Emotron DIETZ GSV 544 400 Series User manual

DIETZ GSV 544X-xxx/400
12.04.07 Emotron AB g444_04e.doc
DIETZ GSV 544X-xxx/400
Current Converter For Brush-Type
DC Motors
Attachment
Operating Instructions
DIETZ DSV 5444, DSV 5445 Lift
Edition 04/07
Subject to technical modifications
(Interim)

DIETZ GSV 544X-xxx/400
Seite 2 Emotron AB 12.04.07
Dear customer / user,
System DSV 5445 - Lift offers you a high-quality, modern and very powerful drive concept for old
and new lift and lifting gear systems.
The field oriented system DSV 5445 - Lift can power all common winch types (both with and with-
out gearing and independent of synchronous or asynchronous technology).
The customer/user should read these instructions carefully and should have understood them be-
fore starting work.
The following products:
GSV 544X ; DSV 5445 ; DSV 5452 ; DSV 5453 ; DSV 5445/5453-Plus-series
KD 915 , KD 920 ; Fine HF-SET 93251340268 (DSV 5452 incl. movable cubicle) ;
Brake resistors 4...40 Ohm (Type Cressall, Frizlen, Danotherm),
comply with the following directives and standards:
Low voltages directive 73/23/EWG - amendment 93/68/EWG - EMC directive 89/336/EWG, amendments
92/31/EWG and 93/68/EWG, incl. actually EMC directive 2004/108/EG
including the appropriate amendment directives up to date of drawing.
The following standards are used:
EN 60204-1 1998-11 IEC 61000-3-2: 2002-12 EN 55011: 1998
EN 61800-3 pr A.1.1 1999 IEC 61000-3-2/A1: 1997 EN 55011/A1: 1999
EN 61800-3 pr A11 ; 1999 IEC 61000-3-2/A2: 1998 EN 55011/A2: 2000
EN 61800-3 2002-04 EN 61800-2 1999-08 EN 61800-4 2003-08
EN 12015 2004 EN 12016-08 1998 VDE 0660 Part 500 (IEC 439, EN 60439)
EN 61800-6-3 2002-08 EN 55011B (basic emission standards) incl. IEC801 Part 1-5
VDE 0875 Part 11 2003-08 EN 61000-6-3/AA 2004-07 EN 61800-1 1999-08
Optional on request : EN 954-1 part EN 61508 (not for all products available).
The declaration covers the modules and units delivered by us, but the user must ensure that the machine
complies with the directives applicable to the end product after mounting or installation.
Following the IEEE915 directive line reactors of 4% uk minimum are needed, further information or special
solutions will be projected and quotated on request.
Emotron Lift Center GmbH
Max-Planck-Straße 15
D 72639 Neuffen
Telefon: ++49 (0)7025/101-0
Telefax: ++ 49 (0)7025/5824
eMail: [e-mail]
http://www.emotron.com
(alt) eMail: inf[email protected]
(alt) http://www.Dietz-electronic.de

DIGITAL DC-DRIVE GSV 544X-xxx/400
12.04.07 Emotron AB Seite 3
List of contents
1Introduction 5
2Safety Notice 6
3Technical data 7
3.1 Type code GSV 544x: 7
3.2 Electrical data 7
3.2.1 Power connection and accessories 8
4Power connection 9
4.1.1 Power connection armature circuit with drive contactors for lift applications 10
5Parameter overview 11
5.1 Operating instruction GSV 544X-xxx/400 11
5.1.1 WinDietz 1.19 hints 11
5.2 Software package 11
5.2.1 Standard application GSV.KOM 11
5.2.2 Lift DC standard GSV50MHZ.KOM 11
5.2.3 Shelf access equipment conveyor technique GSVNIKE.KOM / GSVRBG.KOM / GSVDIG.KOM 11
5.3 Description of inverter equipment options 11
5.4 Overview parameters and variables standard 12
5.5 Overview parameters and variables lift 15
5.6 Explanations of parameters 18
5.6.1 "F0" armature excitation 18
5.6.2 t rotor time constant 18
5.6.3 First initialisation flag 18
5.6.4 Commutating limit parameters F1, F2 and variables 0E6A, 0E6E 19
6TIPS, TRICKS 20
7Hotline note 22
8Technical data for 

