to exclude an axis from the switchover for further configuration.
• It is imperative attention is paid to the limitations of the movement range. You are KeStudio DriveManager Function responsible for a safe process. KEBA will not accept liability for any damage that occurs Pre-setting for the supply unit: • Selection of the voltage supply NOTE: •...
5.3.2 Controlling drive using KeStudio DriveManager Settings for the individual axes as follows: KeStudio DriveManager Function For this part of the commissioning it is necessary to switch on the AC mains supply (KeDrive D3-DP supply unit power supply). Check whether the power stage is enabled. Set clock frequency for the power stage.
Commissioning Commissioning Operation Manual KeDrive D3-DA Axis Controller BG1 and BG2 ID no.: 1404.200B.0-00 Date: 01/2022 KeStudio DriveManager Function CAUTION! Damage to the motor due to incorrect operation during motor test run! Open manual mode window Carelessness can result in significant damage to the motor or machine.
Standard operation on the KeDrive D3-DU 5.4.1 Configuration of the KeDrive D3-DU controller controller You will find details about the configuration of the KeDrive D3-DU controller in the online help for KeStudio. For standard operation a KeDrive D3-DU controller is connected to the X40A/IN0 field 5.4.2 Configuration of a controller from another manufacturer bus interface on the first supply unit KeDrive D3-DP as the EtherCAT master.
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Commissioning Commissioning Operation Manual KeDrive D3-DA Axis Controller BG1 and BG2 ID no.: 1404.200B.0-00 Date: 01/2022 Step 2: Assignment of the virtual IP address for the EtherCAT slave Step 3: Establishment of communication with KeStudio DriveManager The virtual IP address configured in the previous step is to be used for the EoE communication.
Diagnostics 6.1.1 Flashing code The Axis 1/2/3 LEDs (yellow) only have a defined function during a software update. LED yellow LED red LED green Axis status Status LEDs short (0.4 Axis 1/2/3 long (0.8 s) long (0.8 s) Reset / starting Depending on the design of the axis controller (single-axis controller, double-axis ...
Diagnostics Diagnostics Operation Manual KeDrive D3-DA Axis Controller BG1 and BG2 ID no.: 1404.200B.0-00 Date: 01/2022 Status and error indication in If an error occurs, a "pop-up" window appears immediately with more detailed information about the actual error. KeStudio DriveManager 5 Click the "Device status"...
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On the "Alarms & Warnings" menu (parameter 100) you will find detailed information on all errors and warnings that have occurred. In the tree in the "Project" window, click "Alarms & Warnings". In the new window that opens you will find the history for the errors and warnings. NOTE: You will find further information on parameter 100 in the program help for KeStudio DriveManager 5.
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Operation Manual KeDrive D3-DA Axis Controller BG1 and BG2 ID no.: 1404.200B.0-00 Date: 01/2022...
Safety design variants Function SD0 The model SD0 contains the safety functions STO (Safe Torque Off) and SBC (Safe Brake Control). The functions are operated via safe digital inputs on the axis controller's control board. NOTE: New control board, from revision state "F", with additional encoder connection functionality and modified safety error handling.
A.2.2 Power section current data, axis controller (12 A to 32 A) D3-DA 310/x-12 D3-DA 310/x-18 D3-DA 320/x-12 D3-DA 330/x-12 D3-DA 320/x-16 D3-DA 310/x-24 D3-DA 310/x-32 Unit/ size Mains (BG1) (BG1) (BG2) (BG2) (BG2) (BG2) (BG2) Rated current 2 x 12 3 x 12 2 x 16 Maximum current for 10 s...
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Appendix Appendix Operation Manual KeDrive D3-DA Axis Controller BG1 and BG2 ID no.: 1404.200B.0-00 Date: 01/2022 D3-DA 310/x-12 D3-DA 310/x-18 D3-DA 320/x-12 D3-DA 330/x-12 D3-DA 320/x-16 D3-DA 310/x-24 D3-DA 310/x-32 Unit/ size Mains (BG1) (BG1) (BG2) (BG2) (BG2) (BG2) (BG2) Rated current 2 x 12 3 x 12...
Ambient conditions NOTE: The climatic conditions apply to the device. For this reason they must also be met in the switch cabinet. Ambient conditions Mechanical conditions Device: IP20 - exception terminals: IP10 (protection against touching, back of Degree of protection hand) As per EN 61800-2, IEC 60721-3-2 class 2M1 Health and safety regulations...
Appendix Appendix Operation Manual KeDrive D3-DA Axis Controller BG1 and BG2 ID no.: 1404.200B.0-00 Date: 01/2022 Power reduction at T ≥ 40 °C Certifications unom If an axis controller is operated outside the specified maximum ambient temperature A.5.1 CE certification ), the output power must be reduced as a function of the higher ambient unom temperature.
Appendix Appendix Operation Manual KeDrive D3-DA Axis Controller BG1 and BG2 ID no.: 1404.200B.0-00 Date: 01/2022 Cooling plate D3-XM 300-060 A.6.2 Additional components We have supplemented the KeDrive D3 system with comprehensive accessories. Important components are, e.g.: Synchronous servomotors from the product ranges DMS2, LSN/LST and LSP with Encoders of type resolver, HIPERFACE®-Multiturn and HIPERFACE®...
Connection system We offer ready-made cables in various lengths for the connection of servomotors in the product ranges DMS2, LST, LSN and LSP to the KeDrive D3-DA axis controllers. A.7.1 Encoder cables NOTE: You will find details about the ready-made cables in the "System Cables Order Catalogue"...
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Operation Manual KeDrive D3-DA Axis Controller BG1 and BG2 ID no.: 1404.200B.0-00 Date: 01/2022...
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