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DBS User`s Manual

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1. RELEASE CLAMP o BRAKE REFERENCE ENABLE 0 rpm P ES MOTOR SPEED Il 31 3 0ct 01 2 13 Sizing of Power Supply Circuit 2 13 1 Sizing of Power Transformer DBS drive is designed to allow direct operation from a 400 460 Vac 50 60 Hz 3 phase source An isolation transformer may still be required to meet local electrical safety regulations It is the user responsibility to determine if an isolation transformer is required to meet these requirements To size the transformer it is necessary to refer to the rated output power of the motors the output power with 65K winding overtemperature is included in the Technical Data table of catalogs of servomotors to sum the power of single axes and to multiply the sum by the contemporaneity factor factors often utilized are K 0 63 for 2 axes K 0 5 for 3 axes Kc 0 38 for 4 axes K 0 33 for 5 axes K 0 28 for 6 axes in case of multi axis application to multiply by a correction coefficient 1 2 accounting for the losses of the motor drive system P Y Pim Ke 1 2 W 2 13 2 Auxiliary Power For a correct sizing especially for small drives auxiliary power 30 W for each module and fan power Pran 7 W for DBS 3 6 8 15 25 35 and 15W for DBS 50 60 must be added Paux 30 Pran W 2 14 Power Dissipation To calculate cabinet cooling requirements table below provides estimated equipment power dissipation values If the application emp
2. Fault on oscillator circuit Resolver fault or connection not OK at motor side NO A N Vref carrier present on J4 20 Vpp 10 kHz NO oA So Sin and cos signals Se present on J4 6 5 Vpp max 10 kHz for Vickers resolver YES Internal fault IV 14 3 0ct 01 FIG 4 12 DRIVE FAULT red LED on Red LED DRIVE FAULT ON NO Other red LEDs lit Check via FA command the fault not reported by LEDs It can be Velocity error see EV command EEPROM error YES Bus Bars overvoltage undervoltage See the figure with the proper LED fault IV 15 3 Oct 01 FIG 4 13 Motor vibrates Axis enabled Motor with overspeed or running at a speed not related to the reference or vibrates Ed Ed Ta NO i _ 6 resolver motor a a poles or x 8 resolver motor SE poles d aJ Ed 2 pole resolver N lt with 6 pole YES motor X YES x oe bS E E PA A EN 4 E x Check via RS Ra i command RS N NO NO approx 6000 or gt lt 27000 or 49000 Check via RS commands RS approx 48000 YES YES Check power and resolver connections Remake Autophasing Internal fault IV 16 3 0ct 01 FIG 4 14 Keypad fault Keypad does not work NO Serial cable and or Make correct connection J10 cable OK YES Baud rate gt
3. by multiplying if it possible i e when KI lt 63 KP and KI by 4 by using a structure VS 0 or VS 2 which internally multiply the gains by 4 V 30 3 Oct 01 PS Display the active parameter set 1 or 2 Range Range protection Default Password Parameters SE DF IL KI KP MR and MV exist in two different sets 1SE 1DF 1IL 1KI 1KP 1MR 1MV and 2SE 2DF 2IL 2KI 2KP 2MR 2MV 3 The opto isolated input SPARE IN determines which parameter set will be used for the drive operation and control The SPARE IN OFF will select the first parameter set while the SPARE IN ON will point to the second parameter set The status of the SPARE IN and the parameter set currently active might be read through the serial link by using 1PS command AJ1PS lt CR gt command will interrogate the DBS drive The drive will respond with the lt CR gt followed by the string parameter set 1 or the string parameter set 2 DBS will end the response with a lt CR gt character NO PW Switch the password ON or OFF Range Range protection Default Password Second set See also Crucial parameters of the drive are protected by the password That is the access to these parameters will not be granted unless a proper password is entered When the password status is OFF the 1PW command will be interpreted as an attempt to set the password status ON In this case the password will be switched ON onl
4. phase S2 is defined by PX and PY parameters At the same time these two parameters along with the PH parameter will determine the slope of the phase curve in the interval IQ 0 S2 According to requirements the phase current curve might increase at a steeper slope for the values of IQ superior to S2 For this purpose the sixth PQ parameter is provided in order to program the slope of the phase current curve for the values bigger than S2 7 3 Parameters Setting for FAS T V To optimize the match between FAST V brushless servomotors and DBS 400V drive the following parameters settings have been found to be the best choice With these parameters the motor provides at the nominal speed and with 360Vac corresponding to 400Vac 10 power supply a Max Torque from 1 5 to 3 times the Max Torque without the optimization algorithm VII 2 3 Oct 01 Tab 7 1 Parameters Setting for 400V and 6 pole resolver FASTV DBS IL PF PG PH PY PX PQ FAS T00 V2100 3 9 77 46 1 0 255 128 128 A MA eee ee I A FASTOV2060 3 9 100 30 5 o 115 128 147 V4060 39 100 30 6 o 87 128 154 8 O30 39 100 15 12 o 76 128 143 8 GO 615 100 53 8 o 127 128 149 ES St A ees A ee FAST1V2030 3 9 100 19 15 O 94 128 150 v2060 615 100 53 8 o 127 128 149 4030 615 100 29 13 O 166 128 158 V4045 615 100
5. The recovery resistor is connected to the internal Dc Bus and can reach a value of 810 Vdc CAUTION DBS 3 9 DBS 6 15 DBS 8 22 and DBS 15 42 have internal recovery resistor To disable the internal resistor and connect an external resistor it is necessary to disconnect the jumper between P1 and P2 on J5 CAUTION an unusual application with motor driven by the load a large portion of the time could result in overheating of the recovery resistor If the application requires frequent decelerations with high inertia starting from high speed and in short times it may be necessary to use a non standard external recovery resistor It is suggested contacting our Customer Service CAUTION shielding of the recovery resistor cable provided in kit for test purposes is recommended for ensuring compliance with the EMC standards CAUTION for UL approval in the end use installation the Dynamic Brake Unit Recovery Resistor when external shall have the connection wiring made with R C AVLV2 or insulated with R C YDPU2 or R C UZCW2 Il 19 3 Oct 01 2 8 Serial Link Connection DBS drive is equipped with the low speed serial link hardware and associated software drivers for the protocol implementation The purpose of the link is the inspection and modification of drive related parameters monitoring of the drive status and errors and the communication of the commands and parameters during the installation phase Up to 15 DBS drives mig
6. ca A OS a AS A cee 11 16 19 Il 4 3 Oct 01 2 6 2 I O Wiring All the signal cables must be separated from power cables by a distance gt 30 cm See Section 3 for shielding procedures according to EMC Directive REMARKS e DRIVE OK J7 connector it is suggested to connect the isolated output DRIVE OK to a remote control switch so that if a fault occurs the power supply is disconnected to avoid system damages e SIMULATED ENCODER SIGNALS J7 connector in specially noisy environments it is suggested to connect a 220 680 Q resistor between A and A B and B C and C at the receiver input for lengths in excess of 5 m 16 ft the cable must have 3 pairs each pair twisted FIG 2 3 SPEED REFERENCE WIRING DIFFERENTIAL INPUT DBS CNC i f gt a s 1 Eat ec ee ae 6 ov ov N Z gt 2 5 mm min Ground l 19 GND J1 Do Kae cable shield must be RF s E grounding of shie connected to the housing F via hose clamp UNIPOLAR INPUT DBS CNC fy 5 gt 1 REF Covi hal rr il r gt Y 6 ov 2 5 mm min Ground 19 GND J1 ble shield must be RF REA SA grounding of shield connected to the housing E via hose clamp Il 5 3 Oct 01 Tab 2 4 J1 Connector I O Commands And Signals Panel side male type Wago 231 450 code AK5953 Wiring side female type Wago 231 120 026 000 code AK4960 Differ
7. noisy cables must be kept away from sensitive cables by at least 30 cm 12 in Noisy cables include input power wires motor power and brake wiring Sensitive cables include analog or digital signal cables resolver cable reference enable and OK cable RS485 serial link simulated encoder wiring where noisy cables must cross power cables this must be done with angles as near to 90 as possible FIG 3 5 Backpanel Connection Backpanel earth the crossing of the cabinet should be accomplished with a low impedance connection between cable shield and enclosure If a connector is not involved the shortest practical lengths of connecting strap should be used see Fig 3 6 Screen is effectively earthed 360 of its radius 3 4 Recovery Resistor Motor Choke To meet the EMC Directive the enclosures containing dynamic braking resistors must be conductive The cable of recovery resistor must be shielded and the shield must be 360 clamped at both sides In some applications some size 3 FAS T motors a choke in series for each motor phase has to be added This choke must be shielded REMARK when mounting the enclosure of recovery resistor or motor choke to the panel it is essential that any paint or other covering material be removed before mounting the enclosure of recovery resistor or motor choke III 6 3 Oct 01 3 5 Screening To effectively screening the system all the single screens CNC
8. 0 656 NP speed rpm entered through the handheld terminal Torque filter Torque limiter and anti windup AWU algorithm Tr Output torque commagdes to the vector rotator Tr Torque referenc ormat 32768 corresponding t9 100 dripeak torque Fig 2 The error filter in Fig 2 is a second order digital filter of the speed error The damping factor x of the filter is fixed to 0 707 The complex poles of the filter might be programmed by the VI 2 3 Oct 01 DF parameter of the drive in such a way that the module of the complex poles w 2pfpw is varied from 2 6 to 367 Hz fow Hz In 1 1 DF 200 2 pT where T 300 uS p 3 1415926 In natural logarithm DF DF parameter having the range 0 100 for the filter frequency range 2 6 367 Hz If DF O the filter is switched OFF The transfer function WF z is given by the expression below zw2T 2 z2 W T2 2 2 WT z 1 2EWT For the purpose of defining the closed loop gain of the system it is necessary to understand the format of the numbers that appear at the input and on the output of the speed controller The speed reference and the speed error at the level of error discriminator left part of the Fig 2 have the same format This format depends on the number of resolver poles The digital words representing the speed reference and the speed feedback at the summation point are numerically equal to the speed in rpm multiplied by the number of
9. 7 8 Il 3 4 5 8 9 10 update the control card add default values for keypad 11 15 18 19 20 21 22 23 24 setup update parameters settings for IT protection and 26 III ex V 1 3 7 8 IV 5 17 for the adjustment of T S curve add Fig 4 17 Runaway 20 V ex lll 5 6 14 18 19 27 add Par 2 13 Sizing of PS add Par 2 14 Dissipation 28 29 30 32 33 34 38 VI 10 correct miscellaneous errors VII 1 to 6 19 May 00 Add UL markings add DBS 100 240 W120 240 1 1 to 16 Il 1 2 4 to 32 Ill 1 to 4 180 320 add rating plate add new connectors correct 6 7 IV 1 V 18 27 VI 1 7 miscellaneous errors 9 22 Nov 00 Change Logo correct miscellaneous errors 1 3 4 11 Il 4 10 21 Ill 1 2 7 6 July 01 Update UL markings correct miscellaneous errors l 1 to 16 Il 2 4 11 12 IV 10 A 3 Oct 01 Add CE requirements correct miscellaneous errors l 1 to 16 Il 2 4 12 13 14 17 19 Ill 3 7 Accident Protection The safety instructions provided in this Manual are included to prevent injury to personnel WARNINGS or damage to equipment CAUTIONS WARNING High Voltage Bus Bar s can have voltage gt 2810Vdc even after switching off capacitive voltage Discharge Time approx 6 Minutes WARNING High Voltage The recovery resistor is connected to the Bus Bar s and can have voltage 810Vdc WARNING do not touch recovery resistor during operation to avoid scalds CAUTION make sure that the cor
10. Casella Genova ITALY herewith declares that the products Complete Drive Modules series BRD 4S DBC Ill DBS DS2000 PDBS Basic Drive Modules series BRM 4S DBM 03 DBM 033 DBM 04 Feeding sections series ADR BRM P1 BRM P2 DBM 03 PS DBM 033 PS DBM 04 PS Motor groups series FAE F K N T W FAS F K N T W FC are in conformity with the provisions of the following EC directives including all applicable amendments ref n 73 23 EEC Low Voltage Directive 89 336 EEC EMC Directive and that the following harmonized standards or parts thereof have been applied 1998 Rotating electrical machines Part 1 Rating and A performance Rotating electrical machines Part 6 IC Code Do ing electrical machines Part 7 IM code CEI EN 60204 1 1993 Safety of Machinery Electrical Equipment of machines par 6 2 3 Part 1 General requirements 20 3 20 4 aaa CEI EN 61800 3 1996 Adjustable speed electrical power drive systems Part 3 EMC product standard including specific test EN O AAA eae EER CRS OEA EN 61800 3 A11 2000 Amendment A11 Other references or information required by the applicable EC directives The contormity of products is subjected to the installation of filters and to the procedures included in the proper Installation Manual The user has the primary EMC responsibility in following the recommendations of the manufacturer Last two digi
11. advanced through PF PG PH PX PY and PQ parameters see the dedicated Section 7 The values PF 255 PG 0 PH 0 PQ 128 PX 128 and PY 255 disable the function Syntax AJIPG lt CR gt reads the value of the parameter A 1PGnnn lt CR gt will set the new value of the parameter PH Parameter for the adjustment of Torque Speed curve Current loop of a typical AC drive suffers the phase lag at extremely high output frequencies speeds This lag reduces the resulting torque per amp ratio To counterbalance this phenomenon the current vector relative to the motor flux is advanced through PF PG PH PX PY and PQ parameters see the dedicated Section 7 The values PF 255 PG 0 PH 0 PQ 128 PX 128 and PY 255 disable the function Syntax A 1PH lt CR gt reads the value of the parameter A 1PHnnn lt CR gt will set the new value of the parameter See also PF PG PX PY PQ V 28 3 Oct 01 PQ Parameter for the adjustment of Torque Speed curve Current loop of a typical AC drive suffers the phase lag at extremely high output frequencies speeds This lag reduces the resulting torque per amp ratio To counterbalance this phenomenon the current vector relative to the motor flux is advanced through PF PG PH PX PY and PQ parameters see the dedicated Section 7 The values PF 255 PG 0 PH 0 PQ 128 PX 128 and PY 255 disable the function Syntax A 1PQ lt CR gt reads the value of the parameter A 1PQn
12. electronic cabinet machine motor housing cables must be connected together to effectively form one screen see Fig 1 8 3 6 Safety Aspects Noise suppression of Motor and Drive systems involves consideration of the earthing system and its effectiveness at high frequencies It should not be forgotten that is the safety system too and that the safety must take priority over EMC To reduce the radiated emissions the use of capacitance to earth is very effective In fact DBS drives have Y type capacitors near the input power supply connector and Schaffner filters also include them These capacitors conduct current from phase to earth this can be in the order of hundreds of milliamperes WARNING appropriate safety measures should be taken to ensure that this potentially dangerous current flows to earth CAUTION it is recommended to disconnect the drive and the EMC filters to carry out the AC Voltage Tests of EN 60204 1 1997 par 19 4 in order to not damage the Y type capacitors between phases and ground Moreover the DC voltage dielectric test required by EN 50178 1997 product family standard has been carried out in factory as a routine test The DC Insulation Resistance Tests of EN 60204 1 1997 par 19 8 may be carried out without disconnecting the drive and the EMC filters HI 7 3 0ct 01 This page intentionally blank III 8 3 0ct 01 SECTION 4 PROTECTIONS AND TROUBLESHOOTING 4 1 Protections bit Output R
13. inverted phase C 12 SPARE IN 15 A Digital ov Il 8 3 Oct 01 Tab 2 7 J24 Connector 24V Optional Panel side male type Wago 231 432 code AK5959 Wiring side female type Wago 231 102 026 000 code AK4967 Pos Name TT 1 24 IN Inputs for 24 Vdc 4V to retain auxiliary logic supply 24 IN voltage in case of main supply failure load 1 3A Istdby 0 13A Tab 2 8 Input Output Characteristics z in 1 2 kQ I nom 10 mA 8 to 20 mA Vmin 15Vdc 15 to 25V nom 10 mA 8 to 20 mA Vnom 15Vdc 8 5 to 25V Analog tacho z out 100 Q output max 5 mA Full scale 10V for MV Reference Signals Full scale see MR command Vmax 12V Simulated Encoder z out 100 Q differential output Full scale 7V RS422 RS485 signals compatible Il 9 3 Oct 01 2 6 3 Resolver Wiring Fig 2 5 Resolver Wiring J4 CONNECTOR SUB D 9 CONTACTS MOTOR CONNECTOR grounding of shield via connector shell grounding of shield via connector clamp RESOLVER CONNECTOR MOTOR SIDE Signal FAS T Type FAS K cosq Q O n lt y D h sing A VIVO 5115 3 lt PERL shield Il 10 3 Oct 01 Each DBS must be connected to the resolver via the J4 connector Figure 2 5 shows the wiring lay out of the resolver with differential output We recommend to use 4 pair cables each pair twisted and individually shielded with an independent overall shield 8
14. it is sufficient to press lt CR gt again and the DI command will be executed again This feature might be used to achieve successive speed reversals during the optimization of the speed loop gains at the installation phase See also IA See also Note the status can be interrogated via ST command bit b11 DL Select the digital current limit The drive might have the current limit imposed by the software parameter IL the digital limit or the analog limit taken from the drive analog inputs The DL command will select the digital current limit The IL parameter defines the current limit from O to 100 of the peak drive current Syntax A 1DL lt CR gt selects the digital input for the drive current limit See also AL IL Note the status can be interrogated via ST command bit b9 V 15 3 Oct 01 DR Select the digital reference mode The speed reference for the DBS speed loop might be the digital one set by the 1VE command or the analog speed reference taken from the DBS analog input port The DR command selects the digital reference mode Syntax AJIDR lt CR gt selects the digital speed reference for the DBS speed controller Range Range protection Default Digital reference Password YES Second set See also Note the status can be interrogated via ST command bit b8 EV Set Read the speed error limit When using the drive in speed control mode the
