Dietz DSV 5444 / ML 2 Commissioning Instructions Download

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VECTORDRIVE DSV 5444

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07.07.04 10:12

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Dietz-electronic

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Frequency

inverter

MULTIDRIVE

DSV 5444 / ML 2

For dynamic speed and position setpoint control

of three-phase AC motors

Commissioning Instructions

Issue 04/00

Right to Technical Modification Reserved

All previous issues of this manual are herewith invalid.

Summary of Contents for DSV 5444 / ML 2

Page 1: ...z electronic page 1 of 60 Frequencyinverter MULTIDRIVE DSV 5444 ML 2 For dynamic speed and position setpoint control of three phase AC motors Commissioning Instructions Issue 04 00 Right to Technical Modification Reserved All previous issues of this manual are herewith invalid ...

Page 2: ...ing 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 including the appropriate amendment directives up to date of drawing The following standards are used EN 60204 1 1997 IEC 61000 3 2 1995 EN 55011 1991 EN 61800 3 pr A 1 1 1999 IEC 61000 3 2 A1 1997 EN 55011 A1 1997 EN 61800 3 pr A11 1999 IEC 61000 3 2 A2 199...

Page 3: ...nd Intermediate circuit protection 12 3 10 Voltage Supply of the Fans at Dimension 4 and 5 13 4 Control unit Inputs and Outputs 14 4 1 Digital inputs and outputs 14 4 2 Freely programmable inputs and outputs on connector X2 optional 14 4 3 Fixed programmable inputs and outputs on connector X1 14 4 4 Interface connector X4 15 4 5 Transducer input connector X3 and transducer cable 16 5 Operation 17 ...

Page 4: ...4 2 B2 mode short message operation 45 9 4 2 1 Communication time frame 45 9 4 2 2 Short message commands 45 9 4 2 3 Short message mode commands and messages 45 9 4 2 4 Three digit short message system messages 49 9 4 3 Optimized short message traffic for RS485 49 9 4 3 1 Acknowledged B5 mode 49 9 4 3 2 Unacknowledged B5 mode 49 9 5 Addressed bus mode 50 10 Appendix 50 10 1 Options 50 10 1 1 Trans...

Page 5: ...utputs connector X1 Interface connector X4 Transducer input connector X3 and transducer cable Freely programmable inputs and out puts connector X2 optional Fixed programmable inputs and outputs connector X1 Interface connector X4 Transducer input connector X3 and transducer cable Connect unit Connect unit Optimise parameters Set parameters Operation Set parameters List parameters see note below On...

Page 6: ...uld be short and of adequate cross section Refer to our pro posed sizes for cable sections in the corresponding section together with the standards listed Suitable cut off devices e g main switch main fuse should be provided in the mains feeder Never lay signalling and control cables together with the mains or motor lines or else maintain adequate spacing Screened lines improve immunity to interfe...

Page 7: ...verter outputs are earthing short circuit and idling proof 3 1 Power connection with external mains filter K1 A1 Y1 R1 NF1 PE 400V 50 60 Hz N PE L2 L3 L1 L1 Power terminals F1 F2 F3 Fan connection F4 A2 L1 N PE U2 U1 U3 PE U V W PE 30 31 L2 3 M L2 L3 L1 L2 L3 L1 0030_03e drw L1 Power choke L2 Motor choke only for motor cable lengths 15 m A1 Power terminals underside of unit A2 Fan connection top s...

Page 8: ...ls of frequency converters A3 A5 Fan connection top side of unit size 4 only R1 External mains filter Y1 Y2 Y3 Equipotential bonding rails NF1 External mains filter F1 F3 Mains fuses F6 F9 External intermediate circuit protection 3 3 Mains connection The VECTORDRIVE DSV 5444 is designed for fixed connection to the 400 V AC 50 60 Hz AC network optionally 480 V AC 50 60 Hz Lines for the mains supply...

Page 9: ...rrent safety devices suitable for DC leakage currents Mains filters under some operating conditions e g failure of one phase can cause high discharge current resulting in spurious tripping of the safety device Switching devices on the mains side such as mains switch or fuse must therefore switch symmetrically Rotary switches are generally unsuitable for use with mains filters 3 4 Motor connection ...

