SEW-Eurodrive DCA63/DBC00 Series Operating Instructions Manual Download Page 38

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Startup

Startup procedure

Operating Instructions – Compact Extra-Low Voltage Drives

6.3

Startup procedure

INFORMATION

For startup of the compact extra-low voltage drive, you will need the following:
• Engineering adapter DCZ-048P-DBC-09.
• Interface adapter USB11A or USM21A.
• DCAShell engineering software. Observe the chapter "DCAShell engineering soft-

ware" (→

51).

RJ10

USB

USB11A

Distribution Board

Motor

DCZ

USM21A

9007226100515083

Startup steps

1. Ensure that the compact extra-low voltage drive and any installed options are pro-

perly connected. Observe the chapter "Electrical installation".

2. Connect the engineering adapter.
3.

Switch on the DC 24 V control voltage.

4. Start the DCAShell engineering software.
5. Parameterize your desired operating mode.

26718014/EN – 11/2020

Summary of Contents for DCA63/DBC00 Series

Page 1: ...4_1120 Drive Technology Drive Automation System Integration Services Operating Instructions Decentralized Drives Compact Extra Low Voltage Drives With Expanded Gear Unit Portfolio Edition 11 2020 2671...

Page 2: ...SEW EURODRIVE Driving the world...

Page 3: ...ration 10 2 9 Startup operation 10 3 Device structure 11 3 1 Drive unit DCA63 DBC00 11 3 2 Speed power overview 15 3 3 Example nameplate and type designation 18 3 4 Accessories 20 4 Mechanical install...

Page 4: ...fault messages 73 10 5 Acknowledging error messages 75 10 6 Device replacement 75 10 7 Sending in a unit 76 10 8 Shutdown 76 10 9 Storage 76 10 10 Waste disposal 77 11 Inspection and maintenance 78 11...

Page 5: ...on for all additional components 1 3 Structure of the safety notes 1 3 1 Meaning of signal words The following table shows the grading and meaning of the signal words for safety notes Signal word Mean...

Page 6: ...ded Measure s to prevent the hazard 1 4 Decimal separator in numerical values In this document a period is used to indicate the decimal separator Example 30 5 kg 1 5 Rights to claim under limited warr...

Page 7: ...persons who work on the product pay attention to the following regula tions conditions documentation and information National and regional safety and accident prevention regulations Warning and safet...

Page 8: ...tion and waste disposal must be carried out by persons who are trained appropriately The purpose of the training is to give persons the ability to perform the required tasks and work steps in a safe a...

Page 9: ...er Mechanical installation in the documentation 2 6 1 Restrictions of use The following applications are prohibited unless the device is explicitly designed for such use Use in potentially explosive a...

Page 10: ...eration in the documentation Ensure that all required covers are mounted properly before applying the supply voltage Depending on the degree of protection products may have live uninsulated and someti...

Page 11: ...engineering interface This enables you to make flexible use of the drive and adapt it to suit a variety of applications In the DCA63 DBC00 series drives the motor housing and control electronics 3 are...

Page 12: ...ctronics 5 Power signal and engineering interfaces The B3 brake type is a single disk brake with 2 friction surfaces The brake can be ordered for the drive as an option It is fully integrated into the...

Page 13: ...gearmotor s zero offset and symmetrical structure offer a space saving installation Due to its high level of efficiency the right angle gearmotor does not feature a self locking mechanism Right angle...

Page 14: ...he tried and tested SPIROPLAN gearing and can be delivered with either a hollow or solid shaft Parallel shaft helical gearmotor F 03 DCA63 33322851083 The parallel shaft helical gearmotor of type F 03...

Page 15: ...NZ 63F DCA63S 048P00 DBC00 1 9 47 27 82 84 8 600 0 80 KNZ 63F DCA63S 048P00 DBC00 1 9 609 2 51 6 57 1800 7 56 W WA 03 DCA63S 048P00 DBC00 3 3 390 3 69 10 25 1800 6 78 W WA 03 DCA63S 048P00 DBC00 3 3 2...

Page 16: ...048P00 DBC00 2 2 609 3 63 6 57 1800 5 23 W WA 03 DCA63M 048P00 DBC00 3 6 390 5 33 10 25 1800 4 69 W WA 03 DCA63M 048P00 DBC00 3 6 242 8 04 16 5 1800 3 11 W WA 03 DCA63M 048P00 DBC00 3 6 145 12 51 27...

