Digitax DBE140 User manual

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User Guide
DigitAx
AC Servo Drive
1.4kW to 22kW
Part Number: 0415-0008
Issue Number: 4

General information
The manufacturer accepts no liability for any
consequences resulting from inappropriate,
negligent or incorrect installation or adjustment of
the optional operating parameters of the equipment
or from mismatching the variable speed drive
(Drive) with the motor.
The contents of this User Guide are believed to be
correct at the time of printing. In the interests of a
commitment to a policy of continuous development
and improvement, the manufacturer reserves the
right to change the specification of the product or
its performance, or the contents of the User Guide,
without notice.
All rights reserved. No parts of this User Guide may
be reproduced or transmitted in any form or by any
means, electrical or mechanical including
photocopying, recording or by any information-
storage or retrieval system, without permission in
writing from the publisher.
Important...
Drive software version
This product is supplied with the latest version of
user-interface and machine-control software. If this
product is to be used in a new or existing system
with other DigitAx Drives, there may be some
differences between their software and the
software in this product. These differences may
cause this product to function differently. This may
also apply to Drives returned from a Control
Techniques Service Centre.
If there is any doubt, contact a Control Techniques
Drive Centre.
Use within the European Union, etc
The following information applies where the end use
of the Drive is within the European Union, the
European Economic Area, or other regions which
have implemented Directives of the European
Council or equivalent measures.
The Drive complies with the Low Voltage Directive
73/23/EEC.
The installer is responsible for ensuring that the
equipment into which the Drive is incorporated
complies with all relevant Directives.
The complete equipment into which the Drive is
incorporated must comply with the EMC Directive
89/336/EEC.
If the Drive is incorporated into a machine, the
manufacturer is responsible for ensuring that the
machine complies with the Machinery Directive
98/37/EC. In particular, the electrical equipment
should generally comply with European Harmonised
Standard EN60204-1.
Copyright © January 1999
Control Techniques Drives Ltd
Author: RFD
Issue Code: dgxu4
Issue Date: January 1999
S/W Version: V04.XX.XX

DigitAx User Guide
Issue code: dgxu4 i
Contents
1 Introduction 1-1
1.1 Case styles 1-1
1.2 Method of operation 1-2
1.3 How best to use this User Guide 1-2
2 Safety Information 2-1
3 Data 3-1
3.1 Model range 3-1
3.2 Ingress protection (IP and NEMA 1) 3-1
3.3 AC supply 3-1
3.4 Drive output 3-1
3.5 Ambient temperature and humidity 3-1
3.6 Derating 3-1
3.7 Starts per hour 3-1
3.8 PWM switching frequencies 3-1
3.9 Vibration 3-1
3.10 Serial communications 3-2
3.11 Resolver specification 3-2
3.12 Resolver resolution 3-2
3.13 Response times 3-2
3.14 Electromagnetic compatibility (EMC) 3-2
3.15 Frequency accuracy 3-3
3.16 Weights 3-3
3.17 Power ratings 3-3
3.18 Losses and efficiency 3-3
3.19 DC bus choke ratings 3-4
3.20 Dimensions 3-4
4 Mechanical Installation 4-1
4.1 EMC wiring recommendations 4-1
4.2 Planning the installation 4-2
4.3 Environment 4-4
4.4 RFI filters 4-4
4.5 Ferrite absorber ring 4-4
4.6 Ferrite rings 4-5
4.7 Control Keypad 4-5
4.8 Installing an external DC
braking resistor 4-6
4.9 Installing a DC bus choke 4-6
4.10 Heat dissipation in a
sealed enclosure 4-6
4.11 Heat dissipation in a
ventilated enclosure 4-7
4.12 Motor cooling 4-7
5 Electrical Installation 5-1
5.1 Hazardous areas 5-1
5.2 Access to the power connectors 5-1
5.3 EMC wiring recommendations 5-3
5.4 AC supply cables and fuses 5-8
5.5 Ground connections 5-8
5.6 DC bus choke 5-8
5.7 Protecting the Drive with line reactors 5-8
5.8 Connecting an internal or
external braking resistor 5-9
5.9 Example calculations for
a braking resistor 5-12
5.10 Control Keypad connections 5-14
5.11 Signal connections 5-15

