SIGMATEK DIAS Drive 310-23 servo amplifier

In industrial servo drive systems, SIGMATEK DIAS-Drive 310-23 is a three-axis servo amplifier designed for multi axis motion control, belonging to the DIAS Drive series. It is suitable for frequency, torque, speed, or position control of synchronous servo motors, linear motors, torque motors, and asynchronous motors. For on-site engineers, understanding their electrical boundaries, installation specifications, safety functions, feedback interfaces, fault codes, and maintenance replacement processes is key to quickly locating problems, reducing downtime, and ensuring safe equipment operation. This article will systematically review the technical points and troubleshooting path of DIAS-Drive 310-23 from the perspective of engineering practice.

System positioning and technical data

The model of DIAS Drive 310-23 is SDD310-23, which is a three-axis servo amplifier. Its rated input voltage is 3 × 230 V AC -10% to 480 V AC+10%, frequency is 45 to 65 Hz, suitable for TN or TT power supply systems, neutral point grounded, maximum symmetrical current is 5000 A rms. The rated power is 14 kVA in S1 mode. The rated DC bus voltage is 290 to 680 V DC, and the overvoltage protection limit is 450 to 900 V DC. The auxiliary power supply is+24 V DC, ranging from 22 to 30 V, with a power of 35 W. The braking power supply is maintained at+24 V-BR, ranging from 25 to 27 V, with a maximum holding braking current of 2 A per axis and a maximum switching energy of 100 mJ. The rated current per axis is 10 A rms, and the maximum locked rotor current after starting for 500 ms is 7 A rms. The maximum continuous total current for all axes is 20 A rms. The peak output current of axis 1 and axis 3 is 20 A rms for a maximum of 5 seconds, and axis 2 is 10 A rms. The maximum output frequency is 8 kHz, the PWM frequency is 8 kHz, and the regulator frequency is 16 kHz.

In terms of environmental conditions, the working temperature is rated at 0 to+45 ° C, and a derating of 2.5%/K is required for+45 to+55 ° C. The working humidity is non condensing from 0 to 95%. Installation altitude from 0 to 2000 meters, with a derating of 0.5 ° C per 100 meters above 2000 meters. Pollution level 2, overvoltage category III, protection level IP 20. The installation position should be vertical, and controlled internal fans should be used for forced ventilation. Storage temperature -25 to+70 ° C, maximum variation of 20 K/h, maximum humidity of 95% non condensing. The dimensions are approximately 378/472 mm in height (including connectors), 158 mm in width, and 240 mm in depth. These data are important criteria for selection, replacement, and installation.

Installation and wiring points

During installation, the servo amplifier must be installed vertically to ensure optimal cooling. Adequate cooling and filtered air must be provided inside the control cabinet. The motor cable and control cable must be routed separately, with a minimum spacing of 100mm, to reduce the interference of high noise from the motor cable on the control cable. The motor and feedback cable must use shielded cables, with both ends of the shielding layer grounded. All interfaces connected to the servo amplifier are connector plugs (except for grounding bolts) for easy replacement and cable prefabrication.

The main power supply is connected to X1B and supports 230 V AC to 480 V AC. When non grounded power supply is used, overvoltage protection must be added to the main power supply of the control cabinet. If a group of amplifiers bridges the intermediate circuit, the input voltage of that group must also be bridged. Connect the 24V auxiliary power supply and the holding brake power supply to X1A. The grounding of the 24V power supply must be done near the power supply. Maintaining braking can be independent of the 24 V auxiliary voltage and controlled through a+24 V-BR input. The DC bus can be bridged with other servo amplifiers through X1B/2 (+DC) and 3 (- DC) connectors. When connecting the external regeneration resistor, the connection between Rint (X1B terminal 4) and Rtr (X1B terminal 5) must be removed. The external resistor should be connected to terminals 2 and 5, and a 1000 V DC slow melting fuse must be used at both ends. The brake resistor fuse protects against cable short circuits, and there is electronic protection inside the amplifier.