Page 10: ... U f n n 380 V 300 Hz 127 as 1 27 1 5 power chokes must be used 3 4 2 Thermistor The motor temperature monitoring system protects the connected motor against thermal overload In the event of excessive temperature rise in the winding the inverter automatically cuts out Connect the motor thermistor with a screened line to terminals 23 and 24 on the front panel For motors without a thermistor termina...

Page 11: ...en the power choke and unit input Make sure that depending on type the filter can produce discharge currents up to some 100 mA in the event of failure of one or two phases or major load unbalance in the AC current system Filters must therefore be earthed before switching on The mains filters we recommend are given in the table below VECTORDRIVE DSV 5444 400 Arcotronics 3 3 x 400 V 50 60 Hz 5 A F L...

Page 12: ...ng resistors we recommend are listed in the table below VECTORDRIVE DSV 5444 Braking resistor Ω Ω Ω Ω Power loss S1 Standard kW Cross section Standard mm Power loss S1 Lifting system kW Cross section of lifting system mm 3 9 63 0 0 25 1 5 0 25 1 5mm 2 12 16 41 0 0 33 1 5mm 2 0 33 1 5mm 2 25 20 0 0 45 1 5mm 2 1 00 1 5mm 2 32 45 18 8 1 00 1 5mm 2 2 00 2 5mm 2 60 80 14 4 2 00 2 5mm 2 4 00 2 5mm 2 100...

Page 13: ...om 75 kW up to 100 kW Considering is the pin assignments at the 4 pole supply connector 1 Standard without autotransformer The most uppermost Pin of the connector must not become engaged here 2 Version Focus dynamics with autotransformer devices as from 01 05 99 Important Only if the supplied connector has the denotation L2 at the most uppermost pin the selectable pin allocation is possible with 4...

Page 14: ...t 0 Each input can also be interrogated statically by means of flags The addresses are given in the section Pro gramming Inputs and Outputs 4 3 Fixed programmable inputs and outputs on connector X1 The fixed wired inputs on connector X1 are dominant This means that the commands of a control program are overridden and a control program must be set accordingly The supply conductors for the ISP INT a...

Page 15: ...computer multiple axis application The serial interface has a fixed setting for 9600 Baud 8 bits 1 Stop bit no parity Interface assignment Terminal Designation 1 RS485 2 RS232 TXD 3 RS232 RXD 4 RS485 5 GND 6 RS485 transfer bridge to GND 7 GND 8 External interface bridge to GND FI control deactivated 9 5 V For RS232 operation pin 8 must be connected to GND pin 5 or 7 Pin 6 may not be bridged For RS...

Page 16: ...t 1 5 UA1 IN 2 6 UA1 IN 3 12 VCC 4 10 GND 5 8 UA2 IN 6 1 UA2 IN 7 3 UA0 IN 8 4 UA0 IN 9 I screen 10 15 V 11 11 if required GND Sense 12 Housing 9 if required A screen 13 2 if required VCC Sense 14 7 if required Alarm 15 15 V Use our transducer cable for preference order N 95441812 The unit has a default setting for a transducer with 1 Vss level 4 x 90 1024 pulses as standard Jumper JP3 can be used...

Page 17: ...ive status only error and status messages are displayed 4 7 1 Operation of FI control The four keys of the FI control have the following functions Key Assignment Explanation Up arrow key Select required menu point Down arrow key Select required menu point Left arrow key Leave a menu point without changing a value Quit option Right arrow key Activates selected menu point Edit a value If the require...

Page 18: ...ailable for the FI control Lift variants the function is designed specifically for this application this operating mode is automatically selected with the lift Standard operating mode all parameters and variables are freely accessible but there is no customer application commentary WARNING after change over all values are read in again Any values not stored therefore resume their former status To ...

Page 19: ...arameters Message in display All OK Message in display Change variables Message in display Variable 3 Edit Message in display Change parameters Message in display Target ramp Edit Message in display Store values Message in display Please wait do not switch off after about 10 seconds Please wait Software reset after about 5 seconds All OK Up arrow key Down arrow key Right arrow key Left arrow key M...