DigitAx User Guide
Issue code: dgxu4
ii
6 Control Keypad 6-1
6.1 Models DBE140, DBE220, DBE420,
DBE600, DBE750, DBE1100S 6-1
6.2 Models DBE1500, DBE2200 6-1
6.3 Display and controls 6-1
7 Parameters 7-1
8 Programming Instructions 8-1
8.1 Displaying a parameter 8-1
8.2 Changing a parameter value 8-1
8.3 Saving parameter values 8-1
9 Security 9-1
9.1 Setting up a security code 9-1
9.2 Security access 9-1
9.3 Changing a security code 9-1
10 Getting Started 10-1
10.1 Setting jumpers 10-1
10.2 Setting parameter values 10-1
10.3 Protection parameters 10-2
10.4 PID parameters 10-3
10.5 Speed calibration 10-3
10.6 Resolver phasing 10-4
10.7 Commissioning 10-4
10.8 Calibration 10-5
10.9 Methods of speed control 10-6
10.10 Methods of torque control 10-7
10.11 Methods of position control 10-8
10.12 Quick reference 10-10
10.13 Programmable outputs 10-11
11 List of Parameters 11-1
11.1 Variable parameters 11-1
11.2 Bit parameters 11-5
11.3 Summary of default values 11-11
12 Trip codes and Fault Finding 12-1
12.1 Trip codes 12-1
12.2 Fault finding 12-2
13 Serial Communications 13-1
13.1 Introduction 13-1
13.2 Connecting the Drive 13-1
13.3 Serial communications connector 13-1
13.4 Serial communications configuration 13-1
13.5 Message structure 13-2
13.6 Messages from host to Drive 13-3
13.7 Write data to the Drive 13-3
13.8 Terminal mode 13-4
13.9 Parameters related to serial
communications 13-5
Appendix A PID Loop A1
A.1 Setting the PID gains A-1
A.2 Evaluating the PID gains A-2
A.3 Setting the bandwidth limit A-2

DigitAx User Guide
Issue code: dgxu4 iii
Declaration of Conformity
Control Techniques plc
The Gro
Newtown
Powys
UK
SY16 3BE
DBE140 DBE220 DBE420
DBE600 DBE750 DBE1100S
DBE1500 DBE2200
The DigitAx servo drive products listed above have
been designed and manufactured in accordance
with the following European harmonised, national
and international standards:
EN60249 Base materials for printed circuits
IEC326-1 Printed boards: general information for the
specification writer
IEC326-5 Printed boards: specification for single- and
double-sided printed boards with
plated-through holes
IEC326-6 Printed boards: specification for multilayer
printed boards
IEC664-1 Insulation co-ordination for equipment
within low-voltage systems: principles,
requirements and tests
EN60529 Degrees of protection provided by
enclosures (IP code)
UL94 Flammability rating of plastic materials
UL508C * Standard for industrial control equipment
*Applies to models DBE1500 and DBE2200 only
These products comply with the Low Voltage
Directive 73/23/EEC and the CE Marking Directive
93/68/EEC.
W. Drury
Technical Director
Newtown
Date: 11th November 1998
These electronic Drive products are
intended to be used with an
appropriate motor, controller,
electrical protection components and
other equipment to form a complete
end product or system. The Drive must
be installed only by a professional
assembler who is familiar with the
requirements for safety and
electromagnetic compatibility (EMC).
The assembler is responsible for
ensuring that the end product or
system complies with all the relevant
laws in the country where it is to be
used. This User Guide or the related
EMC Data Sheet should be referred to
for further information on the EMC
standards that the product complies
with, as well as for guidance on
installation.