Page 17: ...048P00 DBC00 2 5 609 4 75 6 57 1800 4 00 W WA 03 DCA63L 048P00 DBC00 4 0 390 6 97 10 25 1800 3 59 W WA 03 DCA63L 048P00 DBC00 4 0 242 10 52 16 5 1800 2 38 W WA 03 DCA63L 048P00 DBC00 4 0 145 16 36 27...

Page 18: ...e 18014427187070347 1 Serial number example 2 QR code example The following figure shows an example of the nameplate of the UL design that can be ordered as an option The nameplate is located on the...

Page 19: ...W Right angle gear unit with SPIROPLAN gearing F Parallel shaft helical gear unit Z Shaft design Z Solid shaft PNZ and KNZ only A Shaft mounted gear unit with hollow shaft Without code letter Solid sh...

Page 20: ...n USB11A enables a PC or laptop with a USB interface to be connected to the DCZ engi neering adapter The USB11A interface adapter supports USB 1 1 and USB 2 0 Scope of delivery Interface adapter USB11...

Page 21: ...osphere Oils Acids Gases Vapors Radiation Clean the output shafts and flange surfaces thoroughly to ensure they are free of anti corrosion agents contamination or similar Use a commercially available...

Page 22: ...taining screws Potential damage to property Notice Do not overload the output shaft in a radial or axial direction see Technical data Observe the maximum tightening torques for the retaining screws Ob...

Page 23: ...revent them from coming loose A chemical thread locking compound for example is suitable here Use thread forming screws according to DIN 7500 for mounting SEW EURODRIVE recommends screw connections co...

Page 24: ...ensure the motors are mounted securely The maximum permissible screw length smax prevents any damage to the motor Minimum screw length smin Emin 6 5 mm x Maximum screw length smax Emax 8 0 mm x Emax...

Page 25: ...en installing the belt pulleys make sure the belt is tensioned correctly in ac cordance with the manufacturer s instructions Make sure the transmission elements are balanced after fitting and do not g...

Page 26: ...ant SEW EURODRIVE recommends NOCO fluid Spread carefully N O C O F L U I N O C O F L U I 9007199466257163 2 Install the shaft and secure it axially For easier installation use a mounting device Exampl...

Page 27: ...he gear unit Do not deform the torque arm during installation The following figure shows a torque arm provided by the customer without tension 4 5 0 mm 0 mm 32413253003 4 4 Connector position at the d...

Page 28: ...with the W 03 right angle gear unit R 2 0 2 5 m m 33562341771 In combination with the F 03 parallel shaft helical gear unit R 2 0 2 5 m m 33562339339 For installation and removal of the straight conn...

Page 29: ...ry side When working on the drive disconnect the system machine from the power sup ply and then secure the system machine to prevent it from being switched back on again Before connecting the systems...

Page 30: ...ys adhere to the relevant standards 5 2 2 Information on applying the motor shield The hybrid cable for connecting the compact extra low voltage drive has 2 shielding levels To minimize the effects of...

Page 31: ...however essential that low impedance HF capable equipotential bonding is provided see EN 60204 1 or DIN VDE 0100 540 Establish a connection over a wide area between the drive and the mounting rail To...

Page 32: ...gy The following graphics show the principle line topology and star topology with the compact extra low voltage drive 5 3 1 Line topology 48 V 24 V 2 5 1 DCA63 3 4 6 6 6 9007226442438795 1 Supply syst...

Page 33: ...nstructions Compact Extra Low Voltage Drives 33 5 3 2 Star topology 48 V 24 V 2 5 1 DCA63 3 6 6 6 4 9007227549789835 1 Supply system 2 Controller 3 Supply voltage 4 Control line 5 Distribution board b...

Page 34: ...ram for motor plug connector1 Plug connector on the motor side M16 15 pin male 12 11 7 9 8 10 2 1 3 5 4 6 C B A 1 For the pin assignment refer to the table in chapter Prefabricated cables Connection c...

Page 35: ...m L Pin Cable cross sec tion Con ductor color Connection Identification A 1 5 mm2 GY Braking resistor Braking resistor B 1 5 mm2 BN UDC48V DC 48 V voltage supply C 1 5 mm2 BK GND Power signal GND 1 0...