Page 20: ... longer possible There are two ways of calling in the program 1 TER The program asks for the required field name Start e g with TER CR 2 TER configuration file The program read out of the inverter for the parameters and variables defined in the Customer CNF Start e g with TER Customer CNF CR 3 For desk parameter setting the terminal program can be started with the following input TER Cus tomer CNF...

Page 21: ... Example interruption in travel by PC with F1 V CR F1 a CR 4 8 4 On line mode F3 After pressing function key F3 in the terminal program TER EXE on line mode is enabled This is used for automatic parameter setting and basic initializing of motor type plate data for monitoring the signal sequence for direct action on the DSVs Prerequisites for automatic parameter setting SHIFT F7 Inverter ready for ...

Page 22: ...ced by a quarter or by a third if the motor is cold Run the drive at full speed If the motor is not running smoothly the time constant I must be doubled If the motor is operated with field control the rotor time constant T must be increased by about 25 if necessary The run up and return ramps should now be set steep enough to not quite reach the torque threshold The torque limit address 74h can be...

Page 23: ... values for the ramps parameters F4 Y0 and Y1 are doubled on the fol lower drive The positioning speed G command parameters F11 and F27 reference travel speed parameter F12 and standardization factor for position control parameter F21 and the zero position offset parameters F8 and F26 must likewise be adapted to suit the purpose if necessary 5 3 Standardization Parameters F1 F2 and F5 are generall...

Page 24: ...o number of sinusoidal periods per revolution a n times evaluation of a sinusoidal period The interval between two points a sinusoidal signal is divided into a sections This multiplied by the number of points on the rotary position trans ducer gives the number of increments per motor revolution standard setting a 64 ntransducer Transducer speed nmotor Motor speed The value for transducer transmiss...

Page 25: ...acteristic F I Serie I Nenn Motor d 0 0 9 3 55 sinϕ Imotor rating for 50 Hz operation star connection F1 Max speed for const torque Explanation Maximum speed for constant torque Adress 0A2h R FI control menu Parameter Value range min 200 max N_MAX Resolution 1 rpm unit rpm F2 Speed at safe commutation limit synchronous speed Explanation Speed at safe commutation limit Address 0A4h R FU control men...

Page 26: ... 32767 Resolution 1 Unit F11 reduz Drehz 1f Position Position control loop Explanation Reduced positioning speed positioning in the same direction as the machine is running Address 0BEh R FI control menu Parameter Value range min 1 max N_MAX Resolution 1 Unit F12 Ref cycle speed Position control loop Explanation Speed of reference cycle Address 0C0h R FI control menu Parameter Value range min N_MA...

Page 27: ...0CEh R FI control menu Parameter Value range min 8 max 2000 Resolution 1 Unit F20 Position SET ACTUAL scan off Position control loop Explanation F20 0 8 milliseconds scan time gives the period in which the position must fall outside the tolerance window to reset the message Set ACTUAL Address 0D0h R FI control menu Parameter Value range min 1 max 400 Resolution 1 Unit F21 Insert factor Position co...

Page 28: ...speed 2 for postg Position control loop Explanation Reduced positioning speed direction of rotation reversed for reference travel Address 0DEh R FI control menu Parameter Value range min N_MAX max N_MAX Resolution 1 Unit F28 Torque dampening Explanation Torque dampening maximum change in acceleration per scan interval The higher F28 the faster the setpoint value is sought Address 0E0h R FI control...

Page 29: ...d control Address 0B6h R FI control menu Parameter Value range min 100 max 5000 Resolution 1 Unit T Rotor time constant Explanation Rotor time constant Address 0A0h R FI control menu Parameter Value range min 25 max 1000 Resolution 1 Unit Note T P kW motor tanϕ 60 for standard motors tan ϕ see Section Appendix Conversion tables for sinϕ cosϕ und tanϕ The rotor time constant T can also be determine...

Page 30: ...er set in EEPROM Check parameters for value range and validity Phase error Phase failure output stage disabled immediately Check mains input voltage and mains fuses Thermistor Motor overheating output stage disabled Thermistor not connected cable faulty or motor too hot Power unit fault Power unit faulty internal fault not ready for operation Check the 15 V power supply to connectors X1 X3 for sho...