enquiry 

order 23

DIETZ GSV 544X-xxx/400
Seite 4 Emotron AB 12.04.07
Explanations of terms:
Nominal device current The current that is available at the device output, taking the operating
time into account.
Dynamic output current The current that is available at the device output for approx. 60 sec-
onds. Declaration normally in %.
Maximum rotational speed nmax Maximum rotational speed at nominal current, as stated on motor rat-
ing plate.
Nominal rotational speed nNRotational speed at maximum current, as stated on motor rating plate.
Field excitation Field current, field voltage; as stated on motor rating plate, can be set
with parameters.
Armature nominal voltage Nominal voltage of armature at nominal excitation and nominal rota-
tional speed. Range for supply voltage 400V 3AC: 400-460 V DC
Armature excitation Preset value actually "25"
Rotor time constant Motor parameter that determines the motor torque
(between 25...250 ms, ex works preset to 100 ms.
PBrake Continuous power of the braking resistor
Load capacity Permitted payload of the lift car in kg.
vmax Maximum speed of the lift car in metres per second.
ηGear Efficiency of the employed gear (value smaller than 1)
Characteristic factor Specific value for the employed motor, actually: "700"
Lifting height Maximum height of the lift hoist way
Start delay Specifies the time in seconds between opening the brakes and start of
travel.
Braking delay Specifies the time in seconds before the brake closes.
OFF delay Time for motor demagnetisation before motor contactors are open.
Stopping distance EH Distance that the lift car travels after reaching the level signal.
Braking ramp B Characteristic of braking gradient.
Run-up ramp HL Characteristic of run-up gradient.
Starting jerk Caused by static friction or mechanical "adhesion" during starting.
suspension Determined by the number of guide pulleys in the lift hoist way.
Translation ratio Gear reduction number.
Number of gear ratios Gear reduction number.
E.g. Declaration on gear 56 : 2 →reduction 56, →number of gear
ratios 2
1 Vpp – encoder type High quality encoder whose output signal has a sinusoidal profile with
a peak-to-peak value of 1 volt. (4 tracks)
TTL encoder type Encoder of average quality with transistor-transistor logic, i.e. output
signal has a rectangular shape and supply voltage is usually 5 V DC.
(4 tracks)
HTL encoder type Encoder of inferior quality with high-transistor logic, i.e. output signal
has a rectangular shape, but supply voltage is up to 30 V DC. (2
tracks, cannot be monitored)
Tracks Number of encoder signals that are displace by 90 ° to each other.

DIETZ GSV 544X-xxx/400
12.04.07 Emotron AB Seite 5
1 Introduction
Inverter for brush-type DC motor with IGBT-inverter technology:
♦ Speed-, position-, torque control without dead times of a thyristor controller.
♦ Armature- and field current control (2,5 - 12 kHz) PWM avoids alternating torques.
♦ Special pulse-width modulation method (2,5 -12 kHz) for «whisper-silent running», no speed
dependent noise.
♦ Conservation of motor winding without additional choke by dv/dt limitation, therefore also suit-
able for converting existing systems.
♦ High efficiency ≥97% at 65% duty cycle (<45º ambient temperature, 10 kHz).
♦ High control performance and optimum concentricity using field oriented current control with
typically 65536 points per motor revolution. All common encoder types and number of pulses
per revolution are possible.
♦ Braking energy dissipated using commercially available resistor cage or using "cos phi = 1"
energy recovery unit. No mains reactive power.
♦ Emergency evacuation possible with UPS or battery supply (option).
♦ Optimum factory presetting, very simple operation using customised menu. Lift data like sus-
pension, translation, number of gears and driving wheel diameter can be input in current physi-
cal units. Automatic fine control using fuzzy controllers.
♦ One inverter for all brush-type DC motors: gearless, epicyclical gear, hypoid gear, worm gear,
V-belt and even hydraulic drives are possible!
♦ The devices handles lift speeds up to 6.0 m/s and supplies all necessary signals for commer-
cially available lift controllers. Constantly reproducible levelling control is possible to within < 0.5
mm with direct approach.
♦ No problems with CE and EMC directives when patented AddOn filter technology is used.
♦ Optimum data administration using project-linked data storage with PC/laptop. Updates guaran-
teed to be compatible with preceding releases.
♦ Standardised lift program (also for digital integral shaft copy)
♦ Unique encoder evaluation process (65536 increments per revolution) guarantees quiet motor
operation even at slow speeds!
♦ Software package 1 GSV.KOM (menu navigation GSV_D.CNF resp. GSV_E.CNF ) for stan-
dard applications with analog and/or digital default set point with GSV 5444-xxx/400
♦ Software package 2 GSV50MHZ.KOM (menu navigation LIFTGSV.CNF ) is a lift program for
system GSV 5445 to operate high- and low speed DC winches with or without gear.
♦ Software package 3 GSVNIKE.KOM / GSVRBG.KOM / GSVDIG.KOM (menu navigation
GSVNIKE.CNF / GSVRBG.CNF / GSVDIG.CNF) system GSV 5444-xxx/400 for shelf access
equipment modernisation is projected.