Page 36: ...PIN 5 PIN 6 PIN 7 PIN 8 PIN 9 PIN 10 PIN 11 24V DC 48V DC GND 48V DC GND 24V DC GND I O RD BU WH BN GN YE GY PK BU RD BK VT GY PK BW 48V DC 27190185483 5 6 Brake chopper braking resistor connection Th...

Page 37: ...fatal injuries Observe the startup instructions Always have the installation carried out by trained specialists Only use settings that are correct for the function 6 2 Prerequisites The following prer...

Page 38: ...ngineering software Observe the chapter DCAShell engineering soft ware 2 51 RJ10 USB USB11A Distribution Board Motor DCZ USM21A 9007226100515083 Startup steps 1 Ensure that the compact extra low volta...

Page 39: ...equired operating mode Changing between operating modes is only possible via software Set the operating mode in the Parameter application menu Before editing the values in the edit boxes read out the...

Page 40: ...rent ramps for acceleration and deceleration Al ternatively 3 fixed setpoints and one analog speed setpoint are also possible Opera tional control is provided via 4 digital inputs 4 DI and an analog i...

Page 41: ...otation IN A on Pin 1 The Clockwise rotation control signal enables the motor The drive accelerates to the parameterized setpoint speed with the parameterized ramp The shaft of the motor turns clockwi...

Page 42: ...ed there is no current supply and the drive can be moved via external torque For drives with optional holding brake the brake is applied when the output stage is disabled and thus acts against the ext...

Page 43: ...meterizing the analog setpoint The Positioning operating mode allows for a combination of speed control 2 fixed speeds N2 and N4 A1 and relative positioning The relative distance is triggered by a sen...

Page 44: ...applied when the output stage is disabled and thus acts against the external torque If control signal 1 is applied at both inputs the positioning mode is activated The behav ior of the drive is now de...

Page 45: ...nce value is not set Reference travel Function Description IN A pin 1 IN B pin 2 0 0 Locked Output stage is inhibited It is active for drives with hold ing brake 0 1 1 0 Reference travel start Enable...

Page 46: ...rized reference offset If the offset is 0 the actual position receives the reference value 0 in the event of a rising edge After reaching the reference cam and setting the reference position the drive...

Page 47: ...his accordingly via the DCAShell engineering interface The easiest and fastest way to enable the analog input is via the parameter fixed speed N4 Once you have entered the value 0 the setpoint is inpu...

Page 48: ...The value for X0 and X4 cannot be changed because X0 always stands for 0 V and X4 always for 10 V All other entries can be made according to the application The unit for parameters X1 X2 and X3 is dig...

Page 49: ...per 1000 3000 4000 2000 1 2 3 4 5 6 7 8 9 10 min 1 V 30636132875 No Parameter Value Unit 0xB Speed characteristics_X1 102 Digits 0xC Speed characteristics_X2 921 Digits 0xD Speed characteristics_X3 92...

Page 50: ...mple the hysteresis range is between 4 V and 6 V 5 V 1 V You find the associated parameters in the table 1000 3000 4000 2000 1 2 3 4 5 6 7 8 9 10 min 1 V 30636129291 No Parameters Value Unit 0xB Speed...

Page 51: ...low voltage drive and your PC as described in the chapter Startup procedure 2 38 1 Start the software A welcome window appears If you do not want to see this window the next time you start the softwar...

Page 52: ...side 3 as a function of time If you are working with a smaller screen you will need to drag the window to make it larger To do so press and hold the left mouse button on the edge of the window and dra...

Page 53: ...nter the duration of the recording in the Time edit box 7 3 General settings This area offers the following functions Edit the default parameters Edit boxes that you have edited but not yet saved are...

Page 54: ...Write button to save modified param eters 2 The Factory reset button resets all of the parameters to their factory settings 7 4 Application parameters You can read and modify the parameters of the 3 o...

Page 55: ...should only be changed after consultation with SEW EURODRIVE and are therefore pass word protected Contact the SEW EURODRIVE Service department if you want to modify these parameters 1 28546760459 1...

Page 56: ...e speed control function if the drive is en abled via input IN A or IN B Press and hold the Counterclockwise or Clock wise button to specify the speed control 4 The drive will turn in the corre spondi...