DigitAx User Guide
Issue code: dgxu4
iv

DigitAx User Guide
Issue code: dgxu4 1-1
1 Introduction
1.1 Case styles
Eight DigitAx models cover the range of power
ratings. There are two styles and three sizes of case
which depend on the power rating of the model.
Size 1 and size 2 cases have ingress protection to IP20;
size 3 case to IP00
The model in the size 1 case is cooled by natural
convection. The models in sizes 2 and 3 cases are fan
cooled.
Figure 1–1 Size 1 case used on models
DBE140, DBE220
Figure 1–2 Size 2 case used on models DBE420,
DBE600, DBE750, DBE1100S
Figure 1–3 Size 3 case used on models
DBE1500, DBE2200

DigitAx User Guide
Issue code: dgxu4
1-2
1.2 Method of operation
Power circuits
The AC supply is rectified and smoothed to apply a
constant voltage on a DC bus. This DC bus supplies a
pulse-width modulated IGBT power stage that
delivers AC power at variable frequency and voltage
to the motor.
Depending on the model, an external DC choke is
required for the DC bus.
In order to enhance the braking capabilities of the
Drive, all but the two most powerful models have an
internal braking resistor, and all models can be used
with an external braking resistor.
When the recommended wiring techniques are used,
the Drive retains EMC compatibility.
Controlling the Drive
Operation of the Drive is controlled by programming
a number of software parameters. These parameters
have default values that enable the Drive to be run
without any initial programming.
The Drives have a Control Keypad which is located on
the front panel of the case. The Control Keypad is
used for the following:
To change parameter values
To stop and start the Drive
To display the operating status of the Drive
An RS485 serial communications port allows the Drive
to be controlled remotely using a host PC or plc.
Warning
Enabling the Drive when zero
speed reference is applied
can sometimes cause the
motor shaft to be rotated in
either direction by up to 10°°.
Even though all DigitAx
Drives are affected in this
way, only a small percentage
cause rotation in excess of
2°°. This effect is caused by
tolerances in the current
sensors.
The effect is usually of no
consequence when the
motor is driving a belt or
gearbox, but may sometimes
cause problems in
applications involving
material held in tension (eg.
film).
If the effect is likely to be
unacceptable for the
application, before installing
the Drive refer to this User
Guide for making just basic
AC power and signal
connections, and test the
Drive for the effect.
If necessary, obtain a
replacement Drive.
1.3 How best to use this
User Guide
This User Guide is arranged logistically: reading from
beginning to end will take you in the correct order
through the basic steps of installing the Drive and
getting it running with a motor.
To make subsequent adjustments to the parameters,
refer to Chapter 11, List of Parameters.

