MANIU20.0504 E - Installation Manual-low

8/10/2019 MANIU20.0504 E - Installation Manual-low

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ABB Sace ABB AC Brushless ServodrivesDGV Converters

for Speed, Torque and PositioningControl of Brushless AC Permanent

Magnet Servomotors

Installation Manual


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ABB AC Brushless ServodrivesDGV Converters

for driving Brushless AC PermanentMagnet Servomotors

Installation Manual

MANIU20.0504 E

EFFECTIVE: 29.04.2005SUPERSEDES: 10.02.2005

2003 ABB Sace S.p.a. All Rights Reserved.


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Safety Instructions

Introduction This chapter states the safety instructions that must be followed whenconfiguring the DGV Converter. The material in this chapter and in thisManual must be studied before attempting any work on, or with, thedevice.

Warnings and Notes This manual distinguishes two sorts of safety instructions. Warningsare used to inform of conditions that can, if proper steps are not taken,lead to a serious fault condition, physical injury and death. Notes areused when the reader is required to pay special attention or when thereis additional information available on the subject. Notes are less crucialthan Warnings, but should not be disregarded.

WARNING Readers are informed of situations that can result in serious physicalinjury and/or serious damage to equipment with the following symbols:

WARNING! Dangerous Voltage:warns of situations inwhich a high voltage can cause physical injury and/ordamage equipment. The text next to this symboldescribes ways to avoid the danger.

WARNING! General Warning:warns of situations thatcan cause physical injury and/or damage equipment bymeans other than electrical. The text next to this symboldescribes ways to avoid the danger.

Electrostatic Discharge Warning: warns of situationsin which an electrostatic discharge can damageequipment. The text next to this symbol describes waysto avoid the danger.

Notes Readers are notified of the need for special attention or additionalinformation available on the subject with the following symbol:

CAUTION! Caution aims to draw special attention to a particularissue.

Note. Notegives additional information or points out moreinformation available on the subject.

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Safety Instructions

Neglecting these instructions can cause physical injury anddeath.

General Safety

Instructions

WARNING!Only properly qualified personnel who arefamiliar with operation on converters are allowed to performthe commissioning and operation activities on DGV.

WARNING!For no reason should any person accessthe internal part of the converter or the terminals of theservomotor, before at least four minutes from thepower outage.

Potentially lethal voltages are present on a DC intermediatecircuit and on the associated circuits.

WARNING!The installation must be done in conformancewith CEE 89/336and CEE 72/23 directives.

WARNING! The machine manufacturer, who commissionsthe converter, must install proper additional protectionfunctions to avoid damages to health or equipment whenthe machine is operating.

Complete safety instructions can be found in Chapter 9 -Standards and Safety of the present Manual.

More Warnings and Notes are printed at appropriateinstances along the text.

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Table of Contents

Safety Inst ru ct ion s . . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . i i i

Introduction.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i i iWarnings and Notes .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i i i

WARNING ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i i iNotes ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i i i

General Safety Instruct ions.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv

Table of Cont ents . . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . .. . v

Chapter 1 - In t r odu ct ion t o th i s Manual . . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . . .. . 1-1

Introduction.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1General Information .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Typical Appl icat ions .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2General Specs of DGV Converters.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Hardware and Firmware ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3Basic Configurat ion .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3User Interface Appl icat ion Software .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3Complementary Equipment .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Chapter 2 - Overv iew .. . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . . 2-1

General Notes .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Block Scheme... . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Chapter 3 - Mechanic a l Ins ta l l a t io n . . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . .. . . . . .. 3-1

Introduction.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1DGV700 ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2DGV300 ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Chapt er 4 - User Int erf ace... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Introduction.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1ABB AC Brushless Servodrives Browser .. . . .. . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . .. . . . . . . . 4-1

Browser and Firmware versions.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Chapt er 5 - Main Featu res .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Introduction.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1Local Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Identi f icat ion of the Converter Model .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1Select ion of Motor Model .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1Control Parameters .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Control Mode... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2Local Operat ing Mode ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2Software Enable .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Local Diagnostic .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

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I /O Sett ings .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3 DGV700... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3DGV300... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3

Waveform Generator .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4 Waveform Type ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4 Waveform Frequency ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4 Waveform Ampl i tude ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4 Waveform Generator Enable .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

Parameters.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5Programmable Protection Functions .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Bus Overvol tage Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5Bus Undervol tage Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5 Brake Current .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5 Clamp Resistor Value ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5 Clamp Power Threshold .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5 Clamp Thermal Time Constant.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5AC Mains Vol tage... . . . . . . . . . .. . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . .. . . . . . . . . 5-5

Overspeed Threshold Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6Ixt Threshold Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . 5-6I2t Threshold Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6 Fol lowing Error .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6

Digi tal Control Parameters .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6 Posit ion Proport ional Gain .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6 Posit ion Feedforward Gain .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6 Kp Speed Gain Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6 Tn Speed ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6 Kp Current Gain Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6 Tn Current.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6Continuous Current .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6

Peak Current .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6 Current Fi l ters .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6

Preprogrammed Functions .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7 Protect ion Functions .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7

Overcurrent .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7 Drive Overtemperature .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7 Motor Overtemperature .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7 Transducer Faul t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7Internal Error .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7

Addi t ional Features.. . . . . . . . . . . .. . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . .. . . . . . . . . 5-7Freeze Configurat ion .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7 Reset Parameters .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7

Save Motor Data .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7 Autophase ... . . . . . .. . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . .. . . . . . 5-7Change Password ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7 Change COM Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7

Field Bus Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7

Chapter 6 - Ins ta l l a t io n Guidel in es . . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . .6-1

Introduction .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1CE Marking ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

EM C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1 Standards .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2