15. o era _ 10 29 14 o 161 128 158 v6045 822 100 58 15 o 230 128 163 tro 15M2 88 3I 11 o 120 128 161 v8030 615 100 38 14 O 245 128 181 tro 822 100 30 13 0 166 128 152 v8045 1542 100 43 10 o 151 128 155 AA E AA AAA FAS T2V2030 8 22 100 27 18 O 143 128 152 v2045 15 42 100 44 12 0 174 128 172 v4020 822 100 23 14 0 197 128 171 4030 15 42 100 30 14 O 166 128 158 G O20 1542 100 19 21 O 166 128 152 v6o3o 15 42 100 36 14 O 222 128 193 po OT 73 33 13 0 133 128 178 vaozo 1542 100 26 17 O 235 128 190 o o 270 2 22 0 140 128 192 vao3o 15 42 100 15 3 0 255 128 128 po o 270 _ 1400 38 13 0 225 128 181 RA O AO e ee OE FAST3V2020 15 42 100 24 18 O 230 128 184 v2030 25170 100 38 26 o 225 128 187 V3020 2570 100 24 24 o 217 128 175 V3030 2570 100 38 17 O 225 128 205 or 380 100 30 18 o 174 128 156 V3030 1 5mH 25 70 100 23 17 O 143 128 152 Hs5mH 35 90 100 19 16 o 110 128 152 V4020 25710 100 25 21 0 225 128 187 NV4030 35 90 100 38 22 o 230 128 199 V4 030 1 5mH 3500 100 27 21 o 133 128 150 V
16. products that bear the UL Mark may have to be revised in the field or at the manufacturer s facility to bring them into compliance with UL s requirements Within Canada there are federal and local statutes and regulations such as the Consumer Packaging and Labeling Act requiring the use of bilingual product markings on products intended for the Canadian market Itis the responsibility of the manufacturer or distributor to comply with this law The UL Follow Up Service Procedures will only include the English version of the marking If we can be of assistance please do not hesitate to contact the undersigned Very truly yours REVIEWED BY el Kann Connelly DU Giuseppe Redaelli Kevin Connelly Engineering Services Engineering Services UL International Italia Srl UL Intemational Germany GmbH Demko A S A subsidiary of UL Underwriters Laboratories Inc and Sede legale e laboratorio Z I Predda Niedda Nord st 18 07100 Sassari italia Iscritta al Reg Imprese di Sassari al n 8101 98 Iscritta alla CCIAA REA di Sassari al n 126205 C F e PIVA 01796660908 4 3 Oct 01 UL Requirements e These Brushless Servo Drives shall be assembled with the guidelines specified in this Manual Only the configurations with the components tested and described in the UL Report file E194181 Vol 1 Sec 2 Issue date 06 09 00 and following Revisions can bear the Listing Mark e These drives shall be used within their ratings
17. velocity error fault might be generated in the cases when the speed error exceeds the value imposed by EV parameter This feature is useful as an additional protection of the CNC s spatial error mechanism The setting EV 0 rpm will switch off the speed error protection mechanism and the velocity error fault will never be generated Syntax A 1EV lt CR gt reads the current value of 1EV A 1EVnnnn lt CR gt Range 0 to MV rpm Range protection YES Default 0 Password YES Second set NO See also Remark while testing the drives via step response it is advisable to disable this protection or set a high value of tolerated error to avoid continuous faults V 16 3 Oct 01 FA Read and attempt Reset of the drive FAULT flags Drive fault flags might be inspected and a reset of the fault flags might be attempted by using the 1FA command For a number of faults the reading through the FA command is the only way to detect the erroneous situation If the cause that originated a fault vanished prior to the FA command execution the fault flag related to the fault will be reset Notice that the fault flags will be displa i Syntax AJ1FA lt CR gt will command the DBS to respond with a string comprising the fault flags REMARK the format of the fault string is the following FA b1b2b3b5b6 P b7b8b9b10b11 MA b12 b13 b14 B b15b16 b17 When all the bits are 0 the status is DRIVE OK and MOTOR OK the main
18. 128 143 6030 1542 100 9 46 O 66 128 142 je SM 23 91 517150 71 40 128 150 8020 15 42 100 5 49 O 102 128 144 rd 210 f 5 44 0 61 128 155 c8030 2570 100 8 42 O 102 128 144 Ita FAST3C2020 15 42 100 5 44 O 140 128 151 c2030 2570 100 7 41 O 135 128 149 c3020 2570 100 4 50 O 122 128 148 3030 25 70 100 7 51 O 79 128 143 rd BN 100 9 53 O 61 128 143 cCsoz0oY 2570 100 6 55 0 94 128 147 c4030 3590 100 8 42 O 76 128 145 c6012 2570 100 3 89 O 112 128 147 6020 35 90 100 5 71 O o 128 137 cCsow 3590 100 3 97 O 76 128 142 8020 50 140 100 5 59 O o 128 138 60180 77 5 59 0 o 428 141 VII 4 3 0ct 01 Tab 7 3 Parameters Setting for 460V and 6 pole resolver FASTV DBS W PF PG PH PY PX PQ FASTOV2060 3 9 100 39 6 0 163 128 157 4060 39 100 41 7 O 140 128 159 8060 615 100 64 8 0 204 128 163 E e RF ae S FAST1V2030 39 100 24 15 o 145 128 154 v2060 615 100 64 8 o 204 128 163 V4030 615 100 38 14 O 245 128 216 V4045 615 100 56 13 o 235 128 172 tro 2 100 46 13 o 158 128 159 v6030 615 100 38 14 o 238 128 178
19. 2 13 and Fig 2 14 On the control common panel there are 5 jumpers which have the following functions These jumpers can be accessed by unscrewing two screws on the front and by extracting the control panel see Fig 1 2 2 9 1 Keypad or Opto Priority G2P G2P open keypad priority the keypad or the device connected to the serial link is the master e it allows to enable or disable motor current whereas the optocouplers can only disable protection they can enable after resetting only The Drive Enable and Reference Enable opto isolated signals J1 pos 15 and pos 16 must be driven at 15V To enable the drive the ON command must be used Such a procedure should be followed during installation and drive test G2P closed opto priority the optocouplers are the master and the keypad can only be used for parameters setup 2 9 2 Default Initialization G3P G3P open default G3P closed and G2P closed G3P closed and G2P open no initialization normal default initialization sets BR 9600 and SA A total default initialization sets the values of Tab 5 2 2 9 3 Serial Link G1P G4P G5P G1P closed default connects TX of serial link to OV via pull down resistor G4P closed default connects TX of serial link to 5V via a resistor G5P closed default connects a 820 Q resistor between RX and RX of the serial link Note in case of multidrop DBS drive allows for the parallel connections of up to 1
20. 44 10 o 133 128 150 gt gr 10 29 9 o 89 128 153 v6030 615 100 29 13 O 127 128 149 po 100 21 13 0 87 128 147 V6045 822 100 46 12 O 127 128 149 po 142 30 10 O 66 128 156 8030 615 100 30 14 o 97 128 142 o da 1w0 24 14 0 66 128 144 8045 1542 100 30 8 o 74 128 151 ES a FE DIT LESS FAST2V2030 822 100 16 11 o 51 128 150 2045 1542 100 30 10 o 102 128 154 4020 822 100 15 17 o 76 128 145 Do Pl t 75 12 12 0 51 128 147 4030 1542 100 18 13 o 74 128 145 6020 1542 100 16 24 o 69 128 143 V6030 1542 100 27 15 o 66 128 142 po 250 738 27 17 o 40 128 150 8020 1542 100 16 16 O 102 128 144 o 20 65 15 14 o 61 128 155 8 O30 1542 100 29 10 o 204 128 145 Pl 250 100 26 14 O 102 128 144 E Ma E FAST3V2020 1542 100 15 14 O 140 128 151 v2030 2570 100 21 13 o 135 128 149 v3020 2570 100 14 16 o 122 128 148 v3030 2570 100 27 17 o 79 128 143 o 3 100 23 17 o 61 128 143 V4020 2570 100 18 18 O 94 128 147 V4030 3590 100 26 14 o 76 128 145 V6012 2570 100 11 29 o 112 128 147 v60
21. 48000 1000 for PR 1 e g 6 pole motor 6 pole resolver RS 6000 or 27000 or 49000 1000 for PR 3 e g 6 pole motor 2pole resolver Otherwise the value of RS might be entered directly through the hand held terminal and the serial link A 1RS lt CR gt reads the value of 1RS AJ1RSnnnn lt CR gt will set the new value of 1RS parameter O to 65535 YES YES NO V 35 3 Oct 01 RX Set Read the upper R D resolution limit The R D converter resolution is switched on line in order to obtain the best possible overall drive performance At very high speeds the resolution is reduced in order to make possible the speed and the position measurement in a situation whence the number of revolutions per second is very high On the other hand at lower speed the resolution is increased automatically so as to reduce the measurement noise the ripple and to increase the precision of the motion control Hence the actual resolution of the R D converter will vary from 10 to 16 bit depending on the drive operating conditions Parameter RX might impose the upper limit of the R D converter resolution to a value lower than 16 bit This might be necessary in application with excessive acceleration rates Parameter RX exists in two parameter sets The values 1RX or 2RX are used depending on the status of the SPARE IN input AJ1RX lt CR gt reads the value of 1RN and 1RX AJ2RX lt CR gt reads the value of 2RN and 2RX A RX lt CR gt
22. 9600 YES V Close G3 on Personality Card Baud rate set to 9600 Keypad Baud Rate and other NO Adjust the keypad setting Press lt CTRL gt then lt CR gt Correct parameters are BAUD 9600 WORD 8D E 1 STOP BLOCK MODE SINGLE LINE MODE FLASHING OFF KEY REPEAT ON SLOW Save at the end parameters correct YES Internal fault IV 17 3 Oct 01 FIG 4 15 Motor at zero speed Axis enabled Motor at zero speed with speed reference not zero ers a SS y Se EA Eq NO lt na a REF EN ON D Make REF EN ON on J1 pin 16 YES Pa 4 RA N YES AR O ON with a digital reference or DR ON with analog reference Check via ST command Use coherent reference Jl NO A Pa e e Ra je N A YES RA ox 4 KI 0 Set correct value for KI NO standard value 10 Internal fault IV 18 3 0ct 01 FIG 4 16 IT red LED on Red LED IT ON je 7 oe N Ed SS NO dl gt Internal protection d Blinking Ask the Service Center YES Undersize the duty cycle IV 19 3 Oct 01 FIG 4 17 Runaway or Locked motor 6 pole motor and resolver Runaway or locked motor 6 pole motor and resolver NO pd a N N Correct resolver wiring f z Resolver wiring ms see Fig 2 5 OK Wrong motor YES conn
23. Application Note GB 4522 high dynamic HD special software see Application Note GB 4526 protection for pollution degree 3 or 4 environment conductive dust or condensation accessible DC Bus from outside for energy exchange among drives 8 3 0ct 01 1 4 Dimensions Fig 1 1 dimensions in mm shows the dimensions and the drilling jig of the drive Leave a clear space of at least 50 cm 19 7 in over and under the system for air circulation FIG 1 1 DBS 3 9 to 60 180 Dimensions and Drilling Jig Drill For M5 Screws 180 Baad 270 mms 310 101 50 es 50 101 282 00 EA O 3 50 DBS 3 9 DBS 15 42 DBS 25 70 DBS 50 140 DBS 6 15 DBS 35 90 DBS 60 180 DBS 8 22 9 3 Oct 01 FIG 1 2 DBS 100 240 Dimensions and Drilling Jig Drill For M5 Screws _ 403 00 370 00 fe 50 101 50 101 50 8 00 329 50 515 00 460 00 ESSE LARES 10 3 Oct 01 FIG 1 4A DBS W120 240 Dimensions and Drilling Jig Drill For M5 Screws WATER IN a 2 5 llmin at 20 C EM or 3 5 l min at 25 C 8 00 F 4385 il iji lt lito Usd 6 uz 1 101 50 101 50 2 i TE E Jim E AL 5 0 PR 10 h 558 g 191 50 101 50 23 00 1
24. External recovery resistor 7 phase three phase output voltage to motor V2 V2 phase three phase output voltage to motor E ais phase three phase output voltage to motor NEED Fig 2 9 J5 and J6 Power Connectors for DBS 25 70 to 60 180 NEW Version Il 15 3 0ct 01 Tab 2 12A J5 and J6 Power Connector for DBS 100 240 W120 240 OLD Version it will be replaced by new terminal blocks see Tab 2 12B Terminal blocks by Phoenix type HDFK 25 code AK7421 HDFK 4 code AK7418 L1 phase three phase input voltage 400Vac or 460Vac HDFK 25 L2 phase three phase input voltage 400Vac or 460Vac Name PHDPK 253 Vi HDFK 25 L3 phase three phase input voltage 400Vac or 460Vac HDFK 25 E Protective bonding HDFK25 RR External recovery resistor HDFK25 RR External recovery resistor J6 LOW TEMP Thermal switch Normally closed contact max 5A HDFK 4 SWITCH Rated to open at 40 C 3 C heatsink temperature With intermittent water flow It can be used to start the water pump when the heatsink temperature becomes gt 40 C With continuous water flow it can be used to check the water temperature the drive overtemperature protection trips at 71 C DBS 100 240 24 Vdc 1 A input voltage for fans DBS W120 240 24 Vdc 0 6 A input voltage for the anti condensation fans CAUTION fans must be powered on 5 min before HDFK 25 U2 U2 phase three phase output voltage to m
25. Section 2 Installation Section 3 EMC Section 4 Protections and Troubleshooting Section 5 Commands Section 6 Block Diagram Section 7 Adjustment of T S curve TABLE OF CONTENTS Description Dimensions Technical data System grounding Rating plate DBU rating plate Fuses Soft start Fans Led s Potentiometer Button Sizing of wires I O wiring Resolver wiring Power wiring Recovery circuit Serial link connection Keypad Connection to PC Dbtalk program G_P jumpers Starting sequence Autophasing Resolver to encoder option Mechanical brake Sizing of Power Supply circuit Power dissipation European Directive Filtering Wiring and grounding Recovery resistor Safety aspects Protections Troubleshooting General Features List of commands Standard default configuration Commands Block Diagram of the Control Structure Phase Speed Relation Phase Current Relation Parameters setting for FAS T V 7 3 Oct 01 SECTION 1 DESCRIPTION 1 1 Description DBS servodrives are identified as very high performance converters thanks to a multiprocessor architecture which maximizes the advantages of digital technology PI regulator for different motors brushless and induction with both resolver feedback or sensorless diagnostics software set up low speed PC PLC serial communication CAN BUS speed reference management Itis a very wide product range motors up to 75 kW can be fed with the capabilities
26. as close as possible to the drive input If the separation between filter and drive exceeds around 30 cm 1 ft then a flat cable should be used for the RF connection between filter and drive REMARK when mounting the drive and the filter to the panel it is essential that any paint or other covering material be removed before mounting the drive and the filter The maximum torque of mounting screws The filter can produce high leakage is as follows currents see Table FILTER Max FILTER Leakage torque current EN 2070 3 06 EN 2070 3 06 EN 250 6 07 EN 250 6 07 EN 258 7 07 EN 258 7 07 Note if two phases are interrupted worst case leakage current could reach 6 times higher levels The capacitors within the filters have discharge resistors CAUTION the filter must be connected to ground before connecting the supply WARNING HIGH VOLTAGE DISCHARGE TIME APPROX 10 seconds III 3 3 Oct 01 3 3 Wiring And Grounding All the following cables must be shielded with 85 minimum shielding coverage power motor cable see Fig 3 1 and 3 2 NOTES if a power terminal board is used at motor side the shield must be RF connected to a metallic PG gland connectors at motor side can have a threaded clamp Cable shield must be grounded in the same way as in Fig 3 2 resolver cable see Fig 2 5 and 3 2 motor side Fig 3 1 Grounding Of Shield To Motor Connector At Drive Side external rec
27. as specified in the marking of the equipment e Cautionary Marking See Accident Protection page e Surrounding Air Temperature Maximum Surrounding Air Temperature 40 C In the final installation considerations shall be given for the need of repeating Temperature test if the unit is mounted with a different Surrounding Air conditions e Pollution degree 2 Installation The drive must be placed in a pollution degree 2 Environment e Environmental designation Open Type Equipment e Short Circuit Ratings 1 DBS 3 9 6 15 15 42 25 70 35 90 50 140 Equipment suitable for use on a circuit capable of delivering not more than 5000 rms Symmetrical Amperes 460 V ac 10 maximum 2 DBS 60 180 100 240 W120 240 180 320 Equipment suitable for use on a circuit capable of delivering not more than 10000 rms Symmetrical Amperes 460 V ac 10 maximum e Branch Circuit Protection The Branch Circuit Protection for Short Circuit shall be provided in the end use applications by external R C Fuses JFHR2 manufactured by Bussmann Div Cooper UK Ltd Semiconductor fuse type rated 660 Vac 200 KA A I C Mod No as follows DBS 3 9 6 15 8 22 15 42 Mod No 50 FE rated 50 Amps DBS 25 70 35 90 Mod No 100 FE rated 100 Amps DBS 50 140 60 180 Mod No 160 FEE rated 160 Amps DBS 100 240 Mod No 280 FM rated 280 Amps DBS W120 240 Mod No 315 FM rated 315 Amps DBS 180 320 Mod No 500 FMM rated 50
28. compensation of analog velocity offset The A D converter offset might be automatically adjusted by 1VO command and memorized in non volatile memory The measurement sequence initiated by 1VO command requires the drive disabled OFF status if G2P is open analog DRV EN grounded if G2P closed In case of residual offset after VO command a finest adjustment can be done with OV command AJ1VO lt CR gt command will initiate the offset measurement procedure When the command is executed while the drive is ON the warning message is transmitted and the execution of the command is stopped Range O to 255 Range protection YES Default 128 no offset compensation Password YES Note VO range from 0 to 255 is operative from V06 1 DSP software version In previous versions the range was 500 mV to 500 mV V 43 3 Oct 01 VS Parameter selection 1 out of 4 possible speed controllers DBS has 4 different speed controller structures built into the standard software package These structures might be selected by the VS parameter 1VS 0 It will select the speed controller structure with the gains 4 times higher relative to the DBMO1 standard Second order digital filter see DF parameter is filtering the speed reference signal 1VS 1 It will select the speed controller structure with the gains equivalent to those of the standard DBMO1 specification Second order digital filter see DF parameter is filtering the speed
29. modulating signal In the situations whence the slope of the amplified current error exceeds the slope of the carrier multiple IGBT switching within same period of the carrier might occur leading to the drive overheating and eventual failure VI 6 3 Oct 01 The slope limiter illustrated in Fig 8 along with its step response is implemented by using the external compensation capacitors in conjunction with LM201 type operational amplifier Rate limiter a Fig 8 Complete block diagram of the current controller is given in Fig 9 As might be seen only two blocks with Pl gains are implemented The current controller is implemented in such a way since the third gain block is obsolete Since the star point of the motor phase windings is not externally connected the sum of the three motor phase currents is identically equal to zero Hence three independent current controllers would be redundant and only two of them are applied Fig 9 shows that only two phase currents are measured The third phase current is reconstructed from the former two The same way the modulating signal or the voltage reference is derived for two phases only the third one is reconstructed as well The gains of the current controller should be adjusted according to the motor leakage inductance These gains are defined by Rp and Cp in Fig 6 Values given in Fig 6 120 kW and 10 nF correspond to the motor leakage inductanc