DigitAx User Guide
Issue code: dgxu4 Safety information 2-1
2 Safety Information
2.1 Warnings, Cautions
and Notes
A Warning contains information which is essential
for avoiding a safety hazard.
A Caution contains information which is necessary
for avoiding a risk of damage to the product or
other equipment.
A Note contains information which helps to ensure
correct operation of the product.
2.2 Electrical safety –
general warning
The voltages used in the Drive can cause severe
electric shock and/or burns, and could be lethal.
Extreme care is necessary at all times when working
with or adjacent to the Drive.
Specific warnings are given at the relevant places in
this User Guide and the accompanying User Guide.
The installation must comply with all relevant safety
legislation in the country of use.
2.3 System design
The Drive is intended as a component for
professional incorporation into complete equipment
or systems. If installed incorrectly the Drive may
present a safety hazard. The Drive uses high
voltages and currents, carries a high level of stored
electrical energy, and is used to control mechanical
equipment which can cause injury.
Close attention is required to the electrical
installation and the system-design to avoid hazards
either in normal operation or in the event of
equipment malfunction. System-design,
installation, commissioning and maintenance must
be carried out by personnel who have the necessary
training and experience. They must read this safety
information and User Guide carefully.
To ensure mechanical safety, additional safety
devices such as electro-mechanical interlocks may
be required. The Drive must not be used in a safety-
critical application without additional high-integrity
protection against hazards arising from a
malfunction.
2.4 Environmental limits
Instructions in this User Guide regarding transport,
storage, installation and use of Drives must be
complied with, including the specified
environmental limits. Drives must not be subjected
to excessive physical force.
2.5 Compliance with
regulations
The installer is responsible for complying with all
relevant regulations, such as national wiring
regulations, accident prevention regulations and
electromagnetic compatibility (EMC) regulations.
Particular attention must be given to the
cross-sectional areas of conductors, the selection of
fuses or other protection, and protective earth
(ground) connections.
This User Guide contains instructions for achieving
compliance with specific EMC standards.
Within the European Union, all machinery in which
this product is used must comply with the following
directives:
98/37/EC: Safety of Machinery
89/336/EEC: Electromagnetic Compatibility.
2.6 Safety of personnel
The STOP function of the Drive does not remove
dangerous voltages from the output of the Drive or
from any external option unit.
The Stop and Start controls or electrical inputs of
the Drive should not be relied upon to ensure safety
of personnel. If a safety hazard could exist from
unexpected starting of the Drive, an interlock that
electrically isolates the Drive from the AC supply
must be installed to prevent the motor being
inadvertently started.
Careful consideration must be given to the
functions of the Drive which might result in a hazard
through incorrect operation due to a fault or trip
(eg. stop/start, forward/reverse, maximum speed).
Under certain conditions, the Drive can suddenly
discontinue control of the motor. If the load on the
motor could cause the motor speed to be increased
(eg. hoists and cranes), a separate method of
braking and stopping the motor must be used (eg. a
mechanical brake).

DigitAx User Guide
Issue code: dgxu4
2-2 Safety information
Before connecting the AC supply to the Drive, it is
important that you understand the operating
controls and their operation. If in doubt, do not
adjust the Drive. Damage may occur, or lives put at
risk. Carefully follow the instructions in this User
Guide.
Before making adjustments to the Drive, ensure all
personnel in the area are warned. Make notes of all
adjustments that are made.
2.7 Risk analysis
In any application where a malfunction of the Drive
could lead to damage, loss or injury, a risk analysis
must be carried out, and where necessary, further
measures taken to reduce the risk. This would
normally be an appropriate form of independent
safety back-up system using simple electro-
mechanical components.
2.8 Motor
Ensure the motor is installed in accordance with the
manufacturer’s recommendations. Ensure the
motor shaft is not exposed.
2.9 Adjusting parameters
Some parameters have a profound effect on the
operation of the Drive and protection of the motor.
They must not be altered without careful
consideration of the impact on the controlled
system. Measures must be taken to prevent
unwanted changes due to error or tampering.