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Electromagnetic Compatibi li ty (EMC) Direct ive.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2Low Voltage Direct ive .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2Normative Documents .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Compl iance with EEC Direct ives and CE Marking ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3Restr icted Distr ibut ion .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3Mounting and Instal l ing Instructions .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3Second Environment.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4Compl iance of the Drive Systems with the Direct ives .. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4Note for the Appl icat ion of Other EEC Direct ives .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Warning and Safety Instruct ions .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5Meaning of the Symbols .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5Instal lat ion Operation .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5Residual Vol tage... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5Dangerous Temperature.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6Power Supply Disconnecting Device .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6Stop Function .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6Emergency Stop ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

Protect ion Degree ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6Appl icat ion Guidelines for Electromagnetic Compatibi l i ty . . . . . . . . .. . . . . . . . . . . . . . . . 6-7 Electr ical Control Cabinet .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8Electr ical Equipment.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9First Environment .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10Second Environment.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

Addit ional Equipment .. . .. . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 6-10

Chapter 7 - Electr ica l Inst a l la t i on of DGV700 .. . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . 7-1

Introduction.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1Descript ion of the avai lable connectors .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Wiring Scheme ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3Power Connections .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Main Power Supply.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6Typical connection scheme ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

Auxil iary Supply .. . . . . . . . . .. . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 7-7EMC Fi l ters .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

Fi l ter Size .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8Fi l ter instal lat ion.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8Fi l ter connection (solut ion 1).. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9Fi l ter connection (solut ion 2).. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9Earthing ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

Braking Resistor Connections.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

Power Stage Basic Diagram ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11Calculat ion of the braking resistor .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

Motor Power Connections.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13Field Bus Connections.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

Diagram of the PROFIBUS cable.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14Diagram of the CANOpen cable .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16

Signal Connections .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17Resolver Connections .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17

Connection Diagram of the Resolver Cable for 8C Servomotors .. . . . . . . . 7-18Connection Diagram of the Resolver Cable for 8N Servomotors .. . . . . . . . 7-18Signals Connections on the Motor Side ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19

Sincos Encoder Connections .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20I /O Connections.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21

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RS 232 Connections .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23Diagram of the RS 232 Serial Cable .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23

Encoder Emulat ion .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24

Chapter 8 - Elect r i ca l Ins ta l l a t io n of DGV300.. . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . 8-1

Introduction .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-1 Single-Phase Version ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-2

Power Connections .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-2 Main Supply Connections .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-2 Clamp Resistor Connection .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-3 Motor Power Connections .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-4

Wiring Scheme ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-5 Direct Connection to 400Vac TN-Network.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6Connection to 400Vac TT-Network with Autotransformer.. . . . . . . . . . . . . . . . . . . . . . . 8-6Direct Connection to 230Vac TT-Network .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7Connection to 400Vac IT-Network with Transformer .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

Instal lation in First Environment.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8Instal lat ion in Second Environment.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-9 Three-Phase Version... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10

Power Connections .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10Main Supply Connections .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10Clamp Resistor Connection .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11Motor Power Connections .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12

Wiring Scheme ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13Connection to 400 Vac TT-Network with Autotransformer.. . . . . . . . . . . . . . . . . . . . 8-14Connection to 400 Vac IT-Network with Transformer .. . . . . . . . . . . . . . . . . . . . . . . . . . 8-14

Auxil iary Supply Connections .. . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . .. . . . . . . . . . . 8-15Brake Connections .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15

Field Bus and Serial Connections .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16Profibus-DP Version ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16CANOpen Version... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18

Encoder Emulat ion .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20Resolver Connections.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21

Connection Diagram of the Resolver Cable .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21Signals Connections on the Motor Side ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22

I /O Connections .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23

Chapter 9 - Technical Data.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-1

Introduction .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-1

Converter Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-1 Customer Service .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-1

Technical Speci f icat ions .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-2 Main Character ist ics .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-3

Output Current Derat ing.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . 9-5Posit ion Transducer Signal Acquisi t ion .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6

Resolever Interface ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-6 Sincos Encoder Interface ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-6

Minimum Wire Cross Sections .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-6 Braking Resistors.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7

DGV700... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-7DGV300... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-9

EMC fi l ters .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10Complete ordering codes... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10

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Overal l d imensions ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10How to choose the f i l ter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10Electr ical character ist ics .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11

Overload ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11EMC Fil ters wi th Smal l Ground Leakage Current .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12

Product Type Designation.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14

Chapter 10 - Select in g th e Servo mot or . . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . .. . . . . . 10-1

Introduction.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1Select ing the Motor.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

A p pen d i x A - Am b ien t Con d i t i o ns .. . . . . . . . . . . .. . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . .. . . . . .A -1

Operating Conditions .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Storage Conditions .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Transportat ion Condit ions.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

Installation Manual - MANIU20.0504 E ix


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Table of Contents

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x Installation Manual - MANIU20.0504 E


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Chapter 1 - Introduction to this Manual

Introduction This manual, cod. MANIU20.0504 E, has been written by ABB SaceS.p.a. and describes the hardware characteristics, the software and thetechnical specs of the DGV vector controlled converter. Moreover itguides the user into the installation, commissioning and selection of theproper motor matching and accessories.

Besides this Installation Manual, the Firmware Manual, the CANOpenGuideand the PROFIBUS Guideare also available under this code.

GeneralInformation

The DGV Converter is a new generation digital converter with field bustechnology. Designed for motion control applications it allows for localor remote control of speed, position and torque with high dynamic

performances.Its main characteristics are:

! Field Bus Profibus-DP, CANOpen

! Motor Transducers :Resolver or Sincos encoder 1 Vpp

! Auxiliary Encoder input

! Programmable encoder emulation output

! Programmable digital inputs

! Programmable digital outputs

! 1 analog input, #10 V

! 1 programmable analog output

! 1 dedicated relais output

! Dynamic management of the emergency braking

! Resolver autophasing to setup every kind of brushless motor

! Notch filters to cancel mechanical resonances

! Auxiliary supply 24V ac/dc

! Internal or external braking resistor

! Setup software with digital oscilloscope, waveform generatorand motor database to create every configuration throughRS232 serial interface

Installation Manual - MANIU20.0504 E 1-1


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Typical Applications The characteristics of the applications that can be configured are:

! Speed and torque control, with analogic commands

! Speed and torque control, field bus managed

! Absolute and relative positioning control, field bus managed! Digital interpolation positioning control (CanOpen)

! Positioning microinterpolator

! Position and speed synchronizations

! Torque slave (in order to connect more motors) in parallel

! Mixed analogic/digital controls

! Management of a second encoder for positioning loop

! Parameters tables changeable via I/0 or via field bus, or self

commutated

! Linear motors control

! Stronger braking duty cycles thanks to DC BUS paralleling

Due to these characteristics, DGV is usually adopted for motion andpositioning applications, from the simpler to the most complicated.