DIETZ GSV 544X-xxx/400
Seite 6 Emotron AB 12.04.07
2 Safety Notice
 The installation, commissioning and parameter configuration may be performed only by quali-
fied personnel, who have thoroughly read and understood these commissioning instructions.
 The technical documents and program versions issued by the manufacturer must always be
used for commissioning.
 The unauthorised removal of parts of the enclosure, improper use and incorrect installation or
operation can cause fatal or serious injury and material damage.
 Set before first initialisation or reconnection the first initialisation -flag (E60)
 The inverter DC-DRIVE GSV 5444-xxx/400 is only for operating DC drives. Other electrical
consumers are prohibited! Otherwise there will be danger of live and material damage.
 Commissioning, i.e. the commencement of operation for the intended purpose, is permitted
only subject to the applicable EMC directives.
 Oil lubrication in a power or force transmission systems with an oil-filled gear casing (geared
motor) or reduction gears can deteriorate during operation at low speeds. Information on the
permissible continuous speed range must be obtained from the gear manufacturer.
 Armature-, field current and encoder have to be the same sense of rotation.
 If reactive power compensation equipment is installed in the power mains, it is to be checked
for correct function.
 If earth-leakage relays are employed, their sensitivity should be 300 mA or more per converter.
The earth-leakage relays must be suitable for pulsed DC currents.
 Check the required motor current at all speeds after completing commissioning (current meas-
urement or evaluation of terminal A6).
 This short manual is only in conjunction with the corresponding operating instructions
for three phase drives valid. There you can find also how to operate this drive and the
pin assignment of the input/output clamps.

DIETZ GSV 544X-xxx/400
12.04.07 Emotron AB Seite 7
3 Technical data
3.1 Type code GSV 544x:
GSV 544X - 40 / 400
Nominal supply voltage [V]
Nominal device current [A]
-4 GSV normal; -5 GSV lift
Type key
3.2 Electrical data
♦ Typical input voltage range: 3 ×400V ±10 % TT-, TN-system
(3 x 500V .+5%/-15%) TT-, TN-system (option)
(1/3 x 230V ±10 % ) TT-, TN-system (option)
Other connection voltages and/or IT system on
request
♦ Power mains frequency: 50...60 Hz ± 5 %
♦ Control voltage for fans from 80A-DSV: 230V +5, -15 %
♦ Control voltage PLC level: +24V ±15 %
♦ Typical power factor: >0,97
♦ Armature voltage: 0...460 V at Un 3AC 400 V
♦ Field voltage: 0...460 V at Un 3AC 400V
♦ Field current: 0...10 A (option 0-25A) controlled
♦ Pulse frequency adjustable: 2,5...12 kHz
♦ Typical du/dt: < 1 kV/µs (with AddOn - filter)
♦ Dynamic output current (Idyn): 150 % (200% size 1 10A)
♦ Duty cycle: 100 % at 2,5 kHz PWM
65 % (50%) at 10 kHz (12 kHz) PWM
♦ Control range (encoder 1Vpp): 1:32000
♦ Field suppression mode: 100...200%
♦ Default set point: digital, analog SPS, bus
♦ Fixed speeds Lift 7TZ: 6
♦ Speed thresholds: 3
♦ Protection class: IP 20
♦ Ambient temperature: 0 ... 40 °C
Power decrease from 40 °C at 1,5 % per 1 °C (maximum up to 55 °C)
♦ Storage temperature: -20 ...70 °C
♦ Humidity rating E to DIN 40040
♦ Installation altitude up to 1000m, thereafter power reduction 6% per 1000m

