Vickers DBM Series User manual

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DBM 03
User's Manual
GB-4019 Rev.8 - May/97
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DBM 03 - USER'S MANUAL
Rev
.Date Description Updated Pages
0June/95 Initial Release
122/June/9
5Correct miscellaneous errors 52, 84, 111
26/July/95 Correct miscellaneous errors 7, 27, 28, 29, 33, 66, 68, 84,
86, 91
328/Sept/9
5Correct miscellaneous errors 55, 73, 83, 94
424/Oct/95 Add facilities to change DBM01 with DBM03 52
56/May/96 Add reference to DBTALK program and
pinouts of RS232/RS485 converter; correct
OC, OV, VO commands; update personality
card; add DBM-PS internal card jumpers;
correct miscellaneous errors
7, 28, 33, 48, 49, 50, 51, 52,
63, 79, 80, 87, 90, 121
630/July/9
6Add EMC paragraph; update motor connector pinout (Fig.1.13); correct soft start
configuration (Fig.2.1, 2.2); update resolver
wiring (Fig.2.3) according to EMC; correct
miscellaneous errors
1, 3, 5, 8, 33, 35, 42, 44, 46,
61, 86
76/Feb/97 Add Section 6 (EMC); change par.1.6 (CE-
marking); update all wiring figures according
to EMC; add Appendix A (serial link
multidrop); add Appendix B (Dbtalk
communication program); update par.2.2.7
(personality card); correct miscellaneous
errors
1, 2, 5, 6, 8, 13, 24, 27, 29,
30, 31, 34, 35, 38, 45, 46, 48,
49, 52, 56, 75, 82, 85, 88,
123, 124,125, 126, 127, 128,
129, 130, 131, 132, 133
823/May/9
7Update standards with EN 61800-3, EMC product standard; correct fig.6.8
(EMC/Equipotential bonding); update 220Vac
with 230Vac; correct tab.3.5 (IT/PC); correct
the leakage current of EMC filters; correct
miscellaneous errors
3, 5, 6, 8, 9, 11, 25, 37, 42,
43, 44, 48, 49, 52, 56, 57, 72,
75, 98, 99, 101, 105, 123,
125, 128, 129, 132, 133
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1 - 23/May/97
Table of Contents
Introduction page 3
Section 1 general features 5
Description standard features 5
technical data 6
interfaces 7
protections 7
CE marking 8
system wiring 8
configurations 8
internal jumpers 13
dimensions 36
fans 37
recovery circuit 37
block diagrams 39
Section 2 wiring 43
Installation transformer/autotransformer connection 43
soft start 45
resolver wiring 47
motor power wiring 47
connection to PC 48
installation 48
keyboard or opto priority 49
autophasing 49
personality card jumpers 52
resolver to encoder (optional) 53
operation 57
Section 3 general features 58
Commands and commands 60
Protections protections 92
Section 4 98
Troubleshooting
Section 5 introduction 114
Principles of torque generation 114
Operation current control loop 117
speed and position sensing 119
speed loop 121
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2 - 23/May/97
Section 6 European Directive 123
EMC filtering 123
wiring and grounding 126
recovery resistor 128
screening 129
safety aspects 130
Appendix A internal jumpers 131
Multidrop personality card jumpers 131
Appendix B dbtalk communication program 132
Dbtalk
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3 - 23/May/97
Introduction
This manual provides the necessary information for a proper installation and an effective use
of DBM Digital Drives in the possible different configurations.
Its contents allow technicians to understand how the system works and to carry out
installation procedures.
The safety instructions provided in this Manual are included to prevent injury to personnel
(WARNINGS) or damage to equipment (CAUTIONS).
To emphasize the differences between new DBM 03 User's Manual and old DBM 01 User's
Manual, a vertical line in the left margin of the text indicates new items.
Accident Protection
Keep to the general security rules for electrical equipments. DBM-PS power supply is
electrically connected to mains.
WARNING: L+ and L- pins and BUS BAR can have voltage ≥ 300Vdc even after
switching off (capacitive voltage). Discharge Time Approx. 6 Minutes.
WARNING: do not touch recovery resistor during operation to avoid scalds.
Ventilated enclosures containing dynamic braking resistors shall
provide a degree of protection of at least IP22 (according to
EN 60204-1, par. 13.3).
WARNING: when required for an emergency stop, opening motor phases must
be preceded by disabling the axis. The delay time must be at least
30 ms.
WARNING: the drive should be located in an environment that is free from dust,
corroding fumes and fluids. In condensating atmospheres, the
cabinet must be provided with an anti-condensation device.