! Plant automation

! Axes motion

! Reel and pallets driving

! Textile

! Mixers

1-2 Installation Manual - MANIU20.0504 E


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General Specs ofDGV Converters

Hardware and

Firmware

Within ABB product family DGV is the first digital converter with field

bus technology for brushless servomotors drives. The hardware andfirmware characteristics are the following:

! A control board that makes position, speed, torque control andspecial functions for the protection and supervision of the drive.

! An I/O board for the management of:

- RS 232 serial interface,

- PROFIBUS-DP/CANOpen field bus interface,

- acquisition of the angular position transducer signals, includinga second encoder input, and of the thermal sensor that can bemounted on the motor,

- encoder emulation output,

- dedicated and configurable analog inputs and outputs,

- dedicated and configurable optical insulated digital I/O.

! A power board to drive the motor.

Basic Configuration DGV Cpnverters are available with one of the following configurations:

! DGV700, 110 $480 Vac three-phase power supply

! DGV300, 110 $230 Vac three-phase power supply

! DGV300, 110 $230 Vac single-phase power supply

User InterfaceAppl ication Software

DGV Converters are equipped with the user interface software ABB ACBrushless Servodrives Browser. The software can makecommissioning, monitoring and supervision of the application. Theoperation of this application software is described in the FirmwareManual and, shortly, in Chapter 4 of this Manual.

ComplementaryEquipment

DGV700 and DGV300 Converters are normally matched with ABBSace of the 8C SERIES, even if motors from other manufacturers arecontrollable as well. For additional info on the motor convertermatching, the uses of other complementary and auxiliary equipmentplease consult Chapter 6.



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Chapter 2 - Overview

General Notes This manual refers to drives made up with DGV Converters and 8CSERIES Servomotors.

DGV uses a vector control strategy and a proportional integral position,speed and current closed loop regulator. Moreover, it has an internalintelligence for the overall drive control and the optimization of itsoperating characteristics.

Block Scheme

- Local and remote control

- Position, speed and current control- DC voltage control

- Hardware and software protection function- Thermal protection of motor and converter- Dynamic and dissipative braking functions

- Autophasing

R2RintR1

R3

AC Mains

Rext

~

=

IU

IV

IW

!*

Id

Iq

- iq-feedback

PWM

generationPI Current Controller

& Current FilertsV*PI Speed-Position

Controller

iq*

- !feedback

Motor PositionFeedback

Motor CurrentFeedback



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Chapter 2 - Overview




19/112

Chapter 3 - Mechanical Installation

Introduction This Chapter illustrates instructions for mechanical installation ofDGV700 and DGV300 Converters.

The DGV hardware equipment is arranged inside a metallic case. Theholes on the back metallic side allow for the fastening of the converteron a holding panel, usually inside an electrical cabinet (see Chapter 6- Installation Guidelines). The front panel of the converter is equippedfor the cable connections. The grids on the top and bottom sides ofthe converter allow for cooling airflow circulation.

Once the cabling of the converter is completed, the protection degreeof the closed metallic case is IP20. The installer and the machine

manufacturer must provide for the completion devices for thesafeguard of the whole installation.

The installer must provide for:

! For DGV700, a minimum 150 mm distance of the converterfrom other external objects both on top and on bottom of theconverter, and a minimum 30 mm distance on the lateral sides.

! For DGV300, a minimum 100 mm distance of the converterfrom other external objects both on top and on bottom of theconverter, and a minimum 20 mm distance on the lateral sides.

! Avoiding placing the converter close to heat sources.

! Making an evaluation of the heat dissipated within the electricalcabinet and provide for suitable cooling devices whennecessary. To know the heat dissipation values of the DGVplease consult Chapter 9 - Technical Data.

! Installing proper protection devices for personnel andmachinery.

The power circuit wirings must be physically separated from thedriving and control circuit wirings (signal circuits); the power circuitsmust be carefully shielded with respect to signal circuits; this can beachieved by using metal wire channels and metal sheaths or shielded

cables, even power cables, arranged within plastic channels (Chapter6 - Installation Guidelines).



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DGV700 Fix the bottom and top bracket with two screws for mounting DGV700Converters.

B

30 mm

150 mm

CD

A E

X5

X6

I/O

X7

30 mm

150 mm

MechanicalDimensions

UnitsSizes

3/6, 5/10, 9/18Sizes

13/26, 18/36, 25/50

A [mm] 91 124

B [mm] 300 325

C [mm] 324 352

D [mm] 336 366E [mm] 248 309

Weight [Kg] 4,6 8,6



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Capitolo 3 - Interfaccia utente

DGV300 Use brackets and screws supplied with the converter for mountingsingle- and three-phase DGV300 Converters.

! Fix the bottom bracket to the mounting panel with two screws.

! Place the converter on the bottom bracket

! Place and fix with a screw the top bracket.

a

c c1

bb1

k1

g

d

c2

=

=

k

m

= =c

k2

=

=

e

Allow a free space for assembling the connecting cables

d

c1

= =

M4 Holes

e1

DGV300 Units a b b1 c c1 c2 d e e1 g k k1 k2 m

Size 3/6 [mm] 70 252 206 16,5 39,5 14 170 174 5,5 4,5 63,5 2 %5,5

Size 5/10 [mm] 70 252 206 16,5 39,5 14 170 174 5,5 4,5 63,5 2 %5,5

238+1-0

238+1-0



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M4 Holes

=

c1

dbb1 d

c1

a

=

c

m

=

c2

=

Allow a free space for assembling the connecting cables

e

e1k1

=

k

g==

DGV300 Units a b b1 c c1 c2 d e e1 g k k1 m

Size 7/14 [mm] 80 268 206 24 39,5 16,5

190 194 5,5 12 63,5 %5,5254+1-0



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Chapter 4 - User Interface

Introduction DGV can be controlled in different ways:

! Analog local control via RS232 serial communication protocolwith the aid of a PC.