Page 31: ...roubleshooting sec tion It is advisable to heavily reduce the current limit for the test S command e g S smax 10 to keep the current load on the motor low In this case the motor will oscillate or vibrate if the rotary field is incor rect Motor reacts independently of setpoint value at very low speed and draws high current levels Attention In the case of high current and low speed the signal A6 is ...

Page 32: ...the terminal program using the block editor F8 in on line mode you can change blocks in the inverter directly or create new blocks of a command program The parameters and variables can then be set manually or you can load a file with parameters and variables The values in the EEPROM can only be changed if the data save switch is in the lower RW position If the switch is in the R position the data ...

Page 33: ...gram a condition can be set on the fla address This address is used for conditions until replaced by another There are now two options for responding to a condition Either wait until the condition is fulfilled com mand or initiate a block command 808 sets the condition on the position setpoint value position actual value flag waits until the set condition is fulfilled In the example below block 25...

Page 34: ... after transducer zero pulse from master drive only with follower drive P Position from speed control to transducer zero pulse H number Move to absolute position in relation to reference point D number Move positioning in incremental dimension relative to actual setpoint value Q1 Return to reference point Q2 Return to synchronization point or second reference point G Zahl Positioning speed in rpm ...

Page 35: ...xed address using 16 bit arithmetic Indexed address using 32 bit arithmetic Add Subtract Multiply Divide Set amount N Negate value input negative numbers Logic AND link Logic NAND link Rotate byte to the left with carry Numerical comparison result stays unchanged 8 2 8 Output commands Command Explanation X1 H number Content of address output on D A inverter 1 standard setting N_SETPOINT X2 H numbe...

Page 36: ...L_NI or LS_GL_LI 1AFh STEHTnicht R Counter flag for STOPPED 10Eh EK_MZ R FFh if earth fault or short circuit 17Ch ACHT_MZ If FFh a program run interrupt can only be cleared by pressing the reset key or switching off the inverter 102h NOT_HALT_MZ R FFh emergency stop triggered 094h NOT_HALT_STB RW If 00h emergency stop only reset by intermediate circuit volt age M command or RESET otherwise automat...

Page 37: ...s given here or added to the content de pending on the control byte EF8h With this function all memory locations can be written The user must check for a suitable function 830h N_F_KNST R Over this speed the unit runs with constant longitudinal current for magnetization Used for motors with large voltage drops in the upper speed range and normally preset to a maximum speed E7Eh NIMPX_STB RW If thi...

Page 38: ...tive run up ramp 82Eh NSOLL_DEC_N R Negative return ramp 1AEh STEHT R Flag is set FFh if the motor is stationary and the setpoint value is reached The signal is also set when the motor is dis abled 1AFh STEHTnicht R Counter flag set at STOPPED 802h NS_GL_NI R The flag is set if the speed setpoint value is the same as the actual speed to set the flag the speed must remain for a time determined by t...

Page 39: ...d is specified in similar manner and the G command ignored 1A2 1A4h LAG_TRIG1_LW HW RW First trigger threshold in increments for actual position value in relation to reference point 1A6 1A8h LAG_TRIG2_LW HW RW Second trigger threshold in increments for actual position value in relation to reference point 1AAh LAG_FLAG1 R Flag set at FFh if the first trigger threshold is exceeded content 00h if the...

Page 40: ... a number 8 3 7 Counter and Timer Address Name RW Explanation 428h TIME0_FLAG R Timer 0 flag 429h TIME0_FLAGnicht R Timer 0 counter flag 430h TIME1_FLAG R Timer 1 flag Reference Point 431h TIME1_FLAGnicht R Timer 1 counter flag 432h ZAEHLER2 RW Counter 2 counter status 434h ZAEHLER2_FLAG RW Counter 2 flag 436h ZAEHLER3 RW Counter 3 counter status 438h ZAEHLER3_FLAG RW Counter 3 flag 43Ah ZAEHLER4 ...

Page 41: ...s the temperature fault signal address 116h 8 3 9 Variables for test purposes Address Name RW Explanation 200h SWITCH RW Operating mode selection 00h Controlled operation 01h Speed control 02h Position control 03h Synchronized position 04h Synchronized speed 124h FRF_MZ RW FFh content disables position control Reference travel is still possible 090h REF_ZYK_STB RW Only used for analog specified se...