Tightening Torque
CAUTION: do not exceed the tightening torque of the table
Screw Tightening torque
Thread [Nm] [lb in]
M3 1.20 10.62
M4 3.00 26.55
M5 6.00 53.10
M6 10.0 88.50
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4 - 23/May/97
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SECTION 1 - DESCRIPTION
1.1 General Features
The modular DBM series drives offer digital speed loop and digital analog interfaces. They
are suitable for use with 4-quadrant, brushless motors having sinusoidal back e.m.f. .
Construction allows the use of the power amplifiers only, if required for easy CNC interface.
Hardware circuits are reduced by using Isolated Gate BipolarTransistor (IGBT) components
in the power section.
Control technique is sinusoidal.
The unique advantages of the digital technology (16/32 bit DSP based) are:
•Simplified installation through optimization of control parameters via software.
•No potentiometer adjustments.
•Autophasing.
•Easy adaption to different applications: e.g. you may change the PI gain variables and
choose between speed or torque control.
•Compact assembly: up to 3-axis control from a single module.
•Flexibility: up to 99 axes, 240A peak per axis.
1.2 Standard Features
•Three-phase full bridge with IGBT
•Current reference refresh time: 100 µs
•Phases refresh time: 300 µs
•R/D resolution automatically switched according to actual speed for optimum system
performance (between 10 and 16 bit)
•Resolution of A/D converter: 12 bit or 14 bit (optional)
•4 different velocity control structures to meet the most challenging requirements
•Digital low-pass filter on speed loop
•Over travel limit switches available (when Expansion is not present)
•Totally programmable control and interface parameters
•Current bandwidth (analog) > 1kHz
•Dead point: absent
•Speed ratio: 1:4000
•Static current gain 10 5A/V
•Max operating temperature / humidity: 45 °C (113 °F) / 90%
•Derating for altitude > 1000 m (3333 feet): 1% per 100 m (333 feet)
•Storage temperature: -10 to +70 °C
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6 - 23/May/97
1.3 Technical Data
DBM Module
Input voltage : 300Vdc, ±10%
Three-phase output voltage : 180V
DBM-PS Power Supply
Three-phase input voltage : 230Vac, ±10%, 50/60 Hz
Auxiliary power supply input voltage : 110Vac (optional) or 230Vac, ±10%, 50/60 Hz
Auxiliary input power : 55W for 3-axis module, 60W for fans pair
BUS BAR output voltage : 300Vdc
230
230
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7 - 23/May/97
1.4 Interfaces
Digital
•Output for simulated encoder (optional)
•Serial Link RS485(1200-19200 Baud) full-duplex to manage:
- Acceleration limits
- Autophasing
- Control parameters
- Monitoring of internal parameters
- Range of analog interface
- System status
•Output for Drive OK axis 1, axis 2, axis 3 (TTL compatible)
On-Off (Optoisolated)
•Drive OK
•Drive Enable
•Motor OK
•Reference Enable
Analog
•Input velocity (see MR command)
•Resolver differential input signals
•Peak current limit input
•Output tachometer (see ET command)
•Max current, velocity reference, velocity error outputs (see ES, SO commands)
1.5 Protection
Module
•Auxiliary voltage out of tolerance
•BUS BAR overvoltage
•BUS BAR undervoltage
•Motor phase grounded
•Motor overtemperature
•Module overtemperature
•IT protection
•Abnormal resolver signal
•Short circuit on motor phases
•Non-coherent three-phase sequence
•Actual speed versus reference error
Power Supply
•Overtemperature
•Recovery unit not OK
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8 - 23/May/97
1.6 CE-Marking
Starting from Jan/97, DBM03 drives have CE-marking according to Low Voltage Directive.
Starting from Apr/97 the CE-marking refers also to EMC Directive (see Section 6).
A Declaration of Conformity is available.
The Low Voltage Directive applies to all electrical equipment designed to use with a voltage
rating of between 50 Vac and 1000 Vac and between 75 Vdc and 1500 Vdc.
The CE-marking states that the electrical equipment has been constructed in accordance
with good engineering practice in safety matters in force in the European Community and it
does not endanger the safety of persons, domestic animals or property when properly
installed and maintained and used in applications for which it was made.
Vickers drives meet the following standard related to Low Voltage Directive:
CEI EN 60204-1 (1993) par. 6.2.3, 20.3, 20.4
1.7 System Wiring
All of the analog and digital signal connectors, auxiliary power supplies and I/O interfaces are
front-connected to the unit.