! Analog remote control with the use of the configurable analogand digital I/Os.

! Digital remote control via field bus and the aid of an externalcontroller or PLC, by configuring the PROFIBUS-DP or theCANOpen module that is incorporated into the converter.

! In a mixed mode manner between Analog and Digital control.

ABB AC BrushlessServodrivesBrowser

This Browser is the user interface of the DGV for the analogue localcommand. The use is very similar to other application programsdeveloped in Windows environment.

It has the following functions:

! Drive commissioning, set-up and save of the operatingparameters of the internal control loops

! Upload and download of data set containing all the data relatedto an application

! Fault diagnosis and elimination

! Local operative control of the drive by means of someprogrammable functions

! Monitoring of the drive state during the local or remote control

Browser andFirmware versions

Since the browser is constantly updated or upgraded by ABB Sace, therevision levels are numbered as follows:

Browser vX.Y.ZZ

Example:

Browser v3.2.62

Where:! The first digit X stands for a version totally renewed with

respect to previous version, that could also have someincompatibility with them.

! The second digit Y stands for a significant variation but thatcompatibility with previous version is guaranteed.

! The third digits ZZ stand for small modifications orimprovements, e.g. bug fixing, minor improvements etc.



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Chapter 4 - User Interface

Usually with the browser there is a firmware version of the converterthat is numbered at the same level or below.

The main page visualizes general and important information and allows

the user for making immediate diagnoses of the drive state. The threegreen lightening LED buttons indicate respectively the presence ofhardware enable, the software enable and the applied main powersupply. The red lightening LED indicates on the contrary the presenceof a fault and, in the section dedicated to error messages, the faultoccurred is visualized.

Messages andFaults

Tool Bar

BrowserPages

Identification ofthe application

Status Bar

Online display of thelocal variables

Front Panel

Title Bar

Menu Bar



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Chapter 5 - Main Features

Introduction This chapter describes the standard functions of the DGV Converters,that are activated both in local analogue control and field bus remotecontrol. There are functions that are pre-programmed, not modifiableby the user, programmable functions to set-up the converteroperating mode, parametric-functions for the protections intervention,and auxiliary functions of various kind.

To allow for saving an application with a data set containing all ofuser defined data, these functions are treated as parameters and formost of them there exist the possibility to modify them on the fly.

Local Control

Identification of theConverter Model

When starting the user interface program, the drive model and themanufacturing characteristics are automatically detected.

After the serial communication is established, the applicationconfiguration can go on.

If the converter is not connected to the PC it is anyway possible tocreate an application configuration, therefore most of the things heredescribed are valid in that situation too.

Selection of MotorModel

Usually DGV are coupled to ABB brushless servomotors of the 8CSERIES, for which ABB Sace provides a data set of motor models.

The installer who wishes to use a motor of different manufacturer cananyway create his motor model if the data set required during theconfiguration is available to him/her.

To make online configuration of DGV please refer to the FirmwareManual, where the complete programming procedures, theparameters and the operating functions of this drive are alsoexplained.



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Control Parameters The parameter list is given in theFirmware Manual.

Control Mode Parameter function for control mode selection:

! Local

! Field Bus

Local Operating Mode Parameter function for selecting the local operating mode:

! Analog Current

! Analog Speed

! Digital Torque

! Digital Speed

! Digital Position

Software Enable Parameter function for software general enable (On/Off) of the driveoperation.

Local Diagnostic The Browser main page displays the process local variables, theoperating status and the fault tracing of the drive.

In addition, the oscilloscope window in the Waveform Generator pagecan display the drive variables both in local and remote control mode.



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I/O Settings DGV Converters provide programmable and manufacturer pre-programmed I/Os. The symbolic names put in brackets refer to thepin labels on the converter front panel, for example:

DGV700 ! VREF One analogue configurable reference input #10 Vdifferential with 12 bit digital conversion

! D-IN Eight optically insulated digital inputs 0-24 V, 30mA

! D-OUT Three digital outputs 24 V, 30 mA max.

! VOUT One differential configurable analogue output

! ENABLE One digital preprogrammed input for powerHardware Enable

! RESET One digital preprogrammed input for Fault Reset

! READY One preprogrammed output fault/drive ready

DGV300 ! One analogue configurable reference input #10 V differential

! Six optically insulated digital inputs 0-24 V, 30 mA

! Two digital outputs 24 V, 30 mA max.

! One differential configurable analogue output

! One digital preprogrammed input for power Hardware Enable

! One digital preprogrammed input for Fault Reset

! One preprogrammed output fault/drive ready



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Wavefo orksset the

rm Generator Waveform Generator provides a digital waveform generator. It win Localcontrol operating mode. This set of functions allows toform, amplitude and period of the digital waveform.

Waveform Type Parameter function for waveform type selection (Step/Square/Triangle/Sine wave). It is a speed or current digital waveformdepending on the analog control mode (Analog Speed or AnalogCurrent) currently selected.

Waveform Frequency Parameter Waveform Frequency.

Waveform Amplitude Parameter Waveform Amplitude which allows you to set commandreference value (speed or current waveform amplitude).

Waveform GeneratorEnable

Parameter Waveform Generator Enable (start/stop). The drive isdisabled with the Stopcommand for safety reasons.

Tuning of thePI-Controller

Oscilloscopedisplay

WaveformGenerator



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Paramet

d personnel can tune the

l

ProgrammableProtecti

rotection functions, i.e.aults

Bus Overvoltage Level ec is

y rated voltage. When the DC voltage exceeds the

Bus Undervoltage Level diate circuit. Should the

esactivated.

dynamic brakingfunction allows you to keep on braking the motor after a stopping

ith

Clamp Resistor Value The DGV Converters embody an electric braking circuit. It is possibleto use an internal or external resistor (clamp) for power dissipation.This parameter displays the resistor value.

Clamp Power Threshold This parameter displays the threshold for power dissipation on theinternal/external braking resistor.

Clamp Thermal TimeConstant

Thermal time constant of the braking resistor.

AC Mains Voltage The supply voltage Vac minimum level allowed is equal to theminimum voltage that guaranties drive operation. When the auxiliarysupply is connected, the fault code is displayed.

ers In the following the PI controller parameters and protection functionparameters are explained. Any numeric parameter is expressed intoits units.

Any time the user selects the servomotor to be coupled with DGV, the

ABB AC Brushless Servodrives Browser internally calculates all theparameter settings and sets the drive ready for operation. Thisautomatic computation procedure uses the motor and convertertechnical data. However, in order to optimize the parameter settingsand avoid mechanical vibrations, qualifieparameter values when customization is necessary or unconventionaloads are used.

This concerns the parameters that affect the pon Functions under voltage and over voltage conditions, thermal protections, f

and error messages.

Over voltage protection on the converter DC intermediate circuit. Thvoltage on the DC link is Udcequivalent to 1.41 * Vac, where Vathe converter suppltrip limit during drive operation, the over voltage protection functionoccurs and the power stage is disabled.

Under voltage protection on the DC intermeDC voltage decrease below the trip limit during drive operation, theunder voltage protection function occurs. When the voltage drop donot persist, the dynamic braking is

Brake Current Parameter for setting the braking current. The

procedure. This function is quite useful in case of applications welastic loads, or vertical axes anyway provided with the motormechanical brake.



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Overspeed ThresholdLevel

If the servomotor speed or the speed command exceeds theoverspeed limit, a fault occurs. This protection may occur even byusing the waveform generator speed command.

Ixt Threshold Level Protection function activated by the converter thermal modelalgorithm. The trip limit is calculated according to the convertercontinuous current. If this alarm occurs, the current is internallylimited to the rated value and the drive continues operation.

I2t Threshold Level Protection function activated by the motor thermal model algorithm.This level is calculated according to the motor ratings. If this alarmoccurs, the motor current is internally limited to the rated current andthe drive continues operation.

Following Error DGV detects the following error. The following error occurs when themotor position runs out of range while performing positioning control.This is generally due to inappropriate parameter settings.

Digital Contro lParameters

The following are the parameters of the drive internal control loop.

Position ProportionalGain

Position proportional gain of the position control loop.

Position FeedforwardGain

Feedforward gain of the position control loop.

Kp Speed Gain Level Proportional gain of the drive speed control loop.

Tn Speed Integrative time constant of the speed control loop.

Kp Current Gain Level Proportional gain of the drive current control loop.

Tn Current Integrative time constant of the current control loop.

Continuous Current Servomotor continuous current during normal operation. Thisparameter is used for the internal computation of the motor ratedtorque.

Peak Current Servomotor peak current. This parameter is used for the internal

computation of the motor peak torque.

Current Filters Three current filters are available to be put in series. They can beconfigured as low pass filter or band rejection filter. They are set Offby default.



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PreprogrammedFunctions

The DGV pre-programmed functions are protection functions orgeneral features set by the manufacturer and not alterable by theuser.

Protection Functions Protection functions are featured with error messages and fault codesdisplayed on the front panel.

Overcurrent Overcurrent hardware protection of the IGBT module.

Drive Overtemperature DGV supervises the inverter temperature by a thermistor elementplaced close to the IGBT module. The protection function stops driveoperation if the inverter temperature exceeds 80C.

Motor Overtemperature It is possible to detect the motor overtemperature by connecting themotor thermistor (PTC) to the converter signal terminal. ABB SERIES8C Servomotors embody PTC Thermik SNM. During normaloperating conditions, the thermistor resistance should be less than

! 1,5 K&. the fault protection occurs when the thermistor resistance

exceeds 4 K&.

Transducer Fault It occurs when the position sensor signal feedback is missing.

Internal Error This is a hardware internal error due to communication fault betweenhardware boards.

Addi tional Features Additional features are available from the menus of the ABB ACBrushless Servodrives Browser.

Freeze Configuration This command stores the application configuration settings into thedrive non-volatile memory.

Reset Parameters This command allows you to cancel all parameters alteration andreset parameters to factory defaults.

Save Motor Data Through this feature it is possible to extend the database of motormodels with new customized models.

Autophase Autophasing procedure. This procedure is not necessary with ABBstandard servomotors of the 8C SERIES, which embody resolvertransducers with a 90 phase offset.Autophase procedure is

mandatory if DGV is coupled with brushless servomotors of othermanufacturers.

Change Password Once the commissioning finishes, the user can change the Browserpassword by this command.

Change COM Port Command for selecting the COM port of your PC.

Field Bus RemoteControl

For the PROFIBUS-DP/CANOpen parameter settings, configurationand communication guidelines please refer to the PROFIBUS Guideor the CANOpen Guide.



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Chapter 6 - Installation Guidelines

Introduction This Chapter recalls the main reference documents for:

! Installing DGV Converters in accordance with the EuropeanDirectives EEC 89/336 and EEC 72/23

! Emergency stop functions and personnel safety

! Directives concerning installation procedures

General DGV must be installed in an electrical control cabinet, as integrativedevices of an operating machine. Therefore the compliance of thedevice with the EEC Directive 89/336 for EMC compatibility, as wellas the compliance with the Low Voltage directive EEC 72/23 and/or

local legislation, must be done by the machine manufacturer.In addition, the machine manufacturer must install:

! The manual control power supply disconnecting devicerequired by EN 60204-2 5.3.1, which can be shared by allthe electrical control cabinet.

! According to EN 60204-1 9.2.2, the machine manufacturermust prepare the stop functions, in particular the 0 categorystop, because they are inherent to the machine logic.

! According to EN 60204-1 9.2.5.4, the emergency stop mustbe a function of the specific characteristics of the operated

machine and therefore it must always be made by themachine manufacturer.

More information on the purpose are given in the following Standards,and Compliance with the EEC Directives and CE Marking andWarning and Safety Instructions of this Chapter. Should you have anyquestion or need further support, please contact our CustomerService.

CE Marking The CE mark on the converter label certifies only the compliance ofthe device with the directives recalled in Low Voltage Directive. Thecompliance of the machine, which integrate DGVs, with the EEC

89/336 is under the responsibility of the manufacturer.

EMC EMC stands for per ElectroMagnetic Compatibility. It is the ability of the electrical/electronicsequipment to operate without problems within an electromagnetic environment. Likewise, theequipment must not disturb or interfere with any other product or system within its locality.

The EMC Directive defines the requirements for immunity and emissions of electrical equipmentused in European Union.

The terminology related to all the subjects concerning the electromagnetic compatibility (EMC)discussed in this Manual is derived from the normative document recalled in [8] of paragraphNormative Documents of this Chapter.



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Standards The main normative documents to which the text of this Manual refersare indicated below. The references in the text are reported betweenbrackets.

ElectromagneticCompatibility (EMC)

Directive

[1] Directive 89/336/EEC, On the approximation of the laws of the Member

States relating to electromagnetic compatibility and the subsequentamendments 92/31/EEC and 93/68/EEC.

[2] Italian Legislative Decree, 4 December 1992, No. 476 Attuazione delladirettiva 89/336/CEE del Consiglio del 3 maggio 1989, in materia diravvicinamento delle legislazioni degli Stati membri relative allacompatibilit elettromagnetica, modificata dalla direttiva 92/31/CEE delConsiglio del 28 aprile 1992 (Directive 89/336/EEC, On theapproximation of the laws of the Member States relating toelectromagnetic compatibility and the subsequent amendments92/31/EEC and 93/68/EEC).

[3] Italian Legislative Decree, 12 November 1996, No. 615 Attuazionedella direttiva 89/336/CEE del Consiglio del 3 maggio 1989, in materiadi ravvicinamento delle legislazioni degli Stati membri relative allacompatibilit elettromagnetica, modificata ed integrata dalla direttiva92/31/CEE del Consiglio del 22 luglio 1993 e dalla direttiva 93/97/CEEdel Consiglio del 29 ottobre 1993 (Implementation of the directive89/336/EEC, 3 May 1989, On the approximation of the laws of theMember States relating to electromagnetic compatibility changed andintegrated by the Directive of the Council 92/31/EEC, 22 July 1993 andby the Directive of the Council 93/97/EEC, 29 October 1993).

IMPORTANT NOTE: This Legislative Decree repeals theLegislative Decree [2], excepting article 14, sub-section 2.

Low VoltageDirective

[4] Directive 73/23/EEC, 19 February 1973, Harmonization of the laws of

Member States relating to electrical equipment designed for use withincertain voltage limits, integrated by the Directive 93/68/EEC, 29 June1993.

[5] Italian Law 18 October 1977, No. 791 Attuazione della direttiva delConsiglio delle Comunit europee (n. 73/23/CEE) relativa alle garanziedi sicurezza che deve possedere il materiale elettrico destinato adessere utilizzato entro taluni limiti di tensione (Directive 73/23/EEC, 19February 1973, Harmonisation of the laws of Member States relating toelectrical equipment designed for use within certain voltage limits,integrated by the Directive 93/68/EEC, 29 June 1993).

[6] Italian Legislative Decree, 25 November 1996, No. 626 Attuazionedella direttiva 93/68/CEE in materia di marcatura CE del materialeelettrico destinato ad essere utilizzato entro taluni limiti di tensione(Implementation of the Directive 93/68/EEC concerning the CE markingof electric material designed for use within certain voltage limits).



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Second Environment The drives defined in the title of this section are primarily intended foruse in the Second Environment; the professional assembler mustfollow the precautions described in section EMC Filters of Chapter 7, 8e 9. in particular, he must install the recommended filters, suitablyrated, on the power supply line.

Compliance of theDrive Systems with

the Directives

Declaration of Conformity

ABB Sace declares that, under the conditions specified in thisdocument, in particular in section Compliance with EEC Directives andCE Marking, the drive systems composed of the DGV ConvertersandSERIES 8C Servomotorscomply with EMC European Directives [1],including the most recent changes, with the related endorsementItalian legislation [2] and [3], and with the Low Voltage EuropeanDirectives [4], [5] and [6]; the applicable regulatory references areindicated in section Normative Documents.

Note for theAppl ication of Other

EEC Directives

Since drive systems are complex electrical components, they are notsubject to other EEC directives, apart from those specified in sectionStandards. As far as the 89/392 EEC Machine Directive andsubsequent changes 91/368/EEC, 93/44 EEC, 93/68 EEC, Italianlegislation for implementation of the Presidential Decree No. 459,24 July 1996, the Certificate of Incorporation (also known asManufacturers declaration) is sometimes required.

Certificate of Incorporation

ABB Sace, according to what required in the Machine Directive (MD)89/392 EEC and subsequent changes, declares that the drive systems,composed of the DGV Convertersand SERIES 8C Servomotors,must be installed in accordance with our installation instructions andmust not be put into service until the machinery into which it is to beincorporated has been declared in conformity with the MachineryDirective.



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Warning and SafetyInstructions

WARNING! Dangerous VoltageMeaning of the

SymbolsWARNING! General Warning

Installation Operationwith installation, troubleshooting and maintenance of drive

systems.

This Manual is intended for qualified personnel who have a relevantexperience

WARNING! Only properly qualified personnel whoare familiar with operation on converters are ato perform the commiss

llowedioning and operation

activities on the drive.

WARNING! The cabinet, the power supply and theauxiliary supply must be disconnected duringmechanical and electrical installation of the drive

terminal blockof the conver

Residual Voltage

systems.

For no reason should an unskilled operator work on theter or open the servomotor terminal box.

WARNING!The DGV Converters contains high capacitycapacitors which, for functional reasons, can not alwaysbe discharged in less than 5 minutes following a power

outage.

WARNING!For no reason should any person accessthe internal part of the converter or the terminals ofthe servomotor, before at least five minutes from the

te warning

power outage.

Potentially lethal voltages are present on a DCintermediate circuit and on the associated circuits!

According to EN 60204-1 6.2.4, an appropriaplaced in a visible place warns of this danger.

WARNING!Potentially lethal voltages may be presentthe drive terminals or inside it for a

att least five minutes

after main supply is switched off.



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Dangerous Temperature WARNING!While operating, the converter could reachabsolute temperature up to 80 C (when ambienttemperature is 40 C), therefore involving burningdanger.

Power SupplyDisconnecting Device

WARNING!Since the converter must be integrated in anelectrical control cabinet, which may contain otherequipment, the manual control power supplydisconnecting device, required by EN 60204-2 5.3.1,can be shared by all the electrical control cabinet andmust be, in any case, installed by the machinemanufacturer.

Stop Function WARNING!According to EN 60204-1 9.2.2, the stopfunctions, in particular the 0 category stop, must beprepared by the machine manufacturer, following the

instructions contained in this manual, because they areinherent to the machine logic, which is obviously differentaccording to the drive machine type.

Emergency Stop WARNING! According to EN 60204-1 9.2.5.4, even theemergency stopmust be a function of the specificcharacteristics of the operated machine and therefore itmust always be made by the machine manufacturer.

Protection Degree DGV Converters have an IP20 protection degree; to comply withsection 4.4.6 Contaminates of the EN 60204-1 standard, themachine manufacturer must install the converters in an appropriate

housing (electrical control cabinet), according to the protection degreerequired.



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Appl icationGuidelines forElectromagneticCompatibility

This section applies to prescriptions specified in Note for theApplication of Other EEC Directives concerning the standard aboutelectromagnetic compatibility for drive systems [8].

The need to follow precise rules as far as EMC is concerned, is due

to the increasing use of electronic power units, which, for the usedtechniques, represent a noise source in a wide frequency range(emission). These devices are at the same time sensitive to noiseproduced by other devices; for this reason they must be provided withan adequate immunitylevel.

Noise is conventionally classified as low frequency(0 = < f < 9 kHz)and high frequency (f > 9 kHz) noise.

In the range of the low frequency noise, the harmonic frequencyphenomena of the power supply line frequency are particularlyimportant.

There are also large spectrumevents, such as electrostaticdischarges in the air or by contact.

Noise can be transmitted both through conductors (; conducted emission: 0,15 MHz $30 MHz) and throughirradiation (; irradiated emission: 30 MHz $1000MHz). Industrial experience showed that the main causes ofcompatibility lack are caused by conducted noise.

The drive system installation must be carried out by closely followingthe instructions in this Manual and, in particular, in Chapter 7 -Electrical Installation of DGV700and Chapter 8 - ElectricalInstallation of DGV300.

For electromagnetic compatibility, the installation must be carried outfollowing some appropriate instructions; the most important follows:

1) Apart from some very specific cases, the DGV Converterisenclosed into a metal cabinet (the so-called electrical controlcabinet), also containing different kinds of electrical equipment(other power electronic converters, contactors, transformers,chokes, etc.).

2) The motor assembly, including the 8C SERIESservomotor andthe angle position transducer, as well as the motor thermal switchand - where necessary - the brake, is usually mounted on the

machine at a certain distance from the electrical control cabinet.There are actually two different types of installations: the one referringto the electrical control cabinet manufacture and the actual on-siteinstallation, which is carried out by the installer at the premises of thefinal user.



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Electrical ControlCabinet

According to the EMC, it is important to keep in mind some importantprescriptions for the electrical control cabinet, which are listed in thefollowing.

! The arrangement of the components within the electrical

control cabinet, both in terms of positioning and distances,must be carried out to minimize the mutual influences of theequipment mounted for the electromagnetic noises.

As an example, note that some types of transformers, powerchokes or also contactor coils can generate rather strong fields atshort distance.

The power circuit wirings must be physically separated from thedriving and control circuit wirings (signal circuits); the powercircuits must be carefully shielded against signal circuits; this canbe achieved by using metal wire channels and metal sheaths orshielded cables, even power cables, arranged within plastic

channels.

As an example, the power circuit wirings of terminal X1 (seePower Connections of Chapter 7 and 8) must be physicallyseparated, in the above mentioned way, from the cables providedwith end terminals or connectors with signal cables.

! All the equipment, for which supplementary units areprescribed in order to comply with EMC standards, must beprovided with these units, mounted according to themanufacturers prescriptions.

Example: anti-noise units to be mounted in line with AC contactor

coils, diodes to be installed in parallel with relays or DC coilcontactors, filters against high frequency conducted noise to bemounted at the line input of some converters.

! Cable shields must end as close as possible to the terminalblock; if the shield has to be connected to ground orsometimes to earth, the connections must be as short aspossible and the conductors must have an adequatesection.

! Within the electrical control cabinet, it is important that allthe panels are connected one to the other with mechanicalconnections and that they have low electrical impedance at

high frequencies.

As an example, to achieve this connection, it could be necessaryto add locking screws, remove the paint in the interconnectingpoints and use special EMC metal gaskets.



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Electrical Equipment As stated above, we refer to the on-site installation, in the finalinstallation of the machine. For some types of machines (such assmall machine tools), the electrical control cabinet is physicallyconnected to the machine and therefore the on-site electricalequipment is reduced to the connection of the machine to the powermains. Nevertheless, the electrical control cabinet is usually placed ata certain distance from the machine, on which the motor assembly ismounted; sometimes there is also a remote control desk, to whichconductors could be connected.

In this case, since the emission problem is strictly linked to installationfactors, the following recommendations come from good techniquestandards and from experience in field and must be basicallyconsidered as guidelines and not as sure solutions.

! For the use foreseen in a Second Environment, i.e.industrial environments where the low voltage network does

not feed residential buildings, it is necessary to follow theinstructions prescribed in this Manual. It is mandatory thatadditional filters are adopted.See section EMC FiltersofChapter 7 and 8.

! The connections in the electrical control cabinet from theMAINS (R,S,T) terminal block of the DGV and the mainscircuit breaker (see Power Supply Disconnecting Device), aswell as the connection lines from this device and thesecondary of the medium voltage transformer of the plantmust avoid voltage drops which can get the power supplyvoltage values at converter terminals out of contractualtolerance.

! Sometimes, the low tension power factor compensationsystems of the power supply line can cause problems, withpossible resonances.

! Carefully study the installation cable routes, minimizing theirlength.

! All the metal channels and sheaths and, in general, all theshields, if not otherwise specified, must be earthed both onthe electrical control cabinet side and on the motor side; theearthing connections must have a largely dimensionedsection and their route must be as short as possible.

This is an EMC specific need, which can seem in contrast withwhat is often prescribed, that is to say the need to earth shieldsat only one side; this prescription requires very efficient earths.



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First Environment The use of the DGV Converters is not foreseen in FirstEnvironment, i.e. where the low voltage network feeds residentialbuildings.

If the drive system has to be used in First Environment, theprofessional installer must provide to their proper shielding.

Second Environment DGV Converters are intended for use primarily in SecondEnvironment only, i.e. industrial environments where the low voltagenetwork does not feed residential buildings.

To comply with the existing normative references on SecondEnvironment, the professional installer must install the recommendedfilters, suitably rated, on the power supply line, and, in any case,autonomously provide for the certification of the whole equipmentaccording to the norms.

See the EMC prescriptions of this Chapter and the followingparagraph Power Connections, together with the ordering codes ofthe line filters recommended by ABB Sace in Chapter 9, EMC filters.

Addi tional Equipment The system or the installation are provided, or may be provided, withthe following additional components:

' Line automatic circuit breaker or breaker plus line fuse;

' Line filters (ABB Sace recommends to use only the approvedfilters listed in Chapter 9).

' Power and signal connecting cables (ABB Sace recommends touse only approved cables listed in Chapter 9).

' External braking resistor.

' Line transformer.

' External controller, generally a PLC.

' PC to be used for start-up and commissioning, or diagnostics andtroubleshooting.

These components are not part of the converter scope of supply. ABBSace may supply these components on request, except for the last

two components, which remain at users choice.

See Chapter 9 - Technical Datafor the ordering codes.

For choosing the servomotor, the user should refer to Chapter 10 -Selecting the Motorand to the ABB 8C SERIES Servomotors Manual,or contact the Customer Service for further information.



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Chapter 7 - Electrical Installation of DGV700

Introduction This Chapter describes how to perform the correct installation ofDGV700 Converters, specially:

! Cabling instructions for power and signal connection

! Braking resistor plug in

! EMC filtering instructions

! Switches, fuses and optional equipment



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Description of theavailable connectors

Terminals are located on the front panel of DGV700 Converters are

! X1 power connections

! X2-X3 field bus connections

! X4 motor signals connections! X5-X6 digital-analog I/O connections

! X7 RS232 serial connections

! X8 encoder emulation connections

Moreover two dip-switches are available for setting node addressand connecting to field bus.

Status display

Node address

X1 power connector

Aux supply 24 V

X2-X3 field bus

X5-X6 D-A I/O

X7 RS232

X8 Encoder emulation

X4 Motore signals



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Wiring Scheme

24V



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Power Connections In the following the DGV700 power terminal connections aredescribed.

DGV700 is to be supplied by a direct three-phase multi voltage acpower system. The DGV700 power stage can be operated at any

voltage supply levels between:

! min rated Vac = 110 Vac

! max rated Vac = 400 Vac

Optionally DGV700 converters can be provided by ABB Sace in aconfiguration capable to be supplied from 400 Vac up to 480 Vac. Forthis option please contact the Customer Service.

The operating frequency of the ac power supply system has to be 50-60 Hz.

WARNING! Standard converters must not be used at

voltages higher than 400 Vac otherwise the DC linkcapacitors are at serious risk of voltage breakdown. In thiscases it is mandatory to use the special version of theconverter.

Moreover, an auxiliary power supply at 24Vac/Vdc is required.

This auxiliary supply feeds the control board and the front panelinterface board. The front panel interface board contains (among theothers connectors) the field bus connectors and the display. Thishelps to maintain the configuration data and fault tracing even after

accidental voltage drops, breakdowns, etc.

24Vac/Vdc auxiliary supply is mandatory.



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The power terminal block X1 on the converter front panel allows toconnect:

! the main power supply,

! the auxiliary supply,

! the servomotor power connections,

! the internal or external braking resistor,

! the DC link voltage.

WARNING! Dangerous Voltage: On the DC link terminalblocks the whole DC link (up to 800Vdc) is present. Thisvoltage can be very dangerous, carefully avoid anyaccidental contact.

Pin Description

U Motor Phase U

V Motor Phase V

W Motor Phase W

R1 Braking resistor internal/external terminal

R2 Braking resistor internal terminal

+VB DC bus positive terminal / Connection of externalbraking resistor

+VB DC bus positive terminal / Connection of externalbraking resistor

-VB DC bus negative terminal

-VB DC bus negative terminal

R Three-phase ac power supply

S Three-phase ac power supply

T Three-phase ac power supply

V24 Single-phase auxiliary supply (24 V ac or dc)

V24 Single-phase auxiliary supply (24 V ac or dc)



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Main Power Supply Connect R, S, T terminals to the main three-phase power supply andthe ground cable to the screwed PE placed on the front panel.

The power supply three-phase line has to be protected by anautomatic circuit breaker or, alternatively, by a disconnecting switch

plus three fuses.In case of systems with power components, e.g. lines and circuitbreakers, common to more drive systems

MANIU20.0504 E - Installation Manual-low

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