30. of IL parameter A 1ILnnn lt CR gt will set the new value of the 1IL parameter A 2ILnnn lt CR gt will set the new value of the 2IL parameter See also D IT Set Read the time constant for I2T protection Software I2T protection performs the thermal simulation of the motor thermal model via 1IT parameter The nominal ratings of the motor is defined by 1PC parameter When the thermal model runs above the temperature limit the I2T fault flag will be set the current limit will be reduced to rated level but the drive will not be switched OFF Syntax A 1IT lt CR gt reads the value of IT parameter A 11Tnnn lt CR gt will set the new value of the 11T parameter Note the status can be interrogated via FA command bit b6 The activation of IT protection is also indicated by the led on the front panel see Sect 4 CAUTION do not change IT parameter A wrong set of IT can damage the motor V 18 3 Oct 01 Tab 5 4 IT Protection The following table shows IT and PC values set in factory Operating time FAS T V at drive peak current pee a FASTOV2060 38 6 17 44 moo FASTOVe030 35 5 19 66 ido a F ee Ea ss a s um fom a par wa a ee 1 ju ESEC o So MES Ss ma Do om a far 255 6 pao 2 fat 451 ido T Ee FAST3V2030 2570 2 38 696 100 Twoje 619 oo FAST3V6012 2570 2 38 696 100 Ds ooj 28 65 77 REMARK the operating time at drive peak current is
31. pollution occurs Occasionally however a temporary conductivity caused by condensation is to be expected when the electronic equipment is out of operation e EMC Requirements The installer of the equipment is responsible for ensuring compliance with the EMC standards that apply where the equipment is to be used Product conformity is subjected to filters installation and to recommended procedures as from Section 3 of this Manual e Second Environment EMC Equipment intended to be connected to an industrial low voltage power supply network or public network which does not supply buildings used for domestic purposes second environment according to EMC Standards It is not intended to be used on a low voltage public network which supplies domestic premises first environment Radio frequency interference is expected if used on such a network e Recovery Resistor Cable Shielding of the recovery resistor cable provided in kit for test purposes is recommended for ensuring compliance with the EMC standards l 3 3 0ct 01 UL International Italia S r l Centro Direzionale Colleoni Palazzo Andromeda 3 I 20041 Agrate Brianza MI Tel 039 6057937 Fax 039 651946 e mail info ulitalia it Agrate Brianza May 30 2001 Spett le MOOG Italiana S r l Electric Division Via Avosso 94 I 16015 Casella Genova Italy Attn Mr Daniele Rolla Subject Listed Industrial Control
32. pulses per electrical revolution Channel B leads channel A by 90 for clockwise rotation when viewed from shaft end e 1 marker pulse per electrical revolution i e 1 3 3 marker pulses per mechanical revolution with a 6 pole resolver e complementary outputs A B and C The simulated encoder resolution can be modified with SE command Fig 2 15 Simulated Encoder CW Rotation When Viewed From Shaft End Channel A Channel B C Marker Channel A Channel B C Marker Note to make C marker high when Channel A and Channel B are high like Siemens exchange Channel A with Channel A and Channel B with Channel B Il 30 3 Oct 01 2 12 Mechanical Brake FAS series servomotors have as option a 24 Vdc electromagnetic safety brake CAUTION safety brake must be clamped and released with motor at standstill Dynamic brakes can seriously damage the brake and reduce the braking torque The release of the brake from OV to 24V and the clamp from 24V to OV must follow the sequence in Fig 2 16 FIG 2 16 Braking Sequence Timing Chart Note T1 gt 200 ms T2 application dependent T3 100 ms T4 gt 200 ms T1 T2 T3 T4 a x RN a ON DRIVE ENABLE ON BRAKE 24V POWER SUPPLY
33. reference signal 1VS 2 It will select the speed controller structure with the gains 4 times higher relative to the DBMO1 standard Second order digital filter see DF parameter is filtering the speed error signal 1VS 3 It will select the speed controller structure with the gains equivalent to those of the standard DBMO1 specification Second order digital filter see DF parameter is filtering the speed error signal Whatever setting of the VS parameter the DF O will select the DBMO1 standard speed controller structure with no digital filtering of the speed reference nor the speed error Still even in this case DF 0 VS 0 and VS 2 will select the gains KP and KI increased 4 times while VS 1 or VS 3 setting will produce the same gains as those of the standard DBM01 for more information see the block diagram of the speed controller Parameter VS does not exist in two parameter sets and has to be addressed by using 1VS command string Syntax A 1VS lt CR gt reads the value of VS parameter A 1VSn lt CR gt will set the new value of the VS parameter V 44 3 Oct 01 SECTION 6 BLOCK DIAGRAM OF THE CONTROL STRUCTURE Control functions of the DBS are illustrated in the following figures Summary of all functions is given in Fig 1 In Fig 1 it might be seen that the synchronous motor with permanent magnet excitation is the object of control The motor has an electromagnetic resolver as the shaft sensor As a part of the d
34. sets The values 1RN or 2RN are used depending on the status of the SPARE IN input A 1RN lt CR gt reads the value of 1RN and 1RX AJ2RN lt CR gt reads the value of 2RN and 2RX A RN lt CR gt reads the current active value of RN and RX A 1RNnn lt CR gt will set the new value of 1RN AJ2RNnn lt CR gt will set the new value of 2RN Range 10 12 14 or 16 bits Range protection YES Default motor dependent Password YES Second set YES See also RX Tab 5 5 Note RN must be lt RX If the value of RN attempted is higher than the current value of RX the error message will be transmitted and the new value of RN will not be rejected Tab 5 5 Max speed versus R D resolution is AE A A EA _ 28800 Max speed with 2 pole resolver rpm 28800 12000 3510 Max speed with 6 pole resolver rpm 16000 4600 1170 Max speed with 8 pole resolver rpm 12000 3510 V 34 3 Oct 01 RS Set Read the angle between motor and resolver shafts Syntax Range Range protection Default Password Second set See also The correct operation of the drive calls for the exact knowledge of the spatial displacement between motor and resolver shafts The angular displacement ranging from O to 360 degrees corresponds to the parameter RS range of 0 65535 In order to measure this displacement in an automatic manner the auto phasing routine might be performed If the autophasing has been correctly made RS
35. the G3P drop on the DBS board the DEFAULT INITIALIZATION of the DBS will set the drive address to A see par 2 8 2 and Tab 5 2 for normal or total default initialization The address may be changed further by using the command SA as described in par 5 2 see SA commana Default value is given with each command 5 1 3 Sets of parameters DBS drive might memorize use and permanently save 2 sets of drive most important parameters Putting into the command sequence 1 or 2 after the drive address A O will address the first or the second parameter set respectively Some parameters do not have two copies and these parameters might be set or interrogated by putting 1 at the beginning of the command string example digital speed reference 1VE commana The DBS drive is using the first or the second parameter set depending on the status of the opto isolated Spare Input atthe J1 connector The current active value of specific parameter that exist in 2 sets might be interrogated by putting character after the drive address into the command string 5 1 4 Type of Commands There are four different types of commands that can be exchanged via RS485 serial link Short description of these four types is given below 5 1 4 1 Drive commands Through the serial link the DBS drive may be switched ON or OFF initiated into speed or torque control mode the status flags may be set and reset and the parameters may be saved into non vol
36. the current active value of MV parameter A 1MVnnnn lt CR gt will set the new value of 1MV A 2MVnnnn lt CR gt will set the new value of 2MV 200 to 10000 rpm YES motor dependent YES YES MR ND Set Read the depth of the notch filter optional Syntax Range Range protection Default Password Second set See also the notch filter with programmable frequency depth and width is available to the user It may be used together with the present error reference digital low pass filter The ND command allows to set and read the notch filter depth that is the amount of suppressing the spectral components at the notch filter AJIND lt CR gt reads the value of 1ND parameter AJ1NDnnn lt CR gt will set the new value of the 1ND parameter 1 to 255 corresponding to OdB to 50dB YES NO NF NW V 22 3 Oct 01 NF Set Read the frequency of the notch filter optional the notch filter with programmable frequency depth and width is available to the user It may be used together with the present error reference digital low pass filter The NF command allows to set and read the notch filter frequency When selecting 1NF 0 the notch filter is switched off AJINF lt CR gt reads the value of 1NF parameter AJ1NFnnn lt CR gt will set the new value of the 1NF parameter Range 1 to 5375 corresponding to 0 1 to 537 5 Hz See also ND NW NP Set Read the number of resolver poles The nu
37. the operating time after a reset In a steady state condition this time is reduced according to the motor thermal simulation An overtemperature protection via PTC on the motor windings is also provided AS T1 V4 030 6 15 V 19 3 0ct 01 KI Set Read the integral gain of the speed controller Parameter KI determines the integral action of the speed controller Integral gain is available in two parameter sets 1Klin set 1 and 2Klin set 2 The opto isolated drive input SPARE IN determines whether 1KI or 2KI is used as the proportional gain A 1KI lt CR gt reads the value of 1KI A 2KI lt CR gt reads the value of 2KI A KI lt CR gt reads the current active value of KI parameter A 1KInnn lt CR gt will set the new value of 1KI A 2KInnn lt CR gt will set the new value of 2KI Range 0 to 255 Range protection YES Default Password Second set YES See also KP V 20 3 Oct 01 KP Set Read the proportional gain of the speed controller Range Range protection Default Password Second set See also Parameter KP determines the proportional action of the speed controller Proportional gain is available in two parameter sets 1KP in set 1 and 2KP in set 2 The opto isolated drive input SPARE IN determines whether 1KP or 2KP is used as the proportional gain AJ1KP lt CR gt A 2KP lt CR gt A KP lt CR gt AJ1KPnnn lt CR gt A 2KPnnn lt CR gt O to 255 YES reads the value of 1KP reads the
38. to meet any servo requirement in conjunction with our FAS FC and FASY resolver equipped servomotors DBS is a single axis servodrive with analog 10V or digital CAN OPEN according to CIA DS 402 speed reference 1 2 General Features built in power supply digital speed loop sinusoidal current waveform SMD technology with boards automatically assembled and tested automatic resolver to digital R D resolution switching from 16 to 10 bit to achieve high motion accuracy in the whole speed range from O to 10000 rpm 10 kHz switching frequency up to size 50 140 included 5 kHz for the other sizes ambient temperature O to 40 C storage temperature 25 to 55 C maximum case depth 370 mm programmable gains of the speed and current loops programmable digital filters see Application Note GB 4522 built in fans with internal power supply built in soft start electronic circuit intelligent IGBT IPM power bridge constant motor torque in the whole speed range thanks to dedicated software algorithm 1 3 Options software programmable from 64 to 16384 pulses per electrical revolution simulated encoder with marker pulse A D 14 bit converter on the speed reference as alternative to the standard 12 bit version 4 arc min R D converter resolution installation and set up keypad PC communication package see par 2 8 2 1 24 Vdc auxiliary power supply voltage notch filter software see
39. value of 2KP reads the current active value of KP parameter will set the new value of 1KP will set the new value of 2KP YES KI MR Set Read the full scale of the input analog reference Range Range protection Default Password Second set See also When the analog speed reference is used the level of the analog input signal that will be interpreted as the speed reference of MV rpm might be set by the MR parameter the Maximum Reference The range 50 100 of the MR parameter corresponds to input voltage levels from 5 to 10 V Parameter MR is available in two parameter sets 1MR in set 1 and 2MR in set 2 The opto isolated drive input SPARE IN determines whether 1MR or 2MR is used as the analog input range AJ MR lt CR gt reads the value of 1MR A 2MR lt CR gt reads the value of 2MR reads the current active value of MR parameter A MR lt CR gt A 1MRnnn lt CR gt will set the new value of 1MR AJ2MRnnn lt CR gt will set the new value of 2MR 50 to 100 5V to 10V YES YES YES V 21 3 Oct 01 MV Set Read the maximum shaft speed in rpm Function Range Range protection Default Password Second set See also it allows to set max velocity referred to MR command Anyway such a max speed can never be overcome either by analog reference or by keyboard command A 1MV lt CR gt reads the value of 1MV A 2MV lt CR gt reads the value of 2MV A MV lt CR gt reads
40. 0 Amps DORAO0ON l 5 3 0ct 01 Overspeed Protection The Power Conversion Equipment is incorporating an Overspeed Protection See MV command in Section 5 of this Manual Overvoltage Control In the equipment the Overvoltage is controlled by a Transient Suppressive device with 1500 V Clamping Voltage and min 120 J 10x1000 us or 2 ms Energy Handling Capability See also Bus not normal protection in Section 4 of this Manual Overload Protection The equipment does not incorporate internal overload protection for the motor load The drive is intended to be used with motors that must have integral thermal protection through a PTC The overtemperature fault of the drive will trip when the PTC reaches 1 2 kQ See J4 connector in Section 2 of this Manual for wiring Over Current Protection The drive is provided with a current limiting circuitry See IL and IT commands in Section 5 of this Manual Wiring Wiring shall be made by stranded and or solid copper Cu 60 75 C 140 167 F conductor only and for terminal blocks the tightening torque values specified in Section 2 of this Manual shall be applied These requirements do not pertain to control circuit terminals Wiring of Recovery Resistor The Dynamic Brake Unit Recovery Resistor when external shall have the connection wiring made with R C AVLV2 or insulated with R C YDPU2 or R C UZCW2 in the end use installation 6 3 0ct 01 Section 1 Description
41. 100 10 44 O 166 128 158 c6020 1542 100 6 63 o 166 128 152 C6030 1542 100 12 44 0 222 128 193 Po FO 731141914190 133 128 178 Cs020 1542 100 8 51 0 235 128 190 po lo BW 8 e6 o 140 128 192 c8030 2570 100 12 39 0 225 128 181 E A a a eeT FAST3C2020 15 42 100 8 55 O 230 128 184 C2030 2570 100 12 79 0 225 128 187 C3020 2570 100 8 72 0 217 128 175 C3030 2570 100 10 55 O 225 128 205 po 380 100 12 53 O 174 128 156 C3030 1 5mH 25 70 100 7 51 O 143 128 152 H5mH 3590 100 6 50 o 110 128 152 C4020 2570 100 8 63 0 225 128 187 C4030 35 90 100 12 66 O 230 128 199 C4030 1 5mH 3590 100 9 64 O 133 128 150 c6012 2570 100 5 88 0 243 128 150 c6020 35 90 100 7 74 0 148 128 146 c8012 35980 100 4 74 0 207 128 157 c8020 50140 100 7 57 o 189 128 160 E E Oe re O As 68 C8020 1 5mH 50 14 100 4 70 O 112 128 148 como 77 4 70 o 87 128 153 VII 6 3 0ct 01 MOOG Moog Italiana S r l Electric Division Via Avosso 94 16015 Casella Genova Italy Phone 39 010 9671 Fax 39 010 9671 280 www moog com GB 4511 Rev A Oct 01 Moog Italiana Srl reserves the right to alter a
42. 20 35 90 100 15 23 o o 128 137 v8012 3590 100 10 32 o 76 128 142 8020 50140 100 15 19 o o 128 138 po cons 77 15 19 o o 128 141 VII 3 3 0ct 01 Tab 7 2 Parameters Setting for 400V and 2 pole resolver FASTV DBS IL PF PG PH PY PX PQ FAS T00 C4 100 319 100 25 13 0 127 128 142 ES E Grass sses FASTOC2060 3 9 100 10 16 O 115 128 147 c4060 39 100 10 19 o 87 128 154 c8060 39 100 15 11 O 153 128 149 po S 100 17 2 0 127 128 149 Esq EC SE FAST1C2030 39 100 6 45 0 94 128 150 c2060 615 100 17 26 O 127 128 149 c4030 615 100 9 40 O 166 128 158 c4045 615 100 14 31 O 133 128 150 Do era too 9 27 O 89 128 153 c6030 615 100 9 40 O 127 128 149 rd RT 100 7 4 0 87 128 147 6045 822 100 15 37 O 127 128 149 po 1542 10 31 O 66 128 156 c8030 615 100 10 44 O 97 128 142 po O era 1400 8 44 O 66 128 144 p 8045 1542 100 10 26 O 74 128 151 EA AA DES SiS FAST2C2030 822 100 5 35 0 51 128 150 c2045 1542 100 10 31 O 102 128 154 c4020 82 100 5 51 O 76 128 145 C4030 1542 100 6 40 O 74 128 145 6020 1542 100 5 74 0 69
43. 5 min coverage 22 AWG 0 38 mm wire with low capacitance max 100 pF m can be used We suggest to use ground connections as shown in Fig 2 5 Cable length should not exceed 30 m 100 ft It is recommended that the signal cable and power cable be separated if possible through the use of independent duct conduit or by a distance of 12 inches 30 cm Tab 2 9 J4 Connector Sub D 9 pos Resolver Panel side female Wiring side male with conductive shell 20 ar 10kHz sinusoidal output signal for supplying primary resolver winding carrier Il 11 3 0ct 01 2 6 4 Power Wiring External recovery resistor cable if applicable and motor phases cable must be shielded to comply with EMC Directive Power supply input cable not shielded must be connected to the input filter see Sect 3 See par 2 6 1 for sizing of wires It is recommended to use motor phases wiring with low capacitance max 500 pF m CAUTION do not parallel power connection cables to achieve requested section this will increase the capacitance value at levels that may irreversibly damage the drive If the value of capacitance of motor and cables seen from drive output exceeds 30 nF it is necessary to verify with Moog technicians the need of an adequate choke in series Fig 2 6 Motor Phases Wiring Motor DBS ON TO Tes UH f U V A v Woe w ground U ground Nad Nor A J5 grounding of shield
44. 5 drives G1P G4P and G5P must be closed only on the last DBS of the multidrop and must be open on all the other drives 2 10 Starting Sequence Check the correct setting of the switch 400V 460V on the top of the drive Switch on 400 Vac or 460Vac three phase power supply Wait for Drive OK optoisolated output Check if NP pole number PR motor resolver pole ratio MR max reference KI integral gain KP proportional gain ST status SE simulated encoder if applicable parameters are OK for the application WARNING High Voltage Discharge Time Approx 6 Minutes CAUTION in case of repetitive switching off and on wait 1 minute between off and on Il 28 3 Oct 01 2 10 1 Autophasing Check that the motor is free to rotate in both directions Check that no fault condition occurs red drive fault leds off Check that the analog drive enable is on via positive logic and digital drive enable off Send the password command for the module Send the autophasing 1AP command and save 2 10 2 Wiring Check Axis being phased it is possible to check the wiring by rotating the motor with no load via its digital reference e Set Kl 10 and KP 20 to avoid motor vibrations e Set DF 0 digital filter disabled Enable analog drive enable and reference enable via positive logic e Send the ON command to enable digital drive enable the VE command for CW slow rotation the VE command for CCW slow rotation