Page 42: ...m f21 Distance factor 64 65536 f21 1024 increments Customer value for one motor revolution l e00 Customer variable 1 m1000 Positioning speed here l e02 Customer variable 2 m10240 Input positioning distance here l e04 Customer variable 3 m500 Speed threshold here l e06 Customer variable 4 m5120 Position threshold here l e08 Customer variable 5 m1500 Endless speed here u1 End of parameter variable p...

Page 43: ...put E0 block 0 reference travel basic position 1 Position message A1 420 delete 808 If position control already active 20 then further on in subroutine block 20 0 basic setting A0 420 to be deleted e Switch on control v Select speed control 1ae wait until drive ready then when condition is fulfilled r1 move to reference point 808 if position found then continue u6 to set all incremental positions ...

Page 44: ... to be deleted o e08 n Run customer variable 5 negative 11 Counter edge to input E2 w21 continue in subroutine block 21 21 Interrupt speed subroutine block 21 v Speed control on o0 Stop 1ae if motor stationary then continue a Control off 0c0f Inputs blocks 0 1 2 3 High Fl Low Fl 2 3 block 10 11 free 8 4 Inverter communication modes The description below of the transmission protocol only applies to...

Page 45: ...12ms 20ms RS485 5ms 10ms RS485 im B5 broadcast mode With communication via an RS485 interface an interval of 0 5 ms must be maintained between two strings 8 4 2 2 Short message commands The protocol units which the control system sends to the VECTORDRIVE DSV 5444 are commands They must have the following syntax Syntax Meaning or 09 Blank or ASCII character 0 to 9 exp n n times repetition of exp CR...

Page 46: ...20 appears Example d 0 for relative position zero E CR Connection of control The response is Z20 if the control was previously switched off Z20 or Z40 are the response otherwise G dddddd CR Gives the positioning speed in rpm G CR Reads off the positioning speed H dddddd CR Gives the absolute position in customer units with regard to the reference point set with the P or R command Otherwise the con...

Page 47: ...osition becomes synchronization point Responses Z55 if the command was executed correctly otherwise a corresponding error message R3 CR First determine reference point at standstill as for R1 then synchronous operation after transducer zero pulse from master drive only with follower drive Responses if the command was executed correctly otherwise a corresponding error message If the refer ence poin...

Page 48: ...he same applies to the C D G and H commands Example for L and M commands Set the address indicator at 0E08h and load this memory location with 16 10h L 0E08 CR M 0010 CR Make sure that the number is made up to four places with zeros after the equals sign Example for X and T commands For a positive 31 bit position such as 1 5 million increments the command is as follows X 0001500000 CR Make sure th...

Page 49: ...tical to the addressed short message commands An acknowledged and unacknowledged system is proposed 8 4 3 1 Acknowledged B5 mode With acknowledged B5 mode there is a uniform end symbol available for communication with a higher ranking control system This transmission protocol corresponds to B2 mode The only difference is a uniform ASCII character 3 ETX or STRG c as an end character This end charac...

Page 50: ...se the inverter will be in unaddressed communication mode The following command must be transmitted A00 CR In addressed bus mode the inverter addresses is present in the short message commands Example Inverter address F25 01 A01E CR A01V CR 9 Appendix 9 1 Options X6 option for further processing rotary position transducer signals Differential 2 channel analog output option for analog presentation ...

Page 51: ...ction 8 No connection 8 No connection 9 No connection 9 GND 10 No connection 11 No connection 12 UA2 OUT 13 UA2 OUT 14 GND 15 UA1 OUT 16 UA1 OUT 9 1 2 Option card Differential 2 channel analog output All channel tracks have ESD protection and supply a max 10V at max 4 mA Terminal Abbr Meaning I O type 1 K1 Channel 1 Output 2 K1 Channel 1 inverted Output 3 GND Earth to channel 1 Output 4 K2 Channel...

Page 52: ...ts per change over contact with switching capacity of 50 W max at 0 5 A max for 230 V AC or 48 V DC at max 0 5 A 9 1 4 Option card SSI absolute value transducer input Pin assignment on option card SSI interface 95444439 for the DSV 5444 system SSIIBSX3 04 Accessories for SSI Interface option 8042341 Flat strap cable connector 50 pole on 50 pole option VECTORDRIVE DSV 5444 8003039 15 pole SUB D mal...