Page 57: ...s during startup The values that are designated with System in the table are used to specify the motor specific properties Only modify these values after consultation with trained experts You can read...

Page 58: ...ed speed N4 0x1A t up clockwise ms for 1000 min 1 100 0 65535 Application Ramp up 1000 min 1 0x1B t down clockwise ms for 1000 min 1 100 0 65535 Application Ramp down 1000 min 1 0x1C t up counterclock...

Page 59: ...5535 System 0x34 Current time con stant ms 1 1 5000 System 0x35 Current gating time ms 0 0 5000 System 0x36 Reversing threshold min 1 10000 0 29999 System 0x37 Reversing threshold delta hysteresis min...

Page 60: ...negative Revolu tions 0 32768 32767 System Position window for message 0x4A UDC48V overvoltage threshold mV 58000 0 65535 System Overvoltage 58 V 0x4B UDC48V under voltage threshold mV 18000 0 65535...

Page 61: ...on 4 1 65535 revolutions 0 0 65535 Application P4 65535 360 de grees 0x58 Position 4 Revolu tions 3 32768 32767 Application P4 number of re volutions 0x59 Homing speed min 1 1000 0 65535 Application S...

Page 62: ...hole revolutions 0x61 Current actual temperature PCB C Status The parameter contains the current actual temperature of the printed circuit board in C 0x62 Current electrical current Id mA Status The p...

Page 63: ...l factory setting INFORMATION With brakemotors the function of digital output OUT 1 cannot be assigned freely as this output is permanently assigned the function of controlling the holding brake 0x4 O...

Page 64: ...inputs IN 1 and IN 2 Fixed speed N4 The following functions are available in parameter value N4 N4 0 Analog input is enabled Depending on the selected operating mode and with corresponding activation...

Page 65: ...too slowly in an idle state increase the value If the drive tends to oscillate in an idle state reduce the value 0x3F Maximum positioning speed Maximum motor speed in revolutions per minute with which...

Page 66: ...ontrol DO1 on Pin 5 The compact extra low voltage drive can optionally be supplied with a mechanical holding brake In drive configurations with a brake the procedures for releasing and applying the br...

Page 67: ...the driven machine is not permitted for safety reasons After a reset make sure that the drive can start up automatically depending on the setting WARNING Danger of burns due to hot surfaces of the dev...

Page 68: ...nding current limitation 53 A 9 3 1 Acknowledging an error condition As soon as the monitoring function of the drive detects an error the output stage is disabled and disconnected from the power suppl...

Page 69: ...the drive and the customer s system The engineering adapter has a sturdy plastic housing with an IP54 degree of pro tection The housing is provided with protective insulation The DC 24 V and DC 48 V...

Page 70: ...DC 48 V supply voltage Green Steady light ON DC 48 V supply voltage is applied LED RS485 Data The RUN LED is supposed to represent the communication status of the RS485 bus LED color State Descriptio...

Page 71: ...10 Service Engineering adapter Operating Instructions Compact Extra Low Voltage Drives 71 LED color State Description Yellow ON Reverse polarity fault connections must be checked 26718014 EN 11 2020...

Page 72: ...djust Position controller Adjust K_FF unsuitable Adjust UDC48V fluctuates Stabilize Motor judders when switching to position hold control K_FF 0 Set K_FF Motor does not position itself Enable missing...

Page 73: ...ineering software The following section shows a sample evaluation of an error message in the DCAShell engineering software 1 Launch the DCAShell engineering software 2 The number that is currently act...

Page 74: ...mperature too high 1 Motor in control A B active 2 Overvoltage error has occurred 3 Undervoltage error has occurred 4 Hardware error has been reported 5 Hardware overcurrent detection error has occurr...

Page 75: ...ed e g mechanical disconnection to prevent unauthorized movement of the system WARNING Improper installation disassembly of drive units and mount on components Risk of injury Adhere to the notes about...

Page 76: ...trol type etc Nature of the fault Accompanying circumstances Your own presumptions as to what has happened Any unusual events preceding the problem etc 10 8 Shutdown To shut down the unit de energize...

Page 77: ...terials are hazardous to health and the environment These materials must be collected and disposed of separately Oil and grease Collect used oil and grease separately according to type Ensure that the...