DigitAx User Guide
Issue code: dgxu4 3-1
3 Data
Warning
The voltages present in the
Drive are capable of
inflicting a severe electric
shock and may be lethal. The
Stop function of the Drive
does not remove dangerous
voltages from the Drive or
the driven machine.
AC supplies to the Drive
must be disconnected at
least 15 minutes before any
cover is removed or
servicing work is performed.
3.1 Model range
Model Case
size Nominal power
rating
Current
ratings
Inom Ipk
DBE140
DBE220
1 1.4kW
2.2kW
2.8
4.4
5.6
8.8
DBE420
DBE600
DBE750
DBE1100S
2 4.2kW
6kW
7.5kW
11kW
8.5
13
16
26
17
26
32
39
DBE1500
DBE2200
3 15kW
22kW
32
48
48
72
AC supply voltage: 380V to 460V
Maximum duration of Ipk: 4 seconds
3.2 Ingress protection
(IP and NEMA 1)
Model sizes 1 and 2 are rated at IP20. The cooling
fans for the heatsink are rated at IP20.
Model size 3 are supplied as a stand-alone unit in a
protective case having an enclosure specification
which is rated as IP00 (in accordance with the
IEC529) or NEMA 1. The cooling fans for the heatsink
are rated at IP20.
For Drives supplied in an IP00 case, a DC bus choke
(inductor) and an optional braking resistor should be
installed externally to the Drive. For Drives supplied
in a NEMA 1 case, a DC bus choke and braking resistor
are installed internally.
3.3 AC supply
Balanced 3-phase
50Hz –2Hz to 60Hz +2Hz
380V –10% to 460V +10%
3.4 Drive output
Maximum motor speed: 6000 RPM
Maximum output voltage:
Equal to the AC supply voltage
3.5 Ambient temperature
and humidity
Ambient temperature range:
–10°C to +50°C (14°F to 122°F) non-condensing
Local heat sources (such as other equipment) that
raise the air temperature above +50°C (122°F) must
be removed.
3.6 Derating
Maximum altitude without derating is 1000m
(3200ft). Derate full load current (FLC) by 1% for
each additional l00m (320ft).
3.7 Starts per hour
Drive
By switching the supply: 20 per hour
Electronic starts: Unlimited
Motor
Refer to motor manufacturer.
3.8 PWM switching frequencies
DBE140 to DBE1100S: 8kHz
DBE1500, DBE2200: 4kHz, 8kHz
3.9 Vibration
Conformance to the requirements of IEC 68–2–34

DigitAx User Guide
Issue code: dgxu4
3-2
3.10 Serial communications
RS485 half-duplex (RS422 can also be used)
Protocol: ANSI x 3.28–2.5–A4–N, positive logic
Timing
Write to Drive:
25ms at 9600 Baud
l5ms at 19.2 kBaud
Read from the Drive:
30ms at 9600 Baud
16ms at 19.2 kBaud
3.11 Resolver specification
Voltage 6V RMS
Frequency 10kHz
Primary Rotor
Number of poles 2
Transformation ratio 0.28 ±10%
Phase shift –14°nominal
Primary current 40mA nominal
Power input 120mW
Electrical error ±15 minutes
Impedance ZRO 73 + j129 Ω
Impedance ZSO 116 + j159 Ω
Impedance ZSS 95 + j162 Ω
Excitation winding
resistance 28Ω
Stator winding
resistance 18Ω
Temperature range –55°C to 155°C
–97°F to 240°F
Inertia 2.0gm2x 10–5
3.12 Resolver resolution
14-bit when Pr99 <3200 RPM
12 bit when Pr99 ≥3200 RPM
3.13 Response times
Scanning rate for speed loop 512µs
Scanning rate for current loop 128µs
Sampling time of analogue inputs 512µs
Rise time of digital outputs 10µs
Speed loop resolution 0.01%
Current loop resolution 10 bits
Speed loop bandwidth 320Hz
Current loop bandwidth 2kHz
Max delay of STOP input 15ms
Max delay of limit switch input 2ms
Max delay of external trip input 5ms
3.14 Electromagnetic
compatibility (EMC)
When all the following conditions are met, the
installation can meet the requirements for
conducted emissions of EN50081-2:
The specified RFI filter (or ferrite absorber ring
and capacitor network) is used
The recommendations for the wiring
arrangements are followed
The motor cable passes through a pair of ferrite
rings (as specified)
Immunity
In accordance with IEC801 without significant
disturbance to operation at the following level:
Part 4 (Transient Burst) Level 3