45. 7 Lo Jam 7 5 s A Era Y Y Y yal Ed 22 fi E Bee Elo Zaz ZI anana Eta El El p Ear ES Ea OBr9cdv 0IBBN S SESAJIA dl Bo HE da EEE a aa nO q HORR ane G1P G2P G3P J E EE eee Ca a fia JO O O E 4S1 ET a6 F Il 26 3 Oct 01 FIG 2 14 G1P G2P G3P G4P G5P JUMPERS Il 27 3 Oct 01 2 9 G P Jumpers see Fig
46. 8 When OFF OV the first parameter set will be selected when ON 15V the second parameter set will be selected re as short as possible Il 6 3 Oct 01 Fig 2 4 Input Output Wiring 24V 24V Power Supply ov 24V LON OV 8 Optoisolated input common Drive Enable 15 Drive Enable Ref Enable 16 Reference Enable 9 SE Drive OK Drive OK 10 sf Optoisolated Output 11 TA Motor OK Motor OK 12 MY Optoisolated Output cable shield must be RF grounding of shield J1 connected to the housing via hose clamp 24V POWER SUPPLY DBS OV Common 15V dc output 8 Optoisolated input common e 15 Drive Enable 16 Reference Enable J1 15V INTERNAL SUPPLY for drive test Il 7 3 Oct 01 Tab 2 5 J2 Connector Sub D 9 pos RS485 Port Signal Panel side female Wiring side male with conductive shell Pos S O 6 Rx RS485seriallinky ________ 8 Tx RS485 serial link 9 N C Tab 2 6 J3 Connector Sub D 15 Pos Simulated Encoder Outputs Panel side female Wiring side male with conductive shell Midis IN 2 B encoderoutputiinvertedphaseB 3 A encoderouiputphaseA 6 15 15Vdc output Imax 30mA T SPARE n c T ONE OUT ME A 9 B encoder output phase Bs encoder output inverted phase A encoder output
47. 9 00 450 00 WATER OUT FIG 1 4B DBS W120 240 Water Ports CAUTION the cooling circuit must be kept clean Cooling media must not contain particles that may deposit causing obstruction to cooling circuit We recommend to check periodically cooling flow the cooling circuit must be kept clean PART FORI 11 3 Oct 01 FIG 1 5 DBS W120 240 Component Identification 12 3 Oct 01 1 5 Technical Data Nominal input voltage 400 or 460 Vac 10 50 60 Hz selectable via switch Three phase output voltage 325 V with 400 Vac or 375 V with 460 Vac Switching frequency 10 kHz Operating temperature O to 40 C exceeding Class 3K3 Relative humidity 5 to 85 no condensation no formation of ice Air pressure 86 kPa to 106 kPa Storage temperature 25 to 55 C Class 1K4 Transportation temperature 25 to 70 C Class 2K3 Immunity to vibration Class V H 2 according to HD 413 3 S1 1987 DBS W120 240 Water Cooled Min water flow rate 2 3 I min 20 C or 3 5 l min 25 C Max water pressure 10 Pa 1 bar Output Current Nominal Max Weight Arms Arms Apeak 49 DBS 3 9 3 65 9 10 DBS 615 6 105 15 10 DBS 8 22 8 155 22 10 DBS 3590 35 64 90 14 DBS 60 180 60 127 180 23 5 kHz switching frequency 1 6 Interfaces 1 6 1 Analog speed reference differential inp
48. EEPROM is detected Effect inhibit torque Reset condition if the condition is not present anymore reset button on drive send pulse to REMOTE RESET or send FA command 4 1 6 Bus not normal Indicated by DRIVE FAULT LED POWER OK LED optoisolated output DRIVE OK bit b12 of the FA string see FA command Set condition when the bus bar voltage is over under than the fixed thresholds see fig 4 1 and fig 4 2 Effect inhibit torque Reset condition if the condition is not present anymore at analog level with hysteresis reset button on drive send pulse to REMOTE RESET or send FA command FIG 4 1 Bus Bar Voltage 400V 720 V overvoltage 680 V Recovery circuit enabled AE 620 V Reset max voltage 560 V Bus nominal voltage ara pras pe qu qe Ey y 440 V Reset min voltage 410 V Undervoltage IV 3 3 Oct 01 FIG 4 2 Bus Bar Voltage 460V 810 V overvoltage 790 V Recovery circuit enabled SPP Ee Dos ie n 690 V Reset max voltage 650 V Bus nominal voltage E serem CNS Sty oP ta 495 V Reset min voltage 470 V Undervoltage 4 1 7 Drive overtemperature Indicated by DRIVE FAULT LED and DRV OVT LED optoisolated output DRIVE OK bit b14 of the FA string see FA command Set condition when a limit temperature is reached on the heatsink Effect inhibit torque Reset condition if the condition is not present anymore power off and on the
49. ES FAULT Reset FA command out of tolerance Reset FA command temperature M OVT MOTOR OK Reset FA command PWR FAULT Reset FA command Reset FA command vertem perature DRV OVT Too O oo JOFFON enas sc o O WTD Reset FA command ni Pr gt eae Reset FA command when the IT LED becomes blinking it indicates the activation of the IT protection when the IT LED becomes steady illuminated it indicates the activation of an internal protection In this case please ask the Service Centers REMARK the reset via Remote Reset can be used only in fault conditions This reset is carried out by sending a pulse 15V for a time t gt 200 ms on J1 connector pos 17 4 1 1 Resolver not ok Indicated by DRIVE FAULT LED RES FAULT Resolver Fault LED optoisolated output DRIVE OK bit b1 of the FA string see FA command Set condition when the resolver is not connected or in short circuit at the power up when the resolver fails or is disconnected during running Effect the drive inhibit torque Reset condition if the condition is not present anymore reset button on drive send pulse to REMOTE RESET or send FA command IV 1 3 Oct 01 4 1 2 Auxiliary voltages out of tolerance Indicated by DRIVE FAULT LED optoisolated output DRIVE OK bit b13 of the FA string see FA command Set condition when the level of 15V or 5V becomes out of tolerance Effect inhibit torque Reset condition if the condition is no
50. ET or send FA command IV 5 3 Oct 01 4 2 Troubleshooting FIG 4 3 POWER OK green LED off Green LED POWER OK OFF we Ps NO lt Is 3 phase 400 Vac gt Connect 3 phase 400 or 460 Vac or 460 Vac 10 connected to DBS YES Internal fault IV 6 3 Oct 01 FIG 4 4 AUX PWR green LED off Auxiliary Power Fault Green LED AUX PWR OFF NO ge N lt Power supply present gt Connect power supply Fault of auxiliary powe circuit IV 7 3 Oct 01 FIG 4 5 REF EN green LED off Reference Enable Green LED REF EN OFF Verify that 8 5 to 25Vdc NO E N voltage with 8 mA min lt Internal 15V used current is applied to J1 pin 16 and OV to J1 pin 8 J1 pin 7 SS x Ed J1 pin 6 common NO Make connection connected to J1 pin 8 opto common YES Fault on input circuit IV 8 3 Oct 01 FIG 4 6 DRV EN green LED off Drive Enable Verify that 8 5 to 25Vdc voltage with 8 mA min current is applied to J1 pin 15 and OV to J1 pin 8 Make connection NO NO Green LED DRV EN OFF Internal 15V used J1 pin 7 e lt Ne we lt J pin 6 common N connected to J1 pin 8 opto common YES Fault on input circuit IV 9 3 Oct 01 FIG 4 7 M OVT red LED on Motor Overtemperature Red LED M OVT
51. Equipment Open Type Power Conversion Equipment Brushless Motor Servo Drives DBS Series Ref File E194181 Vol 1 Sec 2 Project 01ME07523 Report Revision NOTICE OF AUTHORIZATION TO APPLY THE UL LISTING MARK AND UL LISTING MARK FOR CANADA This letter is sent on behalf of Underwriters Laboratories Inc pursuant to the Corporate Services Agreement between Underwriters Laboratories Inc and UL International Italia Srl We find that the product is eligible for Listing and Follow Up Service This letter temporarily supplements the UL Follow Up Services Inspection Procedure and serves as authorization to apply the UL Listing Mark and Listing Mark For Canada to the above product s To provide the manufacturer with the intended authorization to use the UL Listing Mark and Listing Mark For Canada you the Applicant must send a copy of this Notice to each manufacturing location covered by the UL Follow Up Service Procedure File E194181 Vol 1 Sec 2 This authorization is effective only for 90 days from the date of this Notice Records covering your product s are now being prepared and will be sent to you in the near future Products produced which bear the UL Listing Mark and Listing Mark for Canada shall be identical to those which were evaluated by UL and are found to comply with UL s requirements If changes in construction are discovered authorization to use the UL Listing Mark and Listing Mark For Canada may be withdrawn and the
52. LT SCANNING 20 06 40 FAULT DESCRIPTION FAULT DESCRIPTION A01 FA000000 P00000 MADOO B000 A02 FA000000 P0090000 MA000 B000 AOS FA000000 P00000 MA000 B000 Il 23 3 Oct 01 gt Restore store Personality Card parameters To save the actual parameter set select STORAGE PARAMETER select the file e g ST1 press lt TAB gt to change the description and press lt CR gt SETUP PERSONALITY CARD com FUNCTION SELECTION FILE SETUP SELECTION POLI 6 6 RPM 3000 SE 10 24 RESTORE PARAMETER STORAGE PARAMETER STi sT2 ST3 ST4 sts ST ST7 sT8 579 5710 sri1 ST12 ST13 ST14 ST15 ST16 gt Set Baud rates gt Start the Autophasing procedure gt Set the Adjustment of Torque Speed curve procedure e MANUAL to gt See Reset Faults If the fault condition is not present anymore the fault will be reset automatically To reset the fault on the screen go to the next screen with the arrow keys Send Command Driver Answer Communication Status REGULAR ist A SET A DDRESS 01 3 DDRESS 01 POWER SUPPLY FAULT SELECTED AXIS FAULT OVERTEMPERATURE BRAKING CIRCUIT 220Vac INPUT PERSONALITY CARD MOTOR OVERTEMPERATURE RESOLVER DISCONNECTED AXIS SHORT CIRCUIT NOT CONGRUENT PHASE VELOCITY ERROR 127 Protection A MODULE FAULT DBM B MODULE FAULT EBM OVERTEMPERATURE BUS BAR VOLTAGE AUX VOLTAGE R
53. MOOG DBS User s Manual GB 4511 Rev A Oct 01 DBS USER S MANUAL Rev Date Descriptim______________________ UpdatedPages 0 Jan 96 Initial Release PO 1 26 Feb 96 Add Section 6 Block Diagram correct resolver 1 3 4 6 8 10 13 14 15 16 17 connections correct miscellaneous errors 18 21 29 42 66 67 68 69 70 76 77 82 83 84 85 86 87 88 89 90 91 92 15 Mar 96 Add Section 7 add Fig 1 2 Component Identification 1 5 6 16 21 29 31 32 36 42 update defaults for demagnetization parameters add Fig 48 49 50 53 54 93 94 95 3 1 acceleration deceleration update IT table correct miscellaneous errors 3 2 May 96 Correct resolver wiring update fuse rating add pinouts of 7 8 9 10 27 28 29 46 47 64 RS232 RS485 converter update OC OV and VO 69 commands complete Fig 3 2 Bus Bar 460V correct miscellaneous errors All 22 Apr 97 Update standards with EN 61800 3 EMC product l 3 4 7 9 10 Il 3 4 9 11 12 standard add EMC filter for DBS with 24V delete par n 15 16 18 III 6 8 to 44 IV 19 V from commands correct miscellaneous errors 1 2 3 4 6 25 Jun 97 Add note about DBS special version compatible with 1 3 4 11 1 13 14 15 16 III 6 22 condensing atmospheres update recovery resistor for 25 26 DBS 15 42 update range of OV command correct miscellaneous errors 7 10 June 98 Exchange Section V EMC with Section Ill Commands I 1 2 3 4
54. ON rd Motor PTC eanneete IG connected to J4 YES rd N S Ra NO PTC value at 20 C correct 20 to 400 ohm Fault on motor PTC f NY YES Undersize the duty cycle IV 10 3 0ct 01 FIG 4 8 WTD red LED on Watch Dog a Red LED WTD ON Reset via Pushbutton on front panel Remote Reset a j N Ed E A Na YES e Te ra a E Red LEDWTD gt connections OFF 2 NO 8031 or DSP fault IV 11 3 Oct 01 FIG 4 9 DRV OVT red LED on Drive Overtemperature Verify the correct cooling of cabinet Fault on fan drive circuit or locked Red LED DRV OVT ON J YES lt Ambient temperature gt 40 C NO ES As Ed a NO e RS fans Fans running YES Internal recovery resistor undersized Output current gt nominal current IV 12 3 0ct 01 FIG 4 10 PWR FAULT red LED on Short Circuit or Locked Rotor Red PWR FAULT ON YES Motor phases 4 short circuited or grounded Change motor NO oS dd N pd ea o NS Change motor or YES we Ng eliminate the locked Locked rotor condition rotor NO Fault on power stage o on control board IV 13 3 Oct 01 FIG 4 11 RES FAULT red LED on Resolver Fault 4 4 shield connection OK YES Is the resolver NO Make correct connection
55. The recovery circuit is formed by a switching regulator a recovery transistor and a recovery resistance While braking the motor returns energy which cannot be sent to the line since the rectifier circuit is not regenerative Returned energy tends to increase the Dc Bus voltage When HV reaches 680V 790V for 460 Vac the switching regulator brings the recovery transistor into conduction thus connecting the recovery resistance in parallel with filter capacitors The recovery resistance is formed by enameled wire fixed resistor s If the recovery resistance works for intervals shorter than the time necessary to reach thermal equilibrium the resistor can temporarily handle power levels up to 10 times the nominal power rating of the resistor short time overload If not specifically requested systems are provided with DBS 3 9 DBS 6 15 DBS 8 22 5602 250W internal DBS 15 42 47 Q 250W internal DBS 25 70 and DBS 35 90 129 370W external DBS 50 140 and DBS 60 180 8 2 Q 750W external DBS 100 240 W120 240 180 320 3 92 1000W external For UL purposes the following recovery resistors have been tested The UL mark on the drive covers applications up to these ratings DBS 25 70 and DBS 35 90 129 750W 1 6 duty cycle DBS 50 140 and DBS 60 180 8 2 Q 2000W 2 9 duty cycle DBS 100 240 W120 240 3 90 3000W 2 1 duty cycle WARNING do not touch recovery resistor during operation to avoid scalds WARNING High Voltage
56. Voltage Drive type A Vac at 50 C a a 50 C FN 2070 3 06 FN 258 7 07 DBS 6 15 DBS 8 22 FN 258 16 07 FN 258 30 07 FN 258 42 07 FN 258 55 07 FN 258 100 35 A FN 258 180 07 III 1 3 Oct 01 3 2 2 Filter Sizing The filter drive coupling in the previous table is a standard coupling The filter can be undersized according to the rms input current of the actual application This should be done not only because as a matter of fact undersizing the filter means less money but because the undersized filter provides better performance to EMC 3 2 3 Filter Dimensions Code Trade mark Dimensions my lid Ee ECE i il FN 2070 3 06 terminal ied cl Bil Wail Hl o Bl E FN 250 6 07 ed AE DR ad el FN 258 7 07 FN 258 16 07 id A lll DR dl o al FN 258 30 07 A ll ae ll Mie el i Gaal Rel FN 258 42 07 a all Bal dl dl Mell Rall oll all FN 258 55 07 to all Sl ell ll hal Bl FN 258 75 34 block ial incl o i heel o ll FN 258 100 35 block ll bad a ll FN 258 180 07 block FN2070 3 06 has fast on terminals at both sides FN250 6 07 has wiring leads length 300mm at both sides TOP VIEW SIDE VIEW Ls L7 LI K i l HI 2 3 0ct 01 3 2 4 Filter Installation The filter must be mounted on the same panel as the drive CAUTION leave a clear space of at least 60mm around the filter for air circulation when the cabinet does not have forced ventilation The filter must be connected
57. acter 3 the significance of the command mnemonic Numerical value If there is not numerical value than the command issued is an interrogation the DBS should answer and report the current value of specific parameter or status word Otherwise the command issued attempts to set the new value for specific parameter The characters from the 5th to the 9th might be a decimal number This number might have from 1 to 5 digits 0 99999 The only exception is the VE command digital speed reference which will be accepted with the leading minus sign followed by 1 3 decimal digits lt CR gt Following the last least significant digit a lt CR gt will end the message V 1 3 Oct 01 5 1 2 Address Multidrop serial link protocol of the DBS drive allows for the parallel connection of up to 15 drives For the proper operation of this structure each drive must have generic address The drive address might be one from the following set A B C D E F G H I J K L M N O If the drive address is A first the DBS will accept the commands without the leading drive address This feature is adopted in order to preserve full compatibility with all previously shipped DBS drives Hence for the first A drive it is not necessary to enter the commands with the leading drive address such as A1KP A1KP255 A1PW91 A1AP The drive will equally respond to the same commands without the leading character 1KP 1KP255 1PW91 1AP By closing
58. and the triangular 5kHz carrier see Fig 5 below The width of the pulses in Fig 5 depend upon the level of the modulating signal m and so the average phase voltage as well As might be seen the current control takes effect in correcting the average phase voltage in such a way that any current error detected in error discriminators is gradually driven to zero 5 kHz 10V AA Comparator modulating Output binary gt O dr 5 signal is E signal controlling the output of the PI gain block the IGBT switches U Fig 5 VI 5 3 Oct 01 To make sure that the steady state DC error is always driven to zero the current controller comprises besides the proportional gain an integral gain as well The way in which the proportional and integral gains are implemented is illustrated in Fig 6 C 10n V lref 20K Rp 120 K e 15V 12K 7 2 Vil 7 6 Zy Fas Voi 44 15V Fig 6 The signal marked as V lref in Fig 6 is the phase current reference in the analog form The signal marked with V Is is the current feedback measured with LEM sensors The output Vpi in Fig 6 is the modulating signal playing the role of the voltage reference This signal is not fed directly to the comparator but rather first processed through the slope limiter The reason for introducing the slope limitation might be seen from the traces in Fig 7 featuring the triangular carrier along with the
59. as a standard feature of the DBS 7 1 Phase speed relation According to the requirements the phase speed curve equals zero for all the speeds below the speed S1 rpm see Fig 7 1 Above that speed the phase rises with the speed with a constant slope Hence two parameters PF and PG in the following text are sufficient for the purpose of customising the phase speed demagnetisation curve PF parameter will define the speed S1 rpm From the stall up to the S1 rpm the phase speed correction will have the value zero Above S1 rpm the phase speed correction will rise up with the constant slope This slope is defined by the second PG parameter Fig 7 1 Phase Speed Curve Phase degrees Sl rpm PF Es Speed rpm Slope f PG VII 1 3 Oct 01 7 2 Phase current relation The phase current curve might start with the value different from zero That is the phase correction might not be zero for very small values of the current IQ Therefore a dedicated parameter PH is provided for adjusting the initial 1Q 0 value of the phase angle correction of the phase current curve The curve phase IQ is linearly rising or falling for the currents IQ gt 0 The phase attains the value defined by PX parameter at the current level S2 defined by the PY parameter Fig 7 2 Phase Current Curve Phase degrees Slope gt PQ Initial value gt gt PH par Current IQ Hence the point S2