Page 78: ...tenance 11 1 Cleaning the drive Excessive dirt dust or shavings can have a negative impact on the function of syn chronous motors in extreme cases these factors can cause the motor to break down For t...

Page 79: ...mbient temperatures 11 3 1 Motor The following table shows the inspection intervals for the motor Time interval Activity Design Every 3000 operating hours at least every 6 months Check for possible be...

Page 80: ...ed efficiency 12 2 Drive selection data Certain data is required to be able to precisely define the components for your drive These include Drive selection data Your entry nG_max Maximum output speed...

Page 81: ...ructions Compact Extra Low Voltage Drives 81 12 2 2 Selecting the proper drive Based on the calculated values for torque and rotational speed the suitable drive can now be configured under adherence o...

Page 82: ...t SEW EURODRIVE M f t MMotMax at all operating points S1 duty at ambient temperature 25 C Yes Meff MN neff nN Yes Check the braking resistance using the braking energy Thermal check Electromechanical...

Page 83: ...limit the voltage increase until the supply voltage exceeds the switch on threshold of the brake chopper Switched mode power supplies are equipped with output voltage monitoring If the output voltage...

Page 84: ...nformation on regenerative operation CAUTION Danger due to Missing decoupling of control voltage and load voltage Increase in the DC 24 V control voltage EMC influence of load circuit Possible damage...

Page 85: ...tMax 0 1 89 Nm 3 00 Nm 2 55 Nm Maximum motor torque at 1500 min 1 MMotMax 1500 0 95 Nm 1 80 Nm 2 20 Nm Maximum motor torque at 2000 min 1 MMotMax 2000 0 60 Nm 1 00 Nm 1 50 Nm Maximum motor speed nno l...

Page 86: ...voltage threshold mV 18000 0 65535 System Undervoltage 18 V 0x4C UDC48V voltage hys teresis mV 2000 0 65535 System Hysteresis for voltage signal 0x4D Ballast chopper switch on threshold mV 28000 0 655...

Page 87: ...Nm 1 00 Nm 1 50 Nm Maximum motor speed nno load operation 6000 min 1 5000 min 1 5200 min 1 Nominal speed nN 4000 min 1 Motor power PN 188 W 272 W 356 W Nominal voltage UN DC 48 V Nominal current IN 5...

Page 88: ...higher installation altitudes reduce the rated torque to the following values Installation altitude Rated torque 1000 m to 2000 m above sea level 92 MN 2000 m to 3000 m above sea level 83 MN 3000 m to...

Page 89: ...197 74 47 Gear unit max continu ous torque Mamax Nm 40 0 68 0 58 0 1 99 7 95 22 32 22 24 Gear unit 0 9 0 81 0 9 0 81 0 73 Gear unit service factor fB S1 19 75 12 44 3 54 0 73 1 07 1 26 0 80 Gear unit...

Page 90: ...ontinuous torque Mamax Nm 19 25 30 Gear unit 0 85 0 8 0 75 0 7 0 6 0 85 0 85 0 85 0 8 0 8 Gear unit service factor fB S1 7 56 6 78 4 49 2 89 1 93 12 18 7 78 5 23 2 73 1 74 Gear unit backlash 0 5 1 Ser...

Page 91: ...800 267 89 74 47 Gear unit maximum continu ous torque Mamax Nm 40 0 68 0 58 0 22 32 22 24 Gear unit 0 9 0 81 0 73 Gear unit service factor fB S1 13 68 8 61 2 45 0 87 0 55 Gear unit backlash 0 9 1 2 0...

Page 92: ...continuous torque Mamax Nm 19 25 30 Gear unit 0 85 0 8 0 75 0 7 0 6 0 85 0 85 0 85 0 8 0 8 Gear unit service factor fB S1 5 23 4 69 3 11 2 00 1 34 8 43 5 39 3 62 1 89 1 21 Gear unit backlash 0 5 1 Ser...

Page 93: ...min 1 800 267 89 74 47 Gear unit max continuous torque Mamax Nm 40 0 68 0 58 0 22 32 22 24 Gear unit 0 9 0 81 0 73 Gear unit service factor fB S1 10 46 6 58 1 87 0 67 0 42 Gear unit backlash 0 9 1 2 0...

