Category: KEBA

Key features

KeSafe D3-DU is suitable for simple logic operations and safe single-axis functions

as well as complex safety requirements in robot applications.

• Safe integration into the system

The KeSafe D3-DU enables safe communication with a higher-level safety controller

– either as a PROFIsafe F-Device or FSoE© SubDevice.

• Programming & parameterization

With the KeStudio SafeEdit application tool, safety applications can be easily created,

diagnosed and validated. Subsequent adjustments are made using the KeStudio

SafePMT2 parameterization tool.

• Hardware components

The KeSafe D3-DU safety controller combines safety logic and motion monitoring in

one device and enables simple expandability as an FSoE© MainDevice.

Maximum integration and flexibility

The KeSafe system impresses with its seamless compatibility within the Kemro X

automation platform. Whether with the decentralized encoder box solution

(KeDrive D3-SMM) for flexible placement and considerable cable lengths or

the machine-integrated variant with safe axis controller (KeDrive D3-SDC) – both

approaches can be used optimally depending on requirements.

Your freedom – your advantage

All components are fully coordinated and can be flexibly combined. The result is

a consistent safety concept that fits perfectly into any machine architecture –

without any compromises.

The KeSafe D3-DU product is the basis for a compre-hensive safety solution

for machines and/or robots. It is embedded in the compact KeSafe D3-DU

control and drive system and ensures the safe operation of machines and/or

robots in accordance with current standards and directives. KeSafe D3-DU is

field-tested, powerful and flexible and supports the efficient implementation

of a wide range of safety-related requirements and appli-cations in automation.

Pre-certified solution

The KeSafe D3-DU is equipped with pre-certified robotics monitoring modules

that help to meet the requirements of ISO 10218-1:2025.

KeSafe D3-DU safety technology

Compact. Safe. High performance.

The KeSafe D3-DU from KEBA combines control, motion, visualization and

safety on a single platform – including optional integrated safety controller

and compact diagnostic display. The KeSafe D3-DU combines CFast me

mory, integrated HMI, safe digital I/ Os, USB interfaces, an EtherCAT©

and RT-Ethernet controller and two Ethernet ports – ideal for use as an

RT-Ethernet device in sophisticated automation architectures.

Semi-automatable safety application development

KeStudio SafeEditNG software, specially developed for the

KeSafe C5 range, is a user-friendly drag-and-drop  engineering

tool for implementing and diagnosis of safety applications.

Characterized by a high level of automation in the configura

tion of safety applications, it features, among others:

• Flexible assignment of physical hardware to virtual

application I/Os

• Export, adaption and import of safety applications on

AML-based data files

•  Adaption of safety application configurations via

customer engineering tools (SAP, E-Plan, etc.)

• Lower verification efforts thanks to user-defined

checksums, allowing flexible assignment of application

data to checksums.

The whole is greater than the sum of its parts

As often highlighted at KEBA, getting a complete solution

from one source brings numerous benefits in performance,

optimal data exchange, fast diagnostics, and maintenance.

Therefore, KeSafe C5 SCP 501 controller and SDM 570

extension module should be combined with KeContol C5

controllers, KeConnect C5 I/Os, and for the best results,

also with KeDrive drives.

SCP 501 Safety Controller & SDM 570 Extension Module

The KeSafe C5. a modular safety solution consisting of

hardware and software, was developed for the optimal

realization of safety applications in serial machines and plant

engineering. The pioneer of the KeSafe C5 safety system is

the SCP 501 CPU module with a high number of onboard

I/Os, open architecture, and compact size, perfectly

designed to execute complex safety applications, process

safe sensor signals, and control safe actuators. For in

creased  flexibility, the system can be expanded using the

SDM 570 extension module.

Sophisticated solution for hybrid output control

KEBA hardware-based approach for controlling safe outputs

via the functional controller results in excellent repeat accura

cy and cost saving potential. The hybrid output control  offers

the possibility to control the outputs both from the safety

application and the functional control (AND logic).

The KeDrive D3 drive system can be expanded with a controlled energy storage system. 

Essentially, the system consists of an energy manager and an energy storage device.

Energy storage systems are used in a variety of applications. Whether for the storage

of energy generated regeneratively in the drive system or for buffering and the provision

of energy in peak load situations.

The energy manager KeDrive D3-EM, as a dynamically regulated step-down converter,

makes use of a large DC link voltage range.

In this way the system can store and deliver more energy compared to storage modules

of the same capacity directly integrated into the DC link.

The energy storage system can be combined with both passive and active supply units.

The requirements specify the selection of the supply.

Regulated DC link voltage for clearly international drive design

Independent of worldwide mains voltages

Optimised energy storage device in the DC link

Reduction of mains distortion (THD) and reactive power caused by passive mains rectification

Saving in mains connection costs due to limitation of the peak load consumption from the supply

system 

Controlled energy storage device for dynamic application

Take advantage of KEBA expertise from research and applications for your bespoke “smart DC

system” with the KEBA energy storage system.