DIETZ GSV 544X-xxx/400
Seite 8 Emotron AB 12.04.07
3.2.1 Power connection and accessories
GSV 5444 Idyn [A]
Output
power
[kW]
Power-
loss [kW
Rec.
motor type
power
[kW]
Network-
fuse
RFI motor
filter
Addon
Line reactors
Conductor
cross-section
mains/motor
lines
Brake resistor
cable cross-
section
10 20 4,6 0,19 3,0-5,0
3 ×16 AT Size. 1 3 ×1,5 mH
(16A) 1,5 mm² * 41 Ω/ 450 W 2. x.1,5 mm²
20 30 9,2 0,41 6,5-11
3 ×25AT Size. 2 3 ×0,7 mH
(35A) 2,5 mm² * 41 Ω/ 1 kW
2. x.1,5 mm²
30 45 13,8 0,58 9,0-15,0
3 ×50 AT Size. 3/0 3 ×0,7 mH
(35A) 4,0 mm² * 18,8 Ω/ 2 kW
2. x.2,5 mm²
40 60 18,4 0,75 15,5-21,5
3 ×63 AT Size. 3/1 3 ×0,5 mH
(50A) 6,0 mm² * 18,8 Ω/ 2 kW
2. x.2,5 mm²
60 90 27,6 1,2 22,0-29,5
3 ×80 AT Size. 3/3 3 ×0,3 mH
(80A) 10 mm² * 14,4 Ω/ 4 kW
2. x.2,5 mm²
80 120 36,8 1,5 30,0-44,5
3 ×125 AT Size. 4/2 3 ×0,25 mH
(100A) 25 mm² * 14,4 Ω/ 4 kW
2. x.2,5 mm²
120 180 55,2 2,25 45,0-65,0
3 ×160 AT Size. 4/3 3 ×0,18 mH
(130A) 35 mm² * 13 Ω/ 6,5 kW
2. x.4,0 mm²
150 225 69,0 3,0 55,0-75,0
3 ×200 AT Size. 5 3 ×0,12 mH
(200A) 50 mm² * 10 Ω/ 6,5 kW
2. x.4,0 mm²
200 300 92,0 4,0 65,0-110,0
3 ×250 AT Size. 5 3 ×0,12 mH
(200A) 70 mm² * 6,5 Ω/ 11 kW
2. x.4,0 mm²
250 375 115,0 5,0 90,0-132,0
3 ×250 AT Size. 5 3 ×0,10 mH
(250A) 70 mm² * 6,5 Ω/ 11 kW
2. x.4,0 mm²
Motor type [KW] The above mentioned data are suitable for armature nominal voltage of 460V
DC.
Network fuse The type "gL" can be used for the network fuse. In case of using semiconductor
fuses the nominal current has to be increased.
Line reactors Depending on the operating time, mechanical and electrical specifications of the
system the nominal data of the line reactor can drift.
Conductor cross-
section
Field current
The given cross-sections are standard values regardless the ambient conditions,
used cable types and network fuses. Because of this the cross-sections can vary
depending on the applicable regulations.
0 - 10 A 1,5 mm² 0-20 A 2,5 mm²
Brake resistor The dimensioning of the brake resistor has to be verified by means of the lift data!

DIETZ GSV 544X-xxx/400
12.04.07 Emotron AB Seite 9
4 Power connection
Driving via interface only if required.
Bridge the clamps 23 and 24 if thermistor is connected to external controller.
Connect varistor to brake magnet.

DIETZ GSV 544X-xxx/400
Seite 10 Emotron AB 12.04.07
4.1.1 Power connection armature circuit with drive contactors for lift applications
The modern IGBT-based drive technology combined with old DC machines provides an excellent ride quality
at maximum efficiency.
But a few things need to be taken into account if you want the system to operate with the usual reliability for
many years to come. Especially the often very low armature voltage and the electric strength of all windings
against earth must be taken into consideration. There are only a few products able to stand the intermediate
circuit voltage or high du/dt of modern inverters.
When the armature voltage is distinctly below 300V, an isolating transformer is usually required upstream of
the inverter which also assures the electric strength against earth.
High-quality-contactors need to be provided in the armature circuit which in emergencies (i.e. high DC current
and high DC voltage) can interrupt the supply of energy to the armature circuit. But the contactors no longer
need to be dimensioned to provide a steadily recurring isolation under load. The power varistor of the DC
motor armature is a particularly important component as it prevents the collector from being damaged when
the safety circuit is opened. Depending on the performance of the motor, the varistor has a tablet size be-
tween 40 and 80 and a voltage matching the effective intermediate circuit. An inverter with a 3AC 230V net-
work therefore requires a 300V varistor at the armature winding (e.g. type SIOV B60K300).


There must be no contactor in the field circuit. There are only two contactors in the armature
circuit, the three pairs of contacts of which are each connected in series in the below exam-
ple.
Non-binding switching proposal for the power circuit (R3 = 2kΩ0,5W carbon film):