Connectors for auxiliary power supply are made via Molex type connectors. Motor power are
connected via a Harting type connector, while I/O connectors use a Weildmuller type
connector.
All other connectors are made via D-type connectors.
All signals are positive logic:
active = +15V
not active = 0V (or not connected)
1.8 DBM Configurations
Three configurations are possible for the module:
DBM-3A: 3-axis module (see Fig. 1.3)
DBM-2A: 2-axis module (see Fig. 1.4)
DBM-2E: 2-axis module with expansion (see Fig. 1.5)
DBM-L3A: 3-axis 180 mm module (see Fig. 1.6)
DBM-L2A: 2-axis 180 mm module (see Fig.1.7)
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9 - 23/May/97
FIG. 1.1 - Inter module wiring
230 VAC
3 x 230 Vac
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10 - 23/May/97
FIG. 1.2 - DBM-PS Power Supply
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Tab. 1.1 - DBM-PS Power Supply (See Fig. 1.2)
Pos. Name
1 R "L1" phase, three-phase input voltage 230Vac
2 S "L2" phase, three-phase input voltage 230Vac
3 T "L3" phase, three-phase input voltage 230Vac
4 GND Ground
5 RR Recovery resistor
6 RR Recovery resistor
7 AUX Auxiliary power supply 230Vac (110Vac as option)
8 AUX Auxiliary power supply 230Vac (110Vac as option)
9 Yellow LED
PWR-BUS BUS BAR voltage > 40Vdc
10 Red LED
DBR FAULT Recovery unit fault
11 N.C.
12 Red LED
OVER
TEMP
Module overtemperature via PTC (threshold 80 °C)
13 Green LED
AUX
POWER
Auxiliary power supply OK
14 J2 RS485 output port to drives and power control fault
15 J10 RS485 input port
16 J1 Auxiliary power supply flat connector
17 GND Ground
18 L- BUS BAR -HV 300Vdc
19 L+ BUS BAR +HV 300Vdc
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12 - 23/May/97
Tab. 1.2 - DBM-PS Power Supply - J1 Connector
Auxiliary Power Supply
Pos. Name
1 N.C. (Not connected)
2 N.C.
3 - 15Vdc referred to -HV (300Vdc)
4 +18Vdc referred to -HV (300Vdc)
5 150kHz square wave to high side drives
6 N.C.
7 +18Vdc referred to logic 0V
8 - 18Vdc referred to logic 0V
9 +8Vdc referred to logic 0V
10 +8Vdc referred to logic 0V
11 Logic 0V
12 Resolver 0V
13 10 kHz sinusoidal wave for resolver and synchronism (carrier)
Tab. 1.3 - DBM-PS Power Supply - J2 Connector
RS485 Port Signal and PWRS Control
Pos. Name
1 + Rx (RS485 serial link)
2 N.C.
3 + Tx (RS485 serial link)
4 PWRS fault 1 - power supply binary coded faults (level 1)
5 + 5Vdc input referred to logic 0V
6 - Rx (RS485 serial link)
7 Logic 0V
8 - Tx (RS485 serial link)
9 PWRS fault 2 - power supply binary coded faults (level 2)
Note: Rx and Tx are the receiving and transmitting signals with reference to the drive. In the
rest of the manual "RS485 serial link", referring to Rx and Tx, will not be specified anymore.
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13 - 23/May/97
In case of fault, the type of fault is as follows:
J2/pos. 4 J2/pos. 9
00OK
0 1 DBR FAULT. Recovery fault
1 0 OVER TEMP. Overtemperature
1 1 PHASE FAULT.
Tab. 1.4 - DBM-PS Power Supply - J10 Connector
RS485 Port
Pos. Name
1 +Rx
2 N.C.
3+Tx
4 N.C.
5 +5Vdc output referred to logic 0V for power supply
6-Rx
7 Logic 0V
8 -Tx
9 N.C.
1.8A DBM-PS Internal Card
Jumpers
JP1 closed (default) = connects a 120 Ω
resistor between RX+ and RX-.
JP2 closed (default) = connects TX- of
serial link to 0V via pull-down resistor
JP3 closed (default) = connects TX+ of
serial link to +5V via pull-up resistor
FIG. 1.A - DBM-PS Card Jumpers
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14 - 23/May/97
FIG. 1.3 - DBM 3-Axis Module
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15 - 23/May/97
FIG. 1.4 - DBM 2-Axis Module
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16 - 23/May/97
FIG. 1.5 - DBM 2-Axis and Expansion (optional) Module
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17 - 23/May/97
FIG. 1.6 - DBM-L (180 mm) 3-Axis Module
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