Page 94: ...x continuous torque Mamax Nm 19 25 30 Gear unit 0 85 0 8 0 75 0 7 0 6 0 85 0 85 0 85 0 8 0 8 Gear unit service factor fB S1 4 00 3 59 2 38 1 53 1 02 6 45 4 12 2 77 1 45 0 92 Gear unit backlash 0 5 1 S...

Page 95: ...00 mA output depending on connected load Inputs IN A IN B Properties Value comment Input level PLC level Low level DC 5 V High level DC 15 V Protection against reverse polarity and voltages DC 30 V In...

Page 96: ...proof yes Polarity reversal protection no Overload protection Yes thermally self switching Output frequency Iout 100 mA 1 kHz Analog input Analog IN 1 signal connector differential to GNDAnalog Proper...

Page 97: ...ot included in the delivery The braking resistor is tested and designed according to the drive application Observe maximum power loss 13 2 2 Optional braking resistor If the application requires the u...

Page 98: ...ng overload factors For cyclic operation you can determine the overload factor with the known cdf value from the following graphic and table Overload factor depending on cyclic duration factor cycle d...

Page 99: ...ope of delivery USB11A interface adapter USB cable Cable with RJ10 RJ10 plug connectors 13 3 2 USM21A Type USM21A Part number 28231449 Function Interface adapter USB CAN or USB RS485 Scope of delivery...

Page 100: ...r of the drive and the pitch circle of the mounting bores onto the mounting plate and drill see following draw ings 13 4 2 DCA63 048P00 DBC00 63 0 1 0 3 20 0 3 16 3 63 5 5 8 L LB 8 g5 4 x 9 0 30 4 x 9...

Page 101: ...s 101 13 4 4 PNZ63F DCA63 63 52 2 77 3 L 1 20 28 2 5 F R 15h7 40h8 3 15 40 0 5 1 25961502987 1 Key DIN 6885 A 5x5x28 2 4 x M5 15 mm deep Length of possible gearmotor combinations Gearmotor L 1 stage L...

Page 102: ...Drives 102 13 4 5 KNZ63F DCA63 15 20 3 40 h8 15 h7 F R 4 0 0 1 30 0 3 35 66 5 31 5 L 1 63 50 63 1 2 9007225216247563 1 4 x M5 10 mm deep 2 Key DIN 6885 A 5x5x20 Length of possible gearmotor combinati...

Page 103: ...15 h7 FA 3 0 2 0 45 3 0 2 0 81 50 1 2 3 63 L 1 40 5 52 40 36 4 5 6 78 9007225331847947 1 Key DIN 6885 A 5x5x20 2 4 x M5 6 5 mm deep on all face sides 3 Motor center point 4 Bore omitted on the opposit...

Page 104: ...Compact Extra Low Voltage Drives 104 13 4 7 W 03 DCA63 33316748555 Length of possible gearmotor combination Type Length L Length LB W 03 DCA63S 048P00 DBC00 118 5 mm 138 5 mm W 03 DCA63M 048P00 DBC00...

Page 105: ...Compact Extra Low Voltage Drives 105 13 4 8 F 03 DC63 33316753035 Length of possible gearmotor combination Type Length L Length LB F 03 DCA63S 048P00 DBC00 118 5 mm 138 5 mm F 03 DCA63M 048P00 DBC00...

Page 106: ...Have been investigated by UL in accordance with the component requirements in the Standard s indicated on this Certificate UL Recognized components are incomplete in certain constructional features or...

Page 107: ...dtc nord sew eurodrive de East SEW EURODRIVE GmbH Co KG D nkritzer Weg 1 08393 Meerane Zwickau Tel 49 3764 7606 0 Fax 49 3764 7606 20 dtc ost sew eurodrive de South SEW EURODRIVE GmbH Co KG Domagkstr...

Page 108: ...esignation in the documentation 5 Meaning of the hazard symbols 6 P Product names 6 Project planning Data for drive selection 80 Protective separation 10 R Restriction of use 9 Rights to claim under l...

Page 109: ......

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Page 112: ...SEW EURODRIVE Driving the world SEW EURODRIVE GmbH Co KG Ernst Blickle Str 42 76646 BRUCHSAL GERMANY Tel 49 7251 75 0 Fax 49 7251 75 1970 sew sew eurodrive com www sew eurodrive com...

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