DigitAx User Guide
Issue code: dgxu4 3-3
3.15 Frequency accuracy
Output frequency is within 100ppm of the
demanded frequency.
3.16 Weights
The weights of the most powerful model in each
model size are as follows:
Model size 1: 5.5kg (12lb)
Model size 2: 9.5kg (21lb)
Model size 3: 22.3kg (49lb)
3.17 Power ratings
Note
Power ratings are for typical 3-phase
6-pole DutymAx motors.
Displacement factor (fundamental power
factor) at input closely approximates to
unity, but is dependent on supply
impedance.
400V nominal supply voltage
3.18 Losses and efficiency
Note
Figures quoted are at maximum
output power.
Model Total power loss Efficiency
at 460V
4kHz
(100%)
8kHz
(100%)
4kHz 8kHz
W
W
% %
DBE140
105
93.0
DBE220
145
94.4
DBE420
220
95.0
DBE600
310
95.1
DBE750
385
95.1
DBE1100S
510
95.5
DBE1500 436
564
97.1 96.4
DBE2200 623
827
97.2 96.4
Model Output Motor
rating Input
100%
rms
Current
(DutymAx) 100%
rms
Current
100%
fundamental
ANm A A kVA kW
DBE140 2.8 4.5 5.3 4.0 3.7 2.8
DBE220 4.4 7.0 7.8 6.3 5.4 4.4
DBE420 8.5 13.6 8.8 10.6 6.1 7.3
DBE600 13 20.8 13.1 15.2 9.1 10.5
DBE750 16 25.6 15.4 19.7 10.7 13.6
DBE1100S 26 41.6 23.7 30.5 16.4 21.1
DBE1500 32 51.2 29.7 39.0 20.6 27.0
DBE2200 48 76.8 44.9 57.5 31.1 39.8

DigitAx User Guide
Issue code: dgxu4
3-4
3.19 DC bus choke ratings
DC bus chokes are fitted internally on the DBE420 to
DBE1100S drives. No DC bus choke is needed for
models DBE140 and DBE220.
Ripple frequency = 6 ×supply frequency
Ratings and values quoted are design minima.
Drive
model Choke ratings Weight
mH ARMS Apk kg lb
DBE1500 1.50 45 85 6.4 14
DBE2200 0.70 75 143 8.4 19
3.20 Dimensions
Refer to the following diagrams.
Heated air exhaust
Mounting brackets
Position for
through-panel mounting Position for
surface
mounting
Model
size 1
DBE140
DBE220
Model
size 2
DBE420
DBE600
DBE750
DBE1100S Mounting bracket detail
Figure 3–1 Dimensions of model sizes 1 and 2 (See table on opposite page)

DigitAx User Guide
Issue code: dgxu4 3-5
Dimension Model size 1
DBE140, DBE220
Model size 2
DBE420, DBE600
DBE750, DBE1100S
mm in mm in
Height of case h 352 137/8352 137/8
Width of case w 78.5 31/16 127 5
Overall depth d 323.5 123/4328.5 1215/16
Depth of heatsink p 95 37/8100 315/16
Width of heatsink g 62 27/16 109 45/16
Height of heatsink e 332 131/16 330 13
Mounting centres
top bracket to bottom bracket a 359.4 141/8359.4 141/8
Mounting centres of mounting
bracket f45 1
3
/
477 31/16
Height of aperture for
through-panel mounting 334 131/8332 131/16
Width of aperture for
through-panel mounting 64 21/2111 43/8
Fixing hole diameter 4mm (3/16ins) clear

DigitAx User Guide
Issue code: dgxu4
3-6
Heated air exhaust
Model
size 3
DBE1500
DBE2200
Mounting
plate for
through-panel
mounting
Mounting plate
for surface
mounting
Model size 3
Mounting bracket detail Model size 4
Mounting bracket detail
Figure 3–2 Dimensions of model size 3 (See table on opposite page)

DigitAx User Guide
Issue code: dgxu4 3-7
Figure 3–3 Clearances required around
the Drive
Dimension Model
size 3
DBE1500
DBE2200
mm in
Height of case h 490 195/16
Width of case w 330 13
Overall depth d 283 113/16
Depth of heatsink p 139 51/2
Height of heatsink e 466 185/16
Width of heatsink g 295 115/8
Total height of mounting plates b 522 209/16
Mounting centres
top to bottom a 502 193/4
Mounting centres f 248 95/16
Height of aperture for
through-panel mounting 468 181/2
Width of aperture for
through-panel mounting 296 115/8
Fixing hole diameter 6mm (1/4in) clear

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