60. atile memory Example A10N A1VC A1DR A1SV or for the first DBS drive only 10N 1VC 1DR 1SV etc V 2 3 0ct 01 5 1 4 2 Interrogation status and parameters Drive parameters such as feedback gains filter cut off frequencies error levels programmable limits digital references etc may be read through the DBS RS485 serial link Typical interrogation sequence will be initiated by sending for example 1KP lt CR gt from the hand held terminal to the drive The drive will respond with the 1KP string followed by the numerical value of the KP parameter belonging to the first parameter set DBS drive response will not indicate the drive address within the response message In the same way the drive status and faults may be interrogated using the A1ST and A1FA or for the first DBS drive only 1ST and 1FA messages Detailed description is given with each command 5 1 4 3 Parameter setting Programmable parameters of the drive control structure and protection mechanism might be set by sending command mnemonic and the value of the parameter to be set After reception of the set command the DBS drive will check the parameter range eventual password protection of the parameter and finally set the new value for the parameter DBS will clear the hand held screen by sending the character sequence lt FF gt lt US gt lt CR gt lt CR gt At the same time such a response will acknowledge the com
61. cations the magneto motive force MMF that is the stator current vector is perpendicular to the rotor flux In such a way the torque constant Nm per Ampere is maximized In some applications requiring extremely high speed and high frequency of the stator current the phase lag caused by the current controller imperfection might degrade the drive torque constant The current controller implemented within the DBS drive results in a phase lag of 9 degrees at the output frequency of 270 Hz Due to the phase lag the spatial displacement between the rotor flux and the stator MMF will be less than 90 degrees electrical and the torque will diminish as the cosine function of the phase lag DBS drive might compensate this phase lag and the lack of torque through the user programmable phase advance That is an additional phase advance might be inserted into the drive vector rotator rendering the possibility to compensate for the current controller phase lag and to optimize the Torque Speed curve Along with the conventional synchronous PM motors the DBS might run PM motors with pronounced saliency effect Ld Lq and ensuring reluctance torque The peak of total electromagnetic torque for this family of PM motors is obtained with flux MMF angles different that 90 electrical degrees For the purpose of maximizing the torque per Amp constant of synchronous reluctance motors the phase advance in function of the speed and stator current is provided
62. controller 21 KP Set Read the proportional gain of the speed controller 22 MR Set Read the full scale of the input analog reference 24 ND Set Read the depth of the notch filter optional 25 NF Set Read the frequency of the notch filter optional 26 NP Set Readthe number of resolver poles lt 27 NW Set Read the width of the notch filter optional 29 OF Command for switching OFF the drive power section 30 ON Command for turning ON the drive power section V 4 3 Oct 01 33 PF Parameterfor Torque Speed adjustment gt lt o Z o 34 PG Parameter for Torque Speed adjustment 35 PH Parameter for Torque Speed adjustment 36 PQ_ Parameter for Torque Speed adjustment PR Motor Resolver pole ratio parameter 38 PS Display the active parameter set for2 222222 39 PW Switch the password ON or OFF 40 PX__ Parameter for Torque Speed adjustment gt Z o lt o 42 RN Set Read the lower limit of the R D converter resolution 43 RX Set Read the upper limit for the R D converter resolution 44 RS Set Read the angle between motor and resolver shafts 45 SA Base Address select the drive address for multidrop 46 SE Set Read the number of the simulated encoder pulses 47 SM_ Automatic Save Enable bit setting and clearing 49 _ SV_ Save the drive settings into non volatie memory TC Establish the torque control mode of
63. ct the jumper and connect an external recovery resistance to RR pins AT hard braking jumper factory setting Il 1 3 Oct 01 2 1 Fuses 2 1 1 Internal Fuses DBS drive has the following fuses on the bus bars DBS 3 9 DBS 6 15 DBS 8 22 50A ultrafast cod AM6408 2 1 2 External fuses CAUTION equipment suitable for use on a circuit capable of delivering not more than the Short Circuit rating 460V 10 maximum when protected by semiconductor type fuses manufactured by Bussmann Div Cooper UK Ltd according to UL508C 1998 See the following table DBS Model 3 9 to 15 42 25 70 35 90 50 140 60 180 100 240 W120 240 180 320 Short Circuit 5000 rms symmetrical Amps 10000 rms symmetrical Amps Rating Input power Type 50 FE Type 100 FEE Type 160 FEE Type 280 FM Type 315 FM Type 500 FMM line fuse 50A 660Vac 100A 660Vac 160A 660Vac 280A 660Vac 315A 660Vac 500A 660Vac 2 2 Soft Start The soft start is included in the circuit The soft start resistors are short circuited after 250ms 2 3 Fans CAUTION a free circulation must be guaranteed for the air flow 2 3 1 DBS 3 9 to 60 180 Fans The ventilation is provided by fans mounted under the modules The input power is provided by the drive 2 3 2 DBS 100 240 180 320 Fans The ventilation is provided by three 24 Vdc fans for DBS 100 240 and five 24 Vdc fans for DBS 180 320 mounted under the modules They must be powered by the user To
64. d bit b8 AS Address Show it allows display of the basic address of a module if unknown To avoid simultaneous answers on the line from more than one module it is necessary that serial flat is connected only to the questioned module It is different from SA command which is used to change the address Syntax AS lt CR gt reads the address Range Range protection Default Password no Second set See also V 10 3 Oct 01 BR Set Read the Baud rate of the RS485 serial link Function The DBS RS485 serial link might use several baud rate values The baud rate is set and saved through the BR parameter Syntax A 1BR lt CR gt reads the current value of BR A 1BRnnnn lt CR gt will set the new value of the BR parameter Range 1200 2400 4800 9600 19200 See also 3 CG Set Read the gain of the current control loop The current loop gain of the DBS drive might be adjusted through the serial link communication A dedicated CG parameter with 4 discrete values is introduced in order to set the current error gain A 1CG lt CR gt reads the current value of CG AJ1CGn lt CR gt will set the new value of the CG parameter O very low gain 1 medium low 2 medium high 3 very high Range protection YES Default motor dependent Password YES Second set NO See also V 11 3 Oct 01 CP Reads the motor shaft initial position Initial shaft position is read after the drive reset a
65. e of 3 3 mH The gains should be proportionally increased or decreased when the motor leakage inductance is lower or higher respectively More specifically the multiple Lmotor Cp and the quotient Lmotor Rp should be kept constant VI 7 3 Oct 01 Ega Kontra ems V Iret a Rate Limiter2 le Fig 9 Resulting amplitude characteristic of the transfer function of current controller is given in Fig 10 Frequency axes is given in rad s The bandwidth of the current controller is approximately 1kHz 8 OC ee ass pus pi as 101 10 10 104 105 Kp 8 333 Ti 0 001 rad ses VI 8 3 Oct 01 In order to illustrate the phase characteristic of the current controller and the resulting phase delay at relevant frequencies the phase current references and the measured waveforms are given in Fig 11 for the fundamental frequency of 30 Hz and 200Hz 10 Fig 11 Notice for particular applications the PWM modulation with the commutation frequency of 10kHz might be used Higher commutation frequency will decrease the current ripple and provide for better torque control Though certain increase of the drive power losses is to be expected since the commutation losses increase proportionally to the commutation frequency VI 9 3 Oct 01 This page intentionally blank VI 10 3 Oct 01 SECTION 7 ADJUSTMENT OF TORQUE SPEED CURVE In most of the DBS appli
66. ection Exchange V with U Wrong motor YES x connection RS 38000 Exchange W with V NO pas A Su x RES dd SS Wrong motor YES e e connection RS 16000 Exchange U with W NO Ask the Service Center IV 20 3 0ct 01 SECTION 5 COMMANDS 5 1 General Features The DBS drive performs the slave function on the RS485 serial link That is the drive does not initiate any communication by itself Any communication sequence begins with the reception of the command string from the hand held terminal or a PC computer via DBTALK program The drive than responds with the response string The only exception from the slave role is the period after the power up After the reset the DBS will send the wake up message DBS V xx where xx is the software version If the initialization and the self test procedure is passed the RS485 link will slip into the slave mode and respond only when interrogated 5 1 1 Format of the command string In a multidrop configuration the command format is Address CHAR 1 CHAR 2 CHAR 3 numerical value lt CR gt Address Uppercase letters A O with the significance of the drive address A O equivalent to 1 15 Character 1 Numbers 1 2 or the character Significance parameter set 1 First 2 Second current 1 or 2 depending of the O or 1 status of spare input signal see J1 pos 18 Character 2 These characters are uppercase letters A Z with Char
67. ef AT OVERTEMPERATURE BUS BAR VOLTAGE AUX VOLTAGE Ref AT gt Display the Status Send Command Driver Answer Comunication Status REGULAR ist SET ADDRESS 01 ADDRESS 01 T F 7 MODULE STATUS SELECTED AXIS STATUS ENABLED REFERENCE ENABLE ON DRIVE ENABLE ON Opto DRIVE GK OUTPUT OFF TORQUE ENABLE OFF PRIORITY G2 DROP KEYBOARD REFERENCES DIGITAL EXPANSION EBM ADVISED ILIMIT DIGITAL SYSTEM CONTROL VELOCITY ROTATION C CLOCKWISE la 7 SPARE OUTPUT B MODULE FAULT EBM ANALOG OUT 1 EV AXIS 2 OVERTEMPERATURE ANALOG OUT 2 IOUT AXIS 3 BUS BAR VOLTAGE AUX VOLTAGE Ref AT Il 24 3 Oct 01 See Change parameters To change one parameter type the command string on the PC keypad Example 1VE3000 Send Command 1VE3000 ist ADDRESS O1 Driver Answer Communication Status REGULAR SET ADDRESS 03 REFERENCE EN Opto DRIVE OF NP 6 PRIORITY 62 PR 1 EXPANSION ANALOG OUT 1 ANALOG OUT 2 Il 25 3 0ct 01 FIG 2 13 CONTROL CARD JUMPERS a ZZA Z7 77 V Lo toa
68. emory The error message is foreseen if the saving operation is not completed correctly Range Range protection Default Password Second set See also TC Establish the torque control mode of the drive The DBS might work in the speed control mode or the torque control mode That is the reference value may be interpreted as the speed reference or the torque reference In the speed control mode the speed error is calculated and the speed controller algorithm is executed while in the torque control mode the input reference signal determines the torque to be generated by the servo motor The operation mode is selected by the status bit speed torque control mode see 1ST command The 1TC command will put the DBS drive into the torque control mode Note that in this case VE and MV parameters velocity and max velocity mean torque and max torque Syntax AJ1TC lt CR gt will command the DBS to assume the torque control mode Range See also VC Note the status can be interrogated via ST command bit b10 V 41 3 Oct 01 VC Establish the speed control mode of the drive The DBS might work in the speed control mode or the torque control mode That is the reference value may be interpreted as the speed reference or the torque reference In the speed control mode the speed error is calculated and the speed controller algorithm is executed while in the torque control mode the input reference si
69. ential non inverting analog input for the speed reference signal or torque ref signal see TC command max range 10V see MR command See Fig 2 3 Differential inverting analog input for the speed reference signal or torque ref signal see TC command max range 10V see MR eee See Fig 3 ILIMIT Analog A I limit O to 10V Em TACHO TEST Tachometer analog output scale 10V for MV ANALOG OUT Analog output for the lout information which is the absolute value of the current reference measured on the speed loop output RE 2 JK 10V for 100 peak current 6 ov Analog OV 7 15v 15Vdcoutpui imax 30mA _______ 8 INP COMMON Common optoisolatedOV 9 DRIVEOK Collector of Drive OK optoisolator 10 Emitter of Drive OK optoisolator DRIVE OK MOTOR OK Collector of Motor OK optoisolator 12 Emitter of Motor OK optoisolator MOTOR OK SPARE OUT SPARE QUT ne PS DRIVE EN _ Drive enable optoisolated input referred to common OV J1 8 See Fig 2 4 REF EN Reference enable optoisolated input for the confirmation of the reference to the axis REF EN not active means no speed reference or zero torque referred to common 0V J1 8 reser Remote reset optoisolated input for logic section reset equivalent RESET to push button on the front panel referred to common OV J1 8 reser os width of the pulse must be gt 200 ms SPARE IN Spare optoisolated input referred to common OV J1
70. ess motor servo drives is a well known cause of one per electrical period ripple of the speed and position In order to avoid trimmers the necessity to open the drive when performing the trimming parameter CV is introduced for fine trimming of the current loop offset CU parameter is responsible for the V motor phase The value 128 gives zero offset compensation The values below and above 128 give positive and negative corrections Parameter CV is available in one first parameter set Syntax AJ1CV lt CR gt reads the value of 1CV parameter AJ1CVnnn lt CR gt Range 0 255 Range protection YES Default drive dependent Password YES Second set NO See also REMARK do not change CV parameter A wrong set of CV increases torque ripple DE Set Read deceleration ramp time Deceleration parameter is used to limit the rate of change of the speed reference In other words when DE is different that zero any speed reference change will have limited negative slope The slope limit allows the speed reference to be changed from MV rpm to zero in DE milliseconds Syntax A 1DE lt CR gt reads the current value of 11DE AJIDEnnn lt CR gt will set the new value of the 1DE parameter Range 10 to 999 ms or O disabled Range protection YES Default O disabled Password NO Second set NO See also AC Fig 5 1 V 13 3 Oct 01 DF Set Read the cutoff frequency of the digital filter Control st
71. gnal determines the torque to be generated by the servo motor The operation mode is selected by the status bit speed torque control mode see 1ST command The 1VC command will put the DBS drive into the speed control mode Syntax A 1VC lt CR gt will command the DBS to assume the speed control mode Range protection Default velocity control Password YES See also TC Note the status can be interrogated via ST command bit b10 VE Set Read the digital speed reference The DBS drive might work in the analog reference mode or in the digital reference mode see 1ST command When in the digital reference mode the speed reference is defined by the VE parameter This parameter should be interpreted as the speed reference in rpm Direction of rotation might be changed by DI command if necessary If the drive is configured as torque actuator see TC command VE command allows to set torque AJ1VE lt CR gt reads the value of the digital reference A 1VEnnnn lt CR gt will set the new value of the digital speed reference Numerical value of the speed reference might have the leading minus sign An OUT OF RANGE message will be transmitted if the value of VE attempted is higher than the MV parameter If the command is sent while the drive is in analog reference mode the warning message keyboard disabled will be transmitted See also DR TC MV VC V 42 3 Oct 01 VO Automatic
72. grounding of shield via connector clamp via connector clamp or RF connection to PG gland in case of terminal board CAUTION the U V W motor phase sequence of the connector at the drive side must match the U V W motor phase sequence of the connector at the motor side Il 12 3 Oct 01 Tab 2 10 J5 Power Connector for DBS 3 9 6 15 8 22 15 42 Panel side male type Harting 09 06 015 2912 code AK5955 Wiring side female type Harting 09 06 215 2871 code AK4961 L1 phase three phase input voltage 400Vac or 460Vac L2 phase three phase input voltage 400Vac or 460Vac Internal recovery resistance The female connector has a jumper between P1 and P2 factory setting which connects a 56Q 240W internal resistor to HV To use an external resistor this jumper must be disconnected See L3 phase three phase input voltage 400Vac or 460Vac Protective bonding U2 U2 phase three phase output voltage to motor V2 phase three phase output voltage to motor W2 phase three phase output voltage to motor RR External recovery resistor if applicable In this case the O RR O the jumper between P1 and P2 must be disconnected only one wire and one pin per phase shall be used Fig 2 7 J5 Power Connector for DBS 3 9 6 15 8 22 15 42 CAUTION the jumper between P1 and P2 must be disconnected before connecting an external recovery resistance on small DBS drives see Fig 2 2 I
73. haracters a string followed by lt CR gt character The drive responses are strings as well Il 20 3 Oct 01 The string of the DBS response on the serial link begins and ends with a lt CR gt character When a command or a new parameter setting is received by the DBS drive the drive will first clear the hand held screen by sending the character sequence lt FF gt lt US gt lt CR gt lt CR gt At the same time such a response will acknowledge the command reception and the master will be informed that its message is correctly received and understood When inquired for the status word value or a current parameter value the DBS drive will always end the response string with a lt CR gt character 2 8 1 Keypad REMARK for the first installation it is strongly recommended to use either the optional keypad or the DBTALK communication program The keypad is an optional accessory product which can be used for drive setup and monitoring It must be connected to J2 connector If problems occur when attempting to communicate the keypad is most likely set incorrectly To start the setup procedure press lt CTRL gt then lt CR gt For each parameter the current setting is displayed together with a question asking if you want to change it The correct setting is BAUD 9600 WORD 8D E 1 STOP BLOCK MODE SINGLE LINE MODE FLASHING OFF KEY REPEAT ON SLOW Be sure to save at the end of the procedure by pressing lt Y gt whe