Safety technology

The axis controller provides scalable integrated safety technology. In the standard model the functions STO (Safe Torque Off)

and SBC (Safe Brake Control) are available. The expanded, optional “functional safety” forms, together with the central safety

control FSM, a system for axis monitoring connected via EtherCAT. This can include safe and non-safe encoders and encoder

combinations (HIPERFACE DSL®, SinCos, resolver, TTL and HTL) that are evaluated directly on the axis controller.

Field bus

The D3-DA 3xx axis controllers are designed for operation on the EtherCAT CoE field bus system. Bus cycle times of a minimum of

125 µs can be configured. Operation on alternative field bus systems such as Powerlink or PROFINet is also possible.

In operation, service and diagnostics access is by tunnelling via the central controller (EtherCAT EoE). For this purpose the controller

must support the routing function for TCP/IP communication via EoE (Ethernet-over-EtherCAT). Digital inputs are available for axis

related functions, such as limit switch or reference mark evaluation.

Central supply

D3-DA 3xx axis controllers are supplied with power and auxiliary power via a central supply unit D3-DP 300.

The number of axis controllers that can be arranged beside a supply unit is dependent on the power (power supply and auxiliary

power supply) required for the application and must be taken into account during the project planning of the multi-axis system.

A maximum of 8 axis controllers (corresponding to a maximum of 24 axes) can be operated on a supply unit.

With the aid of the expansion module, a second row can be established and in this way the number of axis controllers expanded.

Comprehensive performance scaling

The drive system KeDrive D3 offers axis controllers as single-axis, double-axis and triple-axis controllers in a power range up to

300 A for optimal system design.

Cost-effective drive systems for 4 axes (3 + 1), 5 axes (3 + 2), 6 axes (3 + 3) or more can therefore be combined without problems

and that not only for a specific sector, as the control technology meets the highest requirements even applications in the machine

tool industry are possible. Due to the innovative usage of technology, the control performance also remains identical independent of

the number of drive controller axes. Thanks to the development of a special drive ASIC, consistent performance from single-axis to

triple-axis controllers is realised.

There are also no restrictions on the usage of different encoder technologies, as proven interfaces such as resolver, sine/cosine,

HIPERFACE® or EnDAT are available along with the latest one-cable solutions to the servomotor.

The power supply

The power for the multi-axis system comes from a central supply unit in steps from 10 kW to 140 kW. While for the supply units

BG1+2 (10 – 22 kW) an integrated power supply unit (SMPS) optionally provides the 24 V/480 W auxiliary supply, for the supply

units BG3+4 (45 – 140 kW) an external 24 V supply is required. This 24 V auxiliary supply can be provided by an existing 24 V power

supply unit in the machine.

Axis controllers are arranged on the right of the supply unit on a rail system. The control modules D3-DU 3xx are mounted on the

left. The connection of the axis controllers to the DC link supply and the 24 V DC auxiliary voltage is realised without wiring effort

using the integrated busbar system. Only the 24 V DC auxiliary voltage is transmitted to the controller. Digital outputs indicate the

actual status.

The supply unit supplies the energy for the axis controllers. Configuration, diagnostics and status information are realised via the first

axis on the first axis controller in the drive group. A maximum of 9 modules are allowed to be connected and operated in the axis

group (D3-DP, D3-DC, D3-DA, D3-DE…).

Safety technology

Test outputs provide OSSD output signals. The OSSD output signals are used for the short-circuit and cross-circuit test on the

wiring for the safe, digital inputs on the axis side.

Device protection/mains contactor

A relay output is provided with which it is possible to control an external mains contactor via the controller D3-DU 3xx integrated into

the system.

Use the KEBA expertise from research and application as

well as the KeDrive D3 drive platform with active power

supply and energy storage systems for your energy-efficient

machine or plant.

• Controlled DC link voltage for uniform international

drive sizing

• Independence from worldwide mains voltages

• Optimized energy storage in the DC link

• Reduction of mains distortion (THD) and reactive power

caused by passive rectification

• Savings in grid connection costs by limiting peak power

consumption from the mains

• Controlled energy storage for dynamic applications

Active power supply units

• Energy recovery of regenerative energy into the AC grid

• Controlled DC link voltage for best drive utilization and mains independence

• Limitation of the mains input power

• Reduced mains current distortion (THD) due to sinusoidal mains currents

Controlled energy storage systems

• Temporary storage for regenerative energy

• Peak power reduction through “peak shaving”

• Bridging of mains failures (short time UPS for DC link)

Modular drive system

• Optimal integration into the KeDrive D3 drive system

• Energy efficiency due to energy exchange in the DC link

• Capacity expansion for storing short-term regenerative peaks

• Different cooling concepts