The motor is connected to X3, X4, and X5, and the length of the motor cable is limited to 25 meters. If it is longer, suppression coils need to be added. The classic emergency stop function (Stop Category 0) requires an external KEM coil and REM resistor. The KEM coil must be connected before the amplifier is enabled and disconnected at least 1 ms after the amplifier is disabled. The resistance value and power of REM can be calculated according to the formula: R_EM=maxSPEED × K_Erms/(I-max × 0.8), P_EM=(I-max × 0.8) ² × R_EM/10. For maintaining brake control for personnel safety, it is necessary to add safety contacts that meet safety standards in the+24 V-BR voltage path. Nevertheless, there is still a risk of injury or equipment damage when maintaining brake mechanical failure.

In terms of external fuses, AC voltage supply L1-L3 is suitable for 5000 rms symmetrical amperes, 528 V maximum, RK5 class 20A fuses, depending on the average power consumption of the connected amplifier. 24 V DC input 16 A slow melting, 2.5 mm ² wire diameter. External regeneration resistor 10A delay, 1200 V. In terms of grounding, DIAS Drive must be connected through a grounding terminal with a wire diameter of at least 10 mm ² (8 AWG) copper or 16 mm ² (5 AWG) aluminum. If connected through a plug that complies with IEC 60309, the cross-sectional area of the protective grounding conductor can be smaller, but at least 2.5 mm ² Cu, and appropriate stress relief must be provided. When using a leakage protector, a B-type FI switch must be used. The A-type FI switch may malfunction when encountering a DC grounding fault.

Safety features: STO and SS1

DIAS Drive 310-23, in conjunction with optional VARAN interface module VAC 013, supports SS1 (Safe Stop 1) and STO (Safe Torque Off) safety functions, meeting PL e/Cat. 4 of EN ISO 13849-1 and SIL 3 of EN 62061. The servo amplifier has two safety inputs, ENABLE-L and ENABLE-H. The typical safe input differential voltage is+24 V, with a maximum of+30 V. The low level is ≤+5 V, and the high level is ≥+15 V. The differential voltage is low<+6 V, and high>+14 V. The input current is about 10 mA at+24 V. The input delay is typically 0.1 ms, with a turn-on time of about 20 ms and a turn off time of 0.5 to 1 s. The relay output S3/S4 can be used to indicate the safety function status, but it is not safety related and can be used to test external safety functions. Stopping brake control is not a safety function. If it is necessary to safely turn off the stop brake, the+24 V-BR brake power supply must be turned off externally. 24V power supply can only use PELV/SELV.

The implementation of safety functions is based on modules such as input block IN, AMV multi harmonic oscillator, OPTO 01/02, CONTR 01/02, AMP 01/02, and transformer TR. The input block IN is powered by the AMV generated by the voltage difference between ENABLE-H and ENABLE-L. The voltage difference must exceed the minimum high-level signal. If the input voltage is disconnected, the IN block will provide power to the AMV for approximately 400 ms. Due to the non delayed provision of differential voltage to OPTO03, the motor can actively decelerate before the amplifier enters a safe state. AMV generates constant frequency pulses, which are transmitted to subsequent electronic devices through OPTO01 and OPTO02. These blocks form a safe switch power supply, which generates U-Driver driving voltage through transformer TR. When there is no control signal sent from the AMV, the switching power supply stops transmitting power. The relay outputs S1/S2 are closed when the servo amplifier is powered by 24V and the safety function is activated, but these two blocks are not safety related.

The safety function test must ensure that the entire safety circuit functions properly. Testing should be conducted after installation, at least once a year, and after each machine control change. If the test results are invalid, the errors must be identified and corrected before retesting. If the error occurs repeatedly, the machine must not continue to operate. Test conditions: The servo drive system is ready for operation, with safety inputs ENABLE-L low and ENABLE-H high, software application running, and motor running. According to the wiring, ENABLE-L and ENABLE-H can be disconnected simultaneously, or ENABLE-L can be connected to Ext. GND and ENABLE-H can be controlled by the safety output of the safety PLC. The motor speed should be reduced to zero, and the relay output S1/S2 should close after a minimum of 0.4 seconds and a maximum of 1 second (when the servo drive power supply is 24 V). The servo drive system should enter safe mode. To meet Cat. 4/PL e and SIL 3 requirements, dual channel control must be provided. The wiring of ENABLE-H and ENABLE-L must have protective insulation to avoid external voltage supply errors. When using a safety PLC, a single error safety output (based on Ext. GND) can be connected to ENABLE-H, and ENABLE-L can be connected to Ext. GND; Alternatively, use a dual channel error safety relay input, with the+output connected to ENABLE-H and the - output connected to ENABLE-L.