74. ht be connected in parallel to the RS485 bus Drives will have the slave role they will respond to the queries sent by the master The role of the master normally takes the hand held terminal When available an industrial PC or a notebook may be connected to the RS485 bus via the RS232 RS485 adapter The link is made according to the ElA 485 standard for electrical characteristics of generators and receivers for use in balanced digital multipoint systems issued by the Electronic Industries Association TR 30 1 Subcommittee on Signal Quality April 1983 Receiver of the DBS RS485 line is continuously enabled Transmitter is enabled only at the intervals when the DBS is sending the messages to the caller The BAUD RATE can be adjusted from 1200 to 19200 Baud s The default value is BR 9600 The DBS does not support automatic baud rate adjustment That is the drive is not able to detect the baud rate of the caller so it will not auto adapt Due to this reason it is necessary that the initial baud rate setting of both the caller and receiver be the same lf the communication is not established at the first power up it is necessary to close the G3P drop on the control board and reset the drive This action will set the baud rate of the DBS to a default of 9600 baud s The characters used in commands are ASCII encoded The format of each character is 1 start bit 8 data bits 1 parity bit and 1 stop bit Each command consists of a series of c
75. ine might be performed This routine implies injection of the DC current into the motor windings If the auto phasing is correctly performed the message AXES PHASED will be sent by the DBS When an error occurs during the auto phasing the message ERROR IN AUTOPHASING will be transmitted by the drive AJ1AP lt CR gt will initiate the auto phasing procedure The drive will confirm the action with the response AUTOPHASING IN PROGRESS The auto phasing will not be performed if the drive is in the fault conditions Range Range protection Default Password YE Second set See also Note to execute AP the drive must have the G2P drop on the control board open keyboard priority analog Drive Enable on conn J1 pos 15 and digital Drive Enable off via OF command REMARK as in this phase the motor can rotate for a revolution fraction it is opportune to make sure it is free to rotate to avoid risk of friction which could compromise phasing accuracy So motor must be disconnected from load V 9 3 0ct 01 AR Select the reference from the Analog reference input The speed reference for the DBS speed loop might be the digital one set by the 1VE command or the analog speed reference taken from the DBS analog input port The AR command selects the analog reference mode Syntax A 1AR lt CR gt selects the analog reference Range protection Note the status can be interrogated via ST comman
76. ir full format with the drive address at the beginning of the command string providing that they begin with A the address of the first drive Hence command strings such as A1SA will be accepted as well MODIFICATION OF THE ADDRESS For the purpose of setting the new drive address the hand held terminal or the host computer RS485 port must be connected to the DBS drive only point to point Command string 1SAn lt CR gt should be entered by the terminal host putting the new drive address in the numerical presentation 1 15 as the number n within the string shown After this action parameters should be saved by using the save command Notice that 1SV command string will not take effect after the address modification Instead save command with the leading drive address should be used Example for the second drive save command B1SV lt CR gt should be entered A non zero drive address might be modified as well Example for the second drive in the set the modification might be done by inserting the command string B1SAn lt CR gt with n being the number corresponding to the new address An insertion of the save command is necessary in this case as well 1 A 2 B 3 C 4 D 5 E 6 F 7 G 8 H 9 1 10 J 11 K 12 L 13 M 14 N 15 O YES 1 corresponding to A address YES NO V 37 3 Oct 01 SE Set Read the number of the simulated encoder pulses optional The shaft sensor obligatory fo
77. l 13 3 0ct 01 Tab 2 11A J5 Output Power Connector for DBS 25 70 to 60 180 OLD Version Panel side power connector type Harting Hank 4 0 with 4 female contacts code AK4958 Wiring side power connector type Harting Hank 4 0 with 4 male contacts code AK5950 U2 phase three phase output voltage to motor V2 phase three phase output voltage to motor W2 phase three phase output voltage to motor O fume ooo Tab 2 11B J6 Power Connector for DBS 25 70 to 60 180 OLD Version Terminal blocks type Phoenix HDFK 10 07 07 07 3 code AK7420 L1 phase three phase input voltage 400Vac or 460Vac L2 phase three phase input voltage 400Vac or 460Vac L3 phase three phase input voltage 400Vac or 460Vac Protective bonding External recovery resistor ERR Fig 2 8 J5 And J6 Power Connectors for DBS 25 70 to 60 180 OLD Version Il 14 3 Oct 01 Tab 2 11C J5 and J6 Power Connectors for DBS 25 70 to 60 180 NEW Version for DBS UL Listed Terminal blocks type Phoenix HDFK 16 code AK7427 See also par 2 6 1 Name Function AT Output Dc Bus This optional output can be used to supply AT the Dc Bus of another DBS drive e g DBS of same size with a 50 contemporaneity factor L1 phase three phase input voltage 400Vac or 460Vac L2 phase three phase input voltage 400Vac or 460Vac L3 phase three phase input voltage 400Vac or 460Vac Protective bonding PE
78. l computer simulation delays in the speed feedback signals caused by the observer and the R D network must be taken into account Assuming that the speed loop bandwidth will never exceed BW 100Hz the R D and the observer might be modeled by the real pole Wrpo s 1 1 t s in continuous domain having the time constant t 0 5 ms When required WRDO s might be transformed into the z domain Since the sampling time of the speed loop is T 300 us the approximation of WRDO in z domain is WRpo Z Z 2 z 1 VI 1 3 Oct 01 Having available the speed feedback and the sped error the digital signal processor executes the speed control routine illustrated in Fig 2 The sampling time of the speed control loop is T 300 ms Speed controller is basically a PI controller with the AWU anti wind up mechanism Besides Pl control actions the Fig 2 shows a pre filter of the proportional action the output torque filter and the programmable filter of the speed error WF z Notice that the same transfer functions WF z exists in both proportional and integral actions Separation in two units was necessary in order to obtain proper AWU feature E Second order digitlal KI g E filter of the sp AS Speed error WF z Reference amp Non filtered error Filtered error Second order digitjal Speed filter of the spqed feedback from error WF z the observer Speed reference amp feedback format KP KI Parameters as
79. loys continuous braking it is necessary to include the recovery resistor power dissipation use the nominal power of recovery resistor if actual application recovery dissipation is unknown DBS Model A A A e E RRA OO Power 100W 150W 190 W 310W 475W 650W 900W 1100 W 1600 W 2700 W Dissipation Il 32 3 Oct 01 SECTION 3 ELECTROMAGNETIC COMPATIBILITY EMC 3 1 European Directive 89 336 EC Compliance with the European Directive 89 336 EEC is required for all electric and electronic products brought onto the European market after December 31st 1995 DBS drives with FASTACT motors meet the following EMC product standard related to the Directive EN 61800 3 1996 and EN 61800 3 A11 2000 Adjustable speed electrical power drive systems Part 3 EMC product standard including specific test methods Second environment industrial compatibility levels Remark equipments not intended to be used on a low voltage public network which supplies domestic premises May cause radio frequency interference Tests have been made in an independent competent body test house The installer of the drive is responsible for ensuring compliance with the EMC regulations that apply where the drive is to be used We recommend filtering as per par 3 2 and wiring grounding and screening as per par 3 3 and 3 4 3 2 Filtering 3 2 1 Filter Types The following filters are recommended Code Trade mark Rated Current Max
80. mand reception and the master will be informed that its message is correctly received and understood Parameter modification will be effectuated if the attempted value lies within the range related to specific parameter and the password check is passed In situation when parameter value attempted is out of range the DBS will send the error message OUT OF RANGE and discard the parameter that is keep the previous value of the parameter In cases when parameter is password protected and the password is not entered the DBS will discard the new parameter value and report PASSWORD PROTECTED error message 5 1 4 4 Response messages Startup warning and error messages At the startup time the DBS sends the wake up message DBS V xx where xx is the software version Note care must be taken that the message will be emitted only if the drive address is A one The wake up message consist of the string DBS followed by the number describing the software release In a multidrop configuration this message is emitted by the first A DBS drive in the group of parallel connected DBS drives Other drives having the addresses different from A will not send the wake up message at the power up Such a behavior is necessary since otherwise simultaneous emission of several wake up messages at the power up will provoke collision on the bus Similar text messages are emitted by the DBS in the case of er
81. mber of resolver poles plays important role in the velocity observation Therefore this number must be available for the purpose of drive internal calculations Parameter NP defines the number of resolver poles not the pole pairs Parameter NP does not exist in two parameter sets and has to be addressed by using 1NP command string Syntax A 1NP lt CR gt reads the value of 1NP parameter A 1NPn lt CR gt will set the new value of the 1NP parameter V 23 3 Oct 01 NW Set Read the width of the notch filter optional the notch filter with programmable frequency depth and width is available to the user It may be used together with the present error reference digital low pass filter The NW command allows to set and read the notch filter width The width at 9dB is defined as 1 1000 relative units A 1NW lt CR gt reads the value of 1NW parameter AJ1NWnnn lt CR gt will set the new value of the 1NW parameter Range 1 to 255 corresponding to 0 1 to 25 5 Range protection Default Password YES Second set See also NF ND V 24 3 Oct 01 OC Digital speed offset only for setup technicians it allows to set the digital velocity offset The value 128 gives zero offset compensation The values below and above 128 give positive and negative corrections AJ1OC lt CR gt reads the value of 10C A 20C lt CR gt reads the value of 20C A OC lt CR gt reads the current active value of OC parame
82. mpt to enter wrong SE value will not be accepted and the drive will respond SE TOO HI FOR GIVEN RN RN 10 limits SE max to SE 256 RN 12 limits SE max to SE 1024 RN 14 limits SE max to SE 4096 RN 16 limits SE max to SE 16384 V 38 3 0ct 01 SM Automatic Save Enable bit setting and clearing Parameters of the DBS drives are saved into 2402 EEPROM Read Save procedure is performed through the I2C bus when SAVE 1SV command is executed or optionally after each modification of any drive parameter The mode of SAVE operation is defined by SM Save Mode bit For SM 0 the SAVE operation is performed only when 1SV command is executed When the SM bit 1is set to 1 SM 1 parameters are being saved after each modification of any drive parameter providing that the parameter modification is successful In AUTO SAVE mode that is SM 1 the save operation is avoided if the modification of the parameter is not successful due to password protection or when the attempted value is out of range Syntax AJ1SM lt CR gt reads the value of 1SM AJ1SMn lt CR gt will set the new value of 1SM Range O or 1 Second set NO See also SV V 39 3 0ct 01 ST Display the drive status flags Set of binary signals and flags internal to the drive and external as well is called the drive status The status string might be inspected by using the 1ST command Syntax comprising the status bits AJ1ST l
83. mulation of the motor thermal model Parameter 1IT defines the thermal time constant of the motor The nominal ratings of the motor is defined by 1PC parameter When this thermal model runs above the temperature limit the I2T fault flag will be set the current limit will be reduced to rated level but the drive will not be switched OFF Syntax AJ1PC lt CR gt reads the value of PC AJ1PCnnn lt CR gt will set the new value of the 1PC parameter See also IT CAUTION do not change PC parameter A wrong set of PC can damage the motor PF Parameter for the adjustment of Torque Speed curve Current loop of a typical AC drive suffers the phase lag at extremely high output frequencies speeds This lag reduces the resulting torque per amp ratio To counterbalance this phenomenon the current vector relative to the motor flux is advanced through PF PG PH PX PY and PQ parameters see the dedicated Section 7 The values PF 255 PG 0 PH 0 PQ 128 PX 128 and PY 255 disable the function Syntax AJIPF lt CR gt reads the value of the parameter A 1PFnnn lt CR gt will set the new value of the parameter V 27 3 Oct 01 PG Parameter for the adjustment of Torque Speed curve Current loop of a typical AC drive suffers the phase lag at extremely high output frequencies speeds This lag reduces the resulting torque per amp ratio To counterbalance this phenomenon the current vector relative to the motor flux is
84. n the display shows Make changes permanent Y N 2 8 2 Connection to Personal Computer 2 8 2 1 RS232 RS485 Full duplex Converter The RS422 interface wiring is based on one to one no multidrop principle Four wires are used With RS422 you can transmit and receive data simultaneously full duplex The RS485 half duplex uses only two wires It allows multidrop communication With RS485 half duplex you cannot transmit and receive simultaneously DBS drive supports RS485 full duplex with four wires RS422 compatible Up to 15 DBS drives can be connected in multidrop configuration e RS232 485 CONVERTER KIT This very small external converter provides a full duplex interface between PC and DBS The converter must be fit directly into a COM port RS232 of a PC This way the link becomes purely RS485 less susceptible to noise and able to transmit over much longer distances than RS232 The kit includes the converter to fit into DB25 S connector of the PC COM port The DTE DCE switch of the converter must be set to DCE Data Communications Equipment a DB25 to DB9 interface to be used if the PC COM port is DB9 S a2 m cable to connect the converter to J2 connector II 21 3 0ct 01 e An optoisolated PC board RS 485 full duplex driver can also be used The following wiring must be used RS485 full duplex Connector DBS J2 Connector Male Female 2 8 2 2 DBTALK Program e PC REQUIREMENTS 80286 80386 80486 microp
85. nd stored within the internal RAM memory of the DBS drive That is after each reset the new value of the initial position will be read AJ1CP lt CR gt command will interrogate the DBS drive The drive will respond with the string current position nnnn Range O to 4095 Range protection YES Default Password NO Second set NO See also CU Set Read the current loop DC offset compensation parameter for the phase U only for setup technicians DC offset in the current loop of the Brushless motor servo drives is a well known cause of one per electrical period ripple of the speed and position In order to avoid trimmers the necessity to open the drive when performing the trimming parameter CU is introduced for fine trimming of the current loop offset CU parameter is responsible for the U motor phase The value 128 gives zero offset compensation The values below and above 128 give positive and negative corrections Parameter CU is available in one first parameter set Syntax A 1CU lt CR gt reads the value of 1CU parameter A 1CUnnn lt CR gt Range 0 255 Range protection YES Default drive dependent Password YES Second set NO See also REMARK do not change CU parameter A wrong set of CU increases torque ripple V 12 3 0ct 01 CV Set Read the current loop DC offset compensation parameter for the phase V only for setup technicians DC offset in the current loop of the Brushl
86. nn lt CR gt will set the new value of the parameter V 29 3 Oct 01 PR Parameter ratio between the motor and resolver pole number The number of the motor poles might be different than the number of resolver poles For the proper operation the ratio must be an integer That is to say the number of motor poles must be a multiple of the number of resolver poles For an increase drive flexibility this ratio is set by PR parameter this number must be available for the purpose of drive internal calculations Parameter PR might be inspected and changed through the PR command Parameter PR does not exist in two parameter sets and has to be addressed by using 1PR command string Syntax A 1PR lt CR gt reads the value of 1PR parameter AJ1PRn lt CR gt will set the new value of the 1PR parameter Range 1 to 15 Range protection YES Default motor resolver dependent Password YES Second set NO See also REMARK the motor resolver pole ratio has its effect on the speed loop gains That is for the same KP and KI values equivalent gain will increase as the number or resolver pole pairs increase Example two FAS K 8 pole motors with different resolver pole pairs the first one with 8 pole resolver the second with 2 pole resolver To have the same dynamic behavior the KP and KI gains of motor with 2 pole resolver must have approx four times the KP and KI gains of motor with 8 pole resolver This can be done in two ways
87. ny dimensions or data without prior notice Printed in Italy
88. o check the water temperature the drive overtemperature protection trips at 71 C HDFK 4 24 Vdc DBS 100 240 24 Vdc 33 W input voltage for fans HDFK 4 24 Vdc DBS W120 240 24 Vdc 12 W input voltage for the anti condensation fans CAUTION fans must be powered on 5 min before start up HDFK 50 V2 phase three phase output voltage to motor J5 HDFK 50 W2 phase three phase output voltage to motor HDFK 50 Motor ground Fig 2 11 J5 and J6 Power Connectors for DBS 100 240 W120 240 NEW Version JE U2 V2 w2 O O O O 50 4 50 50 NOTE the Low Temp Switch is mounted only on DBS W120 240 Il 17 3 0ct 01 Tab 2 13 J5 and J6 Power Connectors for DBS 180 320 Terminal blocks by Phoenix type HDFK 4 code AK7418 HDFK 25 code AK7421 HDFK 95 code AK7429 See also par 2 6 1 Block Type HDFK 95 E Protective bonding J6 LINE HDFK 95 L1 phase three phase input voltage 400Vac or 460Vac L3 phase three phase input voltage 400Vac or 460Vac J5 MOTOR HDFK 95 Motor ground HDFK 25 E CRM External recovery resistor HDFK 25 HDFK 25 e Dc Bus This optional output can be used to supply J6 HDFK 25 the Dc Bus of another DBS drive max DBS 60 180 HDFK 4 24 Vdc 55 W input to supply the fans Fig 2 12 J5 and J6 Power Connectors for DBS 180 320 A o a O it il i J MOTOR Il 18 3 Oct 01 2 7 Recovery Circuit
89. o 100 RESET Digital control card reinitialization and reset of protections BUTTON Il 3 3 Oct 01 2 6 Wiring 2 6 1 Sizing of Wires It is recommended to use Cu stranded and or solid wires 60 75 C 140 167 F UL approved per the following table Note that this sizing of wires is referred to new UL version of connectors Tab 2 3A Sizing of Wires DBS Model 3 9 to 15 42 25 70 50 140 100 240 180 320 8 22 35 00 60 180 W120 240 Line Power wiring 4x 4X 4X 4X 4X 4X No of wires x AWG 14 awe 10 awe 8 ane 4 ane 1 0 awe 4 0 AWG Motor Power wiring shielded No of wires x AWG Recovery Resistor wiring 2x 2x 2x 2x 2x 2x shielded No of wires x AWG 14 AWG 10 AWG 8 AWG 8 AWG 8 AWG 2 AWG Optional Dc Bus AT 2x 2x 2x 2x 2x 2x shielded wiring No of wires x AWG 14 AWG 10 AWG 8 AWG 4 AWG 1 0 AWG 2 AWG Optional 24V Power e Supply wiring No of wires 2x 14 AWG x AWG haat 4 pair Resolver wiring each par a No of wires x AWG twisted an 4 x 2 x 22 AWG individually shielded with an independent overall shield Tab 2 3B AWG mm Conversion Table AWG 22 20 18 16_ 14_ 12 10 8 1 6 14 1 3 1 0 410 _ 03 0 5 0 8 1 3 2 1 3 3 5 3 53 z 5 gr 5 54 107 Tab 2 3C Tightening torque of Terminal Blocks pp K4 HDFkio HDFKI6 HDFK25 HDFK50 bin 2 cen A A el tree ame eee a 15 20 Tab 2 3D Wire stripping length for Terminal Blocks ca A ees 0 43 ad A 0 63 ___L
90. otor HDFK 25 V2 V2 phase three phase output voltage to motor J5 HDFK 25 w2 HDFK 25 HDFK 25 W2 phase three phase output voltage to motor HDFK 25 e Motor ground Fig 2 10 J5 and J6 Power Connectors for DBS 100 240 W120 240 OLD Version Jo PAES U2 V2 W2 LO ap ap ab am QUIM NOTE the Low Temp Switch is mounted only on DBS W120 240 Il 16 3 Oct 01 Tab 2 12B J5 and J6 Power Connector for DBS 100 240 W120 240 NEW Version for DBS UL Listed Terminal blocks by Phoenix type HDFK 50 code AK7428 HDFK 25 code AK7421 HDFK 4 code AK7418 See also par 2 6 1 Terminal Name Function Block Type HDFK 50 Output Dc Bus This optional output can be used to supply HDFK 50 AT the Dc Bus of another DBS drive e g DBS of same size with a 50 contemporaneity factor HDFK 50 L1 phase three phase input voltage 400Vac or 460Vac HDFK 50 L2 phase three phase input voltage 400Vac or 460Vac HDFK 50 W1 L3 phase three phase input voltage 400Vac or 460Vac Protective bonding HDFK 25 R R External recovery resistor HDFK25 RR LOW TEMP Thermal switch Normally closed contact max 5A HDFK 4 SWITCH Rated to open at 40 C 3 C heatsink temperature With intermittent water flow It can be used to start the water pump when the heatsink temperature becomes gt 40 C With continuous water flow it can be used t
91. overy resistor cable CAUTION the unshielded cable provided with the drive is only for test purposes and not EMC compliant Reference Enable and OK cable RS485 cable simulated encoder cable if applicable Fig 3 2 Grounding Of Shield To Connectors At Motor Side Cable shield Metal shell Shield must be clean and clamp tightened Motor and resolver connector The shields of the cables must be connected at both ends to the proper housing via full circumferential bond to metallic connectors or hose clamps In case of Sub D connector cable shield must be grounded to the metallic hood When there is not connector at drive side a kit with stand off screws and hose clamps is provided The shield of the cable must be uncovered from insulation coating and RF connected to the stand off through the hose clamp as in Fig 3 3 Fig 3 3 Grounding Of Shield Without Connector WS by Sac C y t HI 4 3 Oct 01 Fig 3 4 Grounding At Drive Side ego DO l n HAIE i i FS unn PNQ ge 1 Reference Enable OK cable 2 Recovery resistor cable 3 Motor power cable Sub D and unshielded cables not shown Ill 5 3 Oct 01 i Z It is not necessary to shield the input power wires REMARKs FIG 3 6 Partition Penetration the shields of cables inside the cabinet must be 360 clamped to the cabinet wall see Fig 3 5
92. power might be turned on The meaning of specific bits is given below b1 Resolver wiring O OK 1 not correct b2 Motor temperature 0 OK 1 overheated b3 Power section 0 0K 1 short circuit b5 Velocity error 0 0K 1 excessive b6 Software IT protection O OK 1 protection ON b11 EEPROM O OK 1 memory error b12 DC bus O OK 1 over under voltage b13 Auxiliary power 15V O OK 1 not OK b14 Heat sink temperature O OK 1 over temperature In analog priority mode with the G2P closed the faults will not be reset until the drive enable opto coupler is switched OFF Hence with G2P closed the fault reset procedure is i Switch OFF the drive enable input ii Clear the faults by using 1FA command iii Turn the drive enable input ON again and the drive will restart All the faults except IT will switch the drive OFF IT fault will set the fault bit reduce the current limit to the level of the PC parameter and keep the drive ON V 17 3 Oct 01 IL Set Read the digital current limit Parameter IL defines the digital current limit in terms 0 100 where 100 level corresponds to the drive peak current Parameter IL exists in two parameter sets The values 1IL or 2IL are used depending on the status of the SPARE_IN input IL parameter is enabled by DL command A 1IL lt CR gt reads the value of 1IL A 2IL lt CR gt reads the value of 2IL A IL lt CR gt reads the current active value
93. power supply Notes the temperature limit is detected by thermo switch IV 4 3 Oct 01 4 1 8 IT Indicated by IT LED bit b6 of the FA string see FA command Set condition when the current exceeds the nominal motor current for a time longer than the time stated by the motor thermal model see IT command and Tab 3 4 Effect when the fault is going on the current limit is reduced to the level of the motor rated current set by PC command Reset condition when the set condition is not present anymore Power OFF and ON the drive to reset the protection REMARK when the IT LED becomes blinking it indicates the activation of the IT protection when the IT LED becomes steady illuminated it indicates the activation of an internal protection In this case please ask the Service Centers 4 1 9 Watchdog Indicated by DRIVE FAULT LED WTD LED optoisolated output DRIVE OK Set condition when the micro controller or DSP fails Effect inhibit torque Reset condition if the condition is not present anymore reset button on drive send pulse to REMOTE RESET 4 1 10 Overspeed Indicated by DRIVE FAULT LED optoisolated output DRIVE OK bit b5 of the FA string see FA command Set condition when an error between set speed and actual speed bigger than the programmed via EV command is detected Effect inhibit torque Reset condition if the condition is not present anymore reset button on drive send pulse to REMOTE RES
94. r the use of the motor in conjunction with the DBS drive is the shaft resolver Most CNC s though call for the incremental encoder signals For that reason internal hardware and software of the DBS produces simulated encoder pulses that is the pulses that a hypothetical encoder would produce The number of pulses per turn of this simulated encoder is programmable by the SE parameter AJ1SE lt CR gt reads the value of 1SE A 2SE lt CR gt reads the value of 2SE A SE lt CR gt reads the current active value of SE parameter AJ1SEn lt CR gt will set the new value of 1SE A 2SEn lt CR gt will set the new value of 2SE REMARK to enable a new SE value after setting and saving reset button on front panel or send pulse to REM Reset in the software versions before vers 11 the range was 0 128 pulses per electrical revolution 1 256 2 512 3 1024 4 2048 5 4096 6 8192 7 16384 From the software vers 11 0 the SE command is now transparent and compatible with the old versions i e 1024 ppr can be set with SE 1024 or with SE 3 The version of the software can be checked at the power up REMARK the DBS will not accept SE values incongruent with the RN parameter Derivation of the encoder signals from the position information coming from the resolver limits the maximum number of simulated encoder pulses according to the RN parameter that is the minimum resolution of the R D converter Atte
95. reads the current active value of RN and RX A 1RXnn lt CR gt will set the new value of 1RX A 2RXnn lt CR gt will set the new value of 2RX Range 10 12 14 or 16 bits Range protection YES Default motor dependent Password YES Second set YES See also Note RX must be gt RN If the value of RX attempted is lower than the current value of RN the error message will be transmitted and the new value of RX will not be rejected V 36 3 0ct 01 SA Selection of the drive address Range protection Default Password Second set See also The SA command is used for setting the drive address This command is related to the applications where DBS drives are used in a multidrop environment that is where unique RS485 serial link bus connects all the DBS drive in parallel and links them to the master Multidrop serial link protocol of the DBS drive allows for the parallel connection of up to 15 drives For the proper operation of this structure each drive must have generic address INITIAL SETTING At the default initialization which might be achieved by closing the drop G3P see par 2 7 1 the initial value of the address is A 1 Therefore after the default initialization the drive will respond to all commands in their shorter form without the drive address at the beginning of the command string Hence command strings such as 1SA will be accepted The drive will also accept all the commands in the
96. rect input voltage 400V or 460V has been set CAUTION it is recommended to disconnect the drive and the EMC filters to carry out the AC Voltage Tests of EN 60204 1 1997 par 19 4 in order to not damage the Y type capacitors between phases and ground Moreover the DC voltage dielectric test required by EN 50178 1997 product family standard has been carried out in factory as a routine test The DC Insulation Resistance Tests of EN 60204 1 1997 par 19 8 may be carried out without disconnecting the drive and the EMC filters CAUTION when required for an emergency stop opening U2 V2 W2 pins and closing motor phases to resistors must be preceded by disabling the axis The delay time must be at least 30 ms CAUTION in case of repetitive switching on and off wait 1 minute between off and on CAUTION the cooling circuit of DBS W120 240 must be kept clean Cooling media must not contain particles that may deposit causing obstruction to cooling circuit We recommend to check periodically cooling flow CAUTION do not exceed the tightening torque of the table but see proper data sheets for the tightening torque of input capacitors and power modules and see Section 2 of this Manual for the tightening torque of terminal blocks 177 0 l 1 3 Oct 01 CENELEC Memorandum N 3 EC DECLARATION OF CONFORMITY The undersigned representing the following manufacturer Moog Italiana S r l Electric Division Via Avosso 94
97. reference In other words when AC is different that zero any speed reference change will have a limited positive slope The slope limit allows the speed reference to be changed from zero to the MV value in AC milliseconds A 1AC lt CR gt reads the current value of AC AJ1ACnnn lt CR gt will set the new value of the AC parameter Range 10 to 999 ms or O disabled Range protection Default Password No Second set See also DE Fig 5 1 FIG 5 1 Acceleration Deceleration V 8 3 0ct 01 AL Select the analog input for the drive current limit The drive might have the current limit imposed by the software parameter IL the digital limit or the analog limit taken from the drive analog inputs The AL command will select the analog current limit The analog input might vary from 0 to 10 V and that will correspond to the current limit 0 100 of the drive peak capacity Syntax AJ1AL lt CR gt selects the analog input for the drive current limit See also DL Note the status can be interrogated via ST command bit b9 AP Command that starts the auto phasing procedure The correct operation of the drive calls for the exact knowledge of the spatial displacement between motor and resolver shafts The angular displacement ranging from O to 360 degrees corresponds to the parameter RS range of 0 65535 In order to measure this displacement in an automatic manner the auto phasing rout
98. resolver poles and the scaling constant 0 656 that is Speedfinternal to DSP 0 656 NP Speed rpm At the output of the speed controller the torque reference is generated The range of the internal number Tr 215 0 215 corresponds to the range of the output torque Tmax 0 Tmax The peak drive torque Tmax is the torque developed by the motor supplied by the DBS peak current EXAMPLE An example that brings the light to the KP and KI adjustment and the effect of these parameters on the drive behavior is given hereafter In the following analysis the filters in Fig 2 will be neglected for simplicity and the load torque will be considered zero If we assume that the drive peak torque that is the motor torque constant multiplied by the drive maximum RMS output is Tmax Nm the number of resolver poles is NP the total drive amp load inertia J kgm2 the closed loop gain of the speed loop can be derived from Fig 2 as NP T 00000537 00112 Po PA KI The speed controller closed loop transfer function will be W s Wop s LOA Wpp s Behavior of the closed loop system might be judged from the poles of the characteristics polynomial F s 1 Wpp s If we assume Tmax 7 Nm NP 8 J 0 001 kgm2 KP 80 default and KI 20 default the closed loop poles will be and will result in a well damped response and the speed loop bandwidth of approximately 17 Hz VI 3 3 Oct 01 The
99. rive analog circuitry the R D converter receives the SIN and COS signals detected in resolver windings and converts them into the digital word This digital word Digital 16 bit position in Fig 1 is fed to the digital signal processor As the received information that is the motor shaft position does not present the motor shaft speed it is necessary to process the input information in order to obtain a proper speed feedback Current Speed reference referencesPhase voltages Torque referenge Digital speed U T IGBT TY Dig vecto inverter E rotator with current lw MOTOR loop controller on TMS320C14 Speed observer 2882 R D PPren peca 16 bit CONVERTER reference Estimate LBS position N POLE RESOLVER Fig 1 Simple way to obtain the speed from the digital word representing the shaft position is by taking the first derivative Though due to the nature of the derivation and the environment of the drive brings in an unacceptable noise For that reason the speed signal is obtained from a reduced order speed observer The inputs to the observer are digital shaft position and the torque while the output is estimated ripple free shaft speed The input output transfer function of the observer is not a linear one and the order of the observer sub system is third Observer equations are executed each 100 ms For the purpose of analytical prediction of the drive behavior or eventua
100. rmally open Once the drive is installed it is normally in analog priority mode The major difference is that the former calls for 1ON and 10F commands on the serial link in order to switch the drive ON or OFF while the later switches the drive according to the opto isolated drive enable input signal When in keyboard priority the 1ON command turns the drive ON 10N and 10F commands will be prevented in analog priority mode and a warning message will be sent not Password NO Note to execute ON the drive must have the analog Drive Enable on conn J1 pos 15 the status can be interrogated via ST command bit b7 OV Set Read the analog velocity offset it allows to monitor and to set the analog offset of speed torque analog reference A fine adjustment of the analog offset can be done with successive steps by setting and monitoring the OV parameter Syntax A 10V lt CR gt reads the value of 10V A 10Vnnn lt CR gt will set the new value of the 10V parameter Range 0 no compensation 1 to 127 positive compensation 255 to 128 negative compensation Note this OV range is operative from DSP software version V11 from version V06 1 OV range was from O to 255 128 no compensation in previous versions the range was from 500 mV to 500 mV 0 no compensation V 26 3 Oct 01 PC Set Read the current level for 12T protection Software I2T protection performs the thermal si
101. rocessor or better Hard disk and one diskette drive You need 2 Mbytes of disk space and 512 kbytes of RAM CGA EGA VGA MCGA graphics card color VGA recommended MS DOS 6 2 or later ANSI SYS in CONFIG SYS e DBTALK PROGRAM CN5501 code The DBTALK program is available on floppy disk e INSTALL PROGRAM Insert diskette into drive A or drive B Type lt a install gt or lt b install gt The installation program will create the Directory C DBTALK will copy all the files in this new directory and will start the program e START PROGRAM after the first installation Type lt cd dbtalk gt Type lt start gt e MOVE IN THE PROGRAM Start the selected procedure Select the field Reread parameters Move up down Go to previous next screen Exit Go to previous menu I 22 3 Oct 01 e SELECT PROGRAM DBM linker DBS linker PDBS Linker see PDBS Application Manual gt Setup SELECTING DESIRED PROGRAM DBM LINKER DBS LINKER PDBS LINKER SETUP PROGRAM e SETUP to choose Language Italian or English gt Serial link COM1 or COM2 PROGRAM SETUP MENU E LANGUAGE SERIAL LINK ESC per Chiudere PROGRAM SETUP MENU ITALIANO ENGLISH ESC per Chiudere Comi at 3F8 como at 2F8 e UTILITY to Scan Baud rates ADDRESS AND BAUDRATE AUTOMATIC SCANNING Scan Faults 06 17 1996 AUTOMATIC FAU
102. roneous commands and wrong numerical values such as Protected by password Command not valid Parameter out of range fatal EEPROM PROCESSOR error messages which are emitted regardless the drive address Also in the cases when the drive self test fails the DBS will send the error message disregarding the drive address V 3 3 0ct 01 5 2 Commands Short summary of all the command mnemonics is listed below along with the brief description of each command Detailed description of the commands and their use is given in the following paragraph Tab 5 1 List of Commands 1 AC Set Read acceleration ramp time in ms units Select the drive current limit from analog limit input 3 _ AP__ Command that starts the auto phasing procedure 4 AR_ Select the reference from the Analog reference input 5 AS Addressshow S O 6 BR Set Read the Baud rate of the RS485 serial link 8 CP__ Reads the motor shaft position found at the startup time 9 CU Current loop offset compensation parameter for phase U 11 DE Set Read deceleration ramp time in ms units 12 DF Set Read the cutoff frequency of the digital filter 13 DI Inversion of the reference direction of the shaft rotation Select the drive current limit according to IL parameter 15 DR Select the digital reference the one set by 1VE 17 FA Read and attempt Reset of the drive FAULT flags 20 KI Set Read the integral gain of the speed
103. ructure of the digital speed controller built into the DBS drive comprises the digital second order filter This filter might process the speed reference or the speed error depending on the version of the control structure applied The damping factor of the filter is fixed to x 0 707 The cutoff frequency of this low pass filter might be set through the DF parameter A 1DF lt CR gt reads the value of 1DF A 2DF lt CR gt reads the value of 2DF A DF lt CR gt reads the current active value of DF parameter AJIDFnnn lt CR gt will set the new value of 1DF A 2DFnnn lt CR gt will set the new value of 2DF Range 0 to 255 Range protection YES Default Password YES Second set YES See also ND NF NW VS Tab 5 3 Filter Bandwidth DF Frequency DF Frequency DF Frequency DF Frequency 155 Hz 254 Hz 5 5Hz 70 77Hz 135 162Hz 200 262Hz 169 Hz 15 15Hz 80 90Hz 145 176Hz 210 280Hz 25 26Hz 90 102Hz 155 191Hz 220 297Hz V 14 3 0ct 01 DI Change the sense of rotation Function it allows to change the sense of rotation of the motor AJ1DI lt CR gt toggles the value of the status bit for the sense of rotation A DI lt CR gt toggles the value of the status bit for the sense of rotation The DBS does not respond to the command Hence the screen of the hand held terminal is not cleared and the command string DI remains within the display buffer Therefore
104. t CR gt will command the DBS to respond with a string REMARK the format of the status string is the following STb1b2b3 Eb4b5b6 Ib7 b8 b9 b10 b11 The meaning of specific bits is given below ST Status b1 Priority mode b2 DRIVE OK opto output 0 analog opto 0 fault condition b3 DPRAM status O OK E External b4 Analog Drive Enable 0 OFF b5 Reference Enable O OFF b6 A D status 0 OK Internal b7 Digital Drive Enable OF and ON commands 0 OFF b8 Reference AR and DR commands 0 analog b9 I LIMIT AL and DL commands 0 analog b10 Control TC and VC commands 0 speed b11 Rotation DI command 0 CW default V 40 3 Oct 01 gt eyboard K rrors detected O 1 1 1 D now oa OO Zz rrors detected D O Z digital digital torque CCW s E Cpe tou o ul SV Save the drive settings into non volatile memory All the drive parameters might be saved into the non volatile memory At the drive startup time or after each reset these parameters are recovered from the non volatile memory and used in the drive operation During the installation phase the drive parameters are set to the values best suited for the application After selecting preferred parameters itis necessary to use the 1SV command in order to permanently save parameter values AJ1SV lt CR gt will command the DBS to start the procedure of saving all the parameters into non volatile m
105. t present anymore reset button on drive send pulse to REMOTE RESET or send FA command 4 1 3 Motor over temperature Indicated by DRIVE FAULT LED M OVT LED optoisolated outputs DRIVE OK and MOTOR OK bit b2 of the FA string see FA command Set condition when a limit temperature is reached inside the motor Effect the drive inhibit torque Reset condition if the condition is not present anymore reset button on drive send pulse to REMOTE RESET or send FA command Notes the fault information via LED s and opto is reset when the motor temperature goes down the limit while the drive is disabled until the reset condition has been met 4 1 4 Power fault Indicated by DRIVE FAULT LED PWR FAULT LED optoisolated output DRIVE OK bit b3 of the FA string see FA command Set conditions 1 When a short circuit is detected between motor phases phase and ground phase and HV 2 When overcurrent is detected in motor phases 3 Overheating of power modules locked rotor condition 4 Undervoltage of internal supply of power modules Effect the drive inhibit torque Reset condition if the condition is not present anymore power off and on the power supply In case of condition 3 overheating wait at least 3 minutes before power up the drive IV 2 3 Oct 01 4 1 5 EEPROM error Indicated by DRIVE FAULT LED optoisolated output DRIVE OK bit b11 of the FA string Set condition when error in writing data into the
106. tal power rating is 33 W for DBS 100 240 and 55 W for DBS 180 320 2 3 3 DBS W120 240 Fans The card ventilation is provided by one fan mounted under the drive The other four fans under the drive are anti condensation devices and must be powered by the user via 24 Vdc 12 W inputs on J6 connector 5 minutes before start up After start up these fans can be powered off CAUTION the anti condensation fans of the DBS W120 240 must be powered on 5 min before start up Il 2 3 Oct 01 2 4 Led s Tab 2 1 Module Led s generic fault the fault can correspond according to the type to a LED on the front end if other red LED s are not on out of the considered one it is necessary to interrogate the drive via serial link to know the fault reason WTD reset Resolver fault signal resolver fault sin cos signals interrupted short RES FAULT circuit between signals or 10kHz carrier abnormal Red LED Motor overtemperature M OVT Red LED Module overtemperature Ed A PWR FAULT REF EN DRV EN IT AUX PWR when the IT LED becomes blinking it indicates the activation of the IT protection when the IT LED becomes steady illuminated it indicates the activation of an internal protection In this case please ask the Service Centers 2 5 Potentiometer Button Tab 2 2 Potentiometer Button LIMIT Peak current control POTENTIOMETER A full CCW rotation will set the current to zero A full CW rotation will set the current t
107. ter A 10Cnnn lt CR gt will set the new value of 10C A J20Cnnn lt CR gt will set the new value of 20C Range O to 255 Range protection YES Default Password NO Second set YES See also OV VO OF Command for switching OFF the drive power section The DBS drive might be set in keyboard priority mode by opening the G2P drop on the control board or in the analog priority mode achieved by closing the drop G2P During the installation phase G2P is normally open Once the drive is installed it is normally in analog priority mode The major difference is that the former calls for 1ON and 10F commands on the serial link in order to switch the drive ON or OFF while the later switches the drive according to the opto isolated drive enable input signal When in keyboard priority the 1OF command switches the drive OFF 1ON and 10F commands will be prevented in analog priority mode and a warning message will be sent not possible Password NO See also ON Note to execute OF the drive must have the analog Drive Enable on conn J1 pos 15 the status can be interrogated via ST command bit b7 V 25 3 Oct 01 ON Command for turning ON the drive power section The DBS drive might be set in keyboard priority mode by opening the G2P drop on the control board or in the analog priority mode achieved by closing the drop G2P During the installation phase G2P is no
108. the OF command to disable the digital drive enable 2 10 3 CNC Priority With CNC the following procedures must be followed 2 10 3 1 Setting Of Analog References To set the modules to use the analog references from the CNC it is necessary to enter the password to send the AR command and to save ST command can be sent to check if the commands have been accepted 2 10 3 2 Drive Enable With CNC Priority To give the priority for enabling and disabling the drive from the CNC it is necessary to close G2P jumper When the above procedure is completed the CNC is the master and the keypad is the slave as follows PARAMETERS MANAGED BY CNC drive enable reference enable speed references PARAMETERS MANAGED BY KEYPAD all dynamic parameters acceleration deceleration KI KP etc status and fault 2 10 4 Velocity Offset With analog reference AR sometimes the motor rotates also with REF EN 0 or with zero analog speed reference You can adjust this analog velocity offset via VO command for an automatic adjustment A fine adjustment can be done with successive steps via OV command REMARK the adjustment of the digital velocity offset is reserved to setup technicians Il 29 3 0ct 01 2 11 Resolver To Encoder Option For position sensing a resolver to encoder option simulated encoder is available Encoder signals are 7V 100 Q impedance as follows e 2 channels of square wave output with a resolution from 64 to 16384
109. the drive Automatic compensation of analog velocity offset 1 of 4 Velocity Structure structures of the speed controller selection 0 1 2 3 V 5 3 0ct 01 TAB 5 2 Standard Default Configuration MA ae ee G3P closed value value jac jo Jo Ja AL DL JDL Ja DR BR 9600 9600 mma BT UA ovjo o PC 100 seeTab54 PF 255 seeTab7 PG OO seeTa7 PH O seeTab7 PRH o 10 ES 2nd set not available Note with G2P closed and G3P closed only BR 9600 and SA 1 A are set V 6 3 0ct 01 REMARK S address letter see par 5 1 2 in all following command descriptions A symbol in command string stands for the drive address letter A O This address is optional for the drive address of A 1 As an option it is given between the brackets parameter set see par 5 1 3 in all following command descriptions the first character after the A symbol in command string stands for the parameter set 1 or 2 In the interrogation mode it is possible to use the character instead of 1 and 2 This means that for SPARE_IN OFF conn J1 pos 18 the first parameter set will be selected and for SPARE IN ON the second parameter set will be selected The availability of two sets of parameter is outlined in the second set row V 7 3 0ct 01 AC Set Read acceleration ramp time Acceleration parameter is used to limit the rate of change of the speed
110. tion code 00 standard 02 resolver interface Vin xxx V nominal three phase input voltage 3 phase 50 60 Hz lin XXX Arms nominal rms input current lout nom xxx Ams nominal rms output current lout max xxx A peak output current C1C2C3 Cy C pulses per electrical revolution C 64 D 128 E 256 F 512 G 1024 H 2048 1 4096 L 8192 M 16384 C gt motor poles A 2 B 4 C 6 D 8 E 10 F 12 C3 resolver poles A 2 B 4 C 6 D 8 E 10 F 12 C marker width A 1 B 1 2 C 1 4 D no marker 1 9 Dynamic Brake Unit Rating Plate The following informations are supplied on the Dynamic Brake Unit rating plate according to UL508C The Max Peak Current is the maximum current compatible with the recovery IGBT the Max Duty Cycle is the duty cycle tested according to UL508C DYNAMIC BRAKE UNIT Recovery Resistor Model Code Max Peak Max Duty Current Cycle DBS 3 9 to 8 22 134A 20 DBS 25 70 35 90 625A 16 DBS 100 240 192A 21 W120 240 180 320 16 3 Oct 01 SECTION 2 INSTALLATION CAUTION make sure that the correct input voltage has been set on the top panel Fig 2 1 400 460V Setting SWITCH CAUTION make sure that the correct FIG 2 2 P1 P2 Jumper wiring for DBS 3 9 6 15 8 22 15 42 has been set for recovery resistance on J5 connector check the jumper between P1 and P2 to use the internal recovery resistor standard braking or disconne
111. torque reference is further processed through the vector rotator see Fig 1 in order to obtain the references for the phase currents of the motor These references ly ly and ly in Fig 3 are calculated as multiples of the torque reference and the cosine function having the shaft position as the argument Torque referend Shaft position measured b resolver and R D conver Fig 3 The phase current references ly ly and ly obtained at the output of the vector rotator are fed to the DAC digital to analog converter Analog signals ranging from 10V to 10V are fed as analog references to the current controller The DBS current controller is implemented in the analog form The current references are compared with the measured phase currents and the current error is derived After processing the current error for each phase through the Pl gain block implemented in an analog form resulting signals are used to control the three phase inverter given in Fig 4 lu Iw do Vc Vb Va TE CKK R e si vde a e AT t Es Vc K va KK VI 4 3 Oct 01 The IGBT switches are controlled through the PWM method with the symmetrical triangular carrier That is the modulating signal is being fed from the output of the Pl block to the comparator that determines the sign of the difference between the modulating signal
112. ts of the year in which the CE marking was affixed 97 lla 2 Nov 2000 Walter Tettamanti GENERAL MANAGER DEC_SALE DOC MOD 176 PMA 4 96 2 3 Oct 01 CE Requirements e Cautionary Marking See previous page e Protection against electric shock Electronic Equipment intended for installation in closed electrical operating areas kept locked The lock shall be only opened by authorized person and the access only allowed to skilled persons whilst energized Where the equipment requires manual intervention 412 2 1 of HD 384 4 41 S2 shall be consulted e Fixed connection for protection The equipment may have a continuous leakage current of more than a c 3 5 mA or d c 10 mA in normal use and a fixed ground connection is required for protection e RCD A d c component can occur in the fault current in the event of a fault connection to earth Only a residual current operated protective device RCD of Type B is allowed When the protection in installations with regard to indirect contact is achieved by means of an RCD their appropriate function combination shall be verified e Climatic Conditions Equipment intended to operate within its performance specification over the range of Class 3K3 as defined in table 1 of EN 60721 3 1 EN 60721 3 2 EN 60721 3 3 EN 60721 3 4 partly modified e Pollution Degree 2 Installation The equipment shall be placed in a pollution degree 2 environment where normally only non conductive
113. ulting torque per amp ratio To counterbalance this phenomenon the current vector relative to the motor flux is advanced through PF PG PH PX PY and PQ parameters see the dedicated Section 7 The values PF 255 PG 0 PH 0 PQ 128 PX 128 and PY 255 disable the function Syntax AJIPY lt CR gt reads the value of the parameter AJ1PYnnn lt CR gt will set the new value of the parameter V 33 3 Oct 01 RN Set Read the lower R D resolution limit The R D converter resolution is switched on line in order to obtain the best possible overall drive performance At very high speeds the resolution is reduced in order to make possible the speed and the position measurement in a situation whence the number of revolutions per second is very high On the other hand at lower speed the resolution is increased automatically so as to reduce the measurement noise the ripple and to increase the precision of the motion control Hence the actual resolution of the R D converter will vary from 10 to 16 bit depending on the drive operating conditions Parameter RN might impose the lower limit of the R D converter resolution to a value higher than 10 bit This might be necessary in applications that utilize simulated encoder pulses produced by DBS When the resolution of simulated encoder is high reduction of the R D resolution cannot be permitted below certain level see SE command for more details Parameter RN exists in two parameter
114. ut 0 10V peak current limit tacho signal resolver signal output current signal 1 6 2 Digital full duplex RS485 serial link simulated encoder output optional CAN OPEN optional 1 6 3 On Off opto isolated drive OK motor OK drive enable motor enable 13 3 Oct 01 FIG 1 6 DBS Common Panel O POWER ok AUX PAR O DIT REF EN O O DRV OVT DRY EN O O PWR FAULT M OVT O O RES FAULT WTD O DRIVE FAULT RESET O O I uma J24 p i 24V IN 1 6Y INP COMMON DRIVE OK DRIVE OK MOTOR OK MOTOR OK SPARE OUT SPARE OUT DRIVE EN REF EN REMOTE RESET SPARE IN ov V 0 RESOLVER 14 3 Oct 01 1 7 System Grounding FIG 1 7 EMC Equipotential Bonding JOPONPUED SAjoejoId LUJOS uw juw sz Jojonpuog sagosjold uju 3d uw uw gt saq LX o000 gt 0 gt 4 o 1 s s a y uogosuuos DIN 1 SIquo Te y y e amar feuondo br 149A JOS9 1 sr J0 0UU er erstr O I sga wejs s SuunseesN ANIHOVIN J19HIW SAI JOSH OWA uw juw 94 feutuso 3d a NO Ieubis sindino elgeua Y eousisJeH vOnoauuoo wels s Buunseaw 13NI8V9 S INOY19413 l 15 3 Oct 01 1 8 Rating Plate The following informations are supplied on the rating plate of DBS CODE CNxxxxxx model code S N AASSNNNNYY serial number where AA year SS week NNNN progressive number YY op
115. v6012 2570 100 15 29 0 243 128 150 v6020 35 90 100 21 24 o 148 128 146 v8012 35 90 100 13 24 o 207 128 157 v8020 50140 100 23 19 o 189 128 160 po cm 7 23 19 o 145 128 168 V8 020 1 5mH 50 140 100 13 23 O 112 128 148 H5mH 60180 77 13 23 o 87 128 153 VII 5 3 0ct 01 Tab 7 4 Parameters Setting for 460V and 2 pole resolver FASTV DBS IL PF PG PH PY PX PQ FAS T0 C2060 3 9 100 13 19 O 163 128 157 c4060 39 100 13 23 0 140 128 159 c8060 615 100 21 24 0 204 128 163 a JESSE A FAST1C2030 3 9 100 8 47 0 145 128 154 c2060 615 100 21 24 0 204 128 163 c4030 615 100 12 44 0 245 128 216 c4045 615 100 14 31 0 235 128 172 lo 82 100 15 4 0 158 128 159 c6030 615 100 12 44 O 238 128 178 o PT epa 100 0 44 O 161 128 158 c6045 822 100 19 47 O 230 128 163 po 1542 88 11 35 O 120 128 164 c8030 615 100 12 44 0 245 128 181 po 2 100 10 39 O 166 128 152 C8045 1542 100 14 32 0 151 128 155 RA O DA A A O A AA FAST2C2030 8 22 100 9 55 0 143 128 152 C2045 1542 100 14 36 0 174 128 172 c4020 822 100 7 44 o 197 128 171 c4030 1542
116. y for command strings 1PW91 When the password status is ON the 1PW command will be interpreted as an attempt to set the password status OFF In this case the PW command does not have to have any argument the string 1PW lt CR gt will switch the password status OFF A 1PW91 lt CR gt will attempt to switch the password ON Wrong argument will be followed by access denied response Correct argument will provoke password on response If the password status was ON already at the time of the command execution the drive will respond password off and switch the password OFF A 1PW lt CR gt will switch the password OFF NO V 31 3 Oct 01 PX Parameter for the adjustment of Torque Speed curve Current loop of a typical AC drive suffers the phase lag at extremely high output frequencies speeds This lag reduces the resulting torque per amp ratio To counterbalance this phenomenon the current vector relative to the motor flux is advanced through PF PG PH PX PY and PQ parameters see the dedicated Section 7 The values PF 255 PG 0 PH 0 PQ 128 PX 128 and PY 255 disable the function Syntax AJIPX lt CR gt reads the value of the parameter A 1PXnnn lt CR gt will set the new value of the parameter V 32 3 Oct 01 PY Parameter for the adjustment of Torque Speed curve Current loop of a typical AC drive suffers the phase lag at extremely high output frequencies speeds This lag reduces the res

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