Page 53: ... l 0144 CR m255 Run in curve m0 run out curve l 072c CR 00FF SSI values valid FF00 SSI values incorrect l 0736 CR m255 SSI values active on position slippage m0 normal position 9 1 5 Option card 2nd transducer The 2nd transducer option 95444437 Accessories for 2nd transducer option for connection loop through of master signal 8042341 Flat strap cable connector 50 pole on 50 pole option VECTORDRIVE...

Page 54: ...t out at 6 x 1 kOhm i e spurious conductance On the options card array E28 should be set in the active position but on all other cards the passive array position should be selected New commands in firmware RSDZA3 HEX 094472 17 01 96 L 8808 H 0F79 r4 CR same meaning as 200 CR synchronous speed operating mode note on r4 CR flags 1ae 1af and 802 803 supported here l 740 CR m255 CR NIMPX2_STB 2nd exte...

Page 55: ...83 1 48 0 82 0 57 0 70 0 58 0 81 1 40 0 84 0 54 0 65 0 6 0 80 1 33 0 86 0 51 0 59 0 62 0 78 1 27 0 88 0 47 0 54 0 64 0 77 1 20 0 9 0 44 0 48 0 66 0 75 1 14 0 92 0 39 0 43 0 68 0 73 1 08 0 94 0 34 0 36 0 7 0 71 1 02 0 96 0 28 0 29 0 72 0 69 0 96 0 98 0 20 0 20 0 74 0 67 0 91 9 5 Other information VECTORDRIVE DSV 5444 Series Id 03 400 32 4 06 400 32 8 09 400 28 12 12 400 28 14 16 400 28 25 25 400 28...

Page 56: ...J K B C L 0071_01D DRW VECTORDRIVE DSV 5444 Size A mm B mm C mm D mm E mm F mm G mm H mm J mm K mm L mm Weight kg 3 9 A I 137 281 177 11 5 107 130 6 6 264 276 171 6 0 12 16 A II 172 353 223 11 5 142 165 6 6 331 343 217 10 0 25 45 A III 172 473 223 11 5 142 165 6 6 451 463 217 14 0 60 130 A IV 220 762 310 26 5 160 213 6 5 6 745 757 304 35 0 ...

Page 57: ...H J K B C L 0073_01d drw VECTORDRIVE DSV 5444 Size A mm B mm C mm D mm E mm F mm G mm H mm J mm K mm L mm Weight kg 3 9 A I 193 281 177 11 5 107 130 6 6 264 276 171 10 2 12 16 A II 234 353 223 11 5 142 165 6 6 331 343 217 16 5 25 45 A III 234 473 223 11 5 142 165 6 6 451 463 217 23 0 60 80 A IV 297 758 310 26 5 160 213 6 5 6 745 757 304 57 0 100 130 A 59 0 ...

Page 58: ...DRIVE DSV 5444 Size A mm B mm C mm D mm E mm F mm G mm H mm J mm K mm L mm Weight kg 3 9 A I 165 281 177 11 5 107 130 6 6 264 276 171 6 7 9 9 Dimension and weight with 2 options and add on filter H J K B 0153_01D DRW E D F A G C L M VECTORDRIVE DSV 5444 size A mm B mm C mm D mm E mm F mm G mm H mm J mm K mm L mm M mm weigth kg 3 9 A I 223 281 177 11 5 107 130 6 6 264 276 171 32 10 9 ...

Page 59: ... and weight size 5 H N 0157_02d cdr K B J M L C E F A G D O DSV 5444 Size A mm B mm C mm D mm E mm F mm G mm H mm J mm K mm L mm M mm N mm O mm Weight kg 150 A V 357 953 286 21 5 307 350 11 10 913 933 280 990 28 5 20 60 0 200 A V 357 953 286 21 5 307 350 11 10 913 933 280 990 28 5 20 65 0 Note AddOn filter on request ...

Page 60: ...Dietz electronic page 60 of 60 9 11 Connection layouts Minimum connection arrangement External 24 V voltage supply with external analog specified setpoint value SPS or master reference voltage External 24 V voltage supply with analogous specified setpoint via potentiometer ...

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