Feedback interface and encoder

DIAS Drive 310-23 supports multiple types of feedback: rotary encoders, EnDAT encoders (single and multi turn), Hiperface encoders (single and multi turn), Sin/Cos, and TTL encoders. For EnDAT, Hiperface, Sin/Cos, and TTL, the maximum feedback signal count per mechanical loop is 8192 (M-RPULSE). Rotary converter is a standard feedback, supporting single speed (2-pole) and multi speed (up to 32 poles) rotary converters, with a maximum cable length of 50 meters. If hot contacts are used, the signal is also connected to the rotary converter cable. The EnDAT encoder is a high-resolution feedback with a cable length limit of 25 m. The Hiperface encoder also has high resolution with a cable length limit of 25 m. The Sin/Cos encoder is used for linear or torque servo motors with a maximum cable length of 10 m. The TTL encoder has an upper limit frequency of 100 kHz and the reference signal is not evaluated in the amplifier. The feedback cable must be shielded and grounded at both ends of the shielding layer. Rotary wiring includes Cosine-(S3)、Cosine+(S1)、Sine-(S2)、Sine+(S4)、Reference-(R1)、Reference+(R2)、 Motor hot contacts GND。 EnDAT includes A-、A+、B-、B+、DATA+、DATA-、CLOCK+、CLOCK-、Up(5V)+、0V、Up(5V) Sense、0V Sense、 Hot contact point GND。 Hiperface includes+COS, REFCOS,+SIN, REFSIN, DATA+, DATA -, U_S, GND, hot contacts GND。 Sin/Cos and TTL include A-(TTL)/+cos(SinCos)、A+(TTL)/-cos(SinCos)、B-(TTL)/+sin(SinCos)、B+(TTL)/-sin(SinCos)、Up(5V)+、0V、Up(5V) Sense、0V Sense、 Motor hot contacts GND。 Wiring errors can lead to feedback errors, commutation errors, overspeed, or motor oscillation.

Troubleshooting of LED display and status register faults

DIAS Drive has two LEDs that display the amplifier status. The combination of green and red LED indicates that the controller is in boot mode (firmware is damaged or unavailable); Green 1 Hz flashing and red Off indicate readiness to start; Green 8 Hz flashing and red Off indicate that the output current is limited by the I ² T value (one or more axes); Green On and red Off indicate operation; Green On and red 1 Hz flashing indicate a warning; Green Off and red On indicate errors. These LEDs are first-hand information for quickly determining the status on site.

I-STATUS can read 32-bit state variables, which contain all error and status information. The amplifier function can be changed by setting the corresponding bits through the G-MASKE1, G-MASKE2, G-MASKW, and G-MASKD commands. According to the mask setting, the amplifier detects errors, warnings, or no response. Error bits include: bit 0 for single-phase operation, main power supply voltage is only single-phase, check amplifier fuses and electrical connections; Bit 1 main voltage supply error. The amplifier is enabled when the main voltage is not applied. Check the main power fuse, electrical power supply, and enable before loading the DC bus voltage; Bit 3 DC overvoltage, internal/external regeneration resistor not connected, internal resistance defect, external resistance defect, connect regeneration resistor, replace amplifier or external resistor; Bit 4 DC undervoltage, enabling the main voltage supply of the amplifier to be too low, disabling the amplifier before the DC bus voltage falls below the undervoltage threshold set by G-VBUSM; Position 6 holding brake error, no holding brake connection but M-BRAKE=1, brake cable short circuit, holding brake short circuit, use holding brake motor, check cable, change M-BRAKE to 0; Position 7 brake switch error, internal stop brake switch defect, no holding brake in parameters but M-BRAKE=1, replace amplifier, use holding brake motor, change M-BRAKE=0, check connectors and motor cables; Temperature of motor 9, trigger the motor temperature switch, check if the motor is undersized, if the environmental conditions are poor, if the feedback cable or connector is broken, and check the feedback cable and connector; The ambient temperature is 10 degrees Celsius, and the internal temperature is too high. Improve the ventilation inside the cabinet and check the installation position; Position 11 radiator temperature, radiator temperature is too high, improve ventilation, check installation position; Feedback error at position 12, feedback cable breakage, feedback equipment defect, feedback poor connection, check feedback cable, replace feedback equipment, check connection; Position 13 commutation error, motor phase position error, motor or feedback cable wiring error, check M-ROFF, motor connection, feedback cable; Motor overspeed at position 14, motor phase position error, motor connection error, feedback cable error, overshoot greater than 1.2 × V-NMAX. Check M-ROFF, motor connection, feedback cable, and optimize control loop; Bit 15 drag error, P-PEMAX lag window is too small, increase P-PEMAX and/or optimize control loop; Bit 16 trajectory error, the speed set value calculated from position change is higher than 10000 r/min. Check the P-SCALE and P-SSCALE parameters and controller reference values; 17 host communication, no new preset values for two consecutive cycles, check A-TIME and A-STIME and control cycles, check interface communication, refer to I-DEROR; Position 18 amplifier error E2, various internal errors, refer to I-DEROR, contact the manufacturer; Position 19 amplifier error E1, various internal errors, refer to I-DEROR, contact the manufacturer; Power output error: motor cable grounding, motor grounding, output stage defect, check motor cable, replace motor, replace amplifier; Brake circuit error: Regenerative resistor cable grounding, Regenerative resistor grounding, Regenerative output stage defect, Replace Regenerative resistor cable, Replace Regenerative resistor, Replace amplifier; Bit 20 "Enable Lock" error, the safety input of the software enabled amplifier is still low, and the amplifier is only enabled when ENABLE and EN-BRAKE are high; Bit 21 driver voltage error, software enables amplifier with LOCK still low, only enables amplifier when LOCK signal is high; When the 22 DC overvoltage and regeneration resistor limit are reached, the power of the regeneration resistor is insufficient, and the power of the braking resistor is reached and the resistor is disabled, an external regeneration resistor must be used to adjust the G-MBAL value; Position 23 brake power supply voltage error, maintain brake power supply 24 V-BR missing, maintain brake switch defect. If the motor has maintained braking, the amplifier can only be enabled when 24 V-BR is applied to the brake. Replace the amplifier; Bit 25 I ² T error, I ² T exceeds the warning value A-I2TERR, increase A-I2TERR; 26 motor temperature warning, I-TEMPIM exceeds warning value A-TEMPIW, increase A-TEMPIW; Option 27 motor parameter error, when using EnDAT or HIPERFACE encoders, the M parameter was not found in the encoder, the M parameter was not loaded into the encoder, encoder defects, signal line or connector defects, wiring errors, or cable breakage; Bit 28+circle error, when using EnDAT or HIPERFACE multi circle encoder, an error occurs when expanding beyond 4096 circles. Replace the motor with multi circle encoder and encoder defect; The total power limit is 29, and the power of all axes exceeds the maximum load, resulting in insufficient drive size and reduced load.

Common faults and solutions

When the motor rotates clockwise, the I-FPOS decreases: it may be due to incorrect rotation function or incorrect rotation connection. Check the rotary transformer and connect it according to the wiring diagram. Motor not turning: The motor current reaches the limit but there is no torque, and the motor connection is incorrect. Check the U, V, and W connections of the motor terminal board. Motor 'sliding': The motor torque is too low or the direction is different, the M-ROFF is not set correctly, and the motor and/or feedback connection is incorrect. Check the M-ROFF parameters, inspect the motor and feedback connections. The motor stops at certain positions: M-POL and/or M-RPOL settings are incorrect, the motor cable is disconnected, and the motor cable is not connected to all wires. Check M-POL and M-RPOL parameters, replace motor cables, and inspect connections. Motor oscillation: Control gain too high, feedback cable shielding defect. Reduce V-KP and/or P-KV, check the feedback cable and replace it. These troubleshooting steps can help engineers quickly locate mechanical, electrical, and parameter issues.

Maintenance, replacement, and storage

The servo amplifier is maintenance free. Opening the casing will result in loss of warranty. The dirt on the shell can be removed with isopropanol or similar products. Internal contamination of the equipment must be handled by the manufacturer. The fan grille can be cleaned with a dry brush. Spraying or immersion is not allowed. Repairs must be carried out by the manufacturer. When replacing the servo amplifier, turn off the power supply to the control cabinet and remove the fuse. After disconnecting the main voltage supply, wait for at least 5 minutes until the intermediate circuit voltage drops below 40 V before touching conductive components or removing connectors. The temperature of the radiator may exceed 80 ° C, and it should be checked and wait for it to drop below 40 ° C before processing. Unlimited storage time of less than 1 year; Greater than or equal to 1 year, the intermediate circuit capacitor must be restructured before the initial start-up. Disconnect all electrical connections and apply 230 V AC single-phase to the L1/L2 terminals for 30 minutes. The original packaging must be used for transportation to avoid dropping. The storage temperature is -25 to+70 ° C, with a maximum variation of 20 K/h and a maximum humidity of 95% without condensation. According to national electronic waste regulations, it cannot be disposed of as household waste.

VARAN interface and shielding

VAC 013 is a VARAN interface module for DIAS Drive 3xx, integrated into the drive. It includes SS1 and STO safety functions, as well as a digital input interface that can be used as a fast position latch input. The VARAN bus can be configured as a linear structure through the VARAN Out port. The interface includes 1 VARAN In (RJ45, maximum 100 m), 1 VARAN Out (RJ45, maximum 100 m), 1 DIAS Drive interface (26 pin blade terminal), 4 fast digital inputs, 2 safety inputs (SS1 and STO), and 1 relay output for indicating safety function status. Power supply+5 V DC is provided by DIAS Drive, with a typical current of 400 mA and a maximum current of 500 mA. Digital inputs D-IN1 to D-IN4 are typically+24 V and a maximum of+30 V, with signal low ≤+5 V and high ≥+15 V, switch threshold typically+9 V, input current+24 V is 10 mA, and input delay typically 0.1 ms. Safety inputs ENABLE-L and ENABLE-H have a differential voltage of typically 24 V and a maximum of 30 V, with low<+6 V and high>+14 V, opening for about 20 ms and closing for 0.5 to 1 s. The relay outputs one normally open, power supply+24 V DC, switching time<10 ms, switching range maximum 30 V DC/minimum 100 μ A, maximum 0.5. A; maximum 42 V AC/minimum 100 μ A, maximum 0.5 A. Safety integrity level SIL 3, performance level PL e, diagnostic coverage rate 99%, PFH_D 0.29 × 10 ⁻⁹, MTTF-D 8694 years, service life 20 years. The ambient temperature is 0 to+60 ° C, storage is -20 to+85 ° C, humidity is 0 to 95% non condensing, altitude is up to 2000 meters, protection is IP20, and pollution level is 2.

VARAN shielding is recommended to use CAT5e industrial Ethernet cables, S-FTP cables, symmetrical multi wire, unshielded pairs, total shielding using foil and braided combinations, and non laminated variants are recommended. VARAN cables must be fixed at a distance of 20 cm from the connector to prevent vibration. When the control cabinet is connected to the external VARAN component, the shielding should be placed at the entrance of the control cabinet casing. If only IP67 modules and connectors are used for wiring outside the control cabinet, no additional shielding support is required. When wiring inside the control cabinet, it is recommended to connect shields in front of all electronic components. When connecting noise generating components, shielding should be placed before the power element or power element group. When connecting two control cabinets, it is recommended to place a shield at the entrance point of each control cabinet. These measures can effectively suppress electromagnetic interference and ensure stable communication